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2009 RANGER 700
4X4 CREW / 6X6
SERVICE MANUAL
PN 9921885
2009 RANGER 700 4X4 CREW / 6X6
SERVICE MANUAL
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools as specified.
Comments or suggestions about this manual may be directed to: Service Publications Dept. @ Polaris Sales Inc.
2100 Hwy 55 Medina Minnesota 55340.
Publication Printed August 2008 (PN 9921885)
© Copyright 2008 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS
Throughout this manual, important information is brought to your attention by the following symbols:
WARNING
SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle.
CAUTION
SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.
CAUTION
CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.
NOTE:
NOTE provides key information by clarifying instructions.
IMPORTANT:
IMPORTANT provides key reminders during disassembly, assembly and inspection of components.
TRADEMARKS
POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:
Loctite, Registered Trademark of the Loctite Corporation
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity-Vac, Registered Trademark of Neward Enterprises, Inc.
Torx, Registered Trademark of Textron
Hilliard, Trademark of the Hilliard Corporation
Warn, Trademark of Warn Industries
FOX, Registered Trademark of FOX RACING SHOX
RydeFX, Registered Trademark of ArvinMeritor
Some Polaris factory publications can be downloaded from www.polarisindustires.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer.
GENERAL INFORMATION
MAINTENANCE
ENGINE
3
ELECTRONIC FUEL INJECTION
4
1
2
BODY / STEERING / SUSPENSION
5
CLUTCHING
FINAL DRIVE
6
7
TRANSMISSION
BRAKES
ELECTRICAL
8
9
10
GENERAL INFORMATION
CHAPTER 1
1
GENERAL INFORMATION
MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER (VIN) LOCATION . . . . . . . . . . . . . . . . . . . . . . . . 1.3
TRANSMISSION I.D. NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
VEHICLE DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
RANGER 4X4 CREW / 6X6 (HEIGHT AND WIDTH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
RANGER 6X6 (LENGTH AND WHEEL BASE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
RANGER 4X4 CREW (LENGTH AND WHEEL BASE) . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
GENERAL: 2009 RANGER 4X4 CREW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
DETAILED: 2009 RANGER 4X4 CREW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
GENERAL: 2009 RANGER 6X6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
DETAILED: 2009 RANGER 6X6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
PUBLICATION NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
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 0 9 W H 6 8 A G
Model Year
Designation
Basic Chassis
Designation
Emissions &
Model Option
Engine Designation
Engine Designation Number
EH068OLE046PLE ............................................................Twin, Liquid Cooled, OHV 4 Stroke, 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 W H 6 8 A * 9 P 0 0 0 0 0 0
Body Style
Engine
Emissions
Powertrain
Model
Year
Plant No.
Check Digit
Individual Serial No.
* This could be either
a number or a letter
Engine Serial Number Location
Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This information can be found on the sticker applied to the cylinder head on the side of engine.
Engine Serial Number
A
1.2
GENERAL INFORMATION
Vehicle Identification Number (VIN) Location
The machine model number and serial number are important for vehicle identification. The vehicle identification number (A) is stamped on the lower LH frame rail close to the front drive wheel. The model and serial numbers are also located on a sticker under the hood (B).
Transmission I.D. Number Location
The transmission I.D. number is located on the right side when installed in the vehicle.
1
A
B
A
1.3
GENERAL INFORMATION
VEHICLE DIMENSIONS
RANGER 4x4 CREW / 6X6 (Height and Width)
75 in.
190.5 cm
11.5 in.
29.2 cm
60 in.
152.4 cm
1.4
RANGER 6X6 (Length and Wheel Base)
120 in.
305 cm
GENERAL INFORMATION
1
42.5 in.
108 cm
90 in.
229 cm
RANGER 4x4 CREW (Length and Wheel Base)
145 in.
386 cm
27 in.
69 cm
36.5 in.
92.7 cm
108 in.
274 cm
1.5
GENERAL INFORMATION
GENERAL SPECIFICATIONS
MODEL: 2009 RANGER 4X4 CREW
MODEL NUMBER: R09WH68AC, AG, AH, AR
ENGINE MODEL: EH68OLE
Category
Length
Width
Height
Wheel Base
Ground Clearance
Turning Radius
Dry Weight
Gross Vehicle Weight
Cargo Box Capacity
Cargo Box Dimensions
Vehicle Payload
Hitch Towing Capacity
Hitch Tongue Capacity
Dimension / Capacity
145 in. / 386 cm
60 in. / 152.4 cm
75 in. / 190.5 cm
108 in. / 274 cm
11 in. / 27.9 cm
224 in. / 569 cm
1460 lbs. / 664 kg
3360 lbs. / 1524 kg
1000 lbs. / 454 kg
54 x 36.5 x 11.5 in.
(137 x 92.7 x 29.2 cm)
1750 lbs. / 794 kg
(Includes driver and five passengers)
2000 lbs. / 907 kg
150 lbs. / 68 kg
1.6
GENERAL INFORMATION
MODEL: 2009 RANGER 4X4 CREW
MODEL NUMBER: R09WH68AC, AG, AH, AR
ENGINE MODEL: EH68OLE
Engine
Platform
Engine Model Number
Engine Displacement
Number of Cylinders
Bore & Stroke (mm)
Compression Ratio
Compression Pressure
Engine Idle Speed
Lubrication
Oil Requirements
Oil Capacity
Coolant Capacity
Overheat Warning
Exhaust System
Polaris Domestic Twin Cylinder,
Liquid Cooled, 4-Stroke
EH068OLE049
683cc
2
80 x 68 mm
9.40:1
150-170 psi
1150 ± 100 RPM
Pressurized Wet Sump
PS-4 PLUS 2W-50 Synthetic
2 qts. / 1.9 L n/a
Instrument Cluster Indicator
2 to 1 Canister Style
Fuel System Type
Fuel Delivery
Fuel Pressure
Fuel Filters
Fuel System
Bosch Electronic Fuel Injection
Electronic Fuel Pump (in tank)
39 psi
See Chapter 4
Fuel Capacity / Requirement
9 gal. (34 L)
87 Octane (minimum)
Alternator Max Output
Electrical
500 Watts @ 3000 RPM
Lights: Main Headlights
Tail
Brake
Indicator Panel Lights
Starting System
Ignition System
Ignition Timing
2 - Single Beam 50W / Halogen
5 Watts x 2
5 Watts x 2
1 Watt (ea.)
Electric Start
Bosch EFI (ECU Controlled)
Spark plug / Gap
Battery / Model / Amp Hr
Instrument Panel Type
DC Outlet
Relays
Circuit Breakers
Fuses
7° BTDC @ 1200 RPM
Champion RC7YC3 /
.035 in. (0.9 mm)
Yuasa YB30L-B /
30 Amp Hr. / 12 Volt
Multifunction Speedometer
Standard
Fan / Power / Rear Diff Solenoid
Fan Motor: 15 Amp
Main Chassis: 20 Amp
Accessory: 20 Amp
Power Relay: 15 Amp
ECU: 6 Amp
Drivetrain
Transmission Type
Transmission Gear Ratio:
Front / Rear
High
Low
Reverse
Shift Type
Polaris Automatic PVT
4.43:1 / 3.83:1
10.08:1 / 8.71:1
6.87:1 / 5.94:1
Front Gearcase Oil Requirements
In Line Shift - H / L / N / R
Polaris Demand Drive Fluid
5 oz. (150 ml)
Transmission Oil Requirements
Rear Gearcase Oil Requirements
Belt
Clutch Center Distance
Polaris Full Synthetic AGL
43.6 oz. (1290 ml)
Polaris ATV Angle Drive Fluid
18 oz. (532 ml)
3211118
10.05” (255 mm)
Steering / Suspension
Front Suspension MacPherson Strut
Front Travel 8 in. (20.3 cm)
Rear Suspension
Rear Travel
Rear Shock Preload Adjustment
Independent Rear Suspension
9 in. (22.9 cm)
Cam Adjustment
Toe Out
Front Wheel Size
1/8 - 1/4 in. (3.2 - 6.35 mm)
Wheels / Brakes
12 x 6
12 x 8 Rear Wheel Size
Front Tire
Make / Model / Size
Rear Tire
Make / Model / Size
Tire Air Pressure - Front / Rear
Carlisle / PXT / 26 x 9 R12
Carlisle / PXT / 26 x 11 R12
Brakes / Brake Fluid
Parking Brake
12 psi / 16 psi
4 Wheel Hydraulic Disc / DOT 4
Hand Actuated (in dash)
CLUTCH CHART
Altitude
Meters
(Feet)
0-1500
(0-5000)
1500-3700
(5000 - 12000)
Shift Weight Drive Spring
21-74
(5632117)
21-70
(5632127)
Red/Blue
(7043372)
Red/Blue
(7043372)
Driven
Spring
Blk/Almd
(7043167)
Blk/Almd
(7043167)
1
1.7
GENERAL INFORMATION
MODEL: 2009 RANGER 6X6
MODEL NUMBER: R09RF68AF, AR
ENGINE MODEL: EH068OLE
Category
Length
Width
Height
Wheel Base
Ground Clearance
Turning Radius
Dry Weight
Gross Vehicle Weight
Cargo Box Capacity
Cargo Box Dimensions
Vehicle Payload
Hitch Towing Capacity
Hitch Tongue Capacity
Dimension / Capacity
120 in. / 305 cm
60 in. / 152.4 cm
75 in. / 190.5 cm
90 in. / 229 cm
7.2 in. / 18.3 cm
186 in. / 472 cm
1410 lbs. / 640 kg
3310 lbs. / 1501 kg
1250 lbs. / 567 kg
54 x 42.5 x 11.5 in.
(137 x 108 x 29.2 cm)
1750 lbs. / 794 kg
(Includes driver and two passengers)
2000 lbs. / 907 kg
150 lbs. / 68 kg
1.8
GENERAL INFORMATION
MODEL: 2009 RANGER 6X6
MODEL NUMBER: R09RF68AF, AR
ENGINE MODEL: EH68OLE
Engine
Platform
Engine Model Number
Engine Displacement
Number of Cylinders
Bore & Stroke (mm)
Compression Ratio
Compression Pressure
Engine Idle Speed
Lubrication
Oil Requirements
Oil Capacity
Coolant Capacity
Overheat Warning
Exhaust System
Polaris Domestic Twin Cylinder,
Liquid Cooled, 4-Stroke
EH068OLE048
683cc
2
80 x 68 mm
9.40:1
150-170 psi
1150 ± 100 RPM
Pressurized Wet Sump
PS-4 PLUS 2W-50 Synthetic
2 qts. / 1.9 L
3.25 qts. (3.08 L)
Instrument Cluster Indicator
2 to 1 Canister Style
Fuel System Type
Fuel Delivery
Fuel Pressure
Fuel Filters
Fuel System
Bosch Electronic Fuel Injection
Electronic Fuel Pump (in tank)
39 psi
See Chapter 4
Fuel Capacity / Requirement
9 gal. (34 L)
87 Octane (minimum)
Alternator Max Output
Electrical
500 Watts @ 3000 RPM
Lights: Main Headlights
Tail
Brake
Indicator Panel Lights
Starting System
Ignition System
Ignition Timing
2 - Single Beam 50W / Halogen
5 Watts x 2
5 Watts x 2
1 Watt (ea.)
Electric Start
Bosch EFI (ECU Controlled)
Spark plug / Gap
Battery / Model / Amp Hr
Instrument Panel Type
DC Outlet
Relays
Circuit Breakers
Fuses
7° BTDC @ 1200 RPM
Champion RC7YC3 /
.035 in. (0.9 mm)
Yuasa YB30L-B /
30 Amp Hr. / 12 Volt
Multifunction Speedometer
Standard
Fan / Power
Fan Motor: 15 Amp
Main Chassis: 20 Amp
Accessory: 20 Amp
Power Relay: 15 Amp
ECU: 6 Amp
Drivetrain
Transmission Type
Transmission Gear Ratio:
Front / Rear
High
Low
Reverse
Shift Type
Polaris Automatic PVT
4.43:1 / 3.83:1
10.08:1 / 8.71:1
6.87:1 / 5.94:1
Front Gearcase Oil Requirements
In Line Shift - H / L / N / R
Polaris Demand Drive Fluid
5 oz. (150 ml)
Transmission Oil Requirements
Mid Gearcase Oil Requirements
Rear Gearcase Oil Requirements
Polaris Full Synthetic AGL
43.6 oz. (1290 ml)
Polaris ATV Angle Drive Fluid
6.75 oz. (200 ml)
Polaris ATV Angle Drive Fluid
10 oz. (300 ml)
Belt
Clutch Center Distance
3211118
10.05” (255 mm)
Steering / Suspension
Front Suspension MacPherson Strut
Front Travel
Center Suspension
Center Travel
Rear Suspension
8 in. (20.3 cm)
Progressive Rate / Independent
5.25 in. (13.3 cm)
Swing Arm w/Dual Shocks
Rear Travel
Rear Shock Preload Adjustment
Toe Out
6.25 in. (16 cm)
Cam Adjustment
1/8 - 1/4 in. (3.2 - 6.35 mm)
Wheels / Brakes
Front Wheel Size
Middle / Rear Wheel Size
Front Tire
Make / Model / Size
Middle / Rear Tire
Make / Model / Size
12 x 6 / 10 gauge
12 x 8 / 10 gauge
Titan / AT489 / 25 x 10 R12
Titan / AT489 / 25 x 11 R12
Tire Air Pressure
Front / Middle / Rear
Brakes / Brake Fluid
8 - 12 psi
4 Wheel Hydraulic Disc / DOT 4
Parking Brake Hand Actuated (in dash)
CLUTCH CHART
Altitude
Meters
(Feet)
0-1500
(0-5000)
1500-3700
(5000 - 12000)
Shift Weight Drive Spring
21-74
(5632117)
21-70
(5632127)
Red/Blue
(7043372)
Red/Blue
(7043372)
Driven
Spring
Blk/Almd
(7043167)
Blk/Almd
(7043167)
1
1.9
GENERAL INFORMATION
VEHICLE INFORMATION
Publication Numbers
Model Model No.
2009 RANGER 4x4 CREW R09WH68AC, AG, AH, AR
Owner’s Manual PN
9921882
Parts Manual PN
9921884
2009 RANGER 6x6 R09RF68AF, AR 9921871 9921874
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.
Paint Codes
Painted Part
Main Frame / Cab Frame / Bumpers
Main Frame / Cab Frame / Plastic
Plastic - Hood / Dash
Plastic - Hood / Dash
Cab Frame / Bumpers
Plastic - Hood / Dash
Plastic - Hood / Dash
Plastic - Hood / Dash
Color Description
Medium Gloss Black
Gloss Black
Dark Green
Solar Red
Flat Black Wrinkle
Mossy Oak
™
Delta Green
Cherry Metallic
Polaris Number
P-067
P-070
P-195
P-342
P-418
P-455
P-492
P-554
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.
KEY COVER
P/N 5533534
Key Series
Number
Series#
23
27
28
31
20
21
22
32
67
68
Part Number
4010278
4010278
4010321
4010321
4010321
4010321
4110141
4110148
4010278
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/.
1.10
MISC. SPECIFICATIONS AND CHARTS
Conversion Table
GENERAL INFORMATION
1
°C to °F:
9/5
(°C + 32) = °F °F to °C:
5/9
(°F - 32) = °C
1.11
GENERAL INFORMATION
Standard Torque Specifications
The following torque specifications are to be used only as a general guideline. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque.
1.12
SAE Tap / Drill Sizes
GENERAL INFORMATION
Decimal Equivalents
1
Metric Tap / Drill Sizes
1.13
GENERAL INFORMATION
Glossary of Terms
ABDC: After bottom dead center.
ACV: Alternating current voltage.
Alternator: Electrical generator producing voltage alternating current.
ATDC: After top dead center.
BBDC: Before bottom dead center.
BDC: Bottom dead center.
BTDC: Before top dead center.
CC: Cubic centimeters.
Center Distance: Distance between center of crankshaft and center of driven clutch shaft.
Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches.
CI: Cubic inches.
Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch.
Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face.
Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close and grip the drive belt.
Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase. Measure at various points especially at PTO.
DCV: Direct current voltage
CVT: Centrifugal Variable Transmission (Drive Clutch System)
DCV: Direct current voltage.
Dial Bore Gauge: A cylinder measuring 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/cm²: 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/in²: 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.
1.14
MAINTENANCE
CHAPTER 2
MAINTENANCE
PERIODIC MAINTENANCE CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PERIODIC MAINTENANCE OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PRE-RIDE - 25 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
50 - 100 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
100 - 300 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
SERVICE PRODUCTS AND LUBES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS . . . . . . . . . . . . 2.7
MAINTENANCE REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
MAINTENANCE REFERENCES, CONTINUED..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 2.10
PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
SHIFT LINKAGE INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
VENT LINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
THROTTLE PEDAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
THROTTLE FREEPLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
AIR INTAKE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
COMPRESSION AND LEAKDOWN TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
BREATHER HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
ENGINE OIL AND FILTER CHANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
TRANSMISSION AND GEARCASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
FRONT GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
MIDDLE GEARCASE LUBRICATION (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
REAR GEARCASE LUBRICATION (4X4 CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
REAR GEARCASE LUBRICATION (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
LIQUID COOLING SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
RADIATOR COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
COOLANT DRAIN / RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
FINAL DRIVE / WHEEL AND TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
WHEEL AND HUB TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
CV SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
WHEEL REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
WHEEL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
TIRE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
2
2.1
MAINTENANCE
ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
BATTERY FLUID LEVEL (CONVENTIONAL BATTERY) . . . . . . . . . . . . . . . . . . . . . . . 2.27
BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
BATTERY STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
BATTERY CHARGING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
ENGINE TO FRAME GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
STEERING AND SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
TIE ROD END / STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
WHEEL TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
FRONT SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
REAR SUSPENSION ADJUSTMENT (4X4 CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
REAR SPRING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
BRAKE PAD / DISC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
PARKING BRAKE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
PARKING BRAKE PAD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
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.
NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately
10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.
2
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 “Owner’s 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
Item
Steering
Front Suspension
Rear Suspension
Tires
Brake Fluid Level
Brake Pedal Travel
Brake Systems
Wheels / Fasteners
Frame Fasteners
E
Engine Oil Level
E
Air Filter / Pre-Filter
E
Air Box Sediment Tube
Coolant Level
-
-
-
-
-
-
-
-
-
Hours
Maintenance Interval
(whichever comes first)
Calendar
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
-
-
-
-
-
-
-
Miles
(KM)
-
-
Pre-Ride -
Daily -
Remarks
Make adjustments as needed.
See Pre-Ride Checklist on Page 2.13.
Inspect;clean often
Head Lamp / Tail Lamp
E
E
E
Air Filter,
Main Element
Brake Pad Wear / Inspect
Parking Brake Pads
Battery
Parking Brake Cable
Adjustment
Front Gearcase Oil
(if equipped)
Middle Gearcase Oil
(if equipped)
Rear Gearcase Oil
(if equipped)
Transmission Oil
Engine Breather
Filter (if equipped)
Engine Oil Change
(Break-In Period)
-
-
-
-
10 H
20 H
25 H
25 H
25 H
25 H
25 H
25 H
25 H
Daily
Daily
Daily
Weekly
Monthly
Monthly
-
Monthly
Monthly
Monthly
Monthly
Monthly
1 M
-
-
-
-
-
-
-
-
-
-
-
-
-
Drain deposits when visible
Check level daily, change coolant every 2 years
Check operation; apply dielectric grease if replacing
Inspect; replace as needed
Inspect periodically
Check terminals; clean; test
Inspect; adjust tension after first 25 hours
Inspect level; change yearly
Inspect level; change yearly
Inspect level; change yearly
Inspect level; change yearly
Inspect; replace if necessary
Perform a break-in oil change at one month
Perform these procedures more often for vehicles subjected to severe use.
E
Emission Control System Service (California)
Have an authorized Polaris dealer perform these services.
2.4
MAINTENANCE
50 - 100 Hour Maintenance Interval
Item
E
E
General Lubrication
Shift Linkage
Steering
Front Suspension
Rear Suspension
Throttle Cable / Throttle
Pedal
Throttle Body Air Intake
Ducts / Flange
Drive Belt
Cooling System
Parking Brake Cable
Adjustment
E
Engine Oil Change
Hours
Maintenance Interval
(whichever comes first)
Calendar
Miles
(KM)
50 H 3 M -
50 H
50 H
50 H
50 H
50 H
50 H
50 H
50 H
100 H
100 H
6 M
6 M
6 M
6 M
6 M
6 M
6 M
6 M
-
6 M
-
-
-
-
-
-
-
-
-
-
Remarks
Lubricate all grease fittings, pivots, cables, etc.
Inspect, lubricate, adjust
Lubricate
Lubricate
Lubricate
Inspect; adjust; lubricate; replace if necessary
Inspect ducts for proper sealing/air leaks
Inspect; adjust; replace as needed
Inspect coolant strength seasonally; pressure test system yearly
Inspect; adjust tension as needed
Perform a break-in oil change at 25 hours/ one month
E
Oil Filter Change 100 H 6 M Replace with oil change
Perform these procedures more often for vehicles subjected to severe use.
E
Emission Control System Service (California)
Have an authorized Polaris dealer perform these services.
2
2.5
MAINTENANCE
100 - 300 Hour Maintenance Interval
Item
Hours
Maintenance Interval
(whichever comes first)
Calendar
Miles
(Km)
Remarks
E
E
Fuel System
Radiator
Cooling Hoses
Engine Mounts
Exhaust Muffler / Pipe
Spark Plug
Wiring
100 H
100 H
100 H
100 H
100 H
100 H
100 H
Clutches (Drive and Driven) 100 H
Front Wheel Bearings 100 H
Toe Adjustment
Brake Fluid
Spark Arrestor
100 H
200 H
300 H
Auxiliary Brake
Headlight Aim
12M
12M
12M
12M
12M
12M
12M
12M
12M
24M
36M
-
-
-
-
-
-
-
-
-
-
-
-
-
Check for leaks at tank cap, fuel lines, fuel pump, and fuel rail.
Replace lines every two years.
Inspect; clean external surfaces
Inspect for leaks
Inspect
Inspect
Inspect; replace as needed
Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.
Inspect; clean; replace worn parts
Inspect; replace as needed
Inspect periodically; adjust when parts are replaced
Change every two years (DOT 4)
Clean out
Inspect daily; adjust as needed
Adjust as needed
Perform these procedures more often for vehicles subjected to severe use.
E
Emission Control System Service (California)
Have an authorized Polaris dealer perform these services.
2.6
MAINTENANCE
SERVICE PRODUCTS AND LUBES
Polaris Lubricants, Maintenance and Service
Products
Part No.
Description
Engine Lubricant
2870791 Fogging Oil (12 oz. Aerosol)
2876244
PS-4 PLUS Performance Synthetic
2W-50 4-Cycle Engine Oil (Quart)
2876245
PS-4 PLUS Performance Synthetic
2W-50 4-Cycle Engine Oil (Gallon)
Gearcase / Transmission Lubricants
2873602
2873603
Premium Synthetic AGL Gearcase Lube
(12 oz. bottle) (12 Count)
Premium Synthetic AGL Gearcase Lube
(1 Gal.) (4 Count)
2871653
2872276
Premium ATV Angle Drive Fluid
(8 oz.) (12 Count)
Premium ATV Angle Drive Fluid
(2.5 Gal) (2 Count)
2870465 Oil Pump for 1 Gallon Jug
2871654
2872277
Premium Demand Drive Fluid
(8 oz.) (12 Count)
Premium Demand Drive Fluid
(2.5 gal.) (2 Count)
Grease / Specialized Lubricants
2871322
2871423
Premium All Season Grease
(3 oz. cartridge) (24 Count)
Premium All Season Grease
(14 oz. cartridge) (10 Count)
2871460 Starter Drive Grease (12 Count)
2871515 Premium U-Joint Lube (3 oz.) (24 Count)
2871551 Premium U-Joint Lube (14 oz.) (10 Count)
2871312 Grease Gun Kit
2871329 Dielectric Grease (Nyogel™)
Coolant
2871323 60/40 Coolant (Gallon) (6 Count)
2871534 60/40 Coolant (Quart) (12 Count)
NOTE: Each item can be purchased separately at your local Polaris dealer.
Part No.
Description
Additives / Sealants / Thread Locking Agents / Misc.
2870585 Loctite™ Primer N, Aerosol, 25 g
2870652 Fuel Stabilizer (16 oz.) (12 Count)
2872189 DOT 4 Brake Fluid (12 Count)
2871557 Crankcase Sealant, 3-Bond 1215 (5oz.)
2872893 Engine Degreaser (12oz.) (12 Count)
NOTE: The number count indicated by each part number in the table above indicates the number of units that are shipped with each order.
2
2.7
MAINTENANCE
MAINTENANCE REFERENCES
Item
1. Engine Oil
2. Brake Fluid
3. Transmission
4. Front Gearcase
5. Middle Gearcase
Lube Rec.
Polaris PS-4 PLUS
Performance Synthetic 2W-50
4-Cycle Engine Oil (2876244)
DOT 4 (PN 2872189)
Polaris AGL Gearcase
Lubricant (PN 2873602)
Premium Demand Drive Fluid
(PN 2871654)
Polaris ATV Angle Drive Fluid
(PN 2871653)
Method
Add oil to proper level indicated on dipstick.
Frequency*
Change after 1st month (25 hrs), 6 months or 100 hours thereafter; Change more often in extremely dirty conditions, or short trip cold weather operation.
Fill reservoir between
MAX and Min lines.
As required. Change fluid every 2 years.
Add lube to bottom of fill plug threads.
Change annually. Change more often if used in severe conditions.
Drain completely. Add lube to specified quantity.
Drain completely. Add lube to specified quantity.
Change annually***
Semi-annually**
* More often under severe use, such as operated in water or under severe loads.
**Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information)
***Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)
2. Brake Master Cylinder
1. Engine
Dipstick / Fill Tube
Master
Cylinder
3. Transmission
Fill Plug
4. Front Gearcase
5. Middle Gearcase (6x6)
Fill Plug
Fill Plug
Drain Plug
2.8
Drain Plug
MAINTENANCE
Maintenance References, Continued.....
Item Lube Rec.
6. Swing Arm Pivot
Polaris All Season Grease (PN
2871423)
7. Rear Prop Shaft Yoke
Polaris Premium U-Joint Lube
(PN 2871551)
8. Front Prop Shaft Yoke
Polaris Premium U-Joint Lube
(PN 2871551)
9. Rear Gearcase
Polaris ATV Angle Drive Fluid
(PN 2871653)
Method Frequency*
Locate grease fitting on inside of the swing arm pivot.
Semi-annually**
Locate fittings and grease with grease gun.
Semi-annually**
Locate fittings and grease with grease gun.
Semi-annually**
Drain completely. Add lube to specified quantity.
Change annually***
* More often under severe use, such as operated in water or under severe loads.
**Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information)
***Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)
Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or Mobilegrease Special
2
Yoke
8. Front Prop Shaft
6. Swing Arm (6x6)
Yoke
Swing Arm Pivot
7. Rear Prop Shaft (6x6)
9. Rear Gearcase
(6x6)
Fill Plug
9. Rear Gearcase
(4x4 CREW)
2.9
MAINTENANCE
GENERAL VEHICLE INSPECTION
AND MAINTENANCE
Pre-Ride / Daily Inspection
Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.
• Tires - check condition and pressures
• Fuel and oil tanks - fill both tanks to their proper level;
Do not overfill oil tank
• All brakes - check operation and adjustment (includes auxiliary brake)
• Throttle - check for free operation and closing
• Headlight/Taillight/Brakelight - check operation of all indicator lights and switches
• Engine stop switch - check for proper function
• Wheels - check for tightness of wheel nuts and axle nuts; check to be sure axle nuts are secured by cotter pins
• Air cleaner element - check for dirt; clean or replace
• Steering - check for free operation noting any unusual looseness in any area
• Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners
• Engine coolant - check for proper level at the recovery bottle
• Check all rear suspension components for wear or damage.
Shift Linkage Inspection / Adjustment
Linkage rod adjustment is necessary when symptoms include:
• No All Wheel Drive light
• Noise on deceleration
• Inability to engage a gear
• Excessive gear clash (noise)
• Shift selectors moving out of desired range
NOTE: Remove necessary components to gain access to shift linkage cable ends (i.e. exhaust heat shield, exhaust pipe, etc.)
1.
Inspect shift linkage cable, clevis pins, and pivot bushings and replace if worn or damaged.
2.
Be sure idle speed is adjusted properly.
3.
Place gear selector in neutral. Make sure the transmission bell crank is engaged in the neutral position detents.
4.
With two wrenches loosen the outside jam nut counterclockwise. Turn the outside jam nut 1 1/2 turns.
Perform this procedure on the shift lever end, also.
Inside Jam Nut Outside Jam Nut
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.
Shift Cable Adjustment
5.
After turning the outside jam nut 1 1/2 turns. Hold the outside jam nut with a wrench and tighten the inside jam nut clockwise, until it is tight against the bracket.
6.
Repeat Step 4 and Step 5 until the proper adjustment is made for the transmission cable.
2.10
7.
Use this procedure to loosen or tighten the shift linkage cable as needed.
Clockwise Inside Jam Nut
Counterclockwise Outside Jam Nut
FUEL SYSTEM AND AIR INTAKE
Fuel System
MAINTENANCE
Fuel Filter
The fuel pump on the RANGER 700 EFI is non-serviceable. If the internal fuel pump filters require service, the fuel tank and fuel pump must be replaced as an assembly.
NOTE: See the “Electronic Parts Catalog” for more information.
NOTE: For all other information related to the EFI
System refer to Chapter 4.
Vent Lines
1.
Check fuel tank and transmission vent lines for signs of wear, deterioration, damage or leakage. Replace every two years.
2.
Be sure vent lines are routed properly and secured with cable ties. CAUTION: Make sure lines are not kinked or pinched
2
Throttle Pedal Inspection
WARNING
Gasoline is extremely flammable and explosive under certain conditions.
Always stop the engine and refuel outdoors or in a well ventilated area.
Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
Do not overfill the tank. Do not fill the tank neck.
If you get gasoline in your eyes or if you swallow gasoline, seek medical attention immediately.
If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing.
Never start the engine or let it run in an enclosed area. Engine exhaust fumes are poisonous and can result loss of consciousness or death in a short time.
Never drain the fuel when the engine is hot.
Severe burns may result.
Throttle Pedal
If the throttle pedal has excessive play due to cable stretch or cable misadjustment, it will cause a delay in throttle speed.
Also, the throttle may not open fully. If the throttle pedal has no play, the throttle may be hard to control, and the idle speed may be erratic.
Check the throttle pedal play periodically in accordance with the
Periodic Maintenance Chart and adjust the play if necessary.
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.
2.11
MAINTENANCE
Throttle Freeplay Adjustment
Inspection
1.
Apply the parking brake.
2.
Put the gear shift lever in the N (Neutral) position.
3.
Start the engine, and warm it up thoroughly.
4.
Measure the distance the throttle pedal moves before the engine begins to pick up speed. Free play should be 1/16”
- 1/8” (1.5 - 3 mm).
Adjustment
1.
Remove the seat.
2.
Locate the throttle cable adjuster.
3.
Squeeze the end of the rubber boot and slide it far enough to expose the end of the inline cable adjuster.
Air Filter Service
It is recommended that the air filter be replaced annually. When riding in extremely dusty conditions replacement will be required more often.
The filter should be inspected periodically before each ride, using the following procedure.
1.
Lift the box to access the filter box cover.
Air Box Location
Boot
Lock Nut
Adjuster
4.
Loosen the adjuster lock nut.
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: While adjusting, lightly flip the throttle pedal up and down.
6.
Tighten the lock nut.
7.
Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position.
2.
Remove clips (2) from air box cover and remove cover.
Inspect the gasket. It should adhere tightly to the cover and seal all the way around.
3.
Remove air filter assembly. Do not clean the main filter, the filter should be replaced.
4.
Inspect main element and replace if necessary. If the filter has been soaked with fuel or oil it must be replaced.
Breather Filter
Cover Seal
Filter
Cover
Installation
1.
Reinstall the filter into the air box container. Be sure the filter fits tightly in the air box.
2.12
NOTE: Apply a small amount of general purpose grease to the sealing edges of the filter before installing.
2.
Check air box. If oil or water deposits are found, drain them into a suitable container.
NOTE: Service more frequently if vehicle is operated in wet conditions or at high throttle openings for extended periods.
3.
Install air box cover and secure with clips.
MAINTENANCE
Air Intake Inspection
1.
Lift the hood.
2.
Inspect the foam insert in the engine intake air baffle box.
If the foam insert is dirty, clean the foam with a high flash point solvent, followed by hot soapy water.
2
NOTE: The PVT intake air baffle box does NOT have a foam insert.
3.
Rinse and dry the foam thoroughly.
4.
Inspect the foam for tears or damage. Replace if necessary.
5.
Reinstall the foam insert into the air baffle box.
Air Baffing
Box
Foam
Air Box
Engine Intake Duct
PVT Intake Duct
2.13
MAINTENANCE
ENGINE
Compression and Leakdown Test
NOTE: This engine does NOT have decompression components. Compression readings will vary in proportion to cranking speed during the test.
Average compression (measured) is about 150-200 psi during a compression test.
A smooth idle generally indicates good compression. Low engine compression is rarely a factor in running condition problems above idle speed. Abnormally high compression can be caused by carbon deposits in the combustion chamber or worn, damaged exhaust cam lobes. Inspect camshaft and combustion chamber if compression is abnormally high.
A cylinder leakdown test is the best indication of engine condition. Follow manufacturer's instructions to perform a cylinder leakage test (never use high pressure leakage testers, as crankshaft seals may dislodge and leak).
Cylinder Compression
Standard: 150-200 PSI
Cylinder Leakdown
Service Limit 15%
(Inspect for cause if test exceeds 15%)
Engine Oil Level
The twin cylinder engine is a wet-sump engine, meaning the oil is contained in the bottom of the crankcase. To check the oil level follow the procedure listed below.
Dipstick
1.
Set machine on a level surface and set the parking brake.
2.
Be sure the machine has sat for awhile before removing the dipstick.
IMPORTANT: Do not run the machine and then check the dipstick.
3.
Stop engine and unlock the lever lock. Remove dipstick and wipe dry with a clean cloth.
Breather Hose Inspection
The engine is equipped with a breather hose (A). Inspect the breather hose for possible kinks or wear. The hose is form fitted for a proper fit. Follow the breather hose from the side of the airbox to the engine valve cover.
Lever Lock
Dipstick
NOTE: Make sure lines are not kinked or pinched.
2.14
MAINTENANCE
4.
Reinstall dipstick and push it into place. Do not lock the dipstick.
NOTE: Make certain the dipstick is inserted all the way into the filler tube to keep the angle and depth of dipstick consistent. When reinstalling the dipstick, make certain to seat the lever lock.
5.
Remove dipstick and check to see that the oil level is in the normal range. Add oil as indicated by the level on the dipstick. Do not overfill (see NOTE below!).
NOTE: Due to the dipstick entry angle into the crankcase, the oil level will read higher on the bottom side of the dipstick. Proper level indication is determined on the upper surface of the dipstick as it is being removed, 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
NOTE: A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the full mark, change the oil immediately.
Engine Oil and Filter Change
WARNING
Personal injury can occur when handling used oil. Hot oil can cause burns or skin damage.
=
Recommended Engine Oil:
Polaris PS-4 PLUS Synthetic 2W-50
(PN 2876244) (Quart)
Ambient Temperature Range
-40° F to 120° F
1.
Place vehicle on a level surface.
2.
To ease access to the oil filter, try to access the oil filter from the front engine cover or remove the storage container located under the driver side seat (refer to Chapter 5 for front engine cover and storage removal).
3.
Run engine two to three minutes until warm. Stop engine.
4.
Clean area around drain plug at bottom of engine. Drain plug is accessible through the skid plate.
CAUTION
Oil may be hot. Do not allow hot oil to come into contact with skin, as serious burns may result.
5.
Place a drain pan beneath crankcase and remove drain plug.
Drain Plug
2
6.
Allow oil to drain completely.
7.
Replace the sealing washer on drain plug.
2.15
MAINTENANCE
NOTE: The sealing surface on the drain plug should be clean and free of burrs, nicks or scratches.
8.
Reinstall drain plug and torque to 16 ± 2 ft. lbs. (21.7 ± 2.7
Nm) .
9.
Place shop towels beneath oil filter. Using Oil Filter
Wrench (PV-43527), turn filter counterclockwise to remove.
Oil Filter
Exhaust Pipe
WARNING
Do not perform clean out immediately after the engine has been run, as the exhaust system becomes very hot.
Serious burns could result from contact with exhaust components.
To reduce fire hazard, make sure that there are no combustible materials in the area when purging the spark arrestor.
Wear eye protection.
Do not stand behind or in front of the vehicle while purging the carbon from the spark arrestor.
Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas.
Do not go under the machine while it is inclined. Set the 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 carbon as follows:
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 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.
13. Remove dipstick and fill sump with 2 quarts (1.9 l) of
Polaris PS-4 PLUS 2W-50 Synthetic engine oil
(PN 2876244).
=
T
Crankcase Drain Plug Torque:
16 ± 2 ft. lbs. (21.7 ± 2.7 Nm)
Oil Filter Torque:
Turn by hand until filter gasket contacts sealing surface, then turn an additional 1/2 turn
Oil Filter Wrench:
(PV-43527)
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.
2.16
Clean Out Plug
2.
Place the transmission in Park and start the engine. Purge accumulated carbon from the system by momentarily revving the engine several times.
3.
If some carbon is expelled, cover the exhaust outlet and lightly tap on the pipe around the clean out plugs with a rubber mallet while revving the engine several more times.
4.
If particles are still suspected to be in the muffler, back the machine onto an incline so the rear of the machine is one foot higher than the front. Set the hand brake and block the wheels. Make sure the machine is in Park and repeat Steps
2 and 3. SEE WARNING
MAINTENANCE
TRANSMISSION AND GEARCASES
Transmission Lubrication
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.
2
5.
If particles are still suspected to be in the muffler, drive the machine onto the incline so the front of the machine is one foot higher than the rear. Set the hand brake and block the wheels. Make sure the machine is in Park and repeat Steps
2 and 3. SEE WARNING
6.
Repeat steps 2 through 5 until no more particles are expelled when the engine is revved.
7.
Stop the engine and allow the arrestor to cool.
8.
Reinstall the clean out plugs.
Transmission 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.
1.
Position vehicle on a level surface.
2.
Remove the fill plug and check the lubricant level.
3.
If lubricant level is not even with 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:
14 ft. lbs. (19 Nm)
2.17
MAINTENANCE
Transmission Lubricant Change
Access the drain plug on the right-hand side of the vehicle through the skid plate.
1.
Remove the fill plug (refer to “Transmission Lubricant
Level Check”).
2.
Place a drain pan under the transmission drain plug.
3.
Remove the drain plug and allow lubricant to drain completely.
Front Gearcase Lubrication
The gearcase lubricant level should be checked and changed in accordance with the maintenance schedule.
• Be sure vehicle is level with parking brake on before proceeding.
• Check vent hose to be sure it is routed properly and unobstructed.
• The correct front gearcase lubricant to use is Polaris
Premium Demand Fluid.
FRONT GEARCASE
Make sure vent is unobstructed
Fill Plug
8-30 ft. lbs.
(11-41 Nm)
Drain Plug: 10 ft. lbs. (14 Nm)
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 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:
43.6 oz. (1290 ml)
7.
Reinstall fill plug with a new O-ring and torque to specification.
=
T
Drain / Fill Plug Torque:
14 ft. lbs. (19 Nm)
8.
Check for leaks. Dispose of used lubricant properly.
2.18
=
Front Gearcase Specifications
Specified Lubricant:
Premium Demand Drive Fluid
(PN 2871654)
Capacity:
5.0 oz. (150 ml.)
=
T
Fill Plug Torque:
8-30 ft. lbs. (11-41 Nm)
Drain Plug Torque:
10 ft. lbs. (14 Nm)
To check the lubricant level:
The front gearcase lubricant level cannot be checked with a dipstick. The gearcase must be drained and re-filled with the proper amount of lubricant or be filled to the bottom of the fill plug hole threads. Refer to procedures.
MAINTENANCE
To change gearcase lubricant:
1.
Remove gearcase drain plug (B) (11 mm) located on the bottom of the gearcase and drain oil. (The drain plug is accessible through the skid plate.) Catch and discard used oil properly.
4.
Remove fill plug (8 mm hex) and check the O-ring.
Fill Plug
2
A
B
10 ft. lbs (14 Nm)
2.
Clean and reinstall drain plug (B) using a new sealing washer (A). Torque to 10 ft. lbs. (14 Nm) .
3.
The fill plug can be accessed through the top hood area by removing the storage box or by removing the left side panel in the left wheel well.
Top View of Hood Area
5.
Fill with the recommended fluid amount (5 oz.) or to the bottom of the fill plug hole threads.
Front Gearcase
Plug Threads
Fill with 5 oz.
LH Side Panel
6.
Install fill plug and check for leaks.
Middle Gearcase Lubrication (6x6)
=
Middle Gearcase Specifications (6x6)
Specified Lubricant:
ATV Angle Drive Fluid (PN 2871653)
Capacity: 6.75 oz. (200 ml.)
Drain Plug / Fill Plug Torque:
14 ft. lbs. (19.4 Nm)
The gearcase lubricant level should be checked and changed in accordance with the maintenance schedule.
• Be sure vehicle is level with parking brake on before proceeding.
• Check vent hose to be sure it is routed properly and unobstructed.
2.19
MAINTENANCE
• The correct middle gearcase lubricant to use is ATV
Angle Drive Fluid
To check the lubricant level:
The gearcase must be drained and re-filled with the proper amount of lubricant. Refer to the procedure below.
To change middle gearcase lubricant:
1.
With the RANGER on a level surface, remove the fill plug and check the lubricant level. Lubricant should be kept at the specified level, according to the proper gearcase specifications listed.
2.
Support the vehicle securely with a jack stand and remove the front tire on the driver’s side.
3.
Remove gearcase drain plug located on the bottom of the gearcase and drain oil. (The drain plug is accessible through the skid plate.) Catch and discard used oil properly.
4.
Clean and reinstall drain plug using a new sealing washer.
5.
Remove the fill plug and add the recommended amount of lubricant.
6.
Install fill plug. Check for leaks.
MIDDLE GEARCASE (6X6)
Make sure vent is unobstructed
Side View
Rear Gearcase Lubrication (4x4 CREW)
=
Rear Gearcase Specifications (4x4 CREW)
Specified Lubricant:
ATV Angle Drive Fluid (PN 2871653)
Capacity:
18 oz. (532 ml)
Lubricant Level Check:
The fill plug is located on the right side of the rear gearcase.
Maintain the fluid level even with the bottom of the threads of the fill plug hole.
Fill Plug
40-50 ft. lbs.
(54-68 Nm)
Fill to bottom of fill plug hole threads: 6.75 oz.
Fill Plug
14 ft. lbs. (19 Nm)
Bottom View
Maintain Level at
Bottom of Threads
1.
Position the vehicle on a level surface.
2.
Remove the fill plug and check the fluid level. The lubricant level should be even with the bottom of the threads of the fill plug hole.
3.
Add the recommended lubricant as needed.
4.
Reinstall the fill plug and torque to 40-50 ft. lbs.
(54-68 Nm)
=
T
Fill Plug Torque:
40-50 ft. lbs. (54-68 Nm)
Drain Plug Torque:
30-45 in. lbs. (3-5 Nm)
2.20
Drain Plug
14 ft. lbs. (19 Nm)
MAINTENANCE
Lubricant Change:
The drain plug is located on the bottom right side of the rear gearcase.
Fill Plug
Drain Plug
1.
Remove the fill plug.
2.
Place a drain pan under the drain plug.
3.
Remove the drain plug and allow the lubricant to drain completely.
4.
Clean the drain plug.
5.
Reinstall the drain plug and torque to 30-45 in. lbs.
(3-5 Nm) .
Fill Plug
40-50 ft. lbs.
(54-68 Nm)
Maintain Level at
Bottom of Threads
Drain Plug
30-45 in. lbs.
(3-5 Nm)
Rear Gearcase Lubrication (6x6)
=
Rear Gearcase Specifications (6x6)
Specified Lubricant:
ATV Angle Drive Fluid (PN 2871653)
Capacity:
10 oz. (300 ml)
The gearcase lubricant level should be checked and changed in accordance with the maintenance schedule.
• Be sure vehicle is level before proceeding with parking brake on.
• Check vent hose to be sure it is routed properly and unobstructed.
• The correct rear gearcase lubricant to use is Polaris
ATV Angle Drive Fluid
To check the lubricant level:
The gearcase must be drained and re-filled with the proper amount of lubricant. Refer to the procedure below.
To change rear gearcase lubricant:
1.
With the vehicle on a level surface, remove the fill plug and check the lubricant level. Lubricant should be kept at the specified level, according to the proper gearcase specifications listed.
2.
Support the vehicle securely with a jack stand and remove the front tire on the driver’s side.
3.
Remove gearcase drain plug located on the bottom of the gearcase and drain oil. (The drain plug is accessible through the skid plate.) Catch and discard used oil properly.
4.
Clean and reinstall drain plug using a new sealing washer.
REAR GEARCASE - 6X6
Make sure vent is unobstructed
2
Fill Plug
6.
Add the recommended lubricant. Maintain the fluid level even with the bottom threads of the fill plug hole.
7.
Reinstall the fill plug and torque to 40-50 ft. lbs.
(54-68 Nm) .
8.
Check for leaks. Discard used lubricant properly.
Drain Plug
2.21
MAINTENANCE
5.
Remove fill plug (A).
A
Coolant Level Inspection
The recovery bottle, located on the left side of the machine, must be maintained between the minimum and maximum levels indicated on the recovery bottle.
Surge Tank Cap
6.
Fill with 10 oz. (300 ml.) or fill to the bottom of the threads of the fill plug hole.
7.
Install fill plug and torque to 14 ft. lbs (19 Nm) . Check for leaks.
=
T
Drain Plug / Fill Plug Torque:
14 ft. lbs. (19.4 Nm)
With the engine at operating temperature, the coolant level should be between the upper and lower marks on the coolant reservoir. If not:
1.
Remove reservoir cap. Inner splash cap vent hole must be clear and open.
2.
Fill reservoir to upper mark with Polaris Premium 60/40
Anti Freeze / Coolant or 50/50 or 60/40 mixture of antifreeze and distilled water as required for freeze protection in your area.
3.
Reinstall cap.
COOLING SYSTEM
Liquid Cooling System Overview
The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose.
As coolant operating temperature increases, the expanding
(heated) excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle. As engine coolant temperature decreases the contracting (cooled) coolant is drawn back up from the tank past the pressure cap and into the radiator.
NOTE: Some coolant level drop on new machines is normal as the system is purging itself of trapped air.
Observe coolant levels often during the break-in period.
Overheating of engine could occur if air is not fully purged from system.
Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water.
Surge Tank
NOTE: If overheating is evident, allow system to cool completely and check coolant level in the radiator and inspect for signs of trapped air in system.
2.22
MAINTENANCE
Radiator Coolant Level Inspection
NOTE: This procedure is only required if the cooling system has been drained for maintenance and/or repair. However, if the recovery bottle has run dry, or if overheating is evident, the level in the radiator should be inspected and coolant added if necessary.
Radiator Cap
• Straight water or antifreeze may cause the system to freeze, corrode, or overheat.
Polaris 60/40 Anti-Freeze / Coolant
(PN 2871323)
Cooling System Pressure Test
Refer to Chapter 3 for cooling system pressure test procedure.
Cooling System Hoses
1.
Inspect all hoses for cracks, deterioration, abrasion or leaks. Replace if necessary.
Coolant Lines
2
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.
NOTE: Use of a non-standard pressure cap will not allow the recovery system to function properly.
To access the radiator pressure cap raise the front hood.
The radiator cap is located on the drivers side.
Coolant Strength / Type
Test the strength of the coolant using an antifreeze hydrometer.
Radiator
2.
Check tightness of all hose clamps.
CAUTION
Do not over-tighten hose clamps at radiator, or radiator fitting may distort, causing a restriction to coolant flow. Radiator hose clamp torque is
36 in. lbs. (4 Nm).
Antifreeze Hydrometer
• 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.
2.23
MAINTENANCE
Radiator
1.
Check radiator (A) air passages for restrictions or damage.
A
3.
Remove the drain plug and drain the coolant from the radiator. Drain the coolant into a suitable container and properly dispose of the coolant.
4.
Remove the outlet radiator hose, inlet radiator hose, surge tank hose, and overflow hose from the radiator.
5.
Disconnect the fan motor harness and remove the radiator from the vehicle. Take care not to damage the cooling fins.
6.
Remove the radiator.
Inlet Radiator Hose
Outlet Radiator Hose
2.
Carefully straighten any bent radiator fins.
3.
Remove any obstructions with compressed air or low pressure water.
Coolant Drain / Radiator Removal
1.
Remove the front bumper. Remove three bolts that secure the bumper to the bottom of the frame. Remove six screws
(both sides) that secure the wheel well panel to the frame.
Remove two bolts that secure the top bumper to the frame.
Remove the darts that attach the plastic to the bumper.
Surge Tank Hose
Plug
Bolts
Wheel Well
Bolts
2.
Remove two mounting screws that secure the top of the radiator to the frame. Remove the radiator cap. Pull the radiator out of the frame at an angle.
NOTE: If you have trouble reaching the top radiator bolts, remove four screws from the top front of the hood liner. Prop the front of the hood up 1.5 inches
(38.10 mm) to help remove the top bolts that secure the radiator to the frame.
2.24
MAINTENANCE
FINAL DRIVE / WHEEL AND TIRE
Wheel and Hub Torque Table
Wheel Removal
Front & Rear
Wheel Nuts (4)
Item
Aluminum Wheels
(Cast)
Steel Wheels
(Black / Camo)
Front Hub Nut
Rear & Center Hub
Retaining Nut
Nut Type Specification
Lug Nut (1) 90 ft. lbs. (122 Nm)
Flange Nut (2) 35 ft. lbs. (47 Nm)
-
-
60 ft. lbs. (81 Nm)
110 ft. lbs. (150 Nm)
Front Hub Nut
60 ft. lbs. (81 Nm)
Aluminum Wheel
(LE Models)
90 ft. lbs. (122 Nm)
#1
Steel Wheel
(Standard Models)
35 ft. lbs. (47 Nm)
#2
CV Shaft Boot Inspection
Inspect the CV shaft boots for damage, tears, wear, or leaking grease. If the rubber boot exhibits any of these symptoms, replace the boot. Refer to Chapter 7 for CV boot replacement, or have you Polaris dealer replace the boot.
Rear Hub Nut
110 ft. lbs. (150 Nm)
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 hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation.
2.
Attach the washers (if applicable) and wheel nuts and finger tighten them.
3.
Lower the vehicle to the ground.
4.
Securely tighten the wheel nuts to the proper torque listed in the torque table at the beginning of this section.
2
Inspect Boots
CAUTION
If wheels are improperly installed it could affect vehicle handling and tire wear. On vehicles with tapered rear wheel nuts, make sure tapered end of nut goes into taper on wheel.
2.25
MAINTENANCE
Tire Inspection
• Improper tire inflation may affect vehicle maneuverability.
• When replacing a tire always use original equipment size and type.
• The use of non-standard size or type tires may affect vehicle handling.
Tire Tread Depth
Always replace tires when tread depth is worn to 1/8" (3 mm) or less.
Tread
Depth 1/8" (3 mm)
WARNING
Operating a
RANGER
with worn tires will increase the possibility of the vehicle skidding easily with possible loss of control.
Worn tires can cause an accident.
Always replace tires when the tread depth measures 1/8", (.3 cm) or less.
Tire Pressure
CAUTION
Maintain proper tire pressure.
Refer to the warning tire pressure decal applied to the vehicle.
ELECTRICAL AND IGNITION SYSTEM
Battery Maintenance
Keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly.
Be careful not to allow cleaning solution or tap water into the battery
WARNING
Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote:
External:
Flush with water.
Internal:
Drink large quantities of water or milk.
Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately.
Eyes:
Flush with water for 15 minutes and get prompt medical attention.
Batteries produce explosive gases.
Keep sparks, flame, cigarettes, etc. away.
Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries.
KEEP OUT OF REACH OF CHILDREN.
NOTE: Batteries must be fully charged before use or battery life will be reduced by 10-30% of full potential. Charge battery for 3-5 hours at a current equivalent of 1/10 of the battery’s rated amp/hour capacity. Do not use the alternator to charge a new battery.
Tire Pressure Inspection (PSI - Cold)
Model
6x6
4x4 CREW
Front / Rear
8-12 psi / 8-12 psi
12 psi / 16 psi
2.26
Battery Fluid Level (Conventional Battery)
A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. Maintain the fluid level between the upper and lower level marks.
Upper Level
Lower Level
Add only distilled water. Tap water contains minerals that are harmful to a battery.
Battery Removal
1.
Open the Hood.
2.
Remove the battery vent tube from the battery.
3.
Disconnect the black (negative) battery cable.
4.
Disconnect the red (positive) battery cable.
5.
Lift the battery out of the vehicle, being careful not to tip it sideways and spill any electrolyte.
CAUTION
To reduce the chance of sparks: Whenever removing the battery, disconnect the negative
(black) cable first. When reinstalling the battery, install the negative cable last.
MAINTENANCE
Battery Installation
Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging procedure before installing the battery.
1.
Ensure that the battery is fully charged.
2.
Place the battery in the battery holder.
3.
Install the battery vent tube.
NOTE: The vent tube must be free of obstructions and securely installed. Route the tube away from the frame and vehicle body to prevent contact with electrolyte.
4.
Coat the terminals with dielectric grease or petroleum jelly.
5.
Connect and tighten the red (positive) cable first.
6.
Connect and tighten the black (negative) cable last.
7.
Verify that cables are properly routed.
2
Battery Storage
Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge.
NOTE: Battery charge can be maintained by using a
Polaris battery tender charger or by charging about once a month to make up for normal self-discharge.
Battery tenders can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point.
Battery Charging
1.
Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging.
2.
Charge the battery with a charging output no larger than
1/10 of the battery’s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater.
3.
Reinstall the battery.
2.27
MAINTENANCE
Spark Plug Service
1.
Remove both spark plug high tension leads (A). Clean plug area so no dirt and debris can fall into engine when plug is removed.
A
8.
Install spark plug and torque to specification.
Recommended Spark Plug:
Champion RC7YC3
=
T
Spark Plug Torque:
18 ft. lbs. (24 Nm)
B
2.
Remove spark plugs (B).
3.
Inspect electrodes for wear and carbon buildup. Look for a sharp outer edge with no rounding or erosion of the electrodes.
Inspect electrode for wear and buildup
Engine To Frame Ground
Inspect engine ground cable connection. Be sure it is clean and tight. The ground cable runs from the engine to the terminal block located under the front hood next to the battery.
Black Ground
Terminal Block
(under hood)
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.
2.28
STEERING AND SUSPENSION
Steering
The steering components should be checked periodically for loose fasteners, worn tie rod ends, and damage. Also check to make sure all cotter pins are in place. If cotter pins are removed, they must not be re-used. Always use new cotter pins.
Replace any worn or damaged steering components. Steering should move freely through entire range of travel without binding. Check routing of all cables, hoses, and wiring to be sure the steering mechanism is not restricted or limited.
MAINTENANCE
• If abnormal movement is detected, inspect the hub and wheel assembly to determine the cause (loose wheel nuts or loose front hub nut).
• Refer to the Final Drive chapter for more information.
Wheel Toe Alignment Inspection
1.
Place machine on a smooth level surface and set steering wheel in a straight ahead position. Secure the steering wheel in this position.
2.
Place a chalk mark on the center line of the front tires approximately 10” (25.4 cm) from the floor or as close to the hub/axle center line as possible.
2 replaced, check front end alignment.
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 MSDcertified 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 binding.
• Elevate front end of machine so front wheels are off the ground. Check for any looseness in front hub / wheel assembly by grasping the tire firmly at top and bottom first, and then at front and rear. Try to move the wheel and hub by pushing inward and pulling outward.
Measure Here
Mark (A), measure, then roll forward and measure (B).
A
10”
NOTE: It is important the height of both marks be equally positioned to get an accurate measurement.
3.
Measure the distance between the marks and 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).
=
In. / mm.
B
Wheel Toe-Out:
(A) - (B) = 1/8 - 1/4" (.3 to .6 cm)
2.29
MAINTENANCE
Toe Adjustment
If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell you which tie rod needs adjusting.
NOTE: Be sure steering wheel is straight ahead before determining which tie rod(s) need adjustment.
Front Suspension
• Compress and release front suspension. Damping should be smooth throughout the range of travel.
• Check all front suspension components and fasteners for wear or damage.
• Inspect front strut cartridges for leakage.
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 required to achieve the proper toe setting as specified in
“Wheel Toe Alignment”.
• IMPORTANT: When tightening the tie rod end jam nuts, the rod ends must be held parallel to prevent rod end damage and premature wear. Damage may not be immediately apparent if done incorrectly.
Hold
Rod End
Bolt Torque
15 ft. lbs. (20 Nm)
Inspect for leaks
Correctly
Tightened
Jam Nut
Incorrectly
Tightened
Jam Nut
• After alignment is complete, torque jam nuts to 12-14 ft. lbs. (16-19 Nm) .
=
T
Tie Rod Jam Nut Torque:
12-14 ft. lbs. (16-19 Nm)
2.30
Rear Suspension
MAINTENANCE
Rear Suspension Adjustment (4x4 CREW)
The rear suspension may be adjusted to provide a stiffer suspension if necessary.
1.
Remove the top shock mounting bolts from the inside mounting holes.
2.
Reposition the shocks to the outside mounting holes.
3.
Reinstall the shock mounting bolts. Torque to 30 ft. lbs.
(40 Nm).
2
Outside Mounting Holes
RANGER 4X4
Independent Rear Suspension
Inside Mounting Holes
RANGER 6X6
Rear Swingarm Suspension
• Compress and release rear suspension. Damping should be smooth throughout the range of travel.
• Check all rear suspension components for wear or damage.
• Inspect shock for leakage.
Rear Spring Adjustment
The rear shock absorber springs are adjusted by rotating the adjustment cam either clockwise or counterclockwise to increase or decrease spring tension.
To adjust the suspension, use the adjustment cam located near the bottom of the rear shock. This will allow you to increase or decrease the amount of spring preload.
Rear Spring
Adjustment Cam
Shock Spanner Wrench
(PN 2870872)
2.31
MAINTENANCE
BRAKE SYSTEM
Brake Fluid Inspection
Always check the brake pedal travel and inspect the brake fluid reservoir level before each operation. If the fluid level is low, add DOT 4 brake fluid only.
Brake fluid should be changed every two years. The fluid should also be changed anytime the fluid becomes contaminated, the fluid level is below the minimum level, or if the type and brand of the fluid in the reservoir is unknown.
The brake fluid master cylinder reservoir can be accessed by lifting up the front hood.
1.
Position the vehicle on a level surface.
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.
Brake Pad / Disc Inspection
1.
Check the brake pads for wear, damage, or looseness.
2.
Inspect the brake pad wear surface for excessive wear.
3.
Pads should be changed when the friction material is worn to .040” (1 mm).
Measure Pad Material
Thickness Service Limit:
.040" (1 mm)
4.
Check surface condition of the brake discs.
5.
Measure the thickness of the front and rear brake discs.
6.
The disc(s) should be replaced if thickness is less than the specified service limit (see Chapter 9 for specifications).
Measure Brake Disc Thickness
Maximum
Minimum
Front
Disc
Rear
Disc
Brake Hose and Fitting Inspection
Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose fittings and replace any worn or damaged parts.
Parking Brake Cable Adjustment
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 of operation afterwards to ensure proper cable tension.
2.32
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 connector as soon as practicable and adjust the parking brake cable to proper tension.
1.
Pull back on the parking brake lever (located in the dash).
2.
After 2 to 3 clicks the “(P)” brake 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.
3.
If the vehicle moves, adjustment is necessary.
4.
Adjust the parking brake cable where the cable attaches to the caliper mount bracket located on the rear gearcase.
Adjustment Procedure: Refer to “Chapter 9 - Brakes” for complete adjustment procedure.
Parking Brake Pad Inspection
Measure the thickness of the rear caliper parking brake pads.
Replace assembly as needed. See illustration below for proper readings.
Inboard Pad Thickness
New .304” (7.72 mm)
Limit: 0.24” (6.1 mm)
Inboard
Pad
Outboard
Pad
Outboard Pad Thickness
New 0.360” (9.14 mm)
Limit: 0.31” (7.87 mm)
Installed Disc to Park Brake
0.375” (0.953 cm)
New Rotor Disc Thickness
0.150” - 0.164”
(3.81 - 4.16 mm)
MAINTENANCE
2
2.33
MAINTENANCE
NOTES
2.34
ENGINE
CHAPTER 3
ENGINE
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
CRANKCASE EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
ENGINE FASTENER TORQUE PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
700 EFI ENGINE SERVICE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
GENERAL ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
ACCESSIBLE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
PISTON IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
COOLING SYSTEM SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
COOLING SYSTEM EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
COOLING SYSTEM BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
VALVE COVER REMOVAL - 6X6 MODELS (ENGINE INSTALLED) . . . . . . . . . . . . . . 3.17
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
ENGINE INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
OIL FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
ENGINE DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
CYLINDER HEAD ASSEMBLY EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
ROCKER ARMS / PUSH RODS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
CYLINDER HEAD INSPECTION / WARP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
VALVE SEAL / SPRING SERVICE (ON ENGINE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
COMBUSTION CHAMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
CYLINDER HEAD REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29
VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30
CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30
VALVE LIFTER REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30
PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
CYLINDER HONE SELECTION AND HONING PROCEDURE. . . . . . . . . . . . . . . . . . . 3.33
HONING TO DEGLAZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
CLEANING THE CYLINDER AFTER HONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
PISTON / ROD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35
STARTER DRIVE BENDIX REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 3.35
FLYWHEEL / STATOR REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
ENGINE CRANKCASE DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 3.36
CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
ENGINE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45
CRANKCASE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45
FLYWHEEL / STATOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.54
CYLINDER HEAD REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.55
OIL PUMP PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.57
ENGINE BREAK-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.57
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.58
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.58
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59
3
3.1
ENGINE
ENGINE SPECIFICATIONS
Crankcase Exploded Views
A. Journal Bearings
B. Camshaft
C. Thrust Plate
D. Balance Shaft
E. Woodruff Key
F. Flange Seal
G. Crankshaft
H. Oil Pickup
J. Baffle
K. Oil Plug
L. Washer
M. O-ring
N. Crankcase
O. Crankcase Bolts
A
F
60
±
6 in. lbs.
(6.8
±
.68 Nm)
G
H
M
N
O
B
C
22
±
2 ft. lbs. (30
±
3 Nm)
E
D
115
±
12 in. lbs.
(13
±
1.35 Nm)
60
±
6 in. lbs.
(6.8
±
.68 Nm)
I
I
J
NOTE: If needed, heat the oil baffle bolts with a heat gun to remove.
L
K
192
±
24 in. lbs
(21.7
±
2.7 Nm
)
Apply Loctite
™
242 to bolt threads.
Apply White Lithium
Grease
Apply Moly
Lube Grease.
3.2
ENGINE
Oil Pump / Water Pump / Engine Cover Exploded View
A
B
C
D
E
F
A. Split Gear
B. Washer
C. Bolt
D. Oil Rotor
E. Oil Pump
F. Mag Gasket Cover
G. Impeller
H. Washer
I. Nut
J. Counterbalance Gear
K. Washer
L. Bolt
M. Oil Pump Bolts
N. Engine Cover
O. Wire Hold down
P. Stator Housing Bolts
J
22
±
2 ft. lbs. (30
±
3 Nm)
K
L
M
84
±
8 in. lbs. (9.5
±
.90 Nm)
G
H
I
3
Oil Pump Bolt Tighten Sequence
No Grease on this
Portion of the Gasket!
N
Apply corrosion resistant grease to stator grommet area.
108
±
12 in.lbs.
(6.8
±
.68 Nm)
O
P
96
±
3 in.lbs.
(10.85
±
0.35 Nm)
Mag Cover Bolt Tighten Sequence
Apply Polaris 2W-50 oil to component
Apply White Lithium
Grease
3.3
ENGINE
Stator Cover / Starter / Water Pump Exploded View
E
Apply Polaris
Starter Grease
Apply Polaris 2W-50 oil to seal
Loctite
™
Pipe Sealant
(PN 2871956)
A
84
±
8 ft.lbs. (9.5
±
0.9 Nm)
Tighten Top Bolt First
B
1st
2nd
F
C
D
108
±
12 ft.lbs.
(12
±
1.35 Nm)
Water Pump Cover
Bolt Tighten Sequence
3
7
5
2
1
4
6
J
No Grease or Oil
K
L
96
±
12 in. lbs.
(10.85
±
1.35 Nm)
O
N
M
65
±
7 ft. lbs.
(88
±
9.5 Nm)
G
I
A. Bolts
B. Starter
C. Washer
D. Nut
E. Positive Cable
F. Negative Cable
G. Gasket
H. Clamp
I. Bolts
J. Gasket
K. Water Pump Cover
L. Bolts
M. Crank Nut / Washer
N. Flywheel
H
96
±
12 in. lbs. (10.85
±
1.35 Nm)
Stator Cover Bolt
Tighten Sequence
3.4
Oil Filter / Pressure Relief / Dipstick Assembly Exploded View
A. Clamp
B. Oil Fill Tube
C. Dipstick
D. O-ring
E. Hex Plug
F. Oil Filter Nipple
G. Oil Filter
H. Dowel
I. Galley Plug Asm.
J. Screw
K. Relief Spring
C
B
22
±
2 ft. lbs.
(30
±
3 Nm)
I
H
K
J
50
±
5 in. lbs.
(5.65
±
0.56 Nm)
A
D
E
18
±
2 ft. lbs.
(24.4
±
2.71 Nm)
F
35
±
4 ft. lbs.
(47.5
±
5.4 Nm)
ENGINE
3
50
±
5 in. lbs.
(5.65
±
0.56 Nm)
G
3.5
ENGINE
Cylinder / Cylinder Head / Piston Exploded View
Lubricate threads & between washers and underside of bolt heads with engine oil.
Torque in sequence provided.
1
(Apply each
Bolt Threads)
Apply Moly Lube grease to valve tips.
Gasket free of oil. Verify tabs are visible.
A
22 ± 2 ft. lbs.
B
(30 ± 3 Nm)
Apply thin film of 2W-50 to
25-55 mm of cylinder bore.
2
C
Apply 2W-50 to piston pin or pin bore.
Apply 2W-50 to lifters.
Initial:
35
±
4 ft. lbs (47.5
±
5.5 Nm) in sequence. Finalize sequence by tightening an additional 90
°
(1/4 turn)
Head Bolt Tighten
Sequence
D
3
Do Not install expansion plug more than 1.5 mm inward.
1.5 mm
G
F
E
4
Side View
A. Head Bolts
B. Rocker Arms
C. Head Assembly
D. Gasket
E. Pushrods
F. Bushing
G. Expansion Plug
H. Cylinder
I. Piston Assembly
J. Circlip
K. Gasket
L. Hydraulic Lifter
5
3
I
H
4
J
Circlip UP for Install
L
K
6
Apply Polaris 2W-50 Oil
Apply Moly Lube Grease
3.6
Engine Sensors / Valve Cover / General Component Exploded View
ENGINE
84
±
8 in. lbs.
(9.5
±
0.9 Nm)
A
C
A. Screws
B. Rocker Cover
C. Breather
D. O-ring Seal
E. Breather Bolts
F. Spark Plugs
G. Intake Boot
H. Bolts
I. Boot Clamp
J. Throttle Body
K. Crank Position Sensor
L. Thermistor
M. O-ring
N. Thermostat
O. Bolts
P. Gasket
Q. Exhaust Manifold
R. Bolts
20
±
5 in. lbs.
(2.5
±
0.55 Nm)
E
18
±
2 ft. lbs.
(24.5
±
2.7 Nm)
(Apply Dielectric Grease to threads of Spark Plug)
18
±
2 ft. lbs.
(24.5
±
2.7 Nm)
20
±
5 in. lbs.
(2.5
±
0.55 Nm)
I
H
G
J
F
Apply Corrosion
Resistant Grease
B
D
K
84
±
4 in. lbs.
(9.5
±
0.9 Nm)
3
Q
P L
17
±
2 ft. lbs.
(23
±
3 Nm)
S
M
N
O
84
±
8 in. lbs.
(9.5
±
0.9 Nm)
R
18
±
2 ft. lbs.
(24.5
±
2.7 Nm)
3.7
ENGINE
EFI Harness / Fuel Injection Exploded View
A. Fuel Injector
B. Fuel Rail
C. EFI Harness
18
±
2 ft. lbs.
(24.5
±
2.7 Nm)
B
A
C
NOTE: See Chapter 4 for more information on the EFI system.
3.8
Engine Fastener Torque Patterns
Crankcase Bolt Tighten Sequence
ENGINE
3
22
±
2 ft. lbs. (30
±
3 Nm)
Cylinder Head Bolt Tighten Sequence
Lubricate threads and between washer and underside of bolt with engine oil.
Torque in sequence to spec provided, allow the gasket to set for 1 minute, then tighten in sequence 90
°
(1/4 turn).
35
±
4 ft. lbs.
(47.5
±
5.5 Nm) + 90
°
(1/4 turn)
3.9
ENGINE
Torque Specifications
Engine Torque Specifications
Camshaft Gear
Fastener
Camshaft Thrust Plate
Throttle Body Adaptor Bolts
Counterbalance Gear
Crankcase Bolts
Crankcase Breather
Cylinder Head Bolts
Exhaust Manifold
Flywheel
Injector Rail
Magneto Cover
Oil Baffle Weldment
Oil Drain Bolt (Crankcase)
Oil Fill Tube Bolt
Oil Filter Pipe Fitting
Oil Pick Up
Oil Pressure Relief Plug
Oil Pump Housing Screw
Rocker Arm
Rocker Cover
Spark Plug
Starter Motor
Stator Assembly
Stator Housing
Temperature Switch
Thermostat Housing
Timing Plug
Trigger Coil/Stator Wire Holddown
Water Pump Housing Cover
Water Pump Impeller Nut in. lbs. (Nm)
115 ± 12 (13 ± 1.35)
216 ± 24 (24.5-± 2.7)
20 ± 5 (2.5 ± 0.55)
216 ± 24 (24.5 ± 2.70)
216 ± 24 (24.5 ± 2.70)
* 96 ± 3 (10.85 ± 0.35)
60 ± 6 (6.8 ± 0.68)
192 ± 24 (21.7 ± 2.7)
50 ± 5 (5.64 ± 0.56)
60 ± 6 (6.8 ± 0.68)
22 ± 2 (30 ± 3)
* 84 ± 8 (9.50 ± 0.90)
* 84 ± 8 (9.5 ± 0.9)
216 ± 24 (24.5 ± 2.7)
* 84 ± 8 (9.5 ± 0.9)
96 ± 3 (10.85 ± 0.35)
* 96 ± 3 (10.85 ± 0.35)
84 ± 8 (9.5 ± 0.9)
* 96 ± 3 (10.85 ± 0.35)
* 96 ± 3 (10.85 ± 0.35)
108 ± 3 (12 ± 0.35)
NOTE: * See exploded views for notes or torque sequences.
8 mm
6 mm
14 mm
6 mm
6 mm
6 mm
3/8 NPT
6 mm
3/4-16
5 mm
6 mm
8 mm
8 mm
14 mm
8 mm
6 mm
5 mm
12 mm
5 mm
20 mm
Size
8 mm
6 mm
8 mm
8 mm
8 mm
5 mm
11 mm
5 mm
10 mm
6 mm ft. lbs. (Nm)
22 ± 2 (30 ± 3)
9.5 ± 1 (13 ± 1.35)
18 ± 2 (24.5 ± 2.7)
22 ± 2 (30 ± 3)
* 22 ± 2 (30 ± 3)
-
* 35 ± 4 (47.5 ± 5.5)
18 ± 2 (24.5 ± 2.7)
65 ± 7 (88 ± 9.50)
18 ± 2 (24.5 ± 2.7)
-
-
16 ± (21.7)
-
35 ± 4 (47.5 ± 5.4)
-
-
-
* 22 ± 2 (30 ± 3)
-
18 ± 2 (24.5 ± 2.7)
-
-
-
17 ± 2 (23 ± 3)
-
7 - 9 (10 - 12)
-
-
-
3.10
ENGINE
700 EFI Engine Service Specifications
Cylinder Head - Engine Specifications
Main Component: Cylinder Head EH068OLE
Camshaft
Cam Lobe Height - Intake / Exhaust 1.3334" (33.8674 mm)
Camshaft Journal Outer Diameter - Mag
Camshaft Journal Outer Diameter - Center
1.654"
±
0.00039" (42
±
0.010 mm)
1.634"
±
0.00039" (41.50
±
0.010 mm)
Camshaft Journal Outer Diameter - PTO 1.614"
±
0.00039" (41
±
0.010 mm)
Camshaft Journal Bore Inner Diameter - Mag 1.656"
±
0.00039" (42.07
±
0.010 mm)
Camshaft Journal Bore Inner Diameter - Center 1.637"
±
0.00039" (41.58
±
0.010 mm)
Camshaft Journal Bore Inner Diameter - PTO 1.617"
±
0.00039" (41.07
±
0.010 mm)
Camshaft Oil Clearance
Camshaft End Play
0.00276"
±
0.00079" (0.07
±
0.02 mm)
0.0167"
±
0.0098" (0.425
±
0.25 mm)
Counter Balance Counter Balance End Play 0.005" (0.127 mm)
Cylinder Head
Cylinder Head - Surface warp limit
Cylinder Head - Standard height
Valve Seat
Valve Guide
Valve
Valve Spring
Valve Seat - Contacting Width - Intake
Valve Seat - Contacting Width - Exhaust
Valve Seat Angle
Valve Guide Inner diameter
Valve Guide Protrusion Above Head
Valve Margin Thickness - Intake
Valve Margin Thickness - Exhaust
Valve Stem Diameter - Intake
Valve Stem Diameter - Exhaust
Valve Stem Oil Clearance - Intake
Valve Stem Oil Clearance - Exhaust
Valve Stem Overall Length - Intake
Valve Stem Overall Length - Exhaust
Valve Spring Overall Length - Free Length
Valve Spring Overall Length - Installed Height
0.00394" (0.1 mm)
3.478" (88.35 mm)
0.0472"
±
0.00787" - 0.0039"
(1.20
±
0.20 - 0.10mm)
0.0591"
±
0.00787" - 0.0039"
(1.50
±
0.20 - 0.10 mm)
45.5
° ±
0.255
°
0.2367"
±
0.00029" (6.012
±
0.007 mm)
0.807"
±
0.0039" (20.50
±
0.01 mm)
Standard: 0.79" (20.06 mm)
Max- 0.98" (24.89 mm) Min.- 0.59" (14.98 mm)
Standard: 0.80" (20.32 mm)
Max- 1.0" (25.4 mm) Min.- 0.60" (15.24 mm)
0.2356"
±
0.00039" (5.985
±
0.01 mm)
0.2351"
±
0.00039" (5.972
±
0.01 mm)
0.00228"
±
0.00098" (0.058
±
0.025 mm)
0.00275"
±
0.00098" (0.0870
±
0.025mm)
4.51"
±
0.01476" (114.5550
±
0.375 mm)
4.5453"
±
.01496" (115.45
±
0.38 mm)
1.735" (46.069 mm)
Intake - 1.4638" (37.18 mm)
Exhaust - 1.4736" (37.43 mm)
3
3.11
ENGINE
Cylinder / Piston - Engine Specifications
Main Components: Cylinder / Piston / Connecting Rod
Cylinder
Lifter
Piston
Piston Pin
Cylinder - Surface warp limit
(mating with cylinder head)
Cylinder Bore - Standard
Cylinder Taper Limit
Cylinder Out of Round Limit
Cylinder to Piston Clearance
Lifter Outer Diameter Standard
Lifter Block Bore
Piston - Standard
Piston Standard Inner Diameter of
Piston Pin Bore
Piston Pin Outer Diameter
Piston Pin - Standard Clearance - Piston Pin to
Pin Bore
Piston Pin - Degree of Fit
0.004" (0.10 mm)
EH068OLE
3.1495" (80 mm)
0.00031" (0.008 mm)
0.00030" (0.0075 mm)
.0015"
±
.00059" (.040
±
.015mm)
0.84245"
±
0.00025" (21.39 8
±
0.00635 mm)
0.8438"
±
0.00062" (21.4322
±
0.0157 mm)
3.1477"
±
.000121" (79.954
±
.003mm)
0.78789"
±
.00009" (20.0125
±
0.003 mm)
0.7874" - 0.7872" (20 - 19.995 mm)
0.00059"
±
0.0002" (0.015
±
0.005 mm)
Piston pin must be a push fit (by hand) at 68
°
F (20
°
C)
Piston / Connecting Rod / Crankshaft - Engine Specifications
Main Components: Piston / Connecting Rod
Piston Ring
Connecting Rod
Crankshaft
Installed
Gap
Top Ring - Standard
Top Ring - Limit
Second Ring - Standard
Second Ring - Limit
Oil Ring - Standard
Oil Ring - Limit
Top Ring - Standard
Ring to
Groove
Clearance
Top Ring - Limit
Second Ring - Standard
Second Ring - Limit
Connecting Rod Small End I.D.
Connecting Rod Small End
Radial Clearance
Connecting Rod Big End
Side Clearance
Connecting Rod Big End
Radial Clearance
Crankshaft Runout Limit
EH068OLE
0.0059
±
0.138" (0.15
±
0.35mm)
> 15% Leakdown
0.0098
±
0.197" (0.25
±
0.50mm)
> 15% Leakdown
0.0196
±
0.00984" (0.50
±
0.25mm)
> 15% Leakdown
0.0024"
±
0.0008" (0.060
±
0.020 mm)
> 15% Leakdown
0.0028"
±
0.0008" (0.070
±
0.020 mm)
> 15% Leakdown
0.789"
−
0.78841" (20.030
−
20.015 mm)
0.0098"
±
0.00039" (0.025
±
0.010mm)
0.01181"
±
0.00591" (0.030
±
0.015mm)
0.0015"
±
0.00006" (0.0038
±
0.0015mm)
0.00236" (0.060mm)
3.12
ENGINE
Special Tools
Part Number
PV-43527
2200634
PU-45257
PU-45652
2871043
2870390
PU-45497-1
PU-45497-2
PU-45498
PU-45838
PA-44995
PU-45543
PA-45483
PU-45658
PA-45401
2870975
PU-45778
GENERAL ENGINE SERVICE
Accessible Components
Following Components can be serviced or removed with the engine installed: (See Page 3.17 for 6x6 Valve Cover R & R)
• Flywheel
• Alternator (Stator)
• Starter Motor/Drive
• Cylinder Head (6x6: See Page 3.17)
• Cylinder (6x6: See Page 3.17)
• Piston / Rings (6x6: See Page 3.17)
• Camshaft (6x6: See Page 3.17)
• Rocker Arms (6x6: See Page 3.17)
• Oil pump / Water Pump / Oil Pump Drive Gear
• Gear Train Components
Following Components Require Engine Removal for service:
• Counterbalance Shaft or Bearings
• Connecting Rod
• Crankshaft
• Crankshaft Main Bearings
• Crankcase
Tool Description
OIL FILTER WRENCH
VALVE SEAT RECONDITIONING KIT
VALVE SPRING COMPRESSOR
VALVE PRESSURE HOSE
FLYWHEEL PULLER
PISTON SUPPORT BLOCK
CAM GEAR SPRING INSTALLATION KIT
CAM GEAR TOOTH ALIGNMENT TOOL
CAM SPANNER WRENCH
GEAR HOLDER
WATER PUMP MECHANICAL SEAL INSTALLER
UNIVERSAL DRIVER HANDLE
MAIN SEAL INSTALLER
CRANKSHAFT MAIN SEAL SAVER
WATER PUMP SEAL SAVER
MITY VAC ™ PRESSURE TEST TOOL
OIL SYSTEM PRIMING TOOL
Piston Identification
Four stroke engine rings have a rectangular profile. See
“PISTON RING INSTALLED GAP” for ring installation. Use the information below to identify pistons and rings.
Engine Model
EH068OLE
Piston Diameter
80 mm
Cooling System Specifications
Condition
Thermostat Open
Thermostat Full Open Lift
Thermostat Closed
System Capacity
Radiator Cap Pressure Relief
Specification
180° F (8
2
° C
)
6 mm at 203° F (95° C)
171° F (77° C)
3.25 Quarts (2.13L)
13 PSI
Polaris Premium Antifreeze
2871534 - Quart
2871323 - Gallon
3
3.13
ENGINE
Recommended Coolant
Use only high quality antifreeze/coolant mixed with distilled water in a 50/50 or 60/40 ratio, depending on freeze protection required in your area.
CAUTION: Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Polaris
Premium 60/40 Antifreeze/Coolant is recommended for use in all cooling systems and comes pre-mixed, ready to use.
Radiator
Radiator Cap Pressure Test
WARNING
Never remove radiator cap when engine is warm or hot. The cooling system is under pressure and serious burns may result.
Allow the engine and cooling system to cool before servicing.
1.
Remove radiator pressure cap and test using a cap tester
(commercially available).
2.
The radiator cap relief pressure is 13 lbs. Replace cap if it does not meet this specification.
Thermostat
Water
Pump
Radiator Cap
Cylinder
Head
Cylinder
Cooling System Pressure Test
1.
Lift up the front hood.
2.
Remove the pressure cap from the radiator and pressure test the cooling system using a commercially available tester.
3.
The system must retain 10 psi for five minutes or longer.
If pressure loss is evident within five minutes, check radiator, all cooling system hoses and clamps and water pump seal for leakage.
Coolant Flow Diagram
Surge Tank
From
Thermostat Housing
To Water Pump
Radiator
3.14
Cooling System Exploded View
ENGINE
Radiator Inlet Hose
Engine Outlet Hose
Engine Inlet Hose
Radiator Outlet Hose
3
Radiator Cap
Surge Tank Fan
Radiator
Shroud
Drain Plug
Cooling System Bleeding Procedure
1.
Place the vehicle in Neutral and set the parking brake.
WARNING
Always wear safety glasses and proper shop clothing when performing the procedures in this manual. Failing to do so may lead to possible injury or death.
CAUTION
Use caution when performing these procedures.
Coolant may be hot and may cause severe injury or burns.
NOTE: If the coolant level is LOW in the radiator, or if there are leaks in the system, the coolant system will not draw coolant from the reservoir tank.
NOTE: Use this procedure when a unit overheats and no apparent leaks in the cooling system are found.
CAUTION
Be sure the engine has cooled and there is no pressure built up in the cooling system before removing the radiator cap. The coolant may be hot and could cause severe injury or burns.
2.
Remove radiator cap (A) and top off coolant.
3.
Remove surge tank fill cap (B) and fill the surge tank to the full line.
B
A
3.15
ENGINE
4.
Elevate the driver’s side of the vehicle 20” (50.8 cm) off the ground so the thermostat housing is at the highest point on the cylinder head. This will allow any trapped air to accumulate near the thermostat housing bleed screw.
8.
Add Polaris Premium Antifreeze to the radiator if the level goes down.
9.
Tighten the bleed screw to 70 ± 10 in.lbs. (8 ± 1.13 Nm) on the thermostat housing and properly install the radiator cap.
CAUTION
Serious injury may result if machine tips or falls.
Be sure machine is secure before beginning this service procedure.
WARNING
Be sure to install the radiator cap before shutting off the engine.
Coolant may spit out of the radiator.
10. Stop the engine and let cool, top off the radiator filler neck with coolant. If you hear or see a “glug” at the filler neck or there is a dropping of the coolant level, indicating that coolant has been pulled into the system. Fill the surge tank only after you have completely filled the cooling system at the radiator filler neck.
11. Repeat this procedure, if overheating still occurs.
20” (50.8 cm)
5.
Start the engine and let it idle for 5-10 minutes or until the thermostat opens and allows coolant to flow through the system.
6.
Squeeze the coolant lines by hand to help purge the system of air.
7.
Slightly loosen the bleed screw (C) on the thermostat housing to allow the trapped air to escape. If no air is present, a steady stream of coolant will stream out. If air is present, the screw will bubble and sputter as the air escapes.
Top LH Side of Engine
C
3.16
ENGINE
Valve Cover Removal - 6x6 Models
(Engine Installed)
The RANGER 6x6 models have a different engine mounting system that makes it more difficult to access and remove the engine valve cover. Use the procedure provided in this section of the chapter to remove the valve cover and allow for engine top-end component service.
1.
Remove the seat base.
2.
Remove the clamp from the valve cover breather hose and remove the hose and valve cover vent.
Screws (7)
Valve Cover
Breather Hose
Vent
5.
Remove the heat shield shown below and loosen the exhaust mounts.
Loosen Remove
3.
Remove the 7 screws that retain the valve cover.
4.
Remove the front dog house cover located in the floor panel of the RANGER . The valve cover will have to be removed through the dog house.
Floor Panel
Dog House
Cover
6.
Remove the upper engine mount.
7.
Loosen the lower engine mount bolts, but DO NOT completely remove them.
8.
Remove the front engine mount bolts from the engine case.
NOTE: You may need to support the engine during this step by using a jack or by using wooden blocks between the engine and frame.
Upper Mount
Remove
3
Lower Mount
Front Mount
Remove
Loosen
9.
Move the engine to allow the valve cover to be removed through the dog house cover hole.
10. To reinstall, reverse steps 1-9. Torque all bolts to specification as listed earlier in this chapter.
NOTE: It may be necessary to use a pry bar to get the bolts back in during reassembly.
3.17
ENGINE
Engine Removal
WARNING
Always wear safety glasses and proper shop clothing when performing the procedures in this manual. Failing to do so may lead to possible injury or death.
1.
Clean work area.
2.
Thoroughly clean the engine and chassis.
3.
Disconnect battery (-) negative cable.
4.
Remove the following parts as required:
• Seat
• Storage unit under driver seat (Refer to chapter 5)
5.
Remove middle dog house cover and remove exhaust pipe bolts.
12. Disconnect the air intake hose (D) from the air box and remove the air intake hose.
C
B
A
13. Disconnect the Throttle Position Sensor at the electrical connector (E). Remove the clamps that secure the throttle body (F) to the air intake boot and engine intake boot.
Remove the throttle body (F). Insert a shop towel into the engine intake to prevent dirt from entering the intake port.
E
D
6.
Remove springs from exhaust pipe and remove pipe.
7.
Refer to PVT System in Chapter 6 to remove outer clutch cover, drive belt, drive clutch, driven clutch, and inner cover.
8.
Drain coolant and engine oil.
9.
Remove the air breather line (A).
10. Remove PVT exhaust duct (B).
11. Remove the exhaust shield (C).
F
14. Relieve the fuel pressure in the fuel rail (refer to Chapter 4,
“FUEL INJECTION”) for proper procedure. Carefully remove the fuel rail (G) and injectors.
15. Remove the spark plug high tension leads (H).
G
H
3.18
ENGINE
16. Remove the crank position sensor (I) located on the mag cover.
I
NOTE: Use caution when lifting the engine out of frame. Use an engine lift or other means if the engine is too heavy to be lifted manually.
17. Disconnect the coolant temperature sensor (J) from the left side of the cylinder.
J
22. For engine installation, reverse procedures.
18. Disconnect the coolant hoses. Properly dispose of any antifreeze from the engine or hoses.
19. When removing starter cables, note and mark ground cable and positive (+) cable mounting angle and locations.
Remove the cables.
20. Remove all engine mount nuts and / or engine mount plates.
21. With all hoses and wires disconnected, the engine can be pulled straight out of the chassis.
NOTE: Rotating the engine to the left 90 degrees
(valve cover facing left), may ease engine removal.
Engine Installation Notes
After the engine is installed in the frame, review this checklist and perform all steps that apply:
General Items
1.
Install previously removed components using new gaskets, seals, and fasteners where applicable.
NOTE: Properly route all electrical harnesses and re-attach any fasteners or protective tubing. Check for any possible rubbing points of electrical wires.
2.
Perform regular checks on fluid levels, controls, and all important areas on the vehicle as outlined in the daily preride inspection checklist (refer to Chapter 2 or the Owner's
Manual).
PVT System
1.
Adjust center distance of drive and driven clutch.
(Chapter 6)
2.
Adjust clutch offset, alignment, and belt deflection.
(Chapter 6)
3.
Clean clutch sheaves thoroughly and inspect inlet and outlet ducts for proper routing and sealing. (Chapter 6)
Transmission
1.
Inspect transmission operation and adjust linkage if necessary. Refer to Chapter 2 and Chapter 8.
3.19
3
ENGINE
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 2W-50 Synthetic 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.
1.
Fill fuel tank with unleaded or leaded fuel which has a minimum pump octane number of 87= (R+ M)/2.
2.
Check oil level indicated on dipstick. Add oil if necessary
(Refer to Chapter 2, “Engine Oil Level” ).
3.
Drive slowly at first to gradually bring engine up to operating temperature.
4.
Vary throttle positions. Do not operate at sustained idle or sustained high speed.
5.
Perform regular checks on fluid levels, controls and all important bolt torques.
6.
Pull only light loads during initial break-in.
7.
Change oil and oil filter after break-in period at 25 hours.
Engine Lubrication Specifications
=
Capacity
- Approximately 2 U.S. Quarts (1.9 l)
Oil Type
- Polaris PS-4 PLUS 2W-50 Synthetic
Filter Wrench
- PV-43527 or equivalent
- Oil Pressure Specification -
35-39 PSI @ 5500 RPM, Polaris 2W-50
Synthetic, Engine at operating temperature.
Oil Pressure Test
1.
Remove blind plug/sender from left side of crankcase.
2.
Insert a 1/8 NPT oil pressure gauge adaptor into the crankcase and attach the gauge.
3.
Start engine and allow it to reach operating temperature, monitoring gauge indicator.
NOTE: Use only Polaris PS-4 PLUS 2W-50 Synthetic
Engine Oil.
Oil Pressure at 5500 RPM (Engine Hot):
Standard: 39 PSI
Minimum: 35 PSI
3.20
ENGINE
Oil Flow Chart
This chart describes the flow of oil through the 700 engine. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through the oil filter. If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element. At this point, the oil is supplied to the main oil galley through a crankcase passage.
Oil is then diverted three ways from the main oil galley, with the first path entering the camshaft bores, onto the rear balance shaft journal and then draining back into the crankcase sump. The second oil path from the main oil galley feeds the lifter bores and then drains back to the crankcase sump. The third oil path flows through a crankcase galley to the MAG side crankshaft journal and also to the front balance shaft journal and onto the crankcase sump. The oil pressure switch is fed off the main oil galley.
3
3.21
ENGINE
ENGINE DISASSEMBLY AND INSPECTION
Cylinder Head Assembly Exploded View
Rocker Arms
Retainer Locks (keepers)
Spring Retainers
Springs
Valve Seals
Valve Spring Seats
Cylinder Head
Valves
Push Rods
Hydraulic Lifters
3.22
ENGINE
Rocker Arms
1.
Mark or tag rocker arms in order of disassembly to keep them in order for reassembly.
5.
If the push rod (A) is visibly bent, it should be replaced.
A
2.
Inspect the wear pad at the valve end of the rocker arm for indications of scuffing or abnormal wear. If the pad is grooved, replace the rocker arm.
NOTE: Do not attempt to true this surface by grinding.
3.
Check the rocker arm pad and fulcrum seat for excessive wear, cracks, nicks or burrs.
Cylinder Head Removal
1.
Loosen the six cylinder head bolts evenly 1/8 turn each in a criss-cross pattern until loose.
2.
Remove bolts (A) and tap cylinder head (B) lightly with a soft face hammer until loose. CAUTION: Tap only in reinforced areas or on thick parts of cylinder head casting to avoid damaging the head or cylinder.
3.
Remove cylinder head (B) and head gasket (C) from the cylinder (D).
Push Rods
1.
Clean push rods (A) in a suitable solvent. Blow dry push rods with compressed air.
2.
Use compressed air to confirm the oil passage is clear in the center of the push rod.
A
WARNING
Always wear safety glasses when working with compressed air to prevent personal injury.
3.
Check the ends of the push rods (A) for nicks, grooves, roughness or excessive wear.
4.
The push rods (A) can be visually checked for straightness while they are installed in the engine by rotating them with the valve closed. Push rods can also be checked with a dial indicator or rolled across a flat surface to check for straightness.
C
B
D
3
3.23
ENGINE
Cylinder Head Inspection
Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon.
CAUTION
Use care not to damage sealing surface.
Valve Seal / Spring Service (On Engine)
NOTE: The following procedure is only for servicing the top end of the valve train when replacing valve springs or replacing valve seals.
In some cases the valve train can be serviced while the cylinder head is still on the engine. Keep all parts in order with respect to their location in the cylinder head.
Cylinder Head Warp
1.
Lay a straight edge (A) across the surface of the cylinder head (B) at several different points and measure warp by inserting a feeler gauge between the straight edge and the cylinder head surface. If warp exceeds the service limit, replace the cylinder head.
A
Measure at different points on the surface.
B
WARNING
Wear eye protection or a face shield during cylinder head disassembly and reassembly.
1.
Having already removed the valve cover, rocker arms and pushrods, align the cylinder to be worked on at top dead center (TDC). Install the Valve Pressure Hose (PU-
45652) into the spark plug hole. Hook the hose to an air compressor and supply 50 to 100 psi to the hose. This will seat the valves during valve spring removal. Do not remove air from the hose at anytime until reassembly is completed.
2.
Using the Valve Spring Compressor (PU-45257) , compress the valve spring and remove the valve keepers.
NOTE: A small parts magnet (A) can aid in the removal of the retainers (B).
B
=
In. / mm.
Cylinder Head Warp Limit:
.004" (.1016 mm) max
A
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.
3.24
Cylinder Head Disassembly
1.
Carefully remove the cylinder components.
ENGINE
4.
Remove valve guide seals.
IMPORTANT: It is recommended to replace seals whenever the cylinder head is disassembled.
Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup.
5.
Mark the valves with a white pen. Remove the valves from the cylinder head. This will ensure that the valves are properly placed during engine reassembly.
Mark the Valves
3
2.
Place the hydraulic lifters (C), pushrods (D), and rocker arms (E) in a safe, clean area.
C D
E
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)
3.25
ENGINE
Valve Inspection
1.
Remove all carbon from valves with a soft wire wheel or brush.
2.
Check valve face for runout, pitting, and burnt spots. To check for bent valve stems, mount valve in a drill or use “V” blocks and a dial indicator.
=
In. / mm.
Valve Stem Diameter:
Intake: 0.2356" + 0.00039"
(5.985 + 0.01 mm)
Exhaust: 0.2351" + 0.00039"
(5.972 + 0.01 mm)
6.
Measure valve guide (C) inside diameter at the top middle and end of the guide using a small hole gauge and a micrometer. Measure in two directions.
C
3.
Check end of valve stem for flaring, pitting, wear or damage
(A).
A
B
=
In. / mm.
4.
Inspect split keeper groove for wear or flaring of the keeper seat area (B).
NOTE: The valves can be re-faced or end ground, if necessary. They must be replaced if extensively worn, burnt, bent, or damaged.
5.
Measure diameter of valve stem with a micrometer in three places, then rotate 90 degrees and measure again (six measurements total). Compare to specifications.
Measure valve stem in several places.
Rotate the valve 90 degrees and measure for wear.
Valve Guide I.D.:
0.23672" + 0.000295"
(6.0617 + 0.0075 mm)
7.
Subtract valve stem measurement from the valve guide measurement to obtain stem to guide clearance. NOTE:
The valve guides cannot be replaced. Be sure to measure each guide and valve combination individually.
3.26
Combustion Chamber
1.
Clean all accumulated carbon deposits from combustion chamber and valve seat area with carbon cleaner and a soft plastic scraper.
IMPORTANT: Do not use a wire brush, metal scraper, or abrasive cleaners to clean the bottom of the cylinder head. Extensive damage to the cylinder head may result. Wear safety glasses during cleaning.
Combustion Area
ENGINE
NOTE: Valve seat width and point of contact on the valve face is very important for proper sealing. The valve must contact the valve seat over the entire circumference of the seat, and the seat must be the proper width all the way around. If the seat is uneven, compression leakage will result. If the seat is too wide, seat pressure is reduced, causing carbon accumulation and possible compression loss. If the seat is too narrow, heat transfer from valve to seat is reduced. The valve may overheat and warp, resulting in burnt valves.
3
Valve Seat Reconditioning
NOTE: Polaris recommends that the work be done by a local machine shop that specializes in this area.
NOTE: The cylinder head valve guides cannot be replaced.
1.
Install pilot into valve guide.
2.
Apply cutting oil to valve seat and cutter.
3.
Place 46
°
cutter on the pilot and make a light cut.
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 Cylinder Head Reconditioning Kit (PN
2200634) . Abrasive stone seat reconditioning equipment can also be used. Keep all valves in order with their respective seat.
3.27
ENGINE
4.
Inspect the cut area of the seat:
* If the contact area is less than 75% of the circumference of the seat, rotate the pilot 180
°
and make another light cut.
* If the cutter now contacts the uncut portion of the seat, check the pilot. Look for burrs, nicks, or runout. If the pilot is bent it must be replaced.
* If the contact area of the cutter is in the same place, the valve guide is distorted from improper installation
* If the contact area of the initial cut is greater than 75%, continue to cut the seat until all pits are removed and a new seat surface is evident. NOTE: Remove only the amount of material necessary to repair the seat surface.
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 using an interference angle (46
°
) apply black permanent marker to the entire valve face (A).
NOTE: When using an interference angle, the seat contact point on the valve will be very narrow, and is a normal condition. Look for an even and continuous contact point all the way around the valve face (A).
B
Bottom 60
°
Seat 45
°
A
Proper Seat Contact on Valve Face
Top 30
°
A
6.
Insert valve into guide and tap valve lightly into place a few times.
7.
Remove valve and check where the Prussian Blue
™ indicates seat contact on the valve face. The valve seat should contact the middle of the valve face or slightly above, and must be the proper width.
* If the indicated seat contact 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.
* If the seat is too wide or uneven, use both top and bottom cutters to narrow the seat.
* If the seat is too narrow, widen using the 45
°
cutter and recheck contact point on the valve face and seat width after each cut.
3.28
=
In. / mm.
Valve Seat Width:
Intake Std: .028" (.7 mm)
Limit: .055" (1.4 mm)
Exhaust Std: .039I (1.0 mm)
Limit: .071" (1.8 mm)
Seat
Width
8.
Clean all filings from the area with hot soapy water. Rinse and dry with compressed air.
9.
Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the valve.
NOTE: Lapping is not required with an interference angle valve job.
10. Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem.
ENGINE
Cylinder Head Reassembly
NOTE: Assemble the valves one at a time to maintain proper order.
1.
Apply engine oil to valve guides and seats.
2.
Coat valve stem with molybdenum disulfide grease or
2W-50 Synthetic engine oil.
3.
Install valve carefully with a rotating motion to avoid damaging valve seal.
4.
Valve seals should be installed after the valves are in the head to avoid valve seal damage. Install new valve seals on valve guides.
5.
Dip valve spring and retainer in clean 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
3
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.
3.29
ENGINE
Valve Sealing Test
1.
Clean and dry the combustion chamber area (A).
A
Valve Lifter Removal / Inspection
1.
Remove the valve lifters by reaching into the crankcase and pushing the lifter up through the lifter bore by hand.
2.
Thoroughly clean the lifters in cleaning solvent and wipe them with a clean, lint-free cloth.
3.
Mark the lifters with a white pen if using the lifters for reassembly. This will ensure that the lifters are properly placed during engine 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
1.
Follow engine disassembly procedures to remove rocker cover and cylinder head.
2.
Tap cylinder (A) lightly with a rubber mallet in the reinforced areas only until loose.
3.
Rock cylinder forward and backward while lifting it from the crankcase, supporting pistons and connecting rods.
Support pistons with Piston Support Block (PN 2870390).
4.
Check the lifters for wear or scores.
5.
Check the bottom end of lifter to make sure that it has a slight convex.
6.
If the bottom surface has worn flat, it may be used with the original camshaft only.
A
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.
3.30
Piston Removal
1.
Remove circlip (A). Mark the piston with a white pen to ensure proper orientation (if reused) during assembly.
ENGINE
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 a locating tab on the end which fits into a notch (B) in the upper oil ring land of the piston.
To Remove:
A) Remove the top rail first followed by the bottom rail.
B) Remove the expander.
Compression
Rings
B
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.
3.31
ENGINE
Cylinder Inspection
1.
Remove all gasket material from the cylinder sealing surfaces.
2.
Inspect the top of the cylinder (B) for warp using a straight edge (A) and feeler gauge (C). Refer to Ill. 1 and Ill. 2.
A
3.
Inspect cylinder for wear, scratches, or damage.
3.32
A
B
B
Measure at different points on surface.
4.
Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge. Measure in two different directions, front to back and side to side, on three different levels (1/2, down from top, in the middle, and 1/
2, up from bottom). Record measurements. If cylinder is tapered or out of round beyond .002", the cylinder must be replaced.
1/2” Down From Top of Cylinder
C
=
In. / mm.
Cylinder Warp: .004" (0.1 mm) Max.
1/2” Up From Bottom
=
In. / mm.
Cylinder Taper Limit:
.002" (9.05mm) Max.
Cylinder Out of Round:
Limit: .002" (.0 mm) Max.
700 Standard Bore Size
(Both Cylinders): 3.1496
"
(80 mm)
ENGINE
Cylinder Hone Selection And Honing
Procedure
Cylinders may be wet or dry honed depending upon the hone manufacturer’s recommendations. Wet honing removes more material faster and leaves a more distinct pattern in the bore.
If cylinder wear or damage is excessive, it will be necessary to replace the cylinder. The cylinders are lined with a nicasil coating and are not repairable. Hone only enough to de-glaze the outer layer of the cylinder bore.
CAUTION
A hone which will straighten as well as remove material from the cylinder is very important.
Using a common spring loaded glaze breaker for honing is not advised for nicasil cylinders.
Polaris recommends using a rigid hone or arbor honing machine. Cylinders may be wet or dry honed depending upon the hone manufacturer's recommendations.
Wet honing removes more material faster and leaves a more distinct pattern in the bore.
Example of Cross Hatch Pattern
Honing To Deglaze
A finished cylinder should have a cross-hatch pattern to ensure piston ring seating and to aid in the retention of the fuel/oil mixture during initial break in. Hone cylinder according to hone manufacturer's instructions, or these guidelines:
• Honing should be done with a diamond hone. Cylinder could be damaged if the hone is not hard enough to scratch the nicasil lining.
• Use a motor speed of approximately 300-500 RPM, run the hone in and out of the cylinder rapidly until cutting tension decreases. Remember to keep the hone drive shaft centered (or cylinder centered on arbor) and to bring the stones approximately 1/2, (1.3 cm) above and below the bore at the end of each stroke.
• Release the hone at regular intervals and inspect the bore to determine if it has been sufficiently de-glazed, and to check for correct cross-hatch.
NOTE: Do not allow cylinder to heat up during honing.
• After honing has been completed, inspect cylinder for thinning or peeling.
IMPORTANT: Clean the cylinder after honing
If cylinder wear or damage is excessive, it will be necessary to replace the cylinder. The cylinders are lined with a nicasil coating and are not repairable. Hone only enough to de-glaze the outer layer of the cylinder bore.
Cleaning the Cylinder After Honing
It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material. Wash the cylinder in a solvent, then in hot, soapy water. Pay close attention to areas where the cylinder sleeve meets the aluminum casting (transfer port area). Use electrical contact cleaner if necessary to clean these areas. Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris Lubricant.
3
3.33
ENGINE
Piston-to-Cylinder Clearance
Measure piston outside diameter at a point 5 mm up from the bottom of the piston at a right angle to the direction of the piston pin.
Subtract this measurement from the maximum cylinder measurement obtained in Step 5.
5 mm
2.
Measure piston pin O.D. Replace piston and/or piston pin if out of tolerance.
Piston Pin Measurement Locations
Piston
Piston Pin
Piston to Cylinder Clearance:
See “700 EFI Engine Service
Specifications” on page 3.11
Piston Pin O.D.:
See “700 EFI Engine Service
Specifications” on page 3.11
3.
Measure connecting rod small end ID.
Piston O.D.:
See “700 EFI Engine Service
Specifications” on page 3.11
Piston / Rod Inspection
1.
Measure piston pin bore.
Connecting Rod Small End I.D.:
See “700 EFI Engine Service
Specifications” on page 3.11
3.34
Piston Pin Bore:
See “700 EFI Engine Service
Specifications” on page 3.11
4.
Measure piston ring to groove clearance by placing the ring in the ring land and measuring with a thickness gauge.
Replace piston and rings if ring-to-groove clearance exceeds service limits.
Piston
Ring
Feeler Gauge
See “700 EFI Engine Service
Specifications” on page 3.11
Piston Ring Installed Gap
1.
Place each piston ring (A) inside cylinder (B) using piston to push ring squarely into place as shown.
A
ENGINE
3.
If the bottom installed gap measurement exceeds the service limit, replace the rings. If ring gap is smaller than the specified limit, file ring ends until gap is within specified range.
NOTE: Always check piston ring installed gap after re-boring a cylinder or when installing new rings. A re-bored cylinder should always be scrubbed thoroughly with hot soapy water, rinsed, and dried completely. Wipe cylinder bore with oil immediately to remove residue and prevent rust.
Starter Drive Bendix Removal / Inspection
1.
Remove stator housing bolts and remove housing.
2.
Remove the flywheel nut and washer. Install Flywheel
Puller (PN 2871043) and remove flywheel.
NOTE: Do not thread the puller bolts into the flywheel more than 1/4, or stator coils may be damaged.
3.
Remove starter bendix assembly (A). Note the thrust washers located on both sides of the bendix.
3
C
B
25-50 mm
A
Piston Ring Installed Gap
See “700 EFI Engine Service
Specifications” on page 3.11
NOTE: Ring should be installed with the mark facing upward.
2.
Measure installed gap with a feeler gauge (C) at both the top and bottom of the cylinder.
4.
Inspect the thrust washer for wear or damage and replace if necessary.
5.
After the bendix is removed, remove the two bolts retaining the starter. Tap on the starter assembly (B) with a soft faced mallet to loosen the starter from the crankcase.
B cylinder taper. The cylinder should be measured for excessive taper and out of round.
3.35
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
Flywheel / Stator Removal / Inspection
1.
Remove stator housing bolts and remove housing.
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.
Remove Stator
Cover
2.
Remove flywheel nut and washer.
3.
Install Flywheel Puller (PN 2871043) and remove flywheel
(A).
CAUTION
Do not thread the puller bolts into the flywheel more than 1/4, or stator coils may be damaged.
E D
B
5.
Remove the bendix (E) if necessary.
Engine Crankcase Disassembly / Inspection
1.
Remove the stator cover (A) and water pump cover (B).
B
A
3.36
ENGINE
2.
Remove the nylok nut (C), washer (D), and water pump impeller (E). Remove part of the water pump seal behind the impeller.
5.
Remove the starter bendix (G), wire holddown plate (H), and the woodruff key (I) from the crankshaft. The stator does not have to be removed at this point.
I
E
G
D H
C
3.
Remove flywheel nut and washer.
4.
Install Flywheel Puller (PN 2871043) and remove flywheel
(F).
6.
Remove the gear/stator housing bolts and remove the gear/ stator housing cover (J) and gasket from the crankcase. Be sure to catch the excess oil from the crankcase.
CAUTION
Do not thread the puller bolts into the flywheel more than 1/4, or stator coils may be damaged.
3
J
2871043 F
7.
Note the positions of the gears in the photo.
Camshaft Gear
Crank Gear
Counterbalance Gear
3.37
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 alignment and timing during reassembly of the gears.
K
Timing Marks
Water Pump Gear
CAUTION
Wear safety glasses at all times. Use caution when working with the top gear.
The springs could cause injury or become lost should they pop out.
12. Remove all three springs using one of the tapered pins from the Tapered Pins (PU-45497-1) .
M
N recommended that all of the gears be replaced. A gear kit is available.
9.
Use the Cam Gear Tooth Alignment Tool (PU-45497-2)
(O) to align the cam split gear assembly. With the split gear aligned, remove the bolt and cam gear assembly.
NOTE: Install the Cam Gear Tooth Alignment Tool
(PU-45497-2) into the assembly hole counter clockwise from the timing mark as shown.
10. Inspect the cam gear teeth and check to make sure there is spring tension offsetting the teeth between the two gears.
If there is no tension, check the springs inside of the cam gear assembly.
3 Loaded Springs
PU-45497-1
13. With a white marking pen, accent the timing mark on the gear that contains the 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.
3.38
14. Inspect the gear teeth and the three tabs on the gears for wear.
Inspect Teeth & Tabs
ENGINE
To Assemble:
* Hold the spring with one finger.
* Start the pointed end of the tapered pin into the cam gear hole and slowly push the dowel through the hole until the end of the dowel is almost flush with the spring.
* Perform this procedure with all three tapered pins.
* Do not push the pins too far through or the springs will pop out.
NOTE: Do not remove the tapered pins at this time.
17. Note in the photograph that the Tapered Pins (PU-45497-
1) are below flush with end of the springs. This helps to align the three gear tabs during the next step.
3
Replace 3 Springs
15. Install the new springs into the grooves of the cam gear.
Install Springs
PU-45497-1
16. Insert the pointed dowels from the Tapered Pins (PU-
45497-1) into the cam gear.
Cam Gear Spring Installation Tool Kit:
(PU-45497)
Tapered Pins:
(PU-45497-1)
Cam Gear Tooth Align Tool:
(PU-45497-2)
18. Line up the two gears using the timing marks and the three gear tabs that were referenced earlier. Push the gears back together, using both hands and hold securely.
Align Timing Marks
PU-45497-1
3.39
ENGINE
19. Once the gears are pressed together, firmly hold the gears together with one hand. Carefully remove the Tapered Pins
(PU-45497-1) by pulling them out one at a time with the other hand.
21. To remove the balance shaft gear, the flat side of the camshaft (P) must face the balance shaft gear. To rotate the camshaft, use the Cam Spanner Wrench (PU-45498) to rotate the camshaft so the flat side of the camshaft faces the balance shaft gear.
PU-45498
P
20. After the tapered pins are removed, be sure the cam gear assembly is held together tightly. Place the cam gear assembly on a flat surface. Use the Cam Gear Tooth
Alignment Tool (PU-45497-2) to align the teeth of the cam gears, as shown in the picture.
NOTE: Install the Cam Gear Alignment Tool (PU-
45497-2) into one assembly hole counter clockwise from the timing mark.
NOTE: This Cam Spanner Wrench (PU-45498) is only needed to rotate the camshaft when the entire valve train is assembled. If the rocker arms are removed, the cam-shaft can be turned by hand.
22. Remove the bolt and nut from the balance shaft gear. Try to remove the balance shaft gear. If the gear does not come off manually, use the Flywheel Puller (PN 2871043) to remove the balance shaft gear.
2871043
PU-45497-2
Alignment Tool (PU-45497-2), use a twisting motion when pushing down on the tool.
3.40
ENGINE
23. Inspect the crankshaft gear (Q) for broken or worn teeth. If the crankshaft gear does not need to be replaced, it does not need to be removed. If the crankshaft gear is damaged, remove the crankshaft gear with the Flywheel Puller
(PN 2871043).
26. Rotate the water/oil pump gear (S), so that all four bolts are visible though the gear. Remove the four bolts with a hex wrench. Pull out the pump.
S
Q
3
24. Install the two puller bolts (R). Tighten the puller bolts up so that the bolts are at equal length.
27. Inspect the oil pump rotors for wear. Mark the rotors with a white pen to ensure, upon reassembly, that the correct sides of the rotors are installed and mesh with the same edges as previously installed.
Mark Rotors
R
25. Install the Flywheel Puller ( PN 2871043 ) and remove the crankshaft gear, if needed.
2871043
NOTE: If replacing the old rotors, new replacement rotors will fit into the original oil/water pump housing.
28. Use a feeler gauge to measure the clearance between the two rotors. Measure the gap between the two rotor tips as shown below. The clearance should not exceed 0.006"
(0.15 mm) .
Max Tip Clearance
0.006” (0.15 mm)
3.41
ENGINE
29. Remove the oil pressure relief. The oil pressure relief consists of a bolt, washer, spring, and valve (dowel).
Inspect the valve (dowel) for signs of possible obstructions.
Use compressed air to blow out any debris.
31. Carefully press the gear off the assembly while supporting the housing assembly.
Press Off Gear
30. Reinstall the valve (dowel chamfered end first). Install the spring, washer, and bolt. Torque to specification .
22 ± 2 ft. lbs.
(30 ± 3 Nm).
Chamfer
End First
CAUTION
Wear appropriate safety gear during this procedure. Protective gloves, clothing and eye wear are required.
32. Remove the snap ring from the assembly. Place the housing in a support and press out the bearing/shaft assembly.
Press out shaft and bearing assembly.
Bearing
=
T
22
±
2 ft. lbs. (30
±
3 Nm)
NOTE: Be sure to place the tapered end of the valve
(dowel) in first. If the valve is installed incorrectly, oil pressure and oil priming problems will occur.
Retaining Ring
33. Place the shaft in a press to remove the bearing.
Press Off Bearing
3.42
34. Press shaft into the new bearing..
Press On Bearing
37. Remove thrust plate (U).
U
ENGINE
35. Press the bearing/shaft assembly using the bearing's outer race. Do not use the shaft to press the assembly into the housing, as bearing damage may result. Install retaining ring.
Press Bearing / Shaft
Assembly using outer race only
38. Remove PTO end engine mount. Remove crankcase bolts.
Tap on the reinforced areas on the cases using soft hammer.
Carefully separate the two crankcase halves.
Separate
Crankcase Halves
3
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.
39. Remove and clean oil pick up (V) and oil baffle weldment
(W).
W
V
3.43
ENGINE
40. Remove balance shaft and crankshaft.
Camshaft Inspection
1.
Thoroughly clean the cam shaft.
2.
Visually inspect each cam lobe for wear or damage.
3.
Measure height of each cam lobe using a micrometer.
Compare to specification.
41. Remove and inspect crankshaft main journal bearings for abnormal wear. It is recommended to replace the bearings anytime the engine is disassembled .
Cam Lobe Height
=
In. / mm.
Cam Lobe Height
(Intake & Exhaust):
Std: 1.3334" (33.8674 mm)
4.
Measure camshaft journal outside diameters (O.D.).
C
B
A
=
In. / mm.
Camshaft Journal O.D. :
A. (Mag): 1.654" ± .00039" (42 ± .010 mm)
B. (Ctr.): 1.634" ± .00039" (41.50 ± .010 mm)
C. (PTO): 1.614" ± .00039" (41 ± .010 mm)
3.44
ENGINE
5.
Measure ID of camshaft journal bores.
ENGINE REASSEMBLY
Crankcase Reassembly
=
In. / mm.
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)
(PTO) 1.617" ± 0.00039" (41.07 ± 0.010 mm)
6.
Calculate oil clearance by subtracting journal O.D.s from journal bore I.D.s. Compare to specification.
=
In. / mm.
CAUTION
After any reassembly or rebuild, the engine must be primed using the Oil Priming Adapter
(PU-45778) and a 3/4-full oil filter before initial start-up (see “Oil Pump Priming”).
NOTE: Before assembly, clean bolts and bolt holes with Primer N (PN 2874275) to remove any debris.
This will ensure proper sealing when installing bolts.
1.
Install oil pick up (A), if removed. Torque to specification.
3
Calculated Camshaft Oil Clearance:
Std: 0.0027" (.070mm)
Limit: .0039" (.10 mm)
NOTE: Replace camshaft if damaged or if any part is worn past the service limit.
NOTE: Replace engine block if camshaft journal bores are damaged or worn excessively.
B
A
2.
Install oil baffle weldment (B). Torque to specification.
=
T
Oil Baffle Weldment &
Oil Pick Up Bolt Torque:
60 ± 6 in. lbs. (6.8 ± 0.68 Nm)
3.45
ENGINE
3.
Install the balance shaft. Inspect balance shaft clearance
(C) in both gearcase halves. Rotate balance shaft to ensure there is clearance between it and the oil baffle weldment.
6.
Apply Crankcase Sealant (PN 2871557) to the top gearcase halve.
NOTE: Do not apply sealant to cam relief hole (E).
C
E
NOTE: Always install new balance shaft bearings.
4.
Apply assembly lube to cam journals and balance shaft bearing surfaces of the MAG case halve. Install camshaft and balance shaft.
7.
Assemble the crankcase halves. Apply LocTite™ 242 (PN
2871949) to the threads and pipe sealant to the bolt flanges.
Torque bolts to specification following torque pattern at beginning of this chapter.
=
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.
D
3.46
ENGINE
NOTE: Always replace the camshaft and lifters as a set.
12. Orientate the piston rings on the piston before installation 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
10. Lubricate connecting rods with 2W-50 synthetic engine oil.
3. Oil Ring
13. Install piston assemblies into cylinder aligning the piston pin holes, to ensure proper alignment of the pistons to the connecting rods upon assembly. Partially install the piston pins into the pistons.
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.
3.47
ENGINE
14. Position cylinder and piston assemblies onto the connecting rods and push the piston pins through the piston and connecting rods.
NOTE: New bolts have patch lock on the threads and do not require Loctite™.
G
Push in Piston Pins
15. Install the piston pin circlips. The circlip ends should be installed at the 12 O'clock position.
=
T
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 O’clock 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.
3.48
19. Align the bolt holes and install oil pump assembly into crankcase. Rotate the rotors in the housing during installation, as this checks for binding if new rotors are used.
NOTE: For assembly of the gears, the cam gear and the crankshaft gear are stamped with “This Side
Out." This indicates the side of the gear that faces outward or away from the case.
ENGINE
21. Apply Loctite
™
242 (PN 2871949) to the crankshaft.
3
NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2874275) to remove any 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.
22. Before installing the crankshaft gear (I), heat the crankshaft gear to 250
°
F (121
°
C) on a hot plate (J).
I J
H
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 from the hot plate. Use a pair of pliers and leather gloves when handling the crankshaft gear.
installing bolts to check for binding of the rotors.
=
T
84
±
Oil Pump Bolt Torque:
8 in.lbs. (9.50
±
0.90 Nm)
* Torque in Sequence
3.49
ENGINE
24. Install the crankshaft gear (I) onto the crankshaft.
NOTE: For assembly of the gears, the cam gear and the crankshaft gear are stamped with This Side Out."
This indicates the side of the gear that faces outward or away from the case.
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 the Cam Gear Alignment Tool still in place) onto the camshaft. The timing marks on the camshaft gear should align with the keyway on the balance shaft gear.
PU-45497-2
M
I
25. Install counter balance shaft gear (J) with new key, aligning timing marks with crankshaft gear (I). Install washer and bolt. Use the Gear Holder (PU-45838).
Torque to specification.
J
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.
NOTE: Cam Spanner Wrench (PU-45498) is only needed to rotate the camshaft when the entire valve train is assembled.
PU-45498
PU-45838
=
T
Balance Shaft Gear Bolt Torque:
22
±
2 ft. lbs. (30
±
3 Nm)
27. Reinstall the camshaft gear; so the timing marks are properly aligned. Install the washer and bolt. Torque to specification.
3.50
NOTE: Be sure all of the timing marks are properly aligned.
K
Timing Marks
Water Pump Gear
M
Timing Marks
N
ENGINE
IMPORTANT: Due to seal design and construction, seals MUST be installed DRY (no lubricant) during assembly. Use of lubricants (oil, soapy water, etc.) will not allow the seal to wear-in and seal properly. Do not touch seal surface or allow seal surface to come in contact with contaminates during installation.
Thoroughly clean parts, tools and hands before installation.
NOTE: To remove the water pump seal, the gear/ stator housing must be removed. The water pump seal cannot be removed or installed with the gear/ stator housing attached to the engine. Shaft damage will occur.
NOTE: Install the water pump seal (N) with the seal lip facing out (towards the crankcase). Use of a hydraulic press is recommended for this procedure.
29. Install 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
3
P
=
T
Counterbalance Gear and Camshaft
Gear Bolt Torque:
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
/ stator housing. Use the Water Pump Mechanical Seal
Installer (PA-44995) to properly install the seal to the correct depth in the cover.
PA-45483
NOTE: Install the crankshaft seal (P) with the seal lip facing out (towards the crankcase).
P
PA-44995
O
P
A
-4
49
95
N
Seal lip goes towards the crankcase.
3.51
ENGINE
30. Once the crankshaft seal is installed into the gear / stator housing cover, set the direction of the paper lip by sliding the Main Crankshaft Seal Saver (PA-45658) into the crankshaft seal from the rubber lipped side to the paper lip side (back to front). Remove the tool.
Important: Set the direction of the paper lip seal
32. Before installing the gear/stator housing cover, install the
Water Pump Seal Saver (PA-45401) onto the water pump shaft.
PA-45401
PU-45658
31. Carefully install the tapered end of the Crankshaft Seal
Protection Tool (PA-45658) through the paper side of the crankshaft seal (back to front). Leave the seal protector installed in the crankshaft seal. Check the crankshaft seal lips to verify they have not been rolled or damaged.
33. Install a NEW gasket to the gear/stator housing cover and crankcase. With the tools installed, carefully place the gear/stator housing cover over the protection tools.
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.
3.52
ENGINE
NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2874275) to remove any debris. This will ensure proper sealing when installing bolts.
37. Install shaft seal with ceramic surface facing inward.
35. Install the gear/stator housing gasket onto he crankcase.
Gear / Stator
Housing Gasket
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.
38. Install water pump impeller (P). Secure the impeller with the washer and a new nylok nut (Q) . Torque the nut to specification.
P
Q
=
T
Water Pump Impeller Nut Torque:
108
±
6 in. lbs. (6.8
±
0.68 Nm)
PA-45401
PA-45658
=
T
Gear/Stator Housing Bolt Torque:
96
±
3 in. lbs. (10.85
±
0.35 Nm)
*Torque in proper sequence
3.53
3
ENGINE
39. Install water pump cover (R) with new O-ring seal. Torque bolts to specification in proper sequence (See front of this chapter).
Install the O-ring dry, no lubricants
96 ± 3 in. lbs.
(10.85 ± 1.35 Nm)
R
Flywheel / Stator Installation
NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2874275) to remove any debris. This will ensure proper sealing when installing bolts.
1.
Install stator assembly (S) and bolts. Torque bolts to specification.
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.
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.
NOTE: There are thrust washers on both sides of starter drive.
T
U
S
=
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)
3.54
ENGINE
=
T
Flywheel Nut Torque
65 ± 7 ft.lbs. (88 ± 9.50 Nm)
4.
Install stator housing with new o-rings. Torque the bolts to specification and follow proper bolt torque sequence at the beginning of this chapter.
3.
Lubricate threads and top of washers underside of bolt head with engine oil. Install head bolts (C) and torque to specification.
C
3
96 ± 3 in. lbs.
(10.85 ± 0.35 Nm)
=
T
96
Stator Housing Bolt Torque:
±
3 in. lbs. (10.85
±
0.35 Nm)
Cylinder Head Reassembly
NOTE: Before reassembly, clean the bolts and bolt holes with Primer N (PN 2874275) to remove any debris. This will ensure proper sealing when installing bolts.
1.
Install the head gasket (A) on the cylinder (B).
=
T
Cylinder Head Bolt Torque:
Initial setting: 35
±
4 ft. lbs. (47.5
±
5.5 Nm)
Allow to set for 1 minute, then turn additional 90
°
(1/4 turn)
*Torque Bolts In Sequence
4.
Lubricate push rods (D) and install into lifters.
D
A
B
2.
Install cylinder head on cylinder.
3.55
ENGINE
5.
Lubricate rockers (E) with engine oil.
E
6.
Verify pushrods are engaged in lifters.
7.
Install rockers. Be sure that tab of fulcrum (F) is seated in head stand-off. Torque bolts to specification.
=
T
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 bolts.
10. Install rocker cover. Torque bolts to specification.
F
=
T
Rocker Arm Bolt Torque
22 + 2 ft. lbs. (30
±
3 Nm)
8.
Install breather reed (G) into rocker cover (H). Lightly apply black RTV sealant to the outer edges of the breather reed. The reed has a tab and will assemble one-way only.
Torque the breather bolts to specification.
20 ± 5 in.lbs.
(2.5 ± .55 Nm)
H
=
T
Rocker Cover Bolt Torque:
84
±
8 in.lbs. (9.5
±
0.9 Nm)
Torque in Sequence
11. Install thermostat (J), new O-ring, and thermostat housing.
Torque to specification .
K
17 ± 2 ft. lbs.
(23 ± 3 Nm)
I
J
84 ± 8 in. lbs.
(9.5 ± 0.9 Nm)
3.56
G
=
T
Thermostat Housing Bolt Torque:
84
±
8 in. lbs. (9.5
±
0.9 Nm)
12. Install temperature sender (K) and torque to specification.
ENGINE
2.
Remove primer plug from the engine. Install Oil System
Priming Adapter (PU-45778) into the oil plug hole. Push
3-5 oz. (approx.) of Polaris PS-4 PLUS 2W-50 Synthetic into the adapter or until resistance is felt. Remove the adapter. Apply sealant to the plug threads. Install the plug and torque to specification.
PU-45778
3
K
=
T
Temperature Sender Torque:
17 ± 2 ft.lbs. (23 ± 3 Nm)
Oil Pump Priming
1.
After the engine is completely assembled and ready for installation, the engine must be properly primed with
Polaris PS-4 PLUS 2W-50 Synthetic Oil (PN 2876244).
Fill the oil filter three-quarters full with Polaris PS-4 PLUS
2W-50 Synthetic Engine Oil (PN 2876244). Let the oil soak into the filter for 8-10 minutes. Install the filter onto the engine.
Fill 3/4 full with 2W-50
=
T
Primer Plug Torque
18
±
2 ft.lbs. (24.4
±
2.71 Nm)
CAUTION
After any reassembly or rebuild, the engine must be primed using the Oil Priming Adapter
(PU-45778) and a 3/4-full oil filter before initial start-up. Follow 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
Refer to “Engine Break-In Period” under “Engine Installation
Notes” listed earlier in this chapter.
3.57
ENGINE
TROUBLESHOOTING
Engine
Spark Plug Fouling
• Spark plug cap loose or faulty
• Incorrect spark plug heat range or gap
• PVT system calibrated incorrectly/ components worn or mis-adjusted
• Fuel quality poor (old) or octane too high
• Low compression
• Restricted exhaust
• Weak ignition (loose coil ground, faulty coil, or stator)
• Restricted air filter (main or pre-cleaner) or breather system
• Improperly assembled air intake system
• Restricted engine breather system
• Oil contaminated with fuel
Engine Turns Over But Fails To Start
• No fuel
• Dirt in fuel line or filter
• Fuel will not pass through fuel valve
• Fuel pump inoperative/restricted
• Tank vent plugged or pinched
• Engine flooded
• Low compression (high cylinder leakage)
• No spark (Spark plug fouled) ignition component failure
Engine Does Not Turn Over
• Dead battery
• Starter motor does not turn
• Engine seized, rusted, or mechanical failure
Engine Runs But Will Not Idle
• Restricted carburetor pilot system
• Low compression
• Crankcase breather restricted
Engine Idles But Will Not Accelerate
• Spark plug fouled/weak spark
• Broken throttle cable
• Obstruction in air intake
• Air box removed (reinstall all intake components)
• Incorrect or restricted carburetor jetting
• Reverse speed limiter limiting speed
• Incorrect ignition timing
• Restricted exhaust system
• Cam worn excessively
Engine Has Low Power
• Spark plug fouled
• Cylinder, piston, ring, or valve wear or damage (check compression)
• PVT not operating properly
• Restricted exhaust muffler
• Cam worn excessively
Piston Failure - Scoring
• Lack of lubrication
• Dirt entering engine through cracks in air filter or ducts
• Engine oil dirty or contaminated
Excessive Smoke and Carbon Buildup
• Excessive piston-to-cylinder clearance
• Wet sumping
• Worn rings, piston, or cylinder
• Worn valve guides or seals
• Restricted breather
• Air filter dirty or contaminated
Piston Failure - Scoring
• Lack of lubrication
• Dirt entering engine through cracks in air filter or ducts
• Engine oil dirty or contaminated
3.58
Excessive Smoke and Carbon Buildup
• Excessive piston-to-cylinder clearance
• Wet sumping due to over-full crankcase
• Worn rings, piston, or cylinder
• Worn valve guides or seals
• Restricted breather
• Air filter dirty or contaminated
Low Compression
• Cylinder head gasket leak
• No valve clearance ( cam wear )
• Cylinder or piston worn
• Piston rings worn, leaking, broken, or sticking
• Bent valve or stuck valve
• Valve spring broken or weak
• Valve not seating properly (bent or carbon accumulated on sealing surface)
• Rocker arm sticking
Backfiring
• Speed limiter system malfunction
• Fouled spark plug or incorrect plug or plug gap
• Exhaust system air leaks
• Exhaust system air leaks
• Ignition system faulty:
Spark plug cap cracked / broken
Ignition coil faulty
Ignition switch circuit faulty
Poor connections in ignition system
Ignition timing incorrect
Sheared flywheel key
• Valve sticking
ENGINE
Cooling System
Overheating
• Low coolant level
• Air in cooling system
• Wrong type/mix of coolant
• Faulty pressure cap or system leaks
• Restricted system (mud or debris in radiator fins causing restriction to air flow, passages blocked in radiator, lines, pump, or water jacket, accident damage)
• Lean mixture (restricted jets, vents, fuel pump or fuel valve)
• Fuel pump output weak
• Electrical malfunction
• Water pump failure/ Loose impeller
• Thermistor failure
• Cooling fan inoperative or turning too slowly (perform current draw test)
• Low oil level
• Spark plug incorrect heat range
• Faulty hot light circuit
• Thermostat stuck closed or not opening completely
• Radiator is missing its internal diverter plate not allowing coolant to flow through entire radiator
Temperature Too Low
• Thermostat stuck open
Leak at Water Pump Weep Hole
• Faulty water pump mechanical seal (coolant leak)
• Faulty pump shaft oil seal (oil leak)
3
3.59
ENGINE
NOTES
3.60
ELECTRONIC FUEL INJECTION
CHAPTER 4
ELECTRONIC FUEL INJECTION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
EFI SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
FUEL TANK EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
EFI SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
EFI SYSTEM COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
FUEL LINES - QUICK CONNECT REMOVAL / INSTALLATION. . . . . . . . . . . . . . . . . . . 4.9
ELECTRONIC FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
PRINCIPAL COMPONENTS / EFI OPERATION OVERVIEW. . . . . . . . . . . . . . . . . . . . 4.10
INITIAL PRIMING / STARTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
ELECTRONIC CONTROL UNIT (ECU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
ECU SERVICE / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
FUEL SENDER TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
FUEL PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
FUEL PUMP / TANK ASSEMBLY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
FUEL PRESSURE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
FUEL PRESSURE REGULATOR TEST / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 4.14
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
FUEL INJECTOR SERVICE / 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 TEST PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
TPS INITIALIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
TPS REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20
ENGINE COOLANT TEMPERATURE SENSOR (ECT) . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
ECT SENSOR TEST / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22
IGNITION COIL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22
IGNITION COIL / HT LEAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22
GENERAL TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23
DIAGNOSTIC “BLINK CODES” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23
EFI TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24
EFI SYSTEM BREAK-OUT DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25
FUEL INJECTOR CIRCUIT (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25
FUEL INJECTOR CIRCUIT (MAG). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25
CRANKSHAFT POSITION SENSOR (CPS) CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . 4.26
FUEL PUMP CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.26
ENGINE COOLANT TEMPERATURE SENSOR (ECT). . . . . . . . . . . . . . . . . . . . . . . . . 4.27
TEMPERATURE OVERHEAT INDICATOR LAMP CIRCUIT. . . . . . . . . . . . . . . . . . . . . 4.27
THROTTLE POSITION SENSOR (TPS) CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.28
AIR TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP) CIRCUIT . 4.28
DIAGNOSTIC CONNECTOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29
DIAGNOSTIC INDICATOR LAMP CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29
4
4.1
ELECTRONIC FUEL INJECTION
GENERAL INFORMATION
WARNING
* Gasoline is extremely flammable and explosive under certain conditions.
* EFI components are under high pressure. Verify system pressure has been relieved before disassembly.
* Never drain the fuel system when the engine is hot.
Severe burns may result .
* Do not overfill the tank. The tank is at full capacity 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 gasoline is stored.
* 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 clothing.
* Always stop the engine and refuel outdoors or in a well ventilated area.
Special Tools
PART
NUMBER
PU-43506-A
PV-48656
PU-47082
4010264
PU-47063
PU-47471
TOOL DESCRIPTION
Fuel Pressure Gauge Kit
Fuel Pressure Gauge Adaptor
Throttle Position Sensor Tester
TPS Tester Regulator
Digital Wrench
™
Diagnostic Software
(Includes most recent version of software and a serial number)
Digital Wrench
™
SmartLink Module Kit
(PU-47470, PU-47469, PU-47468)
PU-47470
Digital Wrench
™
PC Interface Cable
PU-47469
PU-47468
Digital Wrench
™
Vehicle Interface Cable
Digital Wrench
™
SmartLink Module
IMPORTANT: For the most recent information on
Digital Wrench
™
software and fileset downloads please visit the website: www.polaris.diagsys.com
4.2
ELECTRONIC FUEL INJECTION
Fuel Pressure Gauge Kit - PU-43506-A
IMPORTANT: The EFI fuel system remains under high pressure, even when the engine is not running.
Before attempting to service any part of the fuel system, pressure must be relieved (if applicable). The
Fuel Pressure Gauge Kit has an integrated pressure relief valve that can be used to bleed off pressure once you have completed the fuel pressure test.
Throttle Position Sensor Tester - PU-47082
This tester allows the use of a digital multi-meter to test TPS function and perform the TPS Adjustment procedure.
Relief Valve
Adaptor shown is included with kit.
Fuel Pressure Gauge Adaptor - PV-48656
Adaptor works with
PU-43506-A
NOTE: Voltage Regulator 4010264 is required if using TPS harness PU-47082. If your dealership sells Polaris snowmobiles, you may already have this regulator from TPS tool PN 2201519. If you do not have this regulator, you must order one from
SPX at 1-800-328-6657.
TPS Tester Regulator - 4010264
This tester regulator regulates the 9 volt battery voltage to a 5 volt input, required when using the TPS harness PU-47082.
Disconnect here and connect in-line w/fuel pump outlet
4
NOTE: If your dealership sells Polaris snowmobiles, you may already have this regulator from TPS tool
PN 2201519. If you do not have this regulator, you must order one from SPX at 1-800-328-6657.
4.3
ELECTRONIC FUEL INJECTION
Digital Wrench
™
Diagnostic Software
PU-47063
This dealer-only software installs on laptop computers equipped with a CD drive and serial port connection, and is designed to replace multiple shop tools often used to test EFI components.
It also includes step-by-step diagnostic procedures to aid technician repair and troubleshooting.
Digital Wrench
™
- Download Website
Located at: www.polaris.diagsys.com
Digital Wrench
™
SmartLink Module Kit - PU-47471
This module kit contains the necessary cables and hardware to communicate between the vehicle ECU and the Digital
Wrench™ diagnostic software. Polaris dealers can also order the following separately: SmartLink Module PU-47468 ,
Vehicle Interface Cable PU-47469 and PC Interface Cable
PU-47470 . This module kit is used on all 8 pin connector-based
Polaris EFI systems. This kit is available to Polaris dealers through our tool supplier, SPX (1-800-328-6657).
PU-47469
PU-47468
PU-47470
Digital Wrench
™
- Diagnostic Connector
(Located under the hood as shown below)
4.4
ELECTRONIC FUEL INJECTION
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
700 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
4.5
ELECTRONIC FUEL INJECTION
Fuel Tank Exploded View
PFA Nut
Fuel Pump / Regulator
PFA Gasket
Fuel Tank Assembly
Fuel Sender
Float Arm
Preliminary Filter
NOTE: Fuel Pump is NOT Serviceable
Fuel Flow
Fuel Tank
Fuel Filters
Pressure Regulator
Fuel Pump Assembly
4.6
Fuel Rail
Quick Connect Fuel Line
Fuel Injectors
ELECTRONIC FUEL INJECTION
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
6. Fuel Pump / Regulator / Gauge Sender Asm. (Located in tank as an assembly)
7. Fuel Rail
8. Engine Coolant Sensor (ECT)
9. Throttle Position Sensor (TPS)
10. Throttle Body
11. Wire Harness (Part of main harness)
4
4.7
ELECTRONIC FUEL INJECTION
EFI System Component Locations
1.
Electronic Control Unit (ECU)
Located under the seat on the driver’s side.
4.
Fuel Injectors / Fuel Rail
Attached to the fuel rail located in the intake track of the cylinder head.
2.
Intake Air Temperature and Barometric Air Pressure
Sensor (T-BAP)
Located in the rubber intake boot between the air box and throttle body.
5.
Fuel Pump / Regulator / Fuel Gauge Sender Assembly
Located in fuel tank as an assembly.
3.
Crankshaft Position Sensor (CPS)
Located in the magneto cover on the right-hand side of the engine.
6.
Throttle Body
Throttle
Body
4.8
7.
Throttle Position Sensor (TPS)
Located on the right-hand side of the throttle body.
TPS
8.
Engine Coolant Temperature Sensor (ECT)
Located in the cylinder head.
ELECTRONIC FUEL INJECTION
Fuel Lines - Quick Connect
Removal / Installation
CAUTION
Verify fuel system has been depressurized before performing this procedure.
RANGER 700 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.
2.
Squeeze the connector tabs together and slide the green retainer forward.
4
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.
4.9
ELECTRONIC FUEL INJECTION
ELECTRONIC FUEL INJECTION
Principal Components
The Electronic Fuel Injection (EFI) system is a complete engine fuel and ignition management design. This system includes the following principal components:
• Fuel Pump
• Fuel Rai l
• Fuel Line(s)
• Fuel Filter(s)
• Fuel Injectors
• Pressure Regulator
• Throttle Body / lntake Manifold
• Engine Control Unit (ECU)
• Ignition Coils
• Coolant Temperature Sensor
• Throttle Position Sensor (TPS)
• Crankshaft Position Sensor (CPS)
• Intake Air Temperature and Barometric Air
Pressure Sensor (T-BAP)
• Wire Harness Assembly
• Check Engine Light
The ECU controls the amount of fuel being injected and the ignition timing by monitoring the primary sensor signals for air temperature, barometric air pressure, engine temperature, speed
(RPM), and throttle position (load). These primary signals are compared to the programming in the ECU computer chip, and the ECU adjusts the fuel delivery and ignition timing to match the values.
During operation the ECU has the ability to re-adjust temporarily, providing compensation for changes in overall engine condition and operating environment, so it will be able to maintain the ideal air/fuel ratio.
During certain operating periods such as cold starts, warm up, acceleration, etc., a richer air / fuel ratio is automatically calculated by the ECU.
EFI Operation Overview
The EFI system is designed to provide peak engine performance with optimum fuel efficiency and lowest possible emissions.
The ignition and injection functions are electronically controlled, monitored and continually corrected during operation to maintain peak performance.
The central component of the system is the Bosch Engine
Control Unit (ECU) which manages system operation, determining the best combination of fuel mixture and ignition timing for the current operating conditions.
An in-tank electric fuel pump is used to move fuel from the tank through the fuel line and 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.
Initial Priming / Starting Procedure
NOTE: The injection system must be purged of all air prior to the initial start up, and / or any time the system has been disassembled.
If the EFI system is completely empty of fuel or has been disassembled and repaired:
1.
Cycle the key switch from “OFF” to “ON” 6 times, waiting for approximately 3 seconds at each “ON” cycle to allow the fuel pump to cycle and shut down.
2.
Once step 1 is completed, turn the key switch to “START” until the engine starts or 5 seconds has passed.
3.
If the engine failed to start, repeat step 1 for 2 more cycles and attempt to start the engine.
If the engine fails to start, a problem may still exist, and should be diagnosed.
NOTE: Accurate testing of EFI components is recommended utilizing the Digital Wrench™
Diagnostic Software (dealer only).
4.10
ELECTRONIC FUEL INJECTION
ELECTRONIC CONTROL UNIT (ECU)
Operation Overview
The ECU is the brain or central processing computer of the entire EFI fuel/ignition management system. During operation, sensors continuously gather data which is relayed through the wiring harness to input circuits within the ECU. Signals to the
ECU include: ignition (on/off), crankshaft position and speed
(RPM), throttle position, engine coolant temperature, air temperature, intake manifold air pressure and battery voltage.
The ECU compares the input signals to the programmed maps in its memory and determines the appropriate fuel and spark requirements for the immediate operating conditions. The ECU then sends output signals to set the injector duration and ignition timing.
RANGER 700 EFI RPM Limit:
Hard Limit - Injector suppression occurs
• High: 6200
• Low: 6200
• Neutral: 6200
• Reverse: 6200
Soft Limit - Timing suppression occurs
• High: None
• Low: 5900
• Neutral: 5900
• Reverse: 5900
4
During operation, the ECU continually performs a diagnostic check of itself, each of the sensors, and system performance. If a fault is detected, the ECU turns on the “Check Engine” light in the speedometer and stores the fault code in its fault memory.
Depending on the significance or severity of the fault, normal operation may continue, or "Fail-Safe" operation (slowed speed, richer running) may be initiated. A technician can determine the cause of the “Check Engine” light by initiating the “Blink Code” sequence or by using Digital 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 revlimiting feature is programmed into the ECU. If the maximum
RPM limit (6200) is exceeded, the ECU suppresses the injection signals, cutting off the fuel flow. This process repeats it self in rapid succession, limiting operation to the preset maximum.
ECU Service
Never attempt to disassemble the ECU. It is sealed to prevent damage to internal components. Warranty is void if the case is opened or tampered with in any way.
All operating and control functions within the ECU are pre-set.
No internal servicing or readjustment may be performed. If a problem is encountered, and you determine the ECU to be faulty, contact the Polaris Service Department for specific handling instructions. Do not replace the ECU without factory authorization.
The relationship between the ECU and the throttle position sensor (TPS) is very critical to proper system operation. If the
TPS is faulty, or the mounting position of the TPS to the throttle body is altered, the TPS must be adjusted.
For the purpose of troubleshooting, a known-good ECU from another Polaris RANGER 700 EFI of the same model may be used without system or engine component damage.
ECU Replacement
1.
Remove the retaining screws (2) holding the ECU.
2.
With the Ignition turned off, disconnect the wire harness from the ECU.
3.
To install, reverse the procedures and tighten screws to specification.
=
T
ECU Retaining Screws
10 in. lbs. (1.1 Nm)
4.11
ELECTRONIC FUEL INJECTION
FUEL PUMP
Operation Overview
NOTE: All EFI units utilize quick connect lines.
An electric fuel pump assembly is used to transfer fuel to the EFI system from inside the fuel tank. This assembly includes the fuel pump, regulator and fuel gauge sender. The pump is rated for a minimum output of 25 liters per hour at 39 psi and has a nonserviceable internal 60-micron filter.
Fuel pump is not serviceable, picture is for reference only.
Fuel Pump
Fuel Sender Test
If the fuel gauge reading on the instrument cluster is not working, or if the display reading differs in large comparison to the fuel in the tank, perform a resistance test on the fuel sender.
Disconnect the fuel pump / sending unit connection and measure the resistance between the Purple and Brown wires (see chapter
10 for further details). If out of specification, replace the fuel pump / tank assembly.
Fuel Sender Resistance Specifications:
Full: 90
Ω
Empty: 5
Ω
Regulator
Fuel Pump Test
Fuel Gauge
Sender Float serviceable and must be replaced if determined to be faulty. 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
Strainer (Bottom)
When the key switch is turned to "ON", the ECU activates the fuel pump, which pressurizes the system for start-up.
The ECU switches off the pump preventing the continued delivery of fuel in these instances:
• If the key switch is not promptly turned to the "start" position.
• If the engine fails to start.
• If the engine is stopped with the key switch "ON" (as in the case of an accident).
In these situations, the “check engine” light will go on, but will turn off after 4 cranking revolutions if system function is OK.
Once the engine is running, the fuel pump remains on.
WARNING
Fuel is extremely flammable and may cause severe burns, injury, or death.
Do not use any device that produces a flame or electrical devices that may spark around fuel or fuel vapors.
1.
Cover the fuel line connection with a shop towel and disconnect the fuel line from the fuel pump.
2.
Install the Fuel Pressure Gauge Adaptor (PV-48656) in-line between the fuel pump outlet and fuel line.
4.12
3.
Connect the hose from the Fuel Pressure Gauge Kit (PU-
43506-A) to the test valve on the Fuel Pressure Gauge
Adaptor. Route the clear hose into a portable gasoline container or the vehicle’s fuel tank.
PV-48656
PU-43506-A
4.
Turn on the key switch to activate the pump and check the system pressure on the gauge. If system pressure of 39 psi
±
3 is observed, the ignition switch, ECU, fuel pump, and pressure regulator are working properly. Turn the key switch off and depress the valve button on the tester to relieve the system pressure.
Fuel Pump Pressure: 39 psi. ± 3
ELECTRONIC FUEL INJECTION
Fuel Pump / Tank Assembly Replacement
NOTE: All EFI units utilize quick connect fuel lines.
WARNING
Always wear safety goggles when working with high pressure or flammable fluids. Failure to do so could result in serious injury or complications.
NOTE: The fuel pump cannot be replaced as an individual part, the entire fuel pump and fuel tank is replaced as an assembly. Refer to your parts book for the proper part number.
1.
Disconnect the negative battery cable.
2.
Remove the seat.
3.
Disconnect the fuel line from the fuel pump.
Harness
4
Fuel Line
NOTE: If the pressure is too high or too low, replace the fuel pump / tank assembly.
5.
If the pump did not activate (Step 4), disconnect the plug from the fuel pump. Connect a DC voltmeter across terminals “A” and “C” in the plug on the vehicle harness side. Turn on the key switch and observe voltage to ensure a minimum of 7 volts is present.
NOTE: If the voltage was below 7 VDC, test battery, ignition switch, relay(s), wiring harness and ECU.
6.
If the reading is between 7 and 14 volts, turn key switch off and connect an ohmmeter between the terminals “A” and “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 / tank 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 / tank assembly.
Vent Hose
4.
Disconnect the fuel pump electrical harness.
5.
Remove the fuel tank vent hose
NOTE: A small amount of fuel may come out of the fuel line or tank. Plug the fuel line and tank inlet or use a shop towel during removal.
NOTE: Properly drain fuel into a suitable container.
6.
Remove the RH rear fender and fuel cap.
4.13
ELECTRONIC FUEL INJECTION
7.
Remove the two inner bolts that hold the fuel tank to the frame.
Fuel Tank Installation
1.
Reinstall the fuel pump / tank assembly.
2.
Reinstall the four fuel tank mounting bolts that were removed.
3.
Reconnect the electrical harness. Install the fuel line and vent line and verify they are secure.
4.
Reinstall the RH rear fender.
5.
Reconnect the negative battery cable. Test the fuel pump by turning on the key and listening for the pump to activate.
8.
Remove the two outer lower bolts that hold the fuel tank to the frame.
9.
Reinstall the fuel cap and carefully pull the fuel tank out the
RH side of the frame.
FUEL PRESSURE REGULATOR
Operation Overview
The fuel pressure regulator maintains the required operating system pressure of 39 psi + 3psi. A rubber-fiber diaphragm divides the regulator into two separate sections-, the fuel chamber and the pressure regulating chamber. The pressure regulating spring presses against the valve holder (part of the diaphragm), pressing the valve against the valve seat. The combination of atmospheric pressure and regulating spring tension equals the desired operating pressure. Any time the fuel pressure against the bottom of the diaphragm exceeds the desired (top) pressure, the valve opens, relieving the excess pressure, returning the excess fuel back to the tank.
Fuel Pressure Regulator Test
Refer to the “FUEL PUMP TEST” procedure.
See “Fuel Pump Test” on page 4.12.
Fuel Pressure Regulator Replacement
The regulator is a sealed, non-serviceable assembly. If it is faulty, the pump assembly must be replaced. Refer to the Fuel
Pump / Tank Assembly Replacement procedure.
4.14
WARNING
Wear safety goggles while performing this procedure, failure to do so could result in serious injuries.
ELECTRONIC FUEL INJECTION
FUEL INJECTORS
Operation Overview
The fuel injectors mount into the intake manifold, and the fuel rail attaches to them at the top end. Replaceable O-rings on both ends of the injector prevent external fuel leaks and also insulate it from heat and vibration.
NOTE: Do not apply voltage directly to the fuel injector(s). Excessive voltage will burn them out. Do not ground the injector(s) with the ignition on.
lnjector(s) will open/turn on if relay is energized.
If an injector is not operating, it can indicate either a bad injector, or a wiring/electrical connection problem. Check as follows:
Injector leakage is very unlikely, but in rare instances it can be internal (past the 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 injectors is not recommended; they should be replaced.
Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem.
4
Fuel Injector Replacement
1.
Thoroughly clean the area around the throttle body, intake boot and fuel injectors. Allow engine to cool.
2.
Disconnect the fuel injector harness(s) as shown below.
When the key switch is on, the fuel rail is pressurized, and voltage is present at the injector. At the proper instant, the ECU completes the ground circuit, energizing the injector. The valve needle in the injector is opened electromagnetically, and the pressure in the fuel rail forces fuel down through the inside. The
“director plate” at the tip of the injector (see inset) contains a series of calibrated openings which directs the fuel into the intake port in a cone-shaped spray pattern.
The injector is opened and closed once for each crankshaft revolution, however only one-half the total amount of fuel needed for one firing is injected during each opening. The amount of fuel injected is controlled by the ECU and determined by the length of time the valve needle is held open, also referred to as the “injection duration” or “pulse width”. It may vary in length from 1.5-8 milliseconds depending on the speed and load requirements of the engine.
Fuel Injector Service
Injector problems typically fall into three general categorieselectrical, dirty / clogged, or leakage. An electrical problem usually causes one or both of the injectors to stop functioning.
Several methods may be used to check if the injectors are operating.
• With the engine running at idle, feel for operational vibration, indicating that they are opening and closing.
• When temperatures prohibit touching, listen for a buzzing or clicking sound with a screwdriver or mechanic's stethoscope.
• Disconnect the electrical connector from an injector and listen for a change in idle performance (only running on one cylinder) or a change in injector noise or vibration.
3.
Place a catch-container below the fuel line fitting at the fuel rail and remove the fuel line.
4.
Remove the fuel rail mounting screw and carefully loosen
/ pull the rail away from the injectors.
5.
Reverse the procedures to install the new injector(s) and reassemble. Use a new O-ring any time an injector is removed (replacement injectors include new O-rings).
Lubricate O-rings lightly with oil to aid installation. Torque the fuel rail mounting screw to 16-20 ft. lbs. (22-27 Nm) .
4.15
ELECTRONIC FUEL INJECTION
CRANKSHAFT POSITION SENSOR
(CPS)
Operation Overview
The engine speed sensor is essential to engine operation, constantly monitoring the rotational speed (RPM) and position of the crankshaft.
CPS Test
The crankshaft position sensor is a sealed, non-serviceable assembly. If fault code diagnosis indicates a problem within this area, test and correct as follows:
1.
Disconnect main harness connector from ECU.
2.
Connect an ohmmeter between the pin terminals. A resistance value of 560
Ω ±
10% at room temperature (20
C, 68
°
°
F) should be obtained. If resistance is correct, check the mounting, air gap, toothed ring gear (damage, runout, etc.), and flywheel key.
Crankshaft Position Sensor:
560
Ω ±
10% (20
°
C, 68
°
F)
A ferromagnetic 60-tooth ring gear with two consecutive teeth missing is mounted on the flywheel. The inductive speed sensor is mounted 1.0
±
0.26 mm (0.059
±
0.010 in.) away from the ring gear. During rotation, an AC pulse is created within the sensor for each passing tooth. The ECU calculates engine speed from the time interval between the consecutive pulses. The twotooth gap creates an “interrupt” input signal, corresponding to specific crankshaft position for PTO cylinder. This signal serves as a reference for the control of ignition timing by the ECU.
Synchronization of the CPS and crankshaft position takes place during the first two revolutions each time the engine is started.
This sensor must be properly connected at all times. If the sensor fails or becomes disconnected for any reason, the engine will quit running.
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
Ω ±
10% should again be obtained.
NOTE: If the resistance is incorrect, remove the screw securing the sensor to the mounting bracket and replace the sensor. If the resistance in step 2 was incorrect, but the resistance of the sensor alone was correct, test the main harness circuit between the sensor connector terminals and the corresponding pin terminals in the main connector.
Correct any observed problem, reconnect the sensor, and perform step 2 again.
CPS Replacement
1.
Disconnect sensor harness connector.
2.
Using a 6 mm hex wrench, remove the retaining bolt and replace the sensor, using a light coating of oil on the o-ring to aid installation.
3.
Torque the retaining bolt to specification.
=
T
CPS Retaining Bolt Torque:
25 in. lbs. (2.8 Nm)
4.16
TEMPERATURE / BAROMETRIC AIR
PRESSURE SENSOR (T-BAP)
Operation Overview
Mounted on the throttle body intake, the temperature and barometric air pressure sensor (T-BAP) performs two functions in one unit.
ELECTRONIC FUEL INJECTION
THROTTLE POSITION SENSOR (TPS)
Operation Overview
The throttle position sensor (TPS) is used to indicate throttle plate angle to the ECU.
Mounted on the throttle body and operated directly off the end of the throttle shaft, the TPS works like a rheostat, varying the voltage signal to the ECU in direct correlation to the angle of the throttle plate. This signal is processed by the ECU and compared to the internal pre-programmed “maps” to determine the required fuel and ignition settings for the amount of engine load.
Stop Screw
(Factory Set)
DO NOT ADJUST
Throttle Body
4
Air passing through the intake is measured by the T-BAP and relayed to the ECU. These signals, comprised of separate air temperature and barometric air pressure readings, are processed by the ECU and compared to its programming for determining the fuel and ignition requirements during operation.
Yellow
(Output)
TPS
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 sensor should only be tested using the Digital Wrench™
Diagnostic Software (dealer only). Refer to the EFI Diagnostic
Software Manual for more information.
Blue
(Input)
Black
(Ground)
T-BAP Replacement
1.
Disconnect sensor from engine harness.
2.
Using a 10mm wrench, remove the retaining bolt and replace the sensor, using a light coating of oil on the o-ring to aid installation.
3.
Torque the retaining bolt to specification.
=
T
T-BAP Retaining Bolt Torque:
29 in. lbs. (3.3 Nm)
The correct position of the throttle body stop screw is established and set at the factory. DO NOT loosen the throttle body stop screw or alter its position in any manner. The stop screw controls the air flow calibration of the throttle body. If the stop screw is repositioned or adjusted, the throttle body assembly must be replaced.
TPS Tester / Regulator
The throttle position sensor (TPS) reading can be checked by using the TPS Tester Adapter Harness (PU-47082) and TPS
Tester Regulator (4010264) .
4.17
ELECTRONIC FUEL INJECTION
Set-up the TPS Tester Adapter Harness (PU-47082) , according to the instructions that accompanied the tester. Make sure the 9
Volt battery is new.
PU-47082
TPS Tester
Use NEW
9V battery
Verify TPS Tester Reference Voltage
A 5 volt reference voltage from the TPS Tester harness is required for the TPS test to be accurate. Refer to the instructions provided with the TPS Tester Adapter Harness (PU-47082) or follow the bullet point steps below to check reference voltage.
Reference Voltage Test:
• Insert black voltmeter probe into the “Bk” test port.
• Connect the red voltmeter probe into the “R” test port and verify the voltage is 4.99-5.01 Vdc. If this reading is low, verify the 9 volt battery is good or try a new 9 volt battery.
As mentioned in the instructions included with the tester, be sure the TPS Tester Adapter Harness is set up along with the TPS
Tester Regulator (4010264) .
4010264
TPS Tester Regulator
NOTE: If your dealership sells Polaris snowmobiles, you may already have this regulator from TPS Tester
Kit (2201519). If you do not have this regulator, you must order one from SPX at 1-800-328-6657.
Typical Tester
Set-up
Test Ports
9 Volt Battery
Regulator
Cable Ties
Install Regulator
Connections Here
R = RED
P = PINK
Bk = BLACK
Y = YELLOW
4.18
TPS Reference Voltage
5 Vdc Input
IMPORTANT: Always use a fresh 9 Volt battery.
ELECTRONIC FUEL INJECTION
Checking TPS Reading
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
8.
Allow the throttle foot pedal to rest in the idle position. The voltmeter should read .660 ± .010
volts.
PU-47082 Tester
Should Read
.660 ± .010 Vdc
Red
Probe
Red Pink
Black
Black
Probe
.660
4
TPS
TPS
Connector
Figure 4-18
4.
Plug the TPS Tester harness into the TPS harness.
5.
Set your voltmeter to read Vdc. Connect the red voltmeter probe into the “Y” test port and the black voltmeter probe into the “Bk” test port.
6.
Move the throttle open and closed slowly while reading the display. The voltage should increase and decrease smoothly without any “jumps” when the throttle is applied.
PU-47082 Tester
No “Jumps” in read out
Red
Probe
Red Pink
Black
Black
Probe
0.66 ~ 3.7
TPS Output Reading
.660 ± .010 Vdc
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 4-19).
3.
Rotate the TPS until your voltmeter reads .660 ± .010
volts
(see Figure 4-18).
TPS Output Reading
.660 ± .010 Vdc
7.
If voltage varies with throttle movement, continue on to
Step 8. If the sensor did not function correctly, replace it.
4.
Retighten the mounting screw, and verify the voltage did not change. If the voltage changed, repeat steps 2 - 4.
5.
Reconnect the TPS harness to the vehicle harness.
4.19
ELECTRONIC FUEL INJECTION
TPS Replacement
NOTE: The correct position of the TPS angle on the throttle body is established and set at the factory. If the TPS is replaced, repositioned or loosened it must be recalibrated. Refer to the “TPS Adjustment” procedure.
1.
Remove the lower seat base to access the TPS.
2.
Disconnect the TPS harness connection (A).
Coolant passes through the cylinder and by the sensor probe, varying a resistance reading which is relayed to the ECU. This signal is processed by the ECU and compared to its programming for determining the fuel and ignition requirements during operation. The ECU also uses this signal to determine when to activate the fan during operation. If for any reason the engine temperature sensor circuit is interrupted, the fan will default to “ON”.
ECT Sensor Test
A
TPS
Engine Coolant Temperature Sensor
Figure 4-19
B
3.
Remove the mounting screw (B) and replace the sensor.
NOTE: If replacing the TPS or throttle body, you must perform the “TPS Adjustment” procedure.
4.
Refer to “ TPS Adjustment ” for setting the TPS voltage.
To quickly rule out other components and wiring related to the
ECT sensor, disconnect the harness from the ECT sensor. The fan should turn on. This indicates all other components are working properly.
Refer to Chapter 10 for ECT testing. Polaris dealers can also test the sensor by using the Digital Wrench™ Diagnostic Software
(dealer only). Refer to the Digital Wrench™ User Guide for more information.
ECT Sensor Resistance Readings
Temperature
°
F (
°
C) Resistance
68
°
F (20
°
C)
212
°
F (100
°
C)
2.5 k
186
Ω ±
Ω ±
6%
2%
ENGINE COOLANT TEMPERATURE
SENSOR (ECT)
Operation Overview
Mounted on the cylinder head, the engine temperature sensor measures coolant temperature. The engine temperature sensor is a Negative Temperature Coefficient (NTC) type sensor, as the temperature increases the resistance decreases.
ECT Sensor Replacement
1.
Drain coolant to level below sensor.
2.
Disconnect sensor from engine harness.
3.
Using a wrench, remove and replace the sensor, applying a light coating of thread sealant to aid installation.
4.
Torque the sensor to 17 ft. lbs. (23 Nm) .
=
T
ECT Retaining Bolt Torque:
17 ft. lbs. (23 Nm)
4.20
ELECTRONIC FUEL INJECTION
IGNITION COIL
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.
Storage Box
Primary Test
Ignition Coil
Measure Between
Connector Pins
0.4
Ω
Secondary Test
4
Ignition Coil Tests
The ignition coil can be tested by using an ohm meter. Use the following illustration and specification table to test the ignition coil.
NOTE: The left hand storage compartment must be removed to properly access the ignition coil harness for testing purposes.
Ignition Coil Resistance Readings
Test
Primary
Secondary
Pin
Connection
Between 1 & 2
Between 3 & 2
Between
High Tension
Lead Ends
Resistance
0.4
5 k
Ω
Ω
Measure Between
End Caps
5 k
Ω
Ignition Coil / HT Lead Replacement
1.
Remove the seat base and left hand storage compartment to access the ignition coil.
2.
Disconnect the ignition coil harness and remove the high tension leads from the coil.
3.
Remove the fastener retaining the coil and remove the coil from the vehicle. If replacing the high tension lead(s), remove the other end of the lead(s) from the spark plug.
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
ELECTRONIC FUEL INJECTION
GENERAL TROUBLESHOOTING
Diagnostic “Blink Codes”
NOTE: The EFI diagnostic mode is intended to 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.
3.
Any “blink codes” stored in the ECU will display a numerical “blink code”, one at a time, in numerical order, on the instrument cluster display.
4.
The word “End” will display after all of the codes have been displayed or if no codes are present.
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
SAE C
ODE
B
LINK
C
ODE
55
55
55
56
56
52
52
54
54
54
56
58
58
58
46
51
51
51
52
41
41
42
42
45
23
25
26
21
22
22
P0264
P0265
P0655
P1657
P1658
P1651
P1652
P1653
P1231
P1232
P1233
P1480
P1481
P1482
P0335
P0122
P0123
P0601
P0914
P0500
P0113
P0112
P0117
P0118
P0107
P0108
P1260
P0261
P0262
P1263
4.22
N
AME
Loss of Synchronization
TPS: Open or Short Circuit to Ground
TPS: Short Circuit to Battery
RAM Error: Defective ECU
Transmission Input: Invalid Gear
Vehicle Speed Sensor: Implausible
Intake Air Temp Sensor: Open or Short Circuit to +Sensor Voltage (ECU)
Intake Air Temp Sensor: Short Circuit to Ground
Engine Temperature Sensor Circuit: Short To Ground
Engine Temperature Sensor Circuit: Open or Short to Battery
Barometric Pressure Sensor: Circuit Low Input
Barometric Pressure Sensor: Circuit High Input
Injector 1: Open Load
Injector 1: Short Circuit to Ground
Injector 1: Short Circuit to Battery
Injector 2: Open Load
Injector 2: Short Circuit to Ground
Injector 2: Short Circuit to Battery
Engine Temperature Lamp: Open Load
Engine Temperature Lamp: Short Circuit to Ground
Engine Temperature Lamp: Short Circuit to Battery
Diagnostic Lamp: Open Load
Diagnostic Lamp: Short Circuit to Ground
Diagnostic Lamp: Short Circuit To Battery
Pump Relay: Open Load
Pump Relay: Short Circuit to Ground
Pump Relay: Short Circuit to Battery
Cooling Fan: Open Load
Cooling Fan: Short Circuit to Ground
Cooling Fan: Short Circuit to Battery
C
HECK
E
NGINE
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
EFI Troubleshooting
Fuel Starvation / Lean Mixture
Symptoms: Hard start or no start, bog, backfire, popping through intake / exhaust, hesitation, detonation, low power, spark plug erosion, engine runs hot, surging, high idle, idle speed erratic.
• No fuel in tank
• Restricted tank vent, or routed improperly
• Fuel lines or fuel injectors restricted
• Fuel filter plugged
• Fuel pump inoperative
• Air leak in system
• Intake air leak (throttle shaft, intake ducts, airbox or air cleaner cover)
• Incorrect throttle stop screw adjustment
Rich Mixture
Symptoms: Fouls spark plugs, black, sooty exhaust smoke, rough idle, poor fuel economy, engine runs rough/ misses, poor performance, bog, engine loads up, backfire.
• Air intake restricted (inspect intake duct)
• Air filter dirty/plugged
• Poor fuel quality (old fuel)
• Fouled spark plug
• TPS setting incorrect
• Injector failure
ELECTRONIC FUEL INJECTION
Poor Idle
Symptom: Idle Too High (If greater than 1300 RPM when engine is warm)
• Throttle stop screw set incorrect
• Throttle cable sticking, improperly adjusted, routed incorrectly
Symptom: Idle Too Low (if less than 900 RPM when engine is warm)
• Plugged air filter
• Leaking injector (rich condition)
• Belt dragging
• Throttle stop screw tampering
4
Symptom: Erratic Idle
• Throttle cable incorrectly adjusted
• Air Leaks, dirty injector
• TPS damaged or adjusted
• Tight valves
• Ignition timing incorrect
• Belt dragging
• Dirty air cleaner
• Engine worn
• Spark Plug fouled
• Throttle stop screw set incorrectly (out of sync with
ECU)
4.23
ELECTRONIC FUEL INJECTION
EFI SYSTEM BREAK-OUT DIAGRAMS
Fuel Injector Circuit (PTO)
Fuel Injector Circuit (MAG)
4.24
Crankshaft Position Sensor (CPS) Circuit
ELECTRONIC FUEL INJECTION
4
Fuel Pump Circuit
4.25
ELECTRONIC FUEL INJECTION
Engine Coolant Temperature Sensor (ECT)
Temperature Overheat Indicator Lamp Circuit
4.26
Throttle Position Sensor (TPS) Circuit
ELECTRONIC FUEL INJECTION
4
Air Temperature / Barometric Air Pressure Sensor (T-BAP) Circuit
4.27
ELECTRONIC FUEL INJECTION
Diagnostic Connector Circuit
Diagnostic Indicator Lamp Circuit
4.28
BODY / STEERING / SUSPENSION
CHAPTER 5
BODY / STEERING / SUSPENSION
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
BODY COMPONENT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
REMOVAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
LOWER BODY, FLOOR AND FENDERS (4X4 CREW). . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
LOWER BODY, FLOOR AND FENDERS (6X6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
HOOD / DASH COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
DASH INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
CAB FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
ASSEMBLY / REMOVAL (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
ASSEMBLY / REMOVAL (4X4 CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
SEAT / HEAD REST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
CHASSIS / MAIN FRAME (4X4 CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
CHASSIS / MAIN FRAME (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
STEERING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
STEERING AND SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
FRONT A-ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
FRONT STRUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
FRONT STRUT CARTRIDGE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
BALL JOINT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
MID AXLE A-ARM (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
REAR A-ARM (4X4 CREW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
REAR STABILIZER BAR (4X4 CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
SWING ARM (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22
REAR DRIVE AXLE AND SWING ARM EXPLODED VIEW (6X6) . . . . . . . . . . . . . . . . . 5.23
REAR CARGO BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
CARGO BOX - PANELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
CARGO BOX - TAILGATE / BOX SUPPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
BOX REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26
STORAGE BOX (4X4 CREW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
DECAL REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
5
5.1
BODY / STEERING / SUSPENSION
TORQUE SPECIFICATIONS
ITEM TORQUE VALUE ft.lbs. (Nm)
Front A-Arm Attaching Bolt
Front A-Arm Ball Joint Stud Nut
Front Wheel Hub Castle Nut
Rear Shock Bolt (upper)
30 ft. lbs. (41 Nm)
30 ft. lbs. (41 Nm)
60 ft. lbs. (81 Nm)
30 ft. lbs. (41 Nm)
Rear Shock Bolt (lower)
Rear Wheel Hub Castle Nut
30 ft. lbs. (41 Nm)
110 ft. lbs. (150 Nm)
Mid Half Shaft Castle Nut (6x6) 110 ft. lbs. (150 Nm)
Wheel Nuts (Cast Rims)
Wheel Nuts (Steel Rims)
90 ft. lbs. (122 Nm)
35 ft. lbs. (47 Nm)
Upper / Lower Control Arm
Mounting Bolt
Mid Axle Upper / Lower Control
Arm Mounting Bolt (6x6)
Lower Middle Wheel Bearing
Carrier Bolt (6x6)
Lower Rear Wheel Bearing
Carrier Bolt
Upper Middle Wheel Bearing
Carrier Bolt (6x6)
Upper Rear Wheel Bearing
Carrier Bolt
Strut Rod Retaining Nut (Top)
Strut Casting Pinch Bolt
Tie Rod End Jam Nut
Tie Rod End Castle Nut
Seat Belt to Seat Base
Steering Wheel to Shaft
Upper Steering Shaft to
U-Joint Shaft
Lower Steering Shaft to Box
Steering Box
30 ft. lbs. (41 Nm)
35 ft. lbs. (47 Nm)
35 ft. lbs. (47 Nm)
30 ft. lbs. (41 Nm)
35 ft. lbs. (47 Nm)
30 ft. lbs. (41 Nm)
15 ft. lbs. (21 Nm)
17 ft. lbs. (23 Nm)
12-14 ft. lbs. (17-19 Nm
40 ft. lbs. (54 Nm)
40 ft. lbs. (54 Nm)
25-31 ft. lbs. (34-42 Nm)
15-19 ft. lbs. (20-26 Nm)
30 ft. lbs. (41 Nm)
14-18 ft. lbs. (19-24 Nm)
NOTE: Refer to exploded views throughout this chapter for more torque specifications, component identification, and location of components.
SPECIAL TOOLS
TOOL DESCRIPTION
Strut and Ball Joint Tool Set
Shock Spanner Wrench
Shock Spring Compressor Tool
Strut Spring Compressor Tool (LH)
Strut Spring Compressor Tool (RH)
PART NUMBER
2870871
2870872
2870623
2871573
2871574
5.2
BODY / STEERING / SUSPENSION
BODY COMPONENT REMOVAL
Removal Procedures
TO REMOVE:
SEAT
DASH
HOOD
CAB
HOOD LINER
FRONT BUMPER
CARGO BOX
FUEL TANK
LH STORAGE BOX
PERFORM THESE STEPS:
Pull up on front of seat and then pull forward
1. Remove the gear selector handle
2. Then remove the 4 screws that attach the hood to the dash
3. Remove the remaining dash screws that attach the RANGER emblem
4. Disconnect the dash component wires
5. Remove the steering wheel (1 nut)
1. Disconnect headlights
2. Remove the 4 hinge screws
1. Remove seat back and seat base
2. Remove the bolts for the front mounts
3. Remove the bolts for the rear mounts
1. Remove liner darts and screws
2. Disconnect the wiring harnesses
3. Remove the air baffling boxes
1. Lift the hood
2. Remove the 3 front Torx screws from LH and RH wheel well panels
3. Remove the 2 top bumper mounting bolts
4. Remove the 3 lower bumper mounting bolts
1. Place box in the dump position
2. Remove the pin and clip from the shock at the cargo box
3. Disconnect light harnesses
4. Remove (2) screws holding hinge pins
5. Tap out hinge pins
6. Lift the box off the frame with assistance
1. Raise the cargo box
2. Disconnect the vent and fuel lines (note locations)
3. Disconnect electrical connection
4. Remove the RH rear fender and fuel cap
5. Remove the 2 inner bolts and 2 outer bolts that hold the tank to the frame
6. Carefully lift the tank out through the side
1. Raise the cargo box
2. Remove the (2) bottom T27 Torx screws
3. Remove the (2) top T27 Torx screws
4. Remove the (3) T27 Torx screws on the front edge
5. Lift the storage box outward from frame
5.3
5
BODY / STEERING / SUSPENSION
Lower Body, Floor and Fenders (4x4 CREW)
T-27
T-27
Rear Fender
T-27
Mid Fender
T-27
T-27
Main Floor
Speed
Nut
T-27
Rear Floor
Foam
Foil
Foam
Floor
Cover
Floor
Bracket
Rear Floor Ext.
Dog House
Cover
U-Type Nut
Front Fender
Foil
Foil
Foam
Foil
Dog House
Cover
12V
Receptacle
Storage
Box
Speed
Nut
T-27
Mid Fender
T-27
Wheel Well
Panel
T-25
Skid Plate
Front Fender
T-27
Wheel Well
Panel T-25
Washer
Self-tapping
Screws
TORQUE SPECIFICATIONS
T-25 Screws: 20-30 in. lbs. (2-3.5 Nm)
T-27 Screws: 4-5 ft. lbs. (5-6 Nm)
Skid Plate Screws: 6-8 ft. lbs. (8-10 Nm)
5.4
Lower Body, Floor and Fenders (6x6)
BODY / STEERING / SUSPENSION
T-27
Floor
Cover
T-27
Rear
Fender
T-27
Speed
Nut
U-Type
Nut
Front
Fender
T-27
Main Floor
Foam
T-27
Foil
Foam Foil
Foil
Foil
Dog House
Cover
Foam
T-27
Speed
Nut
Rear
Fender
5
T-25
Wheel Well
Panel
T-25
Skid Plate
Front
Fender
T-27
Washer
Self-tapping
Screws
T-27
TORQUE SPECIFICATIONS
T-25 Screws: 20-30 in. lbs. (2-3.5 Nm)
T-27 Screws: 4-5 ft. lbs. (5-6 Nm)
Skid Plate Screws: 6-8 ft. lbs. (8-10 Nm)
5.5
BODY / STEERING / SUSPENSION
Hood / Dash Components
T-30
T-27
Hinges
Glove Box Assembly
T-27
Cup Holder
Grille
Hood
T-27
Headlights
Hood Latch Strap
TORQUE SPECIFICATIONS
T-30 Screws: 8-10 in. lbs. (0.9-1 Nm)
T-27 Screws: 4-5 ft. lbs. (5-6 Nm)
5.6
Hood Liner
Dash Instruments and Controls
A. Speedometer
B. Headlight Switch
C. 2WD/AWD Switch
D. 12 Volt Accessory Receptacle
E. Speedometer “Mode” Button
F. Key Switch
G. Speedometer Mount Plate
BODY / STEERING / SUSPENSION
G
A
B
C
G
B
F
E
D
C
A
5
F
E
D
5.7
BODY / STEERING / SUSPENSION
CAB FRAME
Assembly / Removal (6x6)
1.
Assemble the two rear cab frames at the coupler joint and secure with two 3/8" screws and nuts. Assemble the front frame in same manner. Leave all fasteners finger tight.
2.
Assemble the center cross bracket to the rear cab frame and secure with two 5/16”-18 x .75” hex bolts and nuts. Tighten 5/16" bolts to 16-18 ft. lbs. (20-24 Nm).
3.
Assemble the front cab frame to the rear cab frame at both side coupler joints and secure with 3/8" screws and nuts. Leave all fasteners finger tight.
4.
Place the assembled cab frame onto the vehicle and align the rear mount holes. Secure the rear of the frame using the two 5/
16”-18 x 2.25” bolts and nuts on the outer tubes, and the two 5/16”-18 x .75” bolts and nuts on the inner mounts. Tighten all
5/16" bolts to 16-18 ft. lbs. (20-24 Nm). NOTE: Tighten all nuts finger tight, then tighten to specification.
5.
Secure the front cab frame flanges to the vehicle with 5/16”-18 x .75” bolts and nuts. Tighten all 5/16" bolts to 16-18 ft. lbs.
(20-24 Nm). NOTE: Tighten all nuts finger tight, then tighten to specification.
6.
Tighten all 3/8" cab frame screws to 25-28 ft. lbs. (34-38 Nm).
7.
Check all nuts and bolts for proper torque and installation. To remove the cab frame, reverse the installation instructions.
5.8
BODY / STEERING / SUSPENSION
Assembly / Removal (4x4 CREW)
1.
Assemble the two rear cab frames at the coupler joint and secure with two 3/8" screws and nuts. Assemble the center frame and the front frame in same manner. Tighten all 3/8" screws to 25-28 ft. lbs. (34-38 Nm).
2.
Assemble the center cross bracket to the rear cab frame and secure with two 5/16”-18 x .75” hex bolts and nuts. Tighten the bolts to 16-18 ft. lbs. (20-24 Nm).
3.
Assemble the front cab frame to the center cab frame at both side coupler joints and secure with 3/8" screws and nuts. Attach the center cab frame to the rear cab frame at both side coupler joints and secure with 3/8” screws and nuts. Tighten all 3/8" screws to 25-28 ft. lbs. (34-38 Nm).
4.
Remove the storage box under the front seat.
5.
Place the assembled cab frame onto the vehicle and align the rear and center mounting holes. Secure the rear and center of the frame using the 5/16”-18 x 2.25” bolts on the outer tubes and the 5/16”-18 x .75” bolts on the inner mounts. Tighten all 5/16" bolts to 16-18 ft. lbs. (20-24 Nm). NOTE: Tighten all nuts finger tight, then tighten to specification.
6.
Secure the front flanges to the vehicle with 5/16”-18 x .75” bolts and nuts. Tighten all 5/16" bolts to 16-18 ft. lbs. (20-24 Nm).
NOTE: Tighten all nuts finger tight, then tighten to specification.
7.
Check all nuts and bolts for proper torque and installation. Replace the storage box back into position and fasten with four screws. To remove the cab frame, reverse the installation instructions.
5
5.9
BODY / STEERING / SUSPENSION
SEAT / HEAD REST
Seat Back / Head Rests
1.
Fasten the seat back to the rear cab frame(s) using the Torx-head screws. NOTE: For seats that have staples visible from the rear, the seat back cover will need to be placed between the rear cab frame and seat back assembly . Tighten all Torxhead fasteners to 18-20 in. lbs. (2-2.5 Nm).
2.
Install the headrests on the cab frame using 1/4”-20 x 1” bolts, washers, and 1/4”-20 Nyloc nuts. Place the washers between the bolt heads and headrest as shown below. Torque bolts to 10 in. lbs. (1.1 Nm).
3.
Check all screws and fasteners for proper torque and installation.
5.10
CHASSIS / MAIN FRAME (4X4 CREW)
Exploded View
BODY / STEERING / SUSPENSION
(2) Seat Base
(2) RH Floor Support Main Frame
5
28-32 ft. lbs.
(38-43 Nm)
Front Cab Support
35 ft. lbs.
(47 Nm)
Bumper
Grills
T-27
4-6 ft. lbs.
(6-8 Nm)
28-32 ft. lbs.
(38-43 Nm)
13-15 ft. lbs.
(17-20 Nm)
(2) LH Floor Support
5.11
BODY / STEERING / SUSPENSION
CHASSIS / MAIN FRAME (6X6)
Exploded View
Seat Base
Frame Extension
Front Cab Support
RH Floor Support
45 ft. lbs.
(61 Nm)
Main Frame
28-32 ft. lbs.
(38-43 Nm)
Grills
T-27
4-6 ft. lbs.
(6-8 Nm)
Bumper
13-15 ft. lbs.
(17-20 Nm)
28-32 ft. lbs.
(38-43 Nm)
LH Floor Support
5.12
BODY / STEERING / SUSPENSION
STEERING ASSEMBLY
Exploded View
Rod End & Jam Nut
Tie Rod
Bushing
17 ft. lbs.
(23 Nm)
16 ft. lbs.
(22 Nm)
30 ft. lbs.
(41 Nm)
28 ft. lbs.
(38 Nm)
Steering Wheel
Wave Washers
Cap
Nut
Upper Steering Shaft
Lower Steering Shaft
5
Boots 16 ft. lbs.
(22 Nm)
Steering Box
Tie Rod
End Bolt
40 ft. lbs.
(54 Nm)
5.13
BODY / STEERING / SUSPENSION
STEERING AND SUSPENSION
Exploded View
Always use new cotter pins upon reassembly.
NOTE:
To avoid damage to the tie rod ends and other steering components, be sure to install tie rod end bolts in the proper direction.
Always use new bolts upon reassembly
Apply Loctite TM 242
17 ft. lbs.
(23 Nm)
28 ft. lbs.
(38 Nm)
30 ft. lbs.
(41 Nm)
16 ft. lbs.
(22 Nm)
12-14 ft. lbs.
(16-19 Nm)
16 ft. lbs.
(22 Nm)
Front
30 ft. lbs.
(41 Nm)
40 ft. lbs.
(54 Nm)
5.14
30 ft. lbs.
(41 Nm)
20-30 ft. lbs.
(2-3.5 Nm)
30 ft. lbs.
(41 Nm)
8 ft. lbs.
(11 Nm)
BODY / STEERING / SUSPENSION
FRONT A-ARM
Replacement
1.
Elevate and safely support vehicle with weight removed from front wheel(s).
2.
Remove cotter pin from ball joint stud at wheel end of Aarm and loosen nut until it is flush with end of stud.
3.
Using a soft face hammer, tap nut to loosen A-arm from bolt. Remove nut and A-arm from hub strut assembly.
4.
Loosen two bolts on A-arm bushing by alternating each about 1/3 of the way until A-arm can be removed.
5.
Examine A-arm bushing and A-arm shaft. Replace if worn.
Discard hardware.
6.
Insert A arm bushings and A-arm shaft into new A-arm.
NOTE: On AWD models, install CV joint shields. See
Illustration
7.
Install new A-arm assembly onto vehicle frame. Torque new bolts to 30 ft. lbs. (41.4 Nm).
WARNING
The locking features on the existing bolts were destroyed during removal. DO NOT reuse old bolts. Serious injury or death could result if fasteners come loose during operation.
8.
Attach A-arm to hub strut assembly. Tighten ball joint nut to 30 ft. lbs. (41 Nm). If cotter pin holes are not aligned, tighten nut slightly to align. Install a new cotter pin with open ends toward rear of machine. Bend both ends in opposite directions around nut.
WARNING
Upon A-arm installation completion, test vehicle at low speeds before putting into regular service.
A-arm Attaching Bolt Torque:
30 ft. lbs. (41 Nm)
Ball Joint Stud Nut Torque:
30 ft. lbs. (41 Nm)
5
Apply Loctite TM 242
Vehicle Frame
New Bolt
30 ft. lbs. (41 Nm)
Strut
New Bolt
30 ft. lbs. (41 Nm)
A-Arm Bushing
A-Arm Shaft
T-20 CV Joint Shield
20-30 in. lbs.
(2-3.5 Nm)
New Cotter Pin
30 ft. lbs.
(41 Nm)
Ball Joint
Stud
8 ft. lbs.
(11 Nm)
5.15
BODY / STEERING / SUSPENSION
FRONT STRUT
Exploded View
Nut
15 ft. lbs.
(21 Nm)
Washer
Spacer Rubber
Top
Pivot Ball
Bottom
Pivot Ball
Spring
Retainer
Spacer
Front Strut
Washer
Clamp
18 ft. lbs.
(24 Nm)
Spring
Bolt
Strut Bumper
17 ft. lbs.
(23 Nm)
Washer
Wheel Speed Sensor
(Hall Effect Sensor)
Bearing
Retaining Ring
5.16
BODY / STEERING / SUSPENSION
Front Strut Cartridge Replacement
Refer to Front Strut Exploded View.
1.
Hold strut rod and remove top nut.
2.
Compress spring using strut spring compressor tools.
Strut Spring Compressor Tools
(PN 2871573) and (PN 2871574)
3.
Remove upper strut pivot assembly.
4.
Remove coil spring and collapse strut cartridge.
5.
Remove two pinch bolts from strut casting.
6.
Remove strut cartridge.
7.
Install cartridge until bottomed in strut casting.
8.
Install pinch bolts with wire clamp(s). Torque pinch bolts to 17 ft. lbs. (23 Nm).
9.
Reassemble spring and top pivot assembly. Be sure all parts are installed properly and seated fully.
10. Torque strut rod nut to specification. Do not over torque nut.
Strut Rod Nut Torque
15 ft. lbs. (21 Nm)
4.
Remove cotter pin (A) from ball joint castlenut.
5.
Remove castle nut (B) and separate A-arm (C) from ball joint stud.
6.
Remove screws (D) and ball joint retaining plate (E).
7.
Using ball joint removal/installation tool kit (PN 2870871), remove ball joint (F) from strut housing.
• Install puller guide (G) with extension cap (H).
• Apply grease to extension cap and threads of puller bolt to ease removal.
• Thread bolt (K) with nut (J) onto ball joint stud as shown.
• Apply heat to ease removal.
• Hold bolt (K) and turn nut (J) clockwise until ball joint is removed from strut housing.
K
J
H
G
5
Ball Joint Replacement
1.
Loosen front wheel nuts slightly.
2.
Elevate and safely support machine under footrest/frame area.
CAUTION
Serious injury may result if machine tips or falls.
Be sure machine is secure before beginning this service procedure.
3.
Remove wheel nuts and wheels.
8.
To install new ball joint:
• Remove extension cap and attach puller guide using short bolts provided in the kit.
• Insert new ball joint (L) into driver (M).
L
M
C
F
E
D
B
A
• Slide ball joint / driver assembly into guide.
• Apply heat to ease installation.
• Drive new joint into strut housing until fully seated.
5.17
BODY / STEERING / SUSPENSION
9.
Apply Loctite™ 242 (PN 2871949) to threads of retaining plate screws or install new screws with pre-applied locking agent. Torque screws to 8 ft. lbs. (11 Nm).
10. Install A-arm on ball joint and torque castle nut to 30 ft. lbs.
(41 Nm).
11. Reinstall cotter pin with open ends toward rear of machine.
MID AXLE A-ARM (6X6)
Replacement
1.
Elevate and safely support the center of the vehicle with weight removed from center wheel(s).
2.
Remove the hub cap, cotter pin, spindle nut, wheel nuts, and wheel. Refer to Chapter 7 “MID DRIVE BEARING
CARRIER / HUB REMOVAL” procedure.
3.
Remove the bolts that secure the shock to the upper and lower mid A-arms.
4.
Loosen two bolts on A-arm bushing by alternating each about 1/3 of the way until A-arm can be removed. Perform this procedure on the upper and lower mid A-arms.
5.
Examine the A-arm bushing and A-arm shaft. Replace if worn. Discard hardware.
6.
Insert A-arm bushings and A-arm shaft into new A-arm.
7.
Install new lower mid A-arm assembly onto vehicle frame.
Torque new bolts to 30 ft. lbs. (41 Nm).
8.
Install a new upper mid A-arm assembly. Torque new bolts to 30 ft. lbs. (41 Nm).
WARNING
The locking features on the existing bolts were destroyed during removal. DO NOT reuse old bolts. Serious injury or death could result if fasteners come loose during operation.
9.
Attach A-arm to wheel bearing carrier. Install the shock to the upper mid A-arm. Torque bolts as shown.
10. Locate grease fitting in center of A-arm tube and pump Aarm full of grease.
WARNING
Upon A-arm installation completion, test vehicle at low speeds before putting into regular service.
RANGER 6X6 Mid Drive
A-arm Attaching Bolt torque:
30 ft. lbs. (41 Nm)
Upper Bearing Carrier Bolt Torque:
30 ft. lbs. (41 Nm)
Lower Bearing Carrier Bolt Torque:
50 ft. lbs. (68 Nm)
Frame
Nut
Bushing
Shaft
Upper Mid
A-arm
New Bolt
30 ft. lbs. (41 Nm)
30 ft. lbs.
(41 Nm)
Shock
Mid Axle
A-Arm Assy.
Bushing
30 ft. lbs.
(41 Nm)
New Bolt
Bushings
Washer
Shaft
Lower Mid A-Arm
Bushings
Wheel Bearing
Carrier
50 ft. lbs.
(68 Nm)
5.18
BODY / STEERING / SUSPENSION
REAR A-ARM (4X4 CREW)
Replacement
NOTE: Use the exploded view on the next page as reference during the procedure.
1.
Elevate and safely support vehicle with weight removed from the rear wheel(s).
2.
Remove the wheel nuts, washers, and wheel.
5.
Remove the hub and brake disc assembly by sliding it off of the axle.
6.
Remove the bolt that secures the shock and coil to the upper
A-arm.
7.
Remove the bolt that secures the wheel carrier to the upper
A-arm.
Shock Bolt
5
NOTE: To ease the removal of the spindle bolt, remove the hub cap and loosen the spindle bolts before removing the wheel.
3.
Remove the hub cap, cotter pin, spindle bolt, and washer.
4.
Remove the brake caliper. Suspend the brake caliper from the frame with a wire.
NOTE: Do not let the brake caliper hang from the brake line or damage may occur.
Wheel Carrier
Bolt
8.
Loosen two bolts that secure the A-arm to frame by alternating each about 1/3 of the way until A-arm can be removed. Perform this procedure on the upper A-arm. See exploded view, next page.
9.
Examine the A-arm bushing and A-arm shaft. Replace if worn. Discard hardware.
10. To remove the lower control arm, the wheel bearing carrier needs to be removed. Remove the upper and lower wheel carrier bolts and slide the rear drive shaft from the carrier.
(See Chapter 7 for more details).
5.19
BODY / STEERING / SUSPENSION
11. Remove the bottom stabilizer bar nut.
Stabilizer Bar
12. Loosen two bolts that secure the A-arm bushing to frame by alternating each about 1/3 of the way until the A-arm can be removed. The lower A-arm should now be free to remove.
A-Arm Installation
13. Insert new A-arm bushings and new A-arm shaft into new
A-arm.
14. Install new A-arm assembly onto vehicle frame. Torque new bolts to 30 ft. lbs. (41 Nm).
WARNING
The locking features on the existing bolts were destroyed during removal. DO NOT reuse old bolts. Serious injury or death could result if fasteners come loose during operation.
15. Attach A-arm to wheel bearing carrier. Torque upper and lower carrier bolts as shown.
16. Install the shock and tighten shock bolt to 30 ft.lbs. (41
Nm).
17. Re-install wheel and caliper. Refer to “Chapter 2” for wheel toque specifications.
WARNING
Upon A-arm installation completion, test vehicle at low speeds before putting into regular service.
5.20
Nuts
30 ft. lbs.
(41 Nm)
A-arm Bolts
A-arm
Bolts
Bushings
Nuts
30 ft. lbs.
(41 Nm)
Shaft
30 ft. lbs.
(41 Nm)
Upper A-arm
Bushings
Shock
Bushings
Shaft
Wheel Bearing
Carrier
Lower A-arm
Shaft
Shaft
Carrier Bolt
30 ft. lbs. (41 Nm)
50 ft. lbs.
(68 Nm)
Shaft
Bushings
Bearing
Coil
30 ft. lbs.
(41 Nm)
Caliper
18 ft. lbs.
(24 Nm)
Snap Ring
BODY / STEERING / SUSPENSION
REAR STABILIZER BAR (4X4 CREW)
Removal / Installation
1.
Elevate and safely support vehicle with weight removed from the rear wheel(s).
2.
Remove the rear wheel to gain access to the stabilizer bar, each side.
Stabilizer Bar
4.
Remove the two bolts that secure the stabilizer bar to the main frame, each side.
3.
Remove the stabilizer bar nut from the lower A-arm on each side.
Stabilizer
Bar
5.
Remove the stabilizer from the frame.
6.
Inspect the stabilizer bar for straightness. Inspect the bushings and replace if needed.
7.
Inspect the rubber bushings on the linkage rod and replace if needed.
8.
Reverse the procedure for installation. Torque the stabilizer bolts to 16-18 ft.lbs. (21-25 Nm).
5
Inspect Bushings
Stabilizer Assembly
16-18 ft. lbs.
(21-25 Nm)
Inspect Bushings
5.21
BODY / STEERING / SUSPENSION
SWING ARM (6X6)
Removal
1.
Support machine on a level surface.
2.
Remove rear wheels.
NOTE: The rear axle may be removed to ease the removal of the swing arm. Refer to Chapter 7, “REAR
AXLE HOUSING REMOVAL/INSPECTION”.
3.
Support swing arm, remove rear axle shocks.
4.
Drive spring pin out of rear propshaft at middle angle drive using the Roll Pin Removal Tool (PN 2872608).
PN 2872608
B
A
NOTE: Use jacks and jackstands to help remove the swing arm assembly.
5.
Remove the pivot bolt lock brackets (A), swing arm pivot bolts (B), bolts swing arm bushings, lower swing arm and rear axle.
Installation
1.
Raise swing arm assembly and align the drive shaft to the rear gearcase splined shaft (lube splines).
2.
Insert new bushings, check pivot bolts for wear, replace if necessary, torque bolts to 150 ft. lbs (75.9 Nm). Install bolt lock brackets and bolts, torque to 30 ft. lbs. (41 Nm).
3.
Install rear coil over shocks onto swing arm, torque bolts to 30 ft. lbs (41 Nm).
4.
Install rear wheels, lower machine.
5.
Insert new spring pin on rear propshaft.
Pivot Bolt and Nut Torque:
150 ft. lbs. (75.9 Nm)
Rear Shock Mount Bolt Torque:
30 ft. lbs. (41 Nm)
Frame
Rear Axle
Swing arm
U-Bolt
Shock Coil
Washer & Bolt
Bushings
30 ft. lbs.
(41 Nm)
Pivot Bolt
150 ft. lbs.
(203 Nm)
30 ft. lbs.
(41 Nm)
Bolt Lock
Bracket
Apply Loctite TM 271
5.22
BODY / STEERING / SUSPENSION
REAR DRIVE AXLE AND SWING ARM EXPLODED VIEW (6X6)
Retaining Ring
Wheel
Bearing
Axle Tube
Screw & Washer
60 ft. lbs.
(81 Nm)
Vehicle Frame
Swing Arm
Axle
Wheel
Bearing
150 ft. lbs.
(203 Nm)
O-Ring
Axle Tube
U - Bolt Nut & Washer
5
Rear Gearcase
Assembly
Washer
Jam Nut
Grease Fitting
Swing Arm Bushing
Pivot Bushing
Swing Arm Pivot Bolt
40 ft. lbs.
(54 Nm)
U- Bolt
Bolt Lock
Bracket
150 ft. lbs.
(203 Nm)
30 ft. lbs.
(40 Nm)
Rubber Pad
Skid Plate
Bolt & Washer
60 ft. lbs.
(81 Nm)
Apply Loctite TM 242
5.23
BODY / STEERING / SUSPENSION
REAR CARGO BOX
Cargo Box - Panels
8-10 in. lbs.
(0.9-1.0 Nm)
T-30
Taillight
8-10 in. lbs.
(0.9-1.0 Nm)
T-20
T-27
4-6 ft. lbs.
(5-8 Nm)
Tailgate Support
T-20
T-20
8-10 in. lbs.
(0.9-1.0 Nm)
Front Panel
Seal Foam
Side Panel
T-20
8-10 in. lbs.
(0.9-1.0 Nm)
T-30
8-10 in. lbs.
(0.9-1.0 Nm)
5.24
BODY / STEERING / SUSPENSION
Cargo Box - Tailgate / Box Support
Tailgate
Cable
Latch
Inner Panel
T-20
8-10 in. lbs.
(0.9-1.0 Nm)
Rod
Tailgate Cap
T-20
20-25 in. lbs.
(2-3 Nm)
Outer Panel
5
Tailgate Tube
Box
Box Latch
Assembly
Box Support
Shock Pins
Shock
8-10 ft. lbs.
(10-13 Nm)
Hinge Pin
Heat
Shield
Bolt
5.25
BODY / STEERING / SUSPENSION
Box Removal
1.
Lift the cargo box into the dump position.
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
Slide Hinge Pin Out
CAUTION
Safely support the box during the remainder of the removal process. The box is not as stable with the shock removed.
4.
Remove the screw (A) that secures the hinge pin to the frame on both sides.
6.
With both hinge pins removed, remove the box from the frame. Two people maybe needed to remove the box from the frame.
CAUTION
Use caution when removing the box. It is recommended to have two people carefully remove the box from the frame.
Box Installation
1.
If the shock was replaced, install the lower portion of the shock to the frame and secure it with the pin and clip.
A
Lower
Shock Pin
5.
Remove the hinge pin from both sides.
CAUTION
Safely support the box during the remainder of the removal process. The box is not as stable with the hinge pins removed.
5.26
2.
Place the cargo box onto the frame. Align the hinges of the box with the bracket on the frame.
3.
Install the box hinges on both sides.
4.
Secure the box hinges with the hinge screws on both sides.
5.
With the hinges installed, attach the shock to the cargo box by inserting the pin and clip.
6.
Lower the box and secure the latch.
STORAGE BOX (4X4 CREW)
Removal
1.
Remove the two bottom T-27 torx screws.
2.
Remove the two top T-27 torx screws.
3.
Remove the three T-27 torx screws on the front edge.
BODY / STEERING / SUSPENSION
DECAL REPLACEMENT
Plastic polyethylene material must be “flame treated” prior to installing a decal to ensure good adhesion. The flame treating procedure can often be used to reduce or eliminate the whitish stress marks that are sometimes left after a fender or cab is bent, flexed, or damaged.
Torque screws to:
4-5 ft. lbs. (5-6 Nm)
4.
Lift the storage box towards the rear of the frame for removal.
Installation
1.
Install the storage box back into the frame assembly. Align all screw holes and ensure the storage box is properly fitted to the frame.
2.
Install all of the T-27 torx screws that were removed.
Torque screws to 4-5 ft.lbs. (5-6 Nm).
WARNING
The following procedure involves the use of an open flame. Perform this procedure in a well ventilated area, away from gasoline or other flammable materials.
Be sure the area to be flame treated is clean and free of gasoline or flammable residue.
To flame treat the decal area:
1.
Pass the flame of a propane torch back and forth quickly over the area where the decal is to be applied until the surface appears slightly glossy. This should occur after just a few seconds of flame treating. Do not hold the torch too close to the surface. Keep the torch moving to prevent damage.
2.
Apply the decal.
5
NOTE: Refer to your parts manual for decal part number.
5.27
BODY / STEERING / SUSPENSION
NOTES
5.28
CLUTCHING
CHAPTER 6
CLUTCHING
SPECIAL TOOLS AND SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
PVT SYSTEM FASTENER TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
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
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.23
6
6.1
CLUTCHING
SPECIAL TOOLS AND SUPPLIES
TOOL DESCRIPTION
Drive Clutch Puller
Clutch Holding Wrench
Clutch Holding Fixture
Drive Clutch Spider Removal and
Install Tool
Roller Pin Tool
Clutch Bushing Replacement Tool Kit
Piston Pin Puller
Clutch Compression Tool
Clutch Bushing Replacement Tool Kit
Clutch Alignment Tool
PART NUMBER
2870506
9314177
2871358
2870341
2870910
2871226
2870386
8700220
2871025
PA-49011
SPECIAL SUPPLIES
Loctite™ 609
RTV Silicone Sealer
PART NUMBER
N/A
8560054
TORQUE SPECIFICATIONS
PVT System Fastener Torques
ITEM
Drive Clutch Retaining Bolt
Driven Clutch Retaining Bolt
PVT Inner Cover Bolts
PVT Outer Cover Bolts
Drive Clutch Spider
Drive Clutch Cover Plate
TORQUE VALUE ft. lbs. (Nm)
47 ft. lbs. (64 Nm)
17 ft. lbs. (23 Nm)
12 ft. lbs. (16 Nm)
45-50 in. lbs (5-5.6 Nm)
200 ft. lbs. (271 Nm)
90 in. lbs. (10 Nm)
PVT SYSTEM OVERVIEW
General Operation
WARNING
All PVT maintenance or repairs should be performed only by a certified Polaris Master
Service Dealer (MSD) technician who has received the proper training and understands the procedures outlined in this manual.
Because of the critical nature and precision balance incorporated into the PVT components, it is absolutely essential that no disassembly or repair be made without factory authorized special tools and service procedures.
The Polaris Variable Transmission (PVT) consists of three major assemblies:
1) The Drive Clutch
2) The Driven Clutch
3) The Drive Belt
The internal components of the drive clutch and driven clutch control engagement (initial vehicle movement), clutch upshift and backshift. During the development of a Polaris ATV, the
PVT system is matched first to the engine power curve; then to average riding conditions and the vehicle’s intended usage.
Therefore, modifications or variations of components at random are never recommended. Proper clutch setup and careful inspection of existing components must be the primary objective when troubleshooting and tuning.
Drive Clutch Operation
Drive clutches primarily sense engine RPM. The two major components which control its shifting function are the shift weights and the coil spring. Whenever engine RPM is increased, centrifugal force is created, causing the shift weights to push against rollers on the moveable sheave, which is held open by coil spring preload. When this force becomes higher than the 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
Driven Clutch Operation
Driven clutches primarily sense torque, opening and closing according to the forces applied to it from the drive belt and the transmission input shaft. If the torque resistance at the transmission input shaft is greater than the load from the drive belt, the drive belt is kept at the outer diameter of the driven clutch sheaves.
As engine RPM and horsepower increase, the load from the drive belt increases, resulting in the belt rotating up toward the outer diameter of the drive clutch sheaves and downward into the sheaves of the driven clutch. This action, which increases the driven clutch speed, is called upshifting.
Should the throttle setting remain the same and the vehicle is subjected to a heavier load, the drive belt rotates back up toward the outer diameter of the driven clutch and downward into the sheaves of the drive clutch. This action, which decreases the driven clutch speed, is called backshifting.
In situations where loads vary (such as uphill and downhill) and throttle settings are constant, the drive and driven clutches are continually shifting to maintain optimum engine RPM. At full throttle a perfectly matched PVT system should hold engine
RPM at the peak of the power curve. This RPM should be maintained during clutch upshift and backshift. In this respect, the PVT system is similar to a power governor. Rather than vary throttle position, as a conventional governor does, the PVT system changes engine load requirements by either upshifting or backshifting.
CLUTCHING
Maintenance / Inspection
Under normal use the PVT system will provide years of trouble free operation. Periodic inspection and maintenance is required to keep the system operating at peak performance. The following list of items should be inspected and maintained to ensure maximum performance and service life of PVT components. Refer to the troubleshooting checklist at the end of this chapter for more information.
1.
Belt Inspection, Drive to Driven Clutch Alignment, and
Clutch Center Distance.
2.
Drive and Driven Clutch Buttons and Bushings, Drive
Clutch Shift Weights and Pins, Drive Clutch Spider
Rollers and Roller Pins, Drive and Driven Clutch
Springs.
3.
Sheave Faces.
Clean and inspect for wear.
4.
PVT System Sealing.
Refer to appropriate illustrations on the following pages. The PVT system is air cooled by fins on the drive clutch stationary sheave. The fins create a low pressure area in the crankcase casting, drawing air into the system through an intake duct. The opening for this intake duct is located at a high point on the vehicle (location varies by model). The intake duct draws fresh air through a vented cover. All connecting air ducts (as well as the inner and outer covers) must be properly sealed to ensure clean air is being used for cooling the PVT system and also to prevent water and other contaminants from entering the PVT area.
This is especially critical on units subjected to frequent water forging.
6
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, it’s important to check the inlet and outlet ducting for obstructions. Obstructions to air flow through the ducts will significantly increase PVT system operating temperatures. The vehicle should be operated in Low when plowing or pulling heavy loads, or if extended low speed operation is anticipated.
CLUTCH DRIVE BELT & COVER RELATED ISSUES: DIAGNOSIS
Possible Causes
Loading the vehicle into a truck or tall trailer when in high range.
Starting out going up a steep incline from a stopped position.
Driving at low RPM or low ground speed
(at approximately 3-7 MPH).
Insufficient warm-up of Utility Task
Vehicles™ exposed to low ambient temperatures.
Slow and easy clutch engagement.
Towing/Pushing at low RPM/low ground speed.
Plowing snow, dirt, etc./utility use.
Stuck in mud or snow.
Climbing over large objects from a stopped position.
Belt slippage from water or snow ingestion into the PVT system.
Clutch malfunction.
Poor engine performance.
GENERAL RANGE OPERATION
GUIDELINES:
Solutions / What to do
Shift transmission to Low during loading of the vehicle to prevent belt burning.
When starting out on an incline, use Low, or dismount the vehicle after first applying the park brake and perform the “K” turn.
Drive at higher speed or use Low. The use of Low is highly recommended for cooler PVT operating temperatures and longer component life.
Warm engine at least 5 min., then with transmission in neutral, advance throttle to approx. 1/8 throttle in short bursts, 5 to 7 times. The belt will become more flexible and prevent belt burning.
Fast, effective use of the throttle for efficient engagement.
Use Low only.
Use Low only.
Shift the transmission to Low, carefully use fast, aggressive throttle application to engage clutch.
WARNING:
Excessive throttle may cause loss of control and vehicle overturn.
Shift the transmission to Low, carefully use fast, aggressive, brief throttle application to engage clutch.
WARNING:
Excessive throttle may cause loss of control and vehicle overturn.
Shift the transmission to neutral. Using the throttle, vary the engine rpm from idle to full throttle. Repeat several times as required. During this procedure, 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. Shift transmission to Low during loading of the vehicle to prevent belt burning.
Fouled plugs, foreign material in gas tank, fuel lines, or carburetor. Contact you dealer for further service information.
Low: Heavy pulling, basic operational speeds less than 7 MPH, riding through rough terrain (swamps, mountains, ect.), low ground speeds.
High: High ground speeds, speeds above 7 MPH.
Operating in Low Gear
Low is the primary driving gear. Low should be used in ALL driving applications except for driving on hard packed level surfaces with light loads. In this circumstance, High may be used.
IMPORTANT: Using High for heavy loads, hilly terrain, or in wet, muddy conditions will increase the chance of drive belt burning.
1. Use Low as the primary driving gear for all
RANGER s.
2. Use High only on hard packed, level surfaces with light loads.
RANGER
4X4 / 6X6
H
L
N
R
6.4
PVT SYSTEM SERVICE
PVT Sealing, Guard, and Ducting Components
SEALING AND DUCTING COMPONENTS
Clutch Outlet Duct
Inner Cover
Clamps
CLUTCHING
Inner Cover Seal
Retainer
Outer Cover Seal
Cover Bolts
PVT Outer Cover
Disassembly
Some fasteners and procedures will vary. Refer to the appropriate parts manual for proper fasteners and fastener placement.
1.
Remove seat.
2.
Remove the LH storage box to gain access to PVT outer cover (see Chapter 5 for removal).
3.
Remove PVT air outlet duct hose.
4.
Remove outer PVT cover screws.
5.
Mark the drive belt direction of rotation and remove drive belt. See “Drive Belt Removal”.
A
6.
Install the Drive Clutch Holder (PN 9314177) (A).
7.
Remove drive clutch retaining bolt and remove drive clutch using the Drive Clutch Puller (PN 2870506) (B).
Drive Clutch Puller (PN 2870506)
Drive Clutch Holder (PN 9314177)
8.
Remove the driven clutch retaining bolt and driven clutch.
Retaining Bolt
6
B
6.5
CLUTCHING
9.
Remove driven clutch alignment washer(s) from the transmission input shaft.
Note Number of Washers
3.
Apply RTV silicone sealant to outside edge of inner coverto-engine seal, to ensure a water tight fit between the seal and the cover. Surfaces must be clean to ensure adhesion of silicone sealant.
4.
Reinstall cover and tighten rear cover bolts just enough to hold it in place.
5.
Fit lip of inner cover seal (A) to engine. Install seal retainer plate and tighten screws securely.
B
C
10. Remove screws and retainer plate.
A
Seal outer edge to cover with RTV silicone sealant
11. Remove inner cover retaining bolts at rear of cover.
12. Remove cover along with foam seal on back of cover or shaft.
6.
Torque rear inner cover bolts (B) to specification.
7.
Install clutch alignment washer(s) on transmission input shaft.
Alignment Washer(s)
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 is installed, install so numbers can be easily read.
14. Replace PVT outer clutch cover rubber gasket.
15. Reinstall PVT outer clutch cover and secure with screws.
Torque to 45-50 in. lbs. (5-5.6 Nm).
16. Install the PVT cover outlet duct and tighten the clamps.
DRIVE BELT
Belt Removal
1.
Remove outer PVT cover as described in PVT
Disassembly.
2.
Mark the drive belt direction of rotation so that it can be installed in the same direction.
NOTE: Belt is normally positioned so that part numbers are easily read.
Inner Cover Bolt Torque (Rear):
12 ft. lbs. (16.6 Nm)
Outer Cover Bolt Torque:
45-50 in.lbs. (5-5.6 Nm)
Driven Clutch Retaining Bolt Torque:
17 ft. lbs. (23.5 Nm)
Drive Clutch Retaining Bolt Torque:
47 ft. lbs. (64 Nm)
3.
To remove drive belt, put transmission in gear, apply brake, pull upward and rearward on belt to open driven clutch sheaves, pull out and down on belt to slip over the driven clutch outer sheave.
6
6.7
CLUTCHING
Belt Inspection
1.
Inspect belt for hour glassing (extreme circular wear in at least one spot and on both sides of the belt). Hour glassing occurs when the drive train does not move and the drive clutch engages the belt.
2.
Inspect belt for loose cords, missing cogs, cracks, abrasions, thin spots, or excessive wear. Compare belt 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 the Troubleshooting Chart at the end of this chapter for possible causes.
Belt Installation
1.
Loop belt over the drive clutch and over top of the driven sheave.
2.
While pushing down on top of belt, turn the back or moveable driven sheave clockwise.
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.
CLUTCH ALIGNMENT
Clutch Alignment Tool Use
Clutch alignment is controlled by the number of washers that are placed behind the driven clutch on the transmission input shaft.
Adding washers behind the driven clutch will move the drive 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 seat.
2.
Remove the LH storage box to gain access to the outer PVT cover (see Chapter 5 for removal).
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”).
6.
Install the Clutch Alignment Tool.
CLUTCH ALIGNMENT TOOL
PA-49011
3.
The belt then should be able to be pushed down into and between the sheaves.
Be sure to position belt so part number is easily read.
6.8
CLUTCHING
7.
Place the alignment tool in the sheaves of the driven clutch and hold firmly as you rotate it down between the sheaves of the drive clutch.
PA-49011
10. If the alignment tool touches the shaft bearing but has an excessive amount of clearance between the tool and stationary sheave, the driven clutch will need to be moved in to correct the alignment.
• 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.
Clutch Alignment Tool
PA-49011
8.
As you rotate the tool down between the drive clutch sheaves, the tool should touch the clutch shaft bearing while maintaining a clearance of roughly .020” between the tool and stationary sheave of the drive clutch.
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.
11. After completing the clutch alignment procedure, the belt should ride in the drive clutch with an approximate .020” gap between the belt and stationary sheave and a larger gap of approximately .130” between the belt and moveable sheave.
.020” Gap
6
Stationary
Sheave
Shaft Bearing
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.
CLUTCH CENTER DISTANCE
Alignment Washers
(.030”) PN: 7556454
(.060”) PN: 7556120
Center
Distance
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 upward in the drive clutch sheaves. This is referred to as drive clutch upshift.
There are other components which control upshift, but the spring is one of the primary components in insuring optimum performance. It is very important that the spring 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 stacking of the coils and subsequent clutch cover failure.
Red/White
7043349
Red/Blue
7043372
Red/Green
7043382
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.
PART NUMBER
7041021
7041022
7041063
7041132
7041157
7041168
7043349
7043372
7043382
Primary Clutch Springs
COLOR CODE
Plain
Black
Purple
White
Blue / Green
Green
Red / White
Red / Blue
Red / Green
WIRE DIAMETER
.157"
.140"
.168"
.177"
.177"
.177"
.200"
.187"
.177"
FREE LENGTH ± .125”
4.38"
4.25"
4.37"
2.92"
2.53"
3.05"
2.58"
2.56"
2.63"
6.10
CLUTCHING
Shift Weights
Shown below are the shift weights which have been designed for the PVT system. These shift weights have many factors designed into them for controlling engagement RPM and shifting patterns. Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to sheave clearance, clutch balance and shifting pattern.
6
6.11
CLUTCHING
Exploded View
Non-Braking
Bearing
Bearing
Spacer
Washers
Spring
Spider
Cover
Bearing
Bushing Lock
Washer
Roller
Bolt
Button Cover
Screws
Flat
Washer
Pin
Bolt
Button
Nut
Shift
Weight
Washers
Clutch Disassembly
1.
Using a permanent marker, mark the cover, spider, and moveable and stationary sheaves for reference, as the cast in X's may not have been in alignment before disassembly.
3.
Inspect cover bushing (A). The outer cover bushing is manufactured with a Teflon
™
coating. Wear is determined by the amount of Teflon
™
remaining on the bushing.
A
2.
Remove cover bolts evenly in a cross pattern and remove cover plate.
Cover Bushing Inspection:
Replace the cover bushing if more
brass than Teflon
™
is visible on the bushing. Refer to bushing replacement in this chapter.
6.12
CLUTCHING
4.
Inspect area on shaft where bushing rides for wear, galling, nicks, or scratches. Replace clutch assembly if worn or damaged.
Inspect Shaft
NOTE: It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly. Be sure to note the number and thickness of these washers.
To maintain proper clutch balance and belt-to-sheave clearance, be sure to reinstall original quantity and thickness washers
5.
Remove and inspect the clutch spring. See “Drive Clutch
Spring Specifications” for spring inspection.
Moveable Sheave Bushing Inspection
2.
Inspect the Teflon™ coating on the moveable sheave bushing.
Spider Removal
1.
Install clutch in holding fixture (PN 2871358) and loosen the spider (counterclockwise) using Clutch Spider
Removal Tool (PN 2870341).
6
Teflon
TM
Moveable Sheave Bushing Inspection:
Replace the cover bushing if more brass than Teflon is visible on the bushing.
Refer to bushing replacement in this chapter.
Clutch Holding Fixture:
(PN 2871358)
Spider Removal Tool:
(PN 2870341)
6.13
CLUTCHING
Roller, Pin, and Thrust Washer Inspection
1.
Inspect all rollers, bushings and roller pins by pulling a flat metal rod across the roller. Turn roller with your finger. If you notice resistance, galling, or flat spots, replace rollers, pins and thrust washers in sets of three. Also inspect to see if roller and bushing are separating. Bushing must fit tightly in roller. Use the Roller Pin Tool (PN 2870910) to replace rollers and pins. Take care not to damage roller bushing or bearing surface of the new pin during installation.
Button To Tower Clearance Inspection
1.
Inspect for any clearance between spider button to tower.
If clearance exists, replace all buttons and inspect surface of towers.
See “Spider Removal” procedure.
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.
NOTE: The rubber side of the button is positioned toward the solid roller pin.
Shift Weight Inspection
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.
The contact surface of the weight should be smooth and free of dents or gall marks. Inspect the weight pivot bore and pivot bolts for wear or galling. If weights or bolts are worn or broken, replace in sets of three with new bolts.
Clutch Inspection
NOTE: Remove cover, spring, and spider following instructions for drive clutch removal, then proceed as follows:
1.
Remove the moveable sheave spacer (1) and the thrust washer (2). Visually inspect the washer for damage.
2.
Measure the thickness and compare to specification.
Replace if worn or damaged.
1
Broken Worn Good
NOTE: A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly.
See “Roller, Pin and Thrust Washer Inspection”.
Bearing Inspection
1.
Rotate 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.
Thrust Washer Thickness
Standard: .030” (.76mm)
Service Limit: .025” (.64mm)
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
3
4
6.15
CLUTCHING
5.
Inspect surface of shaft for pitting, grooves, or damage.
Measure the outside diameter and compare to specifications. Replace the drive clutch assembly if shaft is worn or damaged.
Moveable Sheave Bushing Inspection
Inspect the Teflon
™
coating (arrow) on the moveable sheave bushing. Inspect both sheaves for signs of wear, grooving or cracking. De-glaze sheave surfaces with a 3M
™
Scotch-Brite
Pad if needed.
=
In. / mm.
Shaft Diameter:
Standard: 1.3745 - 1.375 (
Service Limit: 1.3730”
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” (.76mm)
Service Limit: .025” (.64mm)
Moveable Sheave Bushing Inspection:
Replace the cover bushing if more brass than Teflon
™
is visible on the bushing.
Refer to bushing replacement in this chapter.
6.16
CLUTCHING
Bushing Service
IMPORTANT: Special Tools Required
EBS Clutch Bushing Tool Kit - 2201379
Item
A, B
C
D
E
--
Qty.
1
1
1
1
1
Part Description
EBS Puller Tool
EBS Puller Nut
EBS Main Adapter
EBS Bushing Removal Tool
Instructions
Part #
5132027
5132501
5132029
5132028
9915111
Additional Special Tools
Qty.
Part Description Part #
1 Clutch Bushing Replacement Tool Kit 2871226
1 Piston Pin Puller 2870386
* Clutch Bushing Replacement Tool Kit (PN 2871226
)
#2
#3
#5
CAUTION
Clutch components will be hot! In order to avoid serious burns, wear insulated gloves during the removal process.
Moveable Sheave - Bushing Removal
1.
Remove clutch as outlined previously in this chapter.
2.
Install handle end of the Piston Pin Puller (PN 2870386) securely into bench vise and lightly grease puller threads.
Piston Pin Puller (PN 2870386)
3.
Remove nut from puller rod and set aside.
Piston Pin Puller
(PN 2870386)
Main Puller Adaptor (#8)
(PN 5020632)
Item
#2
#3
#5
#8
#9
#10
#10
#8
Qty.
1
1
1
Part Description
P-90 Drive/Driven Clutch
Bushing Install Tool
Drive Clutch Cover
Bushing Removal/
Installation Tool (all clutches)
P-90 Driven Clutch Cover
Bushing Removal Tool
1 Main Puller Adapter
1 Adapter Reducer
1
Number Two Puller
Adapter
#9
Part #
5020628
5020629
5020631
5020632
5010279
5020633
NOTE: Bushings are installed at the factory using
Loctite
™
. In order to remove bushings it will be necessary to apply heat evenly to the area around each bushing. Clean all residual Loctite
™
from bushing bore prior to installing new bushing.
4.
Install puller adapter (Item 10 from kit PN 2871226 ).
5.
Install main adapter (Item D) onto puller.
Puller Tool (A,B)
Side “A” toward sheave
Nut (C)
Main
Adapter (D)
Puller
Adapter (10)
Piston Pin
Puller
6.
With towers pointing toward the vise, slide sheave onto puller rod.
7.
Install removal tool (Item A, B) into center of sheave with
“A side" toward sheave.
6
6.17
CLUTCHING
NOTE: Use Bushing Tool PA-47336.
8.
Install nut (C) onto end of puller rod and hand tighten. Turn puller barrel to increase tension on sheave if needed. Using a hand held propane torch, apply heat around outside of 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.
Drive Clutch Bushing Installation
1.
Place main adapter (Item 8) on puller.
Puller Tool (A,B)
Side “A” toward sheave
Nut (C)
Cover Bushing Removal
1.
Install main adapter (Item 8) on puller.
Removal Tool
(3)
Nut (C)
Main
Adapter (8)
Adapter Reducer
(9)
Piston Pin
Puller
Bushing
Main Adapter
(8)
Piston Pin
Puller
2.
Apply Loctite
™
609 evenly to bushing bore inside moveable sheave.
3.
Set bushing in place on sheave.
4.
Insert installation puller tool (Item A/B) with “A” side down, into center of bushing.
NOTE: 700 EFI Clutch - Use Bushing Tool PA-47336 .
5.
With towers pointing upward, slide sheave, bushing and tool onto puller rod.
6.
Install nut on puller rod and hand tighten. Turn barrel to apply additional tension if needed.
7.
Turn sheave counterclockwise, making sure bushing is drawn straight into bore. Continue until bushing is seated.
8.
Remove nut from puller rod and set aside.
9.
Remove sheave from puller.
10. Remove installation tool.
2.
Install adapter reducer (Item 9).
3.
From outside of clutch cover, insert removal tool (Item 3) into cover bushing.
4.
With inside of cover toward vise, slide cover onto puller.
5.
Install nut onto puller rod and hand tighten. Turn puller barrel to increase tension as needed.
6.
Turn clutch cover counterclockwise on puller rod until bushing is removed and cover comes free.
7.
Remove nut from puller rod and set aside.
8.
Remove bushing and bushing removal tool from puller.
Discard bushing.
Cover Bushing Installation
1.
Apply Loctite
™
609 evenly to bushing bore in cover.
2.
Working from inside of cover, insert new bushing and bushing installation tool into center of clutch cover.
3.
With main adapter on puller, insert cover onto puller rod, placing outside of cover toward vise.
4.
Install nut on rod and hand tighten. Turn puller barrel to apply more tension if needed.
5.
Turn clutch cover counterclockwise on puller rod until bushing is seated.
6.
Remove nut from puller rod. Take installation tool and clutch cover off rod.
6.18
CLUTCHING
Clutch Assembly
NOTE: It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly. The Teflon bushings are self-lubricating.
4.
Torque spider to specification using the holding fixture and spider tool. Torque with smooth motion to avoid damage to the stationary sheave.
=
T
Spider Torque:
200 ft. lbs. (271 Nm)
CAUTION
Do not apply oil or grease to the bushings.
Reassemble the drive clutch in the following sequence. Be sure the “X”, or the marks that were made earlier are aligned during each phase of assembly.
CAUTION
Be sure the spider spacer washers are fully seated in the recessed area in the spider.
Any misalignment will alter clutch balance.
Inverting the clutch while initially tightening the spider will help position the washers.
5.
Install shift weights using new lock nuts on the bolts.
1.
Install moveable sheave onto fixed sheave.
2.
Install spider spacers. Use same quantity and thickness as were removed.
Nut on trailing side Rotation
6.
Reinstall clutch spring.
7.
Reinstall cover, aligning “X” mark with other marks.
8.
Torque cover bolts evenly to specification.
Spacer washers
3.
Compress spider buttons for each tower and install spider, making sure that “X”, or the marks that were made earlier, on spider aligns with “X”, or the marks that were made earlier, in moveable sheave.
=
T
Cover Screw Torque:
90 in. lbs. (10.4 Nm)
6
6.19
CLUTCHING
DRIVEN CLUTCH SERVICE
Exploded View
DRIVEN CLUTCH
Compression Spring
Secondary Stationary Sheave
Moveable Inner Sheave
Inner Spring Retainer
Outer Spring Retainer
Retaining Ring
Clutch Disassembly / Inspection
CAUTION
Wear eye protection when removing snap ring to prevent serious personal injury.
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 X’s on the sheaves for reference. This aids in reassembly and maintains clutch balance after reassembly.
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 retainer. Carefully remove the snap ring. Remember the outer spring retainer contains strong spring pressure.
Remove Snap Ring
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 relieved, remove the outer spring retainer (B), compression spring (C), and inner spring retainer (D).
B
7.
Remove the inner spring retainer from the inner sheave.
Inspect for wear and replace as needed.
A
C
D
D
C
5.
Separate the two clutch sheaves.
B
A
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.
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 oil or grease to the bearings.
Assemble Sheaves
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 range, although engine is properly tuned.
-Drive clutch shift weight too heavy.
-Install correct shift weight kit to match engine application.
-Driven clutch spring broken or installed in wrong helix location.
-Replace spring; refer to proper installation 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 during acceleration or load variations.
-Belt worn unevenly - thin / burnt spots.
-Driven clutch malfunction.
Replace belt.
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.
Engine RPM above specified operating range.
-Drive clutch shift weights incorrect for application
(too light).
-Install correct recommended shift weights.
-Drive clutch binding.
-Disassemble and clean clutch, inspecting shift weights and rollers. Reassemble without the spring and move sheaves through entire range to further determine probable cause.
-Driven clutch binding.
-Disassemble, clean, and inspect driven clutch, noting worn sheave bushing and ramp buttons and helix spring location.
6
-Converter sheaves greasy; belt slipage.
-Drive belt worn too narrow.
-Clean sheaves with denatured alcohol or brake cleaner, install new belt.
-Replace belt.
Harsh drive clutch engagement.
-Excessive belt / sheave clearance with new belt.
-Wrong belt for application.
-Perform belt / sheave clearance adjustment with shim washers beneath spider.
-Replace with correct belt.
Drive belt turns over -Clutch alignment out of spec.
-Engine mount broken or loose.
-Abuse (continued throttle application when vehicle is stationary, excess load)
Belt burnt, thin spots -Dragging brake
-Adjust clutch alignment.
-Inspect / adjust or replace.
-Caution operator to operate machine within guidelines.
-Slow, easy clutch engagement
-Vehicle operated with park brake on. Inspect brake system.
-Fast, effective use of throttle for efficient engagement.
6.23
CLUTCHING
Troubleshooting, Continued.....
Situation Probable Cause
-Plugged air intake or outlet.
Remedy
-Clear obstruction
-Belt slippage due to water, oil, grease, etc., rubbing on cover.
-Inspect system. Clean , repair or replace as necessary.
Seal PVT system ducts.
PVT cover overheating (melting)
-Clutches or weight being applied to cover while in operation.
-Remove weight. Inform operator.
Water ingestion
Belt slippage
PVT noise
Engagement erratic or stabby
-High vs. low range.
-Cover seals or ducts leaking
-Operator error
-Instruct operator on guidelines for operation in proper driving range for different terrain as outlined in Owner’s
Safety and Maintenance Manual.
-Find leak and repair as necessary.
-Instruct operator on guidelines for operation in wet terrain as outlined in Owner’s Safety and Maintenance
Manual.
-Replace belt.
-Belt worn out
-Water ingestion
-Belt contaminated with oil or grease
-Belt worn or separated, thin spots, loose belt
-Inspect and seal PVT system.
-Inspect and clean.
-Replace belt.
-Broken or worn clutch components, cover hitting clutches
-Inspect and repair as necessary.
-Thin spots on belt, worn belt -Replace belt. Refer to belt burnt troubleshooting and instruct operator.
-Drive clutch bushings stick -Inspect and repair clutches.
6.24
FINAL DRIVE
CHAPTER 7
FINAL DRIVE
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
FRONT HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
HUB REMOVAL / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
HUBSTRUT BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
HUB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
FRONT HUB EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
DRIVE SHAFT / CV JOINT HANDLING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
OUTER CV JOINT / BOOT REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
INNER PLUNGING JOINT / BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
FRONT PROPSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
6X6 REMOVAL / 4X4 CREW REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
FRONT PROPSHAFT COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
PROPSHAFT U-JOINT SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
FRONT GEARCASE CENTRALIZED HILLIARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
AWD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
CENTRALIZED HILLIARD EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
AWD DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
GEARCASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
GEARCASE DISASSEMBLY / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
GEARCASE REASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21
BACKLASH PAD (THRUST PAD) ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
GEARCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24
MID DRIVE HUB / BEARING CARRIER (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24
HUB DISASSEMBLY / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25
HUB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.26
MID DRIVE EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27
MID DRIVE SHAFT (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27
DISASSEMBLY / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.28
MID PROPSHAFT (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.28
MID DRIVE GEARCASE (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.29
GEARCASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.29
GEARCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30
GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32
GEARCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.35
MID GEARCASE EXPLODED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.36
REAR HUB / BEARING CARRIER (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.37
HUB INSPECTION / REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.37
HUB DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.38
HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.38
HUB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.39
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.40
7
7.1
FINAL DRIVE
REAR DRIVE SHAFT (4X4 CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.41
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.41
OUTER CV JOINT / BOOT REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.41
INNER PLUNGING JOINT / BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 7.44
DRIVE SHAFT EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.46
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.47
REAR PROPSHAFT (4X4 CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.48
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.48
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.48
REAR GEARCASE (4X4 CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.49
GENERAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.49
OPERATION MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.50
GEARCASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.51
GEARCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.51
REAR GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.54
REAR GEARCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.56
REAR GEARCASE EXPLODED VIEW (4X4 CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . 7.57
REAR AXLE / GEARCASE SERVICE (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.58
REAR AXLE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.58
AXLE TUBE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.59
AXLE TUBE BEARING REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.60
GEARCASE DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.60
GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.61
GEARCASE / AXLE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.62
REAR GEARCASE EXPLODED VIEW (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.65
7.2
SPECIAL TOOLS
PART NUMBER
2872608
8700226
PU-48951
TOOL DESCRIPTION
Roller Pin Removal Tool
CV Boot Clamp Pliers
Axle Boot Clamp Tool
TORQUE SPECIFICATIONS
Wheel, Hub, and Spindle Torque Table
ITEM NUT TYPE SPECIFICATION
Aluminum Wheels
(Cast)
Lug Nut (1) 90 ft. lbs. (122 Nm)
Steel Wheels
(Black / Camo)
Front Spindle Nut
Rear & Middle
Hub Retaining Nut
Flange Nut (2) 35 ft. lbs. (47 Nm)
-
70 ft. lbs. (95 Nm)
110 ft. lbs. (150 Nm)
FINAL DRIVE
FRONT HUB
Hub Removal / Inspection
1.
Elevate front end and safely support machine under footrest / frame area.
CAUTION
Serious injury may result if machine tips or falls.
Be sure machine is secure before beginning this service procedure. Wear eye protection when removing bearings and seals.
2.
Check bearings for side play by grasping the tire / wheel firmly and checking for movement. Grasp the top and bottom of the tire. The tire should rotate smoothly without binding or rough spots.
Aluminum Wheel
(LE Models)
90 ft. lbs. (122 Nm)
#1
Steel Wheel
(Standard Models)
35 ft. lbs. (47 Nm)
#2
3.
Remove wheel nuts, washers, and wheel.
4.
Remove the two brake caliper attaching bolts.
CAUTION: Do not hang the caliper by the brake line. Use wire to hang the caliper to prevent possible damage to the brake line.
7
7.3
FINAL DRIVE
5.
Remove hub cap, cotter pin, front spindle nut, and washer.
3.
Drive bearing out evenly by tapping on outer race only.
Once bearing is at bottom of casting, support casting on outer edges so bearing can be removed.
6.
Rotate each bearing by hand and check for smooth rotation.
Visually inspect bearing for moisture, dirt, or corrosion.
Replace bearing if moisture, dirt, corrosion, or roughness is evident.
Hubstrut Bearing Replacement
Bearing Removal
1.
Remove outer snap ring.
Rotate Bearing
NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel. While rotating bearings by hand, inspect for rough spots, discoloration, or corrosion. The bearings should turn smoothly and quietly, with no detectable up and down movement and minimal movement sideways between inner and outer race.
4.
Inspect bearing hubstrut housing for scratches, wear or damage. Replace hubstrut housing if damaged.
Bearing Installation
5.
Thoroughly clean the hubstrut housing and the outer race on the new bearing. Be sure that all oil residue has been removed from each surface.
6.
Apply Loctite ® 603 ™ retaining compound to the outer circumference of the new bearing race and carefully install the new bearing into the strut housing.
Apply Loctite ® 603 ™
2.
From the back side, tap on the outer bearing race with a drift punch in the reliefs as shown in Step 3.
NOTE: Use care to not allow any of the Loctite ® compound to get in the bearing.
7.
Wipe the housing clean of any excess compound and install the retaining ring.
7.4
FINAL DRIVE
Hub Installation
1.
Inspect the hubstrut bearing surface for wear or damage.
2.
Apply grease to drive axle spindle.
3.
Install spindle through the backside of the hubstrut. Install the hub onto the spindle.
4.
Apply grease to washer and install with domed side out.
10. Install brake caliper using new bolts. Tighten bolts to specified torque.
18 ft. lbs.
(24 Nm)
Brake Caliper Bolt Torque
18 ft. lbs. (24 Nm)
Out
Cone
Washer
5.
Install spindle nut and tighten to specification.
Spindle Nut Torque:
70 ft. lbs. (95 Nm)
6.
Install a new cotter pin. Tighten nut slightly if necessary to align cotter pin holes.
7.
Rotate wheel and check for smooth operation. Bend both ends of cotter pin around end of spindle in different directions.
8.
Install hub cap.
9.
Rotate hub. It should rotate smoothly without binding or rough spots or side play.
CAUTION
New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly.
11. Install wheel, washers, wheel nuts, and tighten evenly in a cross pattern to specified torque.
Refer to “Torque Specifications” on Page 7.3
Flange Nuts:
Flat side against wheel
7
7.5
FINAL DRIVE
Front Hub Exploded View
Disc Brake
Stud
Front Hub
Rim
18 ft. lbs. (24 Nm)
Use new bolts with pre-applied locking agent.
Tire
Wheel Nut
(Spec on page 7.3)
Washer
Slotted Nut
70 ft. lbs. (95 Nm)
Cotter Pin
Dust Cover
7.6
FINAL DRIVE
FRONT DRIVE SHAFT
Removal
1.
Elevate front of vehicle and safely support machine under the frame area.
6.
Remove the front wheel hub.
CAUTION
Serious injury may result if machine tips or falls.
Be sure machine is secure before beginning this service procedure. Wear eye protection when removing bearings and seals.
2.
Check bearings for side play by grasping tire / wheel firmly and checking for movement. It should rotate smoothly without binding or rough spots.
7.
Remove cotter pin and castle nut from A-arm ball joint.
3.
Remove the (4) wheel nuts and remove the front wheel.
4.
Remove the two brake caliper mounting bolts.
CAUTION: Do not hang the caliper by the brake line. Use wire to hang the caliper to prevent possible damage to the brake line.
8.
Remove lower A-arm from ball joint using a tie rod fork.
7
5.
Remove and discard the cotter pin, then remove the front hub castle nut.
7.7
FINAL DRIVE
9.
Pull strut assembly out while pivoting front drive shaft downward until it clears strut assembly.
• 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.
Remove the front drive shaft from the vehicle (see
“FRONT DRIVE SHAFT - Removal”).
2.
Remove and discard the boot clamps.
10. With short sharp jerks, remove drive shaft from front gearcase.
CV Boot Clamp Pliers
Earless Type: 8700226
3.
Remove the large end of the boot from the CV joint and slide the boot back.
4.
Use a soft-faced hammer or brass drift to separate the CV joint from the drive shaft.
NOTE: If using a brass drift, be sure to tap on the inner race of the joint only.
Circlip
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 protected during handling to avoid damage.
• Do not allow boots to come into contact with sharp edges or hot engine and exhaust components.
• The drive shaft is not to be used as a lever arm to position other suspension components.
7.8
Pull shaft to remove from CV joint
5.
Make sure the circlip remains on the shaft and not left in the joint. Discard the circlip.
6.
Remove the boot from the drive shaft.
CAUTION
Complete disassembly of the CV joint is NOT recommended. The internal components are a precision fit and develop their own characteristic wear patterns. Intermixing the internal components could result in looseness, binding, and/or premature failure of the joint.
FINAL DRIVE
IMPORTANT: If the grease in the joint is obviously contaminated with water and/or dirt, the joint should be replaced.
7.
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.
8.
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.
9.
Clean the splines on the end of the shaft and apply a light coat of grease prior to reassembly.
10. Slide the small boot clamp and boot (small end first) onto the drive shaft and position the boot in it’s groove machined in the shaft.
11. Install a NEW circlip on the end of the shaft.
12. Grease the joint with the special CV joint grease provided in the boot replacement kit. Fill the cavity behind the balls and the splined hole in the joint’s inner race. Pack the ball tracks and outer face flush with grease. Place any remaining grease into the boot.
13. Slide the joint onto the drive shaft splines and align the circlip with the lead-in chamfer on the inner race of the joint.
14. Use a soft-faced hammer to tap the joint onto the drive shaft until it locks into place.
15. Pull on the joint to make sure it is securely locked into place.
16. Remove excess grease from the CV joint’s external surfaces and place the excess grease in the boot.
17. 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.
18. Install and secure the CV boot with the large clamp using the “earless” clamp pliers.
CV Boot Clamp Pliers
Earless Type: 8700226
19. While pulling out on the CV shaft, fully extend the CV joint and slide a straight O-ring pick or a small slotted screw driver between the small end of the boot and the shaft. This will allow the air pressure to equalize in the CV boot in the position that the joint will spend most of its life. Before you remove your instrument, be sure the small end of the boot is in its correct location on the shaft.
7
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.
NOTE: The amount of grease that’s provided is premeasured, so use all the grease.
20. Install and secure the small clamp on the boot using the
“earless” clamp pliers.
Boot Replacement Grease Requirement:
Grease Only Service Kits
PN 1350059 - 20g
PN 1350046 - 30g
PN 1350047 - 50g
Outer CV Joint Capacity: 150g
CV Boot Clamp Pliers
Earless Type: 8700226
7.9
FINAL DRIVE
Inner Plunging Joint / Boot Replacement
1.
Remove the front drive shaft from the vehicle (see
“FRONT DRIVE SHAFT - Removal”).
2.
Remove and discard the boot clamps.
12. Grease the joint with the special CV joint grease provided in the boot replacement kit. Fill the cavity behind the balls and the splined hole in the joint’s inner race. Pack the ball tracks and outer face flush with grease. Place any remaining grease into the boot.
CV Boot Clamp Pliers
Earless Type: 8700226
3.
Remove the large end of the boot from the plunging joint and slide the boot back.
4.
Use a soft-faced hammer or brass drift to separate the plunging joint from the drive shaft.
NOTE: If using a brass drift, be sure to tap on the inner race of the joint only.
5.
Make sure the circlip remains on the shaft and not left in the joint. Discard the circlip.
6.
Remove the boot from the drive shaft.
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.
NOTE: The amount of grease that’s provided is premeasured, so use all the grease.
Boot Replacement Grease Requirement:
Grease Only Service Kits
PN 1350059 - 20g
PN 1350046 - 30g
PN 1350047 - 50g
Inner Plunging Joint Capacity: 150g
CAUTION
Complete disassembly of the plunging joint is
NOT recommended. The internal components are a precision fit and develop their own characteristic wear patterns. Intermixing the internal components could result in looseness, binding, and/or premature failure of the joint.
IMPORTANT: If the grease in the joint is obviously contaminated with water and/or dirt, the joint should be replaced.
7.
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.
8.
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.
9.
Clean the splines on the end of the shaft and apply a light coat of grease prior to reassembly.
10. Slide the small boot clamp and boot (small end first) onto the drive shaft and position the boot in it’s groove machined in the shaft.
11. Install a NEW circlip on the end of the shaft.
7.10
13. Fully compress the joint and push the drive shaft firmly into the inner race.
14. Align the circlip with the lead-in chamfer.
15. Use a soft-faced hammer to tap the joint onto the drive shaft until it locks into place.
16. Pull on the joint to make sure it is securely locked into place.
17. Remove excess grease from the plunging joint’s external surfaces and place the excess grease in the boot.
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.
19. Install and secure the small clamp on the boot using the
“earless” clamp pliers.
CV Boot Clamp Pliers
Earless Type: 8700226
FINAL DRIVE
20. Pull out on the drive shaft to center the joint in the housing.
Slide a straight O-ring pick or a small slotted screw driver between the large end of the boot and the joint housing and lift up to equalize the air pressure in the boot.
21. Position the boot lip in its groove. Install and secure the boot with the large clamp using the “earless” clamp pliers.
Installation
1.
Install new spring ring on drive shaft. Apply an anti-seize compound to splines. Align splines of drive shaft with front gearcase and install by lightly tapping on drive shaft with rubber faced hammer.
CV Boot Clamp Pliers
Earless Type: 8700226
Exploded View
NOTE: Refer the “Electronic Parts Catalog” for required parts to service the drive shaft. Some drive shafts have “Boot Replacement Kits” that include a new boot, clamps, and the required amount of grease.
Circlip CV Joint
2.
Install drive shaft in strut.
3.
Install the lower A-arm onto the lower ball joint, torque nut to 25 ft. lbs. (35 Nm) and install new cotter pin.
Large
Clamp
Boot
7
Grease
Small
Clamps
Boot
Grease
Cotter Pin 25 ft. lbs.
(35 Nm)
4.
Install hub and tighten spindle nut to 70 ft. lbs. (95 Nm).
Front Spindle Nut Torque
70 ft. lbs. (95 Nm)
Large
Clamp
Circlip
Circlip
Plunging
Joint
7.11
FINAL DRIVE
FRONT PROPSHAFT
6x6 Removal
1.
Elevate and safely support vehicle under the frame. The use of a vehicle hoist is recommended for this procedure.
CAUTION
Serious injury may result if machine tips or falls.
Be sure machine is secure before beginning this service procedure. Wear eye protection when removing bearings and seals.
NOTE: To ease roll pin removal, access the roll pin through the skid plate hole. Proceed to step 4 if you are able to access the roll pin through the skid plate.
2.
Remove wheel nuts and wheel.
3.
Remove cotter pin and nut from the lower A-arm ball joint and then remove the lower A-arm from the ball joint.
NOTE: Remove the drive shaft floor cover to help align the roll pin removal tool. The drive shaft can be removed through the floor covering.
4x4 CREW Removal
1.
Follow steps 1-5 of the “6x6 Removal” procedure.
2.
Remove the additional drive shaft floor cover located in the rear passenger floor area.
3.
Remove both seats and the storage box from under the front seat.
4.
Remove the RH rear fender and the heat shield mounted on the exhaust header pipe to allow enough clearance to remove the propshaft.
5.
Remove the propshaft out the rear RH side of the vehicle.
Front Propshaft Components
4.
Use the Roll Pin Removal Tool (PN 2872608), to drive out the roll pin from prop shaft.
Roll Pin Removal Tool (PN 2872608)
5.
Slide prop shaft back and away from front gearcase, then pull the shaft sharply forward to remove it from the transmission shaft.
6x6
Front Yoke
U-Joint
4x4 CREW Front Yoke
Grease Zerk
Rear Yoke
Grease Zerk
U-Joint Rear Yoke
Skid Plate
Access Hole
7.12
FINAL DRIVE
PROPSHAFT U-JOINT SERVICE
Disassembly
1.
Remove internal or external snap ring from all bearing caps.
3.
Support U-joint in vise as shown and drive inner yoke down to remove remaining bearing caps.
CAUTION
Always wear eye protection.
4.
Force U-joint cross to one side and lift out of inner yoke.
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 repositioning during installation.
2.
Support inner yoke as shown and drive outer yoke down
(bearing cap out) with a soft face hammer.
Assembly
1.
Install new bearing caps in yoke by hand. Carefully install
U-joint cross with grease fitting properly positioned inward toward center of shaft. Take care not to dislodge needle bearings upon installation of cross joint. Tighten vise to force bearing caps in.
7
7.13
FINAL DRIVE
2.
Using a suitable arbor, fully seat bearing cap in one side.
Continually check for free movement of bearing cross as bearing caps are assembled.
7.
When installation is complete, yokes must pivot freely in all directions without binding. If the joint is stiff or binding, tap the yoke lightly to center the joint until it pivots freely in all directions.
3.
Install snap ring to contain bearing cap just installed.
Repeat procedure for other side.
4.
Install outer yoke, aligning marks made before disassembly.
5.
Repeat Steps 1-3 to install bearing caps on outer yoke.
6.
Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown.
7.14
FINAL DRIVE
FRONT GEARCASE / CENTRALIZED HILLIARD
Centralized Hilliard Exploded View
10 ft. lbs.
(14 Nm)
20
2
17 ft. lbs.
(23 Nm)
14
18
14
14 19
15
22
16
14
1
8
10
13 9
3
12
21
4
11
14
5 7
6
2
17 ft. lbs.
(23 Nm) 17
4
R EF # D ESCRIPTION
7
8
5
6
3
4
1
2
Thrust Button Asm. w/O-ring
Screw (5/16-18)
Dowel Pin
Roller Ball Bearing
Thrust Needle Bearing
Internal Retaining Ring
Clutch Housing / Ring Gear
Thrust Plate
9 Roll Cage Asm. (Includes H-Springs)
10 Rollers
11 Set Screw
12 Race / Output Hub Asm.
13 Armature Plate
12
24
1
1
1
1
1
2
1
11
1
2
1
14
1
Q TY R EF # D ESCRIPTION
14 Seal Kit (Includes O-rings and Seals)
15 Roller Ball Bearing
16 Bushing
17 Cover Plate Asm. w/Coil
18 Gearcase LH
19 Input Cover
20 Magnetic Drain Plug Asm.
21 Bushing
22 Pinion Shaft Asm
23 Fill Plug
24 Gear Spacer
25 Vent Fitting
25
23
8-30 ft. lbs.
(11-41 Nm)
1
1
1
1
1
1
1
1
1
1
1
1
Q TY
7.15
7
FINAL DRIVE
All Wheel Drive Operation
The AWD switch may be turned on or off while the vehicle is moving, however, AWD will not enable until the engine RPM drops below 3100. Once the AWD is enabled, it remains enabled until the switch is turned off.
Engage the AWD switch before getting into conditions where the front wheel drive may be needed. If the rear wheels are spinning, release the throttle before switching to AWD.
CAUTION
Switching to AWD while the rear wheels are spinning may cause severe drive shaft and gearcase damage. Always switch to AWD while the rear wheels have traction or are at rest.
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).
AWD Engagement: When the AWD switch is activated, the
AWD coil is powered by a 12 Vdc input which creates a magnetic field. This magnetic field attracts an armature plate that is keyed to the roll cage. When the ring gear and roll cage are spinning (vehicle is moving), the energized coil and armature plate will apply drag to the roll cage that indexes the rollers inside the ring gear to an engagement position. While in the engagement position, the front drive will be in an “overrunning” condition (not engaged), until the rear wheels lose traction. Once the rear wheels begin to lose traction, the front drive will engage by coupling the output hubs to the ring gear via the rollers. The front drive will remain engaged until the torque requirement goes away (i.e. rear wheels regain traction).
Output Hub Rollers
Ring
Gear
Roll Cage
& H-springs
CAUTION
If the rear wheels are spinning, release the throttle before turning the AWD switch on.
If AWD is engaged while the wheels are spinning, severe drive shaft and clutch damage could result.
AWD Disengagement: Once the rear wheels regain traction, 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 wheel traction occurs.
7.16
AWD Diagnosis
Symptom: AWD Will Not Engage
1.
Check the gearcase coil resistance. To test the coil resistance, measure between the Grey and Brown/White wires. The measurement should be within specification.
FINAL DRIVE
Possible
Wear Ring on
Armature Plate
OK Condition
Front Gearcase Coil Resistance:
21.6 - 26.4 Ohms
2.
Turn the ignition and AWD switches on and place gear selector in High or Low gear. Check for minimum battery voltage at the Gray and Brown/White chassis wires that power the coil. A minimum of 11 Vdc should be present.
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 mark may indicate a warped plate, which may cause intermittent operation. See the following illustrations:
Bad Condition
(Wear from coil on armature plate)
5.
Check to make sure the coil is seated in the U-shaped insert that is pressed into the gearcase cover. The top of the coil should be seated below the U-shaped insert. The U-shaped insert controls the pole gap. If the top of the coil is above the surface of the U-shaped insert it raises the armature plate, thereby increasing pole gap. If the pole gap increases the coil will not be strong enough to engage the AWD system. If this is found, replace the cover plate assembly.
Gearcase Cover Plate Asm.
7
Coil
U-shaped insert
Side cutaway view of
Centralized Hilliard cover
Armature Plate
Armature plate design may differ from what is shown
6.
Inspect the rollers for nicks and scratches. The rollers must slide up, down, in and out freely within the roll cage sliding surfaces and H-springs.
Check for wear bands
7.17
FINAL DRIVE
Roll Cage
Asm.
Rollers
8.
The front gearcase and drive shafts can be accessed from both sides of the vehicle and limited access from the top.
7.
Inspect the roll cage assembly for cracks or excessive wear.
If damaged, replace the roll cage assembly.
Gearcase Removal
1.
Stop engine, place machine in gear and set parking brake.
2.
Loosen right front wheel nuts slightly.
3.
Elevate and support machine under footrest/frame area.
CAUTION
Serious injury may result if machine tips or falls.
Be sure machine is secure before beginning this service procedure. Wear eye protection when removing and installing bearings and seals.
4.
Remove right wheel nuts and wheel.
5.
Remove cotter pin, lower ball joint nut, and A-arm from ball joint.
Top View - From under hood
9.
Remove the access panel on the side of the vehicle. T-25 screws secure the panel to the frame.
Left
Side Panel
10. Remove the roll pin from the front drive shaft.Remove the front drive shaft from the front gearcase splines.
11. Remove bolts securing bottom of gearcase to frame.
Remove vent line. Remove gearcase from right side of frame.
6.
Repeat Step 1 through Step 5 on the opposite side.
7.
Pull each axle out from the front gearcase, refer to the
"FRONT DRIVE SHAFT REMOVAL" procedure earlier in this chapter.
7.18
Remove 4 Bolts
FINAL DRIVE
Gearcase Disassembly / Inspection
1.
Drain and properly dispose of used oil. Remove any metal particles from the drain plug magnet.
2.
Remove bolts and output shaft cover.
6.
Remove the roll cage assembly, rollers, and H-springs.
3.
Check the gearcase coil resistance. The resistance value should meet the specifications listed below.
NOTE: To test the gearcase coils resistance, use the coil harness. The gearcase coils should measure between 22.8 ohms and 25.2 ohms.
4.
Remove output shaft assembly
7.
Thoroughly clean all parts. Inspect the rollers (A) for nicks and scratches. The rollers must slide up and down freely within the roller cage surfaces (B).
8.
Inspect the ring gear (C) for consistent wear patterns. The surfaces should be free of nicks and scratches.
B
NOTE: Be careful not to misplace the thrust bearing located between the two output shafts.
5.
Clean all parts and inspect spacers for wear. Inspect ring gear for chipped, broken, or missing teeth.
C
A
9.
Inspect roll cage (B) sliding surface. This surface must be clean and free of nicks, burrs or scratches. Remove and inspect the H-springs.
H-Spring
B
7
7.19
FINAL DRIVE
10. Use a flat head screwdriver to remove the retaining ring from the output cover.
Retaining Ring
13. Remove the output hub (G) from the cover. remove the thrust bearing (F) from the output hub (G). Inspect the thrust bearing (F) and the dowel (H).
H G
F
11. Remove the spacer washer (D), armature plate (E), and rubber O-ring from the output cover.
D
O-Ring
E
14. Inspect the magnetic coil (I) in the output housing.
earlier in this chapter for more details on the coil.
15. Inspect the back lash pad (J) for excessive wear.
NOTE: The backlash for the centralized hilliard is set at the factory. No adjustment is required, unless the front cover needs to be replaced, or the back lash pad screw is removed. See the "Backlash Pad
Adjustment” procedure later in this chapter for details on backlash setting.
J
12. Inspect the armature plate (E) for a consistent wear pattern.
Uneven wear of the armature plate (E) indicates a warped plate, which may cause intermittent operation.
NOTE: See "FRONT GEARCASE DIAGNOSIS" earlier in this chapter for more details.
E
I
Armature plate design may differ from what is shown
7.20
FINAL DRIVE
16. Remove the other output hub (K) from the main gearcase.
Inspect the inner bearing (L) for wear. If there is excessive wear, replace bearing as needed.
19. Install new seals into the gearcase housing and use new Orings for the gearcase input and output covers.
K
L
17. Remove the input cover (M), bearing (N), and the pinion gear (O). Inspect the pinion gear (O) for chipped, broken, or missing teeth. Replace the input cover O-ring.
N
M
O
18. Inspect the output shaft bushing. Replace as needed. Clean the inside surfaces of both gearcase halves.
Gearcase Reassembly / Inspection
1.
As mentioned in the disassembly section, replace all Orings, seals, and worn components.
2.
Press the pinion shaft seal into the pinion cover, until the seal is flush with the sealing surface.
3.
Inspect bearings on output and pinion shafts. To replace, press new bearing on to shaft.
NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel. While rotating bearings by hand, inspect for rough spots, discoloration, or corrosion. The bearings should turn smoothly and quietly, with no detectable up and down movement and minimal movement side to side.
4.
Install pinion shaft, bearing, and input cover with new oring and torque bolts to 17 ft. lbs. (23 Nm).
7
Input Cover Bolts Torque:
17 ft. lbs. (23 Nm)
7.21
FINAL DRIVE
5.
Install the output hub (A) into the gearcase housing. The output hub should spin freely.
8.
Install the retaining ring (F) into the output cover. Be sure the retaining ring is properly seated into the cover.
A
F
6.
Install the other output hub (B) and thrust bearing (C) into the output cover. Apply a small amount of grease onto the thrust bearing.
9.
Install the ring gear (G) onto the output hub on the output cover.
G
B
C
7.
Install the armature plate (D) and spacer washer (E) into the output cover.
10. Install the rollers and roll cage into the ring gear. Insert the rollers as the roll cage is installed.
E
D
Backlash Plate
NOTE: Be sure backlash plate is in place.
7.22
11. Install the output cover assembly onto the main gearcase.
FINAL DRIVE
Backlash Pad (Thrust Pad) Adjustment
1.
Lay the gearcase on the side with the output cover facing up.
2.
The backlash screw has Loctite applied to it. Use a heat gun to lightly heat up the Loctite on the screw (A).
A
NOTE: Be sure armature plate tabs are placed into the slots on roll cage. (See Reference Photo)
Photo for reference only
Armature plate tabs fit into roll cage slots
3.
Using a hex wrench, turn the back-lash screw out 3-4 turns.
Re-apply red Loctite onto the bottom screw threads.
Armature plate design may differ from what is shown
NOTE: This photo is for reference only, the armature plate is actually installed in the output cover.
12. Install output cover with new O-ring and torque bolts to 17 ft. lbs. (23 Nm).
NOTE: Be sure the square O-ring is placed flat on the cover surface. If the O-ring is twisted fluid leakage may occur.
4.
Turn the screw in until it is lightly seated, then turn the screw out 1/4 turn.
5.
Set the gearcase upright. Rotate the pinion shaft at least 4 times. This ensures the ring gear completes one full rotation.
7
Cover Bolts Torque:
17 ft. lbs. (23 Nm)
7.23
FINAL DRIVE
6.
If a tight spot is felt during rotation, loosen the backlash screw another 1/8 turn. Perform the previous step again.
Repeat this procedure until the pinion shaft rotates smoothly 4 times (1 revolution of ring gear).
Gearcase Installation
1.
To install gearcase, reverse removal procedure.Use new spring pin in front prop shaft.
2.
Torque mounting bolts to 30 ft.lbs. (41 Nm).
MID DRIVE HUB / BEARING CARRIER
(6X6)
Removal
1.
Lock the emergency parking brake. Safely raise the center of the machine with a floor jack. Raise the machine just enough to remove the middle wheel.
2.
Remove the four wheel nuts and wheel.
3.
Remove the hub cap and cotter pin.
4 Bolts
30 ft. lbs. (41 Nm)
=
T
Front Housing Mount Bolt Toque:
30 ft. lbs. (41 Nm)
3.
Add the proper lubricant to the front gearcase. Check drain plug for proper torque. Refer to Chapter 2 for fluid fill and change information.
4.
Remove the hub nut, domed washer, and flat washer.
=
Premium Demand Drive Fluid
(PN 2871654)
Front Housing Capacity:
5 fl. oz. (148 ml)
Hub Nut & Washers
5.
Remove the hub from the axle shaft.
7.24
6.
Remove the upper and lower control arm bolts.
Upper Bolt
FINAL DRIVE
NOTE: Drive bearing out evenly by tapping on outer race only. Once bearing is at bottom of casting, support casting on outer edges so bearing can be removed.
Lower Bolt
7.
Remove the bearing carrier from the A-arm assembly.
Hub Disassembly
1.
Remove outer snap ring (A).
A
Figure 7.24
3.
Inspect the bearing.
NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel. While rotating bearings by hand, inspect for rough spots, discoloration, or corrosion. The bearings should turn smoothly and quietly, with no detectable up and down movement and minimal movement sideways between inner and outer race.
4.
Inspect bearing housing for scratches, wear or damage.
Replace housing if damaged.
7
Hub Assembly
1.
Support bottom of bearing carrier housing. (A) Bearing
Carrier Housing; (B) Bearing; (C) Snap Ring
A
C
B
2.
From the back side, tap on the outer bearing race with a drift punch in the reliefs as shown in Figure 7.24.
7.25
FINAL DRIVE
2.
Start bearing (B) in housing (A).
A
B
3.
Install upper A-arm bolt and torque both upper and lower bolts.
Lower Control Arm Bolt Torque:
35 ft. lbs. (47 Nm)
Upper Control Arm Bolt Torque:
35 ft. lbs. (47 Nm)
4.
Pull drive shaft outward and install hub onto drive shaft splines. Apply Anti-Seize compound to the axle splines.
5.
Install the flat washer (A) and cone washer (B) with domed side facing outward. (Refer to next photo)
3.
Press bearing into place until outer race bottoms on housing.
CAUTION
Use an arbor and press only on the outer race, as bearing damage may occur.
Out
Cone
Washer
6.
Install the castle nut (C), wheel, and wheel nuts.
A B C
4.
Install snap ring into groove.
Hub Installation
1.
Install hub carrier to lower A-arm. Hand tighten lower Aarm bolt.
2.
Slide mid drive shaft through the hub carrier.
7.
Remove jackstand and torque mid hub nut to 110 ft. lbs.
(149 Nm) and wheel nuts to 35 ft. lbs. (47 Nm).
Mid Hub Nut Torque:
110 ft. lbs. (149 Nm)
Mid Wheel Nut Torque
35 ft. lbs. (47 Nm)
8.
Install a new cotter pin. Tighten nut slightly to align holes if required.
9.
Install hub cap.
7.26
FINAL DRIVE
Mid Drive Exploded View
35 ft. lbs.
(47 Nm) BUSHING
SHAFT
MID UPPER A-ARM
35 ft. lbs.
(47 Nm)
MID DRIVE AXLE
35 ft. lbs.
(47 Nm)
SHAFT
BEARING CARRIER
BEARING
HUB
BUSHING SNAP RING
MID LOWER A-ARM
35 ft. lbs.
(47 Nm) BUSHING
MID DRIVE SHAFT (6X6)
Removal
1.
Repeat Steps 1-7 in the “Mid Drive Hub / Bearing Carrier
Removal” section.
2.
Slide the middle axle out of the bearing carrier by pulling the bearing carrier assembly outward and down.
3.
Pull the middle axle straight out from the frame. The axle will slide off the mid gearcase splined output shaft.
7
Disassembly / Assembly
NOTE: For mid drive shaft service information, see
“REAR DRIVE SHAFT (4X4 CREW) - CV Joint / Boot
Replacement”
7.27
FINAL DRIVE
Installation
1.
Apply Anti-Seize compound onto the mid gearcase output shaft splines. Slide mid drive shaft (A) onto the mid gearcase output shaft (B).
B
A
5.
Install the flat washer (A) and cone washer (B) with domed side facing outward. (Refer to next photo)
6.
Install the castle nut (C), wheel, and wheel nuts.
A B C
2.
Install the outer end of the mid drive shaft into the hub carrier (C).
7.
Remove jackstand and torque mid hub nut to 110 ft. lbs.
(149 Nm) and wheel nuts to 35 ft. lbs. (47 Nm).
Mid Hub Nut Torque:
110 ft. lbs. (149 Nm)
Mid Wheel Nut Torque
35 ft. lbs. (47 Nm)
C
3.
Lift hub carrier into place and install bolt to upper control arm. Torque bolt to 35 ft. lbs. (47 Nm).
Upper Bolt
8.
Install a new cotter pin. Tighten nut slightly to align holes if required.
9.
Install hub cap.
MID PROPSHAFT (6X6)
Removal
1.
Use the Roll Pin Removal Tool ( PN 2872608 ), to remove the roll pin from prop shaft at rear of transmission.
4.
Pull drive shaft outward and install hub onto drive shaft splines. Apply Anti-Seize compound to the axle splines.
2.
The transmission or middle differential mounting will have to be loosened to allow the propshaft to slide off of the transmission output shaft.
7.28
FINAL DRIVE
MID DRIVE GEARCASE (6X6)
Gearcase Removal
NOTE: To ease the removal of the middle axle gearcase, remove the box from the frame. Refer to the Box Removal Procedure in Chapter 5.
1.
Remove the vent line clamp and vent line (A) from the top of the mid drive gearcase (B).
A B
4.
Use the Roll Pin Removal Tool (PN 2872608) to remove the roll pins that secure the rear prop shaft and middle prop shaft to the mid drive gearcase.
Roll Pin Removal Tool
2872608
C
D
D
2.
Remove the mid drive shafts (D). Repeat steps 1-3 in the
“Mid Drive Shaft Removal” section.
3.
Remove the parking brake caliper (C), refer to Chapter 9,
“Parking Brake Caliper Service - Caliper Removal”.
NOTE: If the rear drive shaft does not slide off the mid gearcase output shaft, compress the rear suspension and the rear drive shaft will move back.
5.
Remove the four bolts and washers that secure the gearcase to the frame. The bolts are accessible through the skid plate on the bottom of the frame.
6.
With the drive shafts removed from the mid gearcase, lift the gearcase out of the frame.
7
PIN
MID DRIVE GEARCASE
REAR DRIVE SHAFT
PIN
TRANSMISSION
COUPLER
MID DRIVE SHAFT
MOUNTING BOLTS
& WASHERS
7.29
FINAL DRIVE
Gearcase Disassembly
1.
Drain the oil from the mid drive gearcase. Properly dispose of the oil.
2.
Remove the output cover bolts (A) and the output cover (B).
B
4.
Remove the output shaft and ring gear assembly (E) from the gearcase. Inspect the ring gear for abnormal wear, broken, or chipped teeth. Inspect and spin the bearings (F), the bearings should rotate smoothly.
E
A
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.
C
F F
5.
Remove the wave spring (G) from the gearcase assembly.
6.
Remove the bolts from the input cover (H).
H
G
D
7.30
FINAL DRIVE
7.
Remove the input cover bolts (I). Remove the input cover
(H) and pinion gear assembly from the gearcase.
9.
Inspect the pinion gear (K) and 26T output gear (L) for nics or uneven wear. Inspect the bearing (M), the bearing should spin smoothly. Replace the parts as needed.
K L M
H
I
8.
Remove the pinion gear assembly (J) from the front cover
(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 on the right), until the pinion gear assembly comes loose
J
1
H
10. Remove the rear output seal (N).
N
4 3
11. Remove the retaining ring (O) and shim (P) from the rear output thru shaft.
O
2
7
P
7.31
FINAL DRIVE
12. Carefully pull the output thru shaft (Q) through the gearcase.
S
Q
13. Remove the retaining ring (O), shim (P), and input gear (R) from the output shaft (Q). Inspect the input gear for abnormal wear, broken, or chipped teeth.
15. Replace all O-ring, seals, and worn components. Replace the seals as shown in the photo.
Q
P
O
14. Inspect the two flange bearings (S) inside the gearcase.
Inspect the pinion shaft bushing (T) for wear that is inside the gearcase.
Gearcase Assembly
1.
Install the shim (A) and a new retaining ring (B) onto the output end of the output shaft (C). Install the output thru shaft into the gearcase.
T
C
S
A & B
7.32
2.
Install the 26T input gear (D), shim (E), and a new retaining ring (F) onto the output shaft.
E
FINAL DRIVE
• Hold the pinion gear assembly
• 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 on the right), until the pinion gear assembly comes loose
1
3
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 step of the gear is facing towards the bearing (see below).
Pinion Shaft Assembly
Step Of Gear
4 2
5.
Apply Polaris Crankcase Sealant (PN 2871557) to the inside surface of the input cover (J).
J
7
I
G
H
Pinion Shaft Assembly Assembled
Sealant
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.
NOTE: Alignment of the pinion shaft bearing into the input cover maybe be difficult. If needed, use the following steps to aid in installation:
K
7.33
FINAL DRIVE
7.
Install the wave spring (L) into the gearcase assembly. Be sure the wave spring is fully seated into the bearing cup of the gearcase.
L
10. Install a new O-ring (O) onto the output cover.
O
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.
11. Carefully install the output cover onto the gearcase.
Install the output cover bolts. Torque the bolts to 18 - 23 ft. lbs. (24 - 31 Nm).
9.
Install the shims (M) into the output cover (N). Install the shims in the order that they were removed during the disassembly process.
M
Input Cover Bolt Torque:
18 - 23 ft. lbs. (24 - 31 Nm)
12. Remove the fill plug (P) and fill the mid gearcase with 6.75
oz. (200 ml) of Polaris ATV Angle Drive Fluid
(PN 2871653). Torque the fill plug to 14 ft. lbs. (19 Nm).
N
P
7.34
Middle Gearcase Specifications:
Capacity: 6.75 oz. (200 ml)
Specified Lubricant: ATV Angle Drive
Fluid (PN 2871653)
Fill Plug Torque: 14 ft. lbs. (19 Nm)
Gearcase Installation
1.
Place the middle gearcase in the frame assembly.
A B
D
C
D
2.
Attach the mid and rear prop shafts to the mid gearcase, but do not install the new roll pins yet.
3.
Install the four middle drive gearcase bolts. Torque the bolts to 30 ft. lbs. (41 Nm) in a cross pattern.
4.
Install a new roll pins into the mid and rear prop shafts and middle gearcase input and rear output shafts.
5.
Install the mid drive shafts (D) onto the mid gearcase (B).
6.
Install the vent tube (A) and clamp.
7.
Lift bearing carrier into place and install bolt to upper control arm. Torque bolt to 35 ft. lbs. (47 Nm). Refer to the
“MID DRIVE SHAFT INSTALLATION” section for more details.
8.
Install hub, flat washer, domed washer (domed side out) and nut. Torque center nut to 110 ft. lbs. (149 Nm). Install new cotter pin and hub cap.
9.
Install rear wheel and torque wheel nuts to specification.
10. Install the parking brake caliper (C), refer to Chapter 9,
“Parking Brake Caliper Service - Caliper Installation”
FINAL DRIVE
7
7.35
FINAL DRIVE
Mid Gearcase Exploded
18-23 ft. lbs.
(24-31 Nm)
R EF # D ESCRIPTION
7
8
5
6
3
4
1
2
Screw (5/16-18 x 1.0)
Plug, Square Socket
Seal, Dual Lip
Tube, Vent 1/4” Hose
Cover, Output
Shim
Bearing, Ball
Gear, Ring 37T
9 Shaft, Output
10 Bearing, Ball
11 Spring, Wave
12 O-Ring
13 Pipe, Knock
14 Seal, Triple Lip
15 Ring, Retaining
7.36
18-23 ft. lbs.
(24-31 Nm)
30 ft. lbs.
(41 Nm)
4
1
2
1
1
1
1
1
1
1
1
2
1
12
3
Q TY R EF # D ESCRIPTION
16 Washer, Thrust
17 Bearing, Plain Flanged
18 Gearcase
19 Bushing
20 Pinion, 10T
21 Gear, 26T Output
22 Bearing, Ball
23 Shaft, Output Thru
24 Gear, 26T Input
25 Cover, Input
26 Seal, Triple Lip
30 Bolt, (5/16-18 x 1.25)
31 Bracket, Caliper Mount
32 Ring, Hog
1
3
1
1
1
2
1
1
1
1
1
1
2
2
Q TY
FINAL DRIVE
REAR HUB / BEARING CARRIER (4X4)
Hub Inspection
1.
Support machine securely with rear wheels elevated.
2.
Grasp wheel / hub and check for movement.
3.
If movement is detected, inspect hub, hub nut torque and bearing condition and correct as necessary.
5.
Remove hub cap, cotter pin, front spindle nut, and washer.
CAUTION
Serious injury may result if machine tips or falls.
Be sure machine is secure before beginning this service procedure. Wear eye protection when removing bearings and seals.
6.
Slide the rear hub from the rear drive axle.
Hub Removal
1.
Elevate rear end and safely support machine under main frame area.
2.
Check bearings for side play by grasping the tire / wheel firmly and checking for movement. Grasp the top and bottom of the tire. The tire should rotate smoothly without binding or rough spots.
3.
Remove wheel nuts and wheel.
4.
Remove the two brake caliper attaching bolts.
CAUTION: Do not hang the caliper by the brake line. Use wire to hang the caliper to prevent possible damage to the brake line.
7.
Remove the upper and lower control arm bolts from the rear hub / bearing carrier.
7
8.
Remove the bearing carrier. Inspect the bearing again for smoothness and side to side movement, replace as needed.
7.37
FINAL DRIVE
Hub Disassembly
1.
Remove outer snap ring (A).
A
Hub Assembly
1.
Support bottom of bearing carrier housing. (A) Bearing
Carrier Housing; (B) Bearing; (C) Snap Ring
A
C
B
2.
From the back side, tap on the outer bearing race with a drift punch in the reliefs as shown.
NOTE: Drive bearing out evenly by tapping on outer race only. Once bearing is at bottom of casting, support casting on outer edges so bearing can be removed.
2.
Start bearing (B) in housing (A).
A
B
3.
Inspect the bearing.
NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel. While rotating bearings by hand, inspect for rough spots, discoloration, or corrosion. The bearings should turn smoothly and quietly, with no detectable up and down movement and minimal movement sideways between inner and outer race.
4.
Inspect bearing housing for scratches, wear or damage.
Replace housing if damaged.
3.
Press bearing into place until outer race bottoms on housing.
CAUTION
Use an arbor and press only on the outer race, as bearing damage may occur.
4.
Install snap ring into groove.
7.38
FINAL DRIVE
Hub Installation
1.
Start the wheel bearing carrier onto the drive shaft.
2.
Align the bottom of carrier housing and lower control arm.
Slide the lower control arm bushings into place. Secure with the lower control arm bolt.
3.
With the drive shaft placed in the wheel bearing carrier, align the carrier with the top control arm. Secure with the upper control arm bolt.
NOTE: The lower shock bolt may need to be removed to allow the upper A-arm to move more freely.
6.
Install the washer with domed side out. Install the spindle retainer nut.
7.
Install the wheel, washers, and wheel nuts. Torque wheel nuts to specification. See “Torque Specifications” table on page 7.3.
8.
Lower the vehicle. Torque the spindle retaining nut to 110 ft.lbs. (149 Nm). Install a new cotter key and the hub cap.
4.
Torque the top and bottom A-arm bolts as shown in the photo.
110 ft. lbs
(149 Nm)
7
30 ft. lbs.
(41 Nm)
5.
Install the hub assembly onto the rear drive axle.
7.39
FINAL DRIVE
Exploded View
Rear Gearcase
30 ft. lbs.
(41 Nm)
A-arm bolts
Bushings
Shaft
Upper A-arm
Bushings
Shock
Rear Drive Axle
A-arm bolts
Nuts
Bushings
Coil
Bearing
30 ft. lbs.
(41 Nm)
Caliper
18 ft. lbs.
(24 Nm)
Lower A-arm
Carrier Bolt
30 ft. lbs.
(41 Nm)
Shaft
Shaft
Bushings
Snap Ring
7.40
FINAL DRIVE
REAR DRIVE SHAFT (4X4 CREW)
Removal
1.
Repeat all steps of the “Rear Hub / Bearing Carrier, Hub
Removal” section.
2.
Remove upper carrier bolt. Slide the rear drive shaft out of the bearing carrier by pulling the bearing carrier assembly outward and tipping it down to remove the shaft.
Outer CV Joint / Boot Replacement
1.
Using a side cutters, cut away and discard the boot clamps.
2.
Remove the large end of the boot from the CV joint and slide the boot down the shaft.
3.
Pull the rear drive shaft straight out of the frame. Use short sharp jerks to free the circlip from the gearcase. The circlip holds the drive shaft in the gearcase.
4.
Inspect the axle splines and CV boots for any damage.
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
7
IMPORTANT: Tap on inner race only!
7.41
FINAL DRIVE
6.
Make sure the circlip is on the shaft and not left in the joint.
Circlip
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 coat of grease prior to reassembly.
11. Slide the small boot clamp and boot (small end first) onto the drive shaft and position the boot in it’s groove machined in the shaft.
12. Install a NEW circlip on the end of 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 joint’s inner race. Pack the ball tracks and outer face flush with grease. Place any remaining grease into the boot.
7.
Remove the CV boot from the shaft.
CAUTION
Complete disassembly of the CV joint is NOT recommended. The internal components are a precision fit and develop their own characteristic wear patterns. Intermixing the internal components could result in looseness, binding, and/or premature failure of the joint.
IMPORTANT: If the grease in the joint is obviously contaminated with water and/or dirt, the joint should be replaced.
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.
NOTE: The amount of grease that’s provided is premeasured, so use all the grease.
Boot Replacement Grease Requirement:
Grease Only Service Kits
PN 1350059 - 20g
PN 1350046 - 30g
PN 1350047 - 50g
Outer CV Joint Capacity: 90g
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.
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.
7.42
FINAL DRIVE
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.
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.
15. Use a soft-faced hammer to tap the joint onto the drive shaft until it locks into place.
16. Pull on the joint to make sure it is securely locked in place.
17. Remove excess grease from the CV joint's external surfaces and place the excess grease in the boot.
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.
19. Install and tighten the large clamp using the Axle Boot
Clamp Tool (PU-48951).
21. Install and tighten the small clamp on the boot using the
Axle Boot Clamp Tool (PU-48951).
7
Axle Boot Clamp Tool
PU-48951
Axle Boot Clamp Tool
PU-48951
7.43
FINAL DRIVE
Inner Plunging Joint / Boot Replacement
1.
Using a side cutters, cut away and discard the boot clamps.
6.
Make sure the circlip is still on the shaft and not left in the joint.
Circlip
2.
Remove the large end of the boot from the plunging joint and slide the boot down the shaft.
7.
Remove the boot from the shaft.
CAUTION
Complete disassembly of the plunging joint is
NOT recommended. The internal components are a precision fit and develop their own characteristic wear patterns. Intermixing the internal components could result in looseness, binding, and/or premature failure of the joint.
IMPORTANT: If the grease in the joint is obviously contaminated with water and/or dirt, the joint should be replaced.
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
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.
9.
Visually inspect the joint for damage. Replace if needed.
10. Clean the splines on the end of the shaft and apply a light coat of grease prior to reassembly.
11. Slide the small boot clamp and boot (small end first) onto the drive shaft and position the boot in its groove machined in the shaft.
IMPORTANT: Tap on inner race only!
7.44
FINAL DRIVE
12. Install a NEW circlip on the end of 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 joint’s inner race. Pack the ball tracks and outer face flush with grease. Place any remaining grease into the boot.
18. Remove excess grease from the plunging joint’s external surfaces and place the excess grease in the boot.
19. Pull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft. Make sure the boot is not dimpled or collapsed.
20. Install and tighten the small clamp using the Axle Boot
Clamp Tool (PU-48951).
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.
NOTE: The amount of grease that’s provided is premeasured, so use all the grease.
Boot Replacement Grease Requirement:
Grease Only Service Kits
PN 1350059 - 20g
PN 1350046 - 30g
PN 1350047 - 50g
Inner Plunging Joint Capacity: 100g
Axle Boot Clamp Tool
PU-48951
14. Fully compress the joint and push the drive shaft firmly into the inner race.
15. Align the circlip with the lead-in chamfer.
21. Pull out on the drive shaft to center the joint in the housing.
Slide a straight O-ring pick or a small slotted screw driver between the large end of the boot and the joint housing and lift up to equalize the air pressure in the boot.
7
22. Position the boot lip in its groove. Install and tighten the large clamp using the Axle Boot Clamp Tool (PU-48951).
16. Use a soft-faced hammer to tap the joint onto the drive shaft until you reach the end of the splines and the joint locks in place.
17. Pull on the joint to test that the circlip is seated and that the joint is securely fastened to the shaft.
Axle Boot Clamp Tool
PU-48951
7.45
FINAL DRIVE
Drive Shaft Exploded View
REAR SHAFT
Spring Ring
Plunging
Joint
Grease Capacity
100 Grams
Gear Side
Boot Kit
Grease Capacity
90 Grams
Wheel Side
Boot Kit
CV Joint
7.46
Installation
1.
Slide the rear drive axle into the bearing carrier hub.
FINAL DRIVE
4.
Lift bearing carrier into place and install the bolt into the upper control arm. Torque bolt to 30 ft. lbs. (41 Nm).
30 ft. lbs.
(41 Nm)
2.
Install a new circlip onto the rear drive shaft. Apply Anti-
Seize Compound onto the rear drive shaft splines (both ends).
5.
Install hub, domed washer (domed side out) and nut.
Torque rear spindle nut to 110 ft. lbs. (149 Nm). Install new cotter pin and hub cap.
Apply Anti-Seize
New Circlip
3.
Reinstall the rear drive shaft into the rear gearcase. Be sure the circlip is securely fit into the rear gearcase. Use a rubber mallet to tap on the outboard end of the drive shaft if necessary.
Rear Hub Nut Torque:
110 ft. lbs. (149 Nm)
6.
Install rear wheel and torque washers and wheel nuts to specification. See “Torque Specifications” on page 7.3.
110 ft. lbs.
(149 Nm)
Flat washer
Wheel Nut (4)
7
Out
Cone
Washer
Cone washer dome to outside
7.47
FINAL DRIVE
REAR PROPSHAFT (4X4 CREW)
Removal
1.
Remove the pin clips from upper and lower cargo box shock pins and remove shock. Carefully allow cargo box to rest in the dump position as you remove the propshaft.
4.
Slide the propshaft off the transmission shaft and rear gearcase input shaft. Orientate the shaft so that it’s parallel with the frame supports as shown below.
WARNING
Support the cargo box while the shock is removed to prevent injury or damage.
2.
Use the Roll Pin Removal Tool (PN 2872608), to remove the roll pin from prop shaft at rear of transmission.
5.
Remove the shaft by placing the brake disc over the top of the rear frame support and under the front frame support.
Rear Frame
Support
Front Frame
Support
Installation
1.
When installing the propshaft, ensure that the shaft is touching the rear frame support and reinstall the shaft the same way it was removed with the brake disc over the top of the rear frame support and under the front frame support.
3.
Remove the two bolts that secure the rear parking brake caliper. Suspend the brake caliper assembly from the frame with a piece of wire. (Refer to Chapter 9 for more information on the rear parking brake)
2.
Slide the shaft onto the rear gearcase input shaft and then slide it onto the transmission shaft.
3.
Install a new roll pin into the propshaft
4.
Install the parking brake caliper and torque mounting bolts to 18 ft. lbs. (24 Nm) .
5.
Install cargo box shock, mounting pins and pin clips.
7.48
REAR GEARCASE (4X4 CREW)
General Operation
The RANGER rear gearcase has three traction operational modes: AWD, Differential Lock, and Differential Unlock.
Locking the rear differential is beneficial in low traction and rough terrain conditions. Unlocking the rear differential makes maneuvering easier and minimizes damage to turf and sensitive terrains.
FINAL DRIVE
Clutch Gear
Differential - Unlock
Shift Yoke
AWD
Differential - Lock
Differential - Unlock
When “Differential-Unlock” is selected on the switch, the rear differential becomes unlocked for tighter turns. An electrical solenoid mounted in the rear gearcase housing actuates the shift yoke. The solenoid plunger extends out to move the shift yoke and slides the clutch gear away from the engagement dogs that are attached to the differential gear assembly. This unlocks the rear differential.
When switch position is set to “Unlock”, the solenoid is powered and the plunger extends to disengage the clutch gear and unlock the differential.
When “Differential-Lock” is selected on the switch, power is removed from the electrical solenoid allowing the solenoid plunger to retract. Spring tension moves the shift yoke back into place and engages the clutch gear into the engagement dogs that are attached to the differential gear assembly, locking the rear differential as a solid rear axle.
When switch position is set to “Lock”, power is removed from the solenoid and the plunger retracts to engage the clutch gear and lock the differential. 7
Clutch Gear
Differential - Lock
Shift Yoke
7.49
FINAL DRIVE
When the clutch gear is unlocked the rear drive shafts are dependent on the differential allowing tighter turns. When it’s locked it becomes a solid rear axle increasing traction.
Operation Modes
AWD Mode
Differential
7.50
Clutch Gear
Axle Shaft
Locked Mode
Clutch Gear
Locked
Axle Shaft
Rear Wheels rotate at same speed.
Front Wheels rotate at same speed when AWD activated.
Differential Locked
Both rear wheels rotate at same speed.
Differential Unlocked
IRS Axle
Unlocked Mode
Axle Shaft
Clutch Gear
Unlocked
Axle Shaft
Rear wheels can rotate at different speeds.
(Allows for sharper turning)
FINAL DRIVE
Gearcase Removal
1.
Follow “Rear Drive Shaft Removal” procedure to remove the rear drive shafts from each side of the rear differential.
2.
Disconnect the differential solenoid 2-wire harness.
3.
Completely drain the lubricant from the rear gearcase
Gearcase Disassembly
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.
Drain Plug
4.
Remove the four bolts that secure the rear gearcase to the frame.
Remove the (2) fasteners from each side.
5.
Remove the (3) fasteners retaining the parking brake caliper bracket to the rear gearcase and carefully pull the rear gear case assembly from the frame. Allow the rear propshaft to slide off of the rear gearcase shaft.
Bracket
(3)
Propshaft
2.
Remove the (7) bolts that secure the cover to the housing.
7
Remove Cover Bolts
7.51
FINAL DRIVE
3.
Remove the differential assembly from the housing. 6.
Remove the shims from the differential assembly. Be sure to keep the shims together for reassembly.
4.
Inspect the bevel gear teeth for chipped, worn, or broken teeth.
7.
Remove the large bearing from the differential assembly.
Inspect the bearing for smoothness and wear.
Inspect Teeth
5.
Remove the small bearing from the differential assembly.
Inspect the bearing for smoothness and wear. 8.
Remove the shims from the differential assembly. Be sure to keep the shims together for reassembly.
7.52
9.
If the solenoid was removed for servicing, inspect the tip of the solenoid for wear. If the tip of the solenoid is flattened the solenoid must be replaced.
12. Loosen the lock assembly pin.
FINAL DRIVE
10. Remove the clutch gear from the gearcase cover.
13. Remove the pin from the gearcase cover.
11. Inspect the shift lever (A), shift lever spring (B), shift return springs (C), and shift yoke (D) for excessive wear or damage. If disassembly is required proceed to the next step.
If no disassembly is required proceed to “Rear Gearcase
Assembly.”
14. Carefully remove the shift yoke assembly from the gearcase cover.
C
D
7
B
A
7.53
FINAL DRIVE
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
A
D
Do Not Disassemble
.
Replace as an assembly if damaged or worn.
C
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.
2.
Replace the drive shaft oil seals located in the main gearcase and 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.
3.
Replace all worn components.
7.54
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.
B
A
6.
If previously removed; assembly the shift lever (A), shift lever spring (B), shift return springs (C), shift yoke (D), and lock pin bushing (E).
C
A
C
B
D
C
E B
7.
Carefully install the shift yoke assembly into the gearcase cover.
A
C
5.
Install the differential assembly into the carrier housing.
8.
Install the lock assembly pin and tighten.
7
7.55
FINAL DRIVE
9.
Install the new lightly greased O-ring onto the carrier cover.
O-Ring
Rear Gearcase Installation
1.
Place the differential 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) .
10. Assemble the gearcase halves and install the (7) bolts that secure the cover to the housing. Torque the bolts in a criss cross pattern to 25-35 ft. lbs. (34-48 Nm) .
25-35 ft. lbs.
(34-48 Nm)
Bracket
Propshaft
17 ft. lbs.
23 (Nm)
40 ft. lbs.
(54 Nm)
4.
Reverse the removal procedure for the rest of the installation.
5.
Add Polaris ATV Angle Drive Fluid (PN 2871653) to rear carrier. Refer to maintenance information in Chapter 2 for more details. Torque drain plug to 30-45 in. lbs. (3-5 Nm) .
Torque fill plug to 40-50 ft. lbs. (54-68 Nm) .
11. If previously removed, install the differential solenoid into the carrier cover. Torque solenoid to 30-40 ft. lbs.
(41-54 Nm) .
30-40 ft. lbs.
(41-54 Nm)
Fill Plug
40-50 ft. lbs.
(54-68 Nm)
Drain Plug
30-45 in. lbs.
(3-5 Nm)
Rear Gearcase Capacity:
18 fl. oz. (532 ml)
7.56
Rear Gearcase Exploded View (4x4 CREW)
40-50 ft. lbs.
(54-68 Nm)
30-45 in. lbs.
(3-5 Nm)
FINAL DRIVE
30-40 ft. lbs.
(41-54 Nm)
25-35 ft. lbs.
(34-48 Nm)
7
R EF # D ESCRIPTION
1 Hypoid Gear Assembly
2 Carrier Housing Half
3 Carrier Cover Half
4 Diff Case Half
5 Diff Case Cover Half
6 Diff Side Gear
7 Diff Pinion Mate Gear 2
8 Pinion Mate Thrust-Washer 2
1
2
1
1
1
1
9 Diff Cross Pin
10 Diff Roll Pin
1
1
11 Hex Bolt - Ring Gear 8
12 Diff Case Thrust-Washer AR
13 Side Gear Thrust-Washer 1
14 Diff Case Thrust-Washer AR
Q TY R EF # D ESCRIPTION
15 Bearing Cone - Diff
16 Bearing Cup - Diff
17 Bearing - Roller
18 Bearing - Cup
19 Bearing Assembly - Collar 1
20 Clutch Gear 1
21 O-Ring - Housing Halves 1
22 Lock Assembly Pin 1
1
1
1
1
23 Vent Tube 1
24 Flanged Hex Bolt - Housing 7
25 Diff Solenoid
26 Spacer - Kit
1
AR
27 Bearing Cup - Pinion
28 Bearing Cone - Pinion
2
2
Q TY R EF # D ESCRIPTION
29 Pinion Nut
30 Oil Seal - Pinion
31 Pinion Thrust-Washer
32 Lock Pin Bushing
33 Shift Return Spring
34 Drain Plug
35 Oil Seal - Shaft
36 Fill Plug
37 Shift Yoke
38 Shift Lever
39 Shift Lever Spring
40 Pinion Spacer
Q TY
2
1
2
1
1
1
AR
1
1
1
1
1
7.57
FINAL DRIVE
REAR AXLE / GEARCASE SERVICE
(6X6)
Rear Axle Removal
1.
Jack up vehicle and support on frame and swing arm.
7.
Remove the bottom shock bolts and shocks (both sides).
CAUTION
Serious injury could occur if machine tips or falls.
2.
Remove rear wheels.
3.
Remove the brake calipers. Suspend the brake calipers from the frame with wire (both sides).
8.
Remove the two bolts that secure the rear axle housing to the frame.
Brake Calipers
4.
Remove the hub cover, cotter pin, spindle nut and washer
(both sides).
5.
Pull the hub off of the axle.
9.
Mark the positions of the four U-bolts that secure the axle to the frame. This will aid with proper U-bolt and axle placement during reassembly.
Mark U-bolt Positions
6.
Remove the hose clamp from the rear gearcase breather hose. Remove the breather hose.
7.58
FINAL DRIVE
10. Loosen the four U-bolts. Loosen each U-bolt nut a few turns at a time, this will reduce stress on all of the U-bolts during
U-bolt removal.
Axle Tube Removal
1.
Place the rear axle assembly on a clean surface.
2.
Remove the bolts that secure the rear gearcase to the axle tubes and remove the rear gearcase skid plate
Loosen U-bolts
11. With the U-bolts removed, carefully lower the rear axle assembly from the frame. Pull the axle assembly out from the frame.
NOTE: The drive shaft yolk (A) slides off of the rear gearcase.
3.
Remove the axle and axle tube’s from the rear gearcase.
Note the placement of the axle spacer seals for placement during reassembly.
A
7
NOTE: Use caution when removing the rear axle assembly. Extra jacks maybe needed to lower the rear axle assembly safely.
4.
Slide the axles out of each axle tube.
NOTE: Make note of the side each axle was removed.
5.
Inspect the splines on the axle ends and the splines on rear gearcase for chips or wear. Replace as needed.
7.59
FINAL DRIVE
Axle Tube Bearing Replacement
1.
Remove the retaining ring from the axle tube.
Gearcase Disassembly / Inspection
1.
Drain and properly dispose of used oil.
2.
Remove the differential housing cover bolts and the gearcase housing cover.
2.
Remove the bearings from the axle tube with a bearing puller. Inspect the bearing contact surfaces in the axle tube.
3.
Remove the shim and O-ring from the differential cover.
O-Ring
Shim
3.
Install the new bearing using a press.
4.
Remove the output shaft and ring gear from the differential.
Inspect the ring gear for abnormal wear, broken, or chipped teeth. Inspect the bearings for wear. Spin the bearings by hand, the bearings should roll smoothly. Replace the bearings if needed.
Bearings
NOTE: The bearing should be properly lubricated before installation.
4.
Reinstall the retaining ring.
7.60
5.
Remove the wave spring from the differential assembly.
Wave Spring
FINAL DRIVE
8.
Inspect the pinion shaft bushing for wear.
6.
Remove the four bolts that secure the pinion gear cover to the differential. Remove the pinion gear cover and O-ring.
Pinion Gear Cover
Gearcase Assembly
1.
Replace all O-rings, seals, and worn components.
4 Bolts
O-Ring
7.
Remove the pinion shaft from the differential. Inspect for abnormal wear, broken, or chipped teeth.
2.
Install the pinion shaft into the differential housing.
7
7.61
FINAL DRIVE
3.
Replace the pinion shaft cover O-ring and install the cover.
Install the four pinion shaft cover bolts and torque the bolts to 26 ft. lbs. (35 Nm).
NOTE: The O-ring is a smaller diameter than the gearcase. Use two hands to work the O-ring onto the gearcase lip.
New O-Ring
Pinion Gear Cover
26 ft. lbs.
(35 Nm)
New O-Ring
Pinion Shaft Cover Bolt Torque:
26 ft. lbs. (35 Nm)
4.
Install the wave spring into the differential assembly. Be sure to properly seat the wave spring into the differential.
7.
Install the output cover onto the differential assembly.
8.
The output cover must be properly aligned and installed straight with the differential when installed. This will ensure that the O-ring is not damaged during output cover installation. This also helps to prevent any gearcase leaks after assembly.
5.
Reinstall the output shaft and ring gear.
9.
Torque the output cover bolts to 30 ft. lbs. (41 Nm).
Output Cover Bolt Torque
30 ft. lbs. (41 Nm)
6.
Install a new O-ring onto the lip of the gearcase housing.
7.62
Gearcase / Axle Installation
1.
Lube the splines of the rear gearcase with anti-seize.
2.
Reinstall the axle spacer seals. Reinstall the axle onto the rear gearcase (both sides) Reinstall the axle tube over the axle and attach it to the gearcase.
3.
Install and tighten the four bolts onto the right side of the gearcase. Install and tighten the two bottom bolts to the left side of the gearcase. Do not torque the bolts.
FINAL DRIVE
NOTE: The two top gearcase / axle tube bolts (B) on the left side are installed into the frame later in this assembly procedure.
B
6.
Install the four U-bolts. Align the U-bolts with the white marks previously made on the axle tube for proper rear axle alignment.
NOTE: Use a floor jack to help align the rear axle assembly for the U-bolt installation.
2 Bolts 4 Bolts
B
4.
Fit the rear axle assembly up to the frame. Slide the rear drive shaft yoke (A) onto the rear gearcase input shaft.
A
U-bolt Alignment Marks
7.
Install the U-bolt nuts, but do not tighten the nuts.
8.
Install the two frame to gearcase bolts (B). Torque the gearcase bolts on both sides of the gearcase to 60 ft. lbs.
(81 Nm).
5.
Fit the rear axle assembly up to frame. Attach the rear axle assembly to the shocks. Leave the shock bolts finger tight until assembly is complete.
NOTE: Use a jack or another person to assist with the rear axle assembly installation.
NOTE: Use caution when removing the rear axle assembly. Extra jacks maybe needed to raise the rear axle assembly safely.
B
Axle Tube to Gear Case Bolt Torque:
60 ft. lbs. (81 Nm)
7
7.63
FINAL DRIVE
9.
Torque the U-bolts nuts to 40 ft. lbs. (54 Nm).
13. Install the brake caliper. Torque the bolts to 18 ft. lbs. (24.8
Nm).
U-Bolt Nut Torque:
40 ft. lbs. (54 Nm)
10. Torque the rear shock bolts to 25 ft. lbs. (35 Nm).
25 ft. lbs. (35 Nm)
Brake Caliper Torque:
18 ft. lbs. (24.8 Nm)
14. Install the tire and four wheel nuts. Torque the castle nut and the wheel nuts to specifications.
Rear Coil Over Shock Bolt Torque
25 ft. lbs. (35 Nm)
11. Reinstall the vent hose and clamp to the rear gearcase housing.
12. Apply anti-seize to the splines of the axle. Reinstall the hub onto the axle. Reinstall the domed washer, and spindle nut onto the axle.
Rear Hub Nut Torque
110 ft. lbs. (149 Nm)
Rear Wheel Nut Torque
35 ft. lbs. (47 Nm)
15. Install a new cotter pin. Tighten nut slightly to align holes if required. Install the hub cap.
7.64
Rear Gearcase Exploded View (6x6)
FINAL DRIVE
26 ft. lbs.
(35 Nm)
R EF # D ESCRIPTION
7
8
5
6
3
4
1
2
Seal, Triple Lip
Screw (5/16-18 x 1.0)
Cover, Input
O-Ring
Bearing, Ball
Pinion, 10T
Bearing, Plain
Plug, Square Socket
9 Seal, Dual Lip
10 Gearcase, Rear Housing
11 Pipe, Knock
30 ft. lbs.
(41 Nm)
1
2
1
1
1
1
1
12
2
1
1
Q TY R EF # D ESCRIPTION
12 O-Ring
13 Spring, Wave
14 Bearing, Ball
15 Shaft, Output
16 Gear, Ring 37T
17 Bearing, Ball
18 Shim
19 Plug, Expansion
20 Tube, Vent 1/4” Hose
21 Cover, Output
1
1
1
1
1
1
1
1
1
1
Q TY
7
7.65
FINAL DRIVE
NOTES
7.66
TRANSMISSION
CHAPTER 8
TRANSMISSION
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
SHIFT LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
TRANSMISSION SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15
TROUBLESHOOTING CHECKLIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15
TRANSMISSION EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16
8
8.1
TRANSMISSION
TORQUE SPECIFICATIONS
3.
Remove the shift lever cover and then remove the screw.
Pull off the shifter knob.
Shift Lever ITEM
Transmission Fill Plug
Transmission Drain Plug
Transmission Case Bolts
Bell Crank Nut
Bell Crank Gear Cover
Transmission Mounting
Bolts
Transmission
Lubricant / Amount
TORQUE VALUE
10-14 ft. lbs.
(14-19 Nm)
10-14 ft. lbs.
(14-19 Nm)
27-34 ft. lbs.
(37-46 Nm)
12-18 ft. lbs.
(16-24 Nm)
7-9 ft. lbs.
(10-12 Nm)
25 ft. lbs. (35 Nm)
AGL Gearcase Lube
43.6 oz. (1290 ml)
Shift Lever Location
4.
Lift the gear shift selector out of mounting bracket and away from frame.
Installation
1.
Repeat the steps in reverse order to install the gear shift selector.
SHIFT LEVER
Removal
1.
Disconnect linkage cable from shifter.
2.
Remove one bolt attaching the gear shift selector mount to machine frame.
Cover
Screw
Shifter knob
Cable
Bearing
Shifter
Grommet
Shift Lever Breakdown
Bolt
SHIFT LINKAGE
Inspection
Linkage rod adjustment is necessary when symptoms include:
• No All Wheel Drive light
• Noise on deceleration
• Inability to engage a gear
• Excessive gear clash (noise)
• Shift selectors moving out of desired range
NOTE: Remove necessary components to gain access to shift linkage cable ends (i.e. exhaust heat shield, exhaust pipe, etc.).
1.
Inspect shift linkage cable, clevis pins, and pivot bushings and replace if worn or damaged.
2.
Be sure idle speed is adjusted properly.
8.2
TRANSMISSION
Adjustment
1.
Place gear selector in neutral. Make sure the transmission bell crank is engaged in the neutral position detents.
Neutral Position
TRANSMISSION SERVICE
Transmission Removal
1.
Remove the PVT system from the left side of the transmission.
2.
Drive roll pin from rear driveshaft yoke.
4x4 Shown
Roll Pin
Removal Tool
2.
With two wrenches loosen the outside jam nut counterclockwise. Turn the outside jam nut 1 1/2 turns.
Perform this procedure on the shift lever end, also.
Inside Jam Nut
Roll Pin Removal Tool (PN 2872608)
Outside Jam Nut
3.
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.
4.
Repeat Step 4 and Step 5 until the proper adjustment is made for the transmission cable.
5.
Use this procedure to loosen or tighten the shift linkage cable as needed.
Clockwise
Inside Jam Nut
NOTE: The front output shaft yolk slides off during the transmission removal.
3.
Remove the air intake hose from the air box that is located above the transmission. Place the hose to the side, this eases the transmission removal. Remove the vent hose from the top of the transmission.
Vent Tube & Air Intake Hose
8
Outside Jam Nut
Counterclockwise
8.3
TRANSMISSION
4.
Disconnect the transmission switch.
Transmission Switch
7.
Remove the mounting bolts from the transmission mounting on both sides of the transmission.
General Transmission Mounting
5.
Remove the cotter pin from the shift linkage rod. Remove the shift linkage rod and a washer from the bellcrank.
8.
Remove the four bottom transmission to frame bolts.
9.
Remove the rear transmission to frame bolt.
10. Remove front transmission-to-engine mount bolt.
11. Remove transmission from right side of frame.
6.
Loosen the jam nuts for the transmission cable. Remove the cable from the mounting bracket.
Jam Nuts
8.4
TRANSMISSION
Transmission Disassembly
NOTE: Refer to the exploded view at the end of this chapter.
1.
Place the bellcrank in neutral position.
2.
Remove the nut, and washer that secure the bell crank.
Remove the bellcrank.
5.
Mark the detent gear with a white pen. Remove the detent gear from the case.
NOTE: It may be helpful to place a mark just above the keyed spline.
Detent Gear
3.
Remove the five bolts that secure the cover and remove the cover from the transmission.
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.
Cover
Lockout Disc
8
7.
Remove the shift shaft and detent lever.
4.
Remove the detent spring.
Spring
8.5
TRANSMISSION
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.
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: Depending on what gear the transmission is in upon disassembly, the stamped timing marks may not be lined up. To avoid confusion, mark the two gears as described in Step 8.
9.
Remove the bolts on the LH transmission case cover. Tap the cover off with a soft face hammer if necessary.
12. Remove the upper gear cluster and shift forks. You may need to move the assembly back and forth to aid in removal
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.
13. Set the upper gear cluster on a flat surface and inspect the components.
8.6
TRANSMISSION
14. Remove the shift forks from the assembly. Note the correct position of each fork.
Shift Fork
17. Remove the bearing from the input shaft with a puller.
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.
15. Remove the bearing from the reverse shaft with a puller.
18. Remove the snap ring and washer from the reverse shaft.
19. Remove low gear (33T) and the needle bearing.
16. Remove the engagement dog. Remove the wave spring and reverse engagement dog.
Engagement
Dogs
20. Remove the reverse gear shaft.
8
8.7
TRANSMISSION
21. Remove the rest of the bearings from the shafts.
24. Remove the gear, split bearing, and washer from the reverse shaft.
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.
8.8
27. Remove bearing and the helical gear.
TRANSMISSION
30. Remove the front housing cover, shim, thrust button, and thrust button shim.
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
8
8.9
TRANSMISSION
36. Remove seals from transmission case.
IMPORTANT: New seals should be installed after the transmission is completely assembled.
37. Inspect bearings for smooth operation. Check for excessive play between inner and outer race.
3.
Before installing the cover make sure the sealing surfaces are clean and dry, and shafts are fully seated in the transmission case. Apply Polaris Crankcase Sealant to the mating surfaces.
Transmission Assembly
1.
Reinstall the chain onto the front output shaft and rear output shaft.
2.
Install front and rear output shafts into the case.
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.
Front Cover Bolt Torque:
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.
7.
Install retainer plate with flat side toward bearing.
8.10
TRANSMISSION
8.
Apply Loctite™ 262 (Red) (PN 2871951) to screw threads and torque screws to 6-12 ft. lbs. (8-16 Nm).
11. Slide the reverse shaft assembly through the silent chain.
Pinion Retainer Plate Bolt Torque:
6-12 ft. lbs. (8-16 Nm)
9.
Install a new needle bearing, the 24T reverse sprocket, washer, and a new snap ring. Install the shift dogs and wave spring. Install the washer, a new needle bearing and the high gear. Install the press fit gear and ball bearing.
10. Install a new snap ring at this time. When installing the new snap ring, open the snap ring just far enough to go over the shaft, to avoid stressing the snap ring. If the snap ring is overstressed it could come off the shaft and cause internal damage to the transmission.
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.
14. Install the ball bearing onto the end of the input shaft.
15. As the engagement dogs are installed onto the shaft, place the wave springs into the spring groove. Keep the spring in place while the fork is being installed on the shaft and while placing the shafts into the case.
NOTE: Use caution when installing the fork, the spring can easily fall out.
8
NOTE: Installing the shift rail will aid in keeping the shift forks, shift dogs, and the springs in place.
8.11
TRANSMISSION
16. Carefully install the shaft assembly and gear cluster as a unit into their respective bearing case recesses. Tap with a soft face hammer to seat shaft assemblies.
20. Lift the shift rail slightly and rotate the rail/fork assembly so it meshes with the tracks on the shift drum. Be sure the wave springs are properly in place and that the shift rail is seated into the pocket on the backside of the case.
17. Position the shift forks up and so the pins point toward the
9 o’clock position, before installing the shift drum assembly.
21. Install the helical gear and bearing onto the pinion shaft.
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 mounting bracket if previously removed.
18. Replace and grease the O-ring’s on the shift drum before installation.
19. Install the shift drum into the case.
NOTE: Make sure shift shaft pins are properly positioned in the slot on selector arms.
8.12
Front Cover Bolt Torque:
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 shaft seal.
TRANSMISSION
25. Install drain plug with a new sealing washer. Torque drain plug to 10-14 ft. lbs. (14-19 Nm).
28. Install the lockout disc with the raised edge facing outward.
Use the white mars that was previously applied for reference.
Lockout Disc
Drain Plug Torque:
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.
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 shift shaft and on the detent gear. Grease the o-ring on the end of the shift drum.
Detent Gear
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.
Detent Lever
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)
8
Tighten This Bolt First
8.13
TRANSMISSION
32. Torque the remaining bolts to 7-9 ft.lbs. (10-12 Nm).
Cover Bolt Torque:
7-9 ft. lbs. (10-12 Nm)
33. Install a new bellcrank onto the shift shaft. Note the keyed spline on the bellcrank and shaft. Install the washer and nut.
Torque the bellcrank nut to 12-18 ft. lbs. (16-24 Nm).
Keyed Spline
Transmission Installation
1.
Install transmission from right side of vehicle.
2.
Align the front input shaft to the front propshaft yoke on the vehicle and install the propshaft.
3.
Align the rear output shaft to the mid or rear propshaft yoke and roll pin hole.
4.
Slide the mid or rear propshaft onto the rear output shaft and drive a NEW roll pin into the propshaft yoke.
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.
Bellcrank Nut Torque:
12-18 ft. lbs. (16-24 Nm)
34. Install transmission and add Polaris AGL Gearcase
Lubricant (PN 2873602).
Transmission Mounting Bolts Torque
25 ft. lbs. (34.5 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. If torque stop was removed, set clearance to .060-.080 in.
(1.52-2.03 mm).
11. Reinstall the shift linkage rod, the air intake hose, and the vent hose on top of the transmission.
NOTE: Align clutches as outlined in Chapter 6.
12. Refer to Chapter 6 for PVT installation.
8.14
=
AGL Gearcase Lube
43.6 oz. (1290 ml)
TRANSMISSION
TROUBLESHOOTING
Troubleshooting Checklist
Check the following items when shifting difficulty is encountered.
• Idle speed adjustment
• PVT alignment
• Transmission oil type/quality
• Transmission torque stop adjustment (where applicable)
• Engine torque stop adjustment (where applicable)
• Drive belt deflection
• Loose fasteners on rod ends
• Loose fasteners on selector box
• Worn rod ends, clevis pins, or pivot arm bushings
• Linkage rod adjustment and rod end positioning
• Shift selector rail travel
• *Worn, broken or damaged internal transmission components
NOTE: To determine if shifting difficulty or problem is caused by an internal transmission problem, isolate the transmission by disconnecting linkage rod from transmission bellcrank. Manually select each gear range at the transmission bellcrank, and test ride vehicle. If it functions properly, the problem is outside the transmission.
If transmission problem remains, disassemble transmission and inspect all gear dogs for wear (rounding), damage. Inspect all bearings, circlips, thrust washers and shafts for wear.
8
8.15
TRANSMISSION
TRANSMISSION EXPLODED VIEW
Exploded View
27-34 ft. lbs.
(37-46 Nm)
10-14 ft. lbs.
(14-19 Nm)
GREASE
7-9 ft. lbs.
(10-12 Nm)
12-18 ft. lbs.
(16-24 Nm)
15-19 ft. lbs.
(20-26 Nm)
10-14 ft. lbs.
(14-19 Nm)
6-12 ft. lbs.
(8-16 Nm)
27-34 ft. lbs.
(37-46 Nm)
FOR REASSEMBLY
Apply White Lithium
Based Grease.
Apply Polaris
Crankcase Sealant.
Apply Loctite TM the bolt threads.
262 to
8.16
Exploded View, Continued
28.
29.
30.
31.
24.
25.
26.
27.
32.
33.
34.
35.
20.
21.
22.
23.
16.
17.
18.
19.
12.
13.
14.
15.
8.
9.
10.
11.
6.
7.
4.
5.
2.
3.
Ref.
Qty.
1.
1 Plug, Fill
1
5
Description
Plug, Drain, Magnetic
Screw, Self-Tapping 1/4-20
2
4
15
1
Screw, 5/16-18
Screw, 1/4-20
Screws, Self-Tapping 5/16-18
Nut, Nylon Lock
2
1
1
1
4
1
1
2
Nut, Nylon Lock
Washer
Washer
Washer
Dowel Pin
Retaining Ring, External
Retaining Ring, External
Retaining Ring, External
1
1
1
1
1
4
4
1
1
1
1
1
2
1
1
1
1
1
1
1
Spacer
Thrust Washer
Shim
Shim
Needle Bearing
Ball Bearing
Ball Bearing
Needle Bearing
Plain Bearing
Needle Bearing
Ball Bearing
Spring, Compression
Spring, Wave
Cover, Sector Gear
Cover, LH Input
Gearcase, Main
Shift Drum
Cover, Output
Sector Gear, 16T
Sector Gear, 31T
TRANSMISSION
63.
64.
65.
66.
59.
60.
61.
62.
67.
68.
69.
70.
55.
56.
57.
58.
51.
52.
53.
54.
47.
48.
49.
50.
43.
44.
45.
46.
39.
40.
41.
42.
Ref.
Qty.
36.
1 Sprocket, 22T
37.
38.
1
1
Lockout Disc
Detent Pawl
1
1
1
1
Detent Star
Description
Bellcrank, Shift Drum
Output Shaft, Front Main
Thrust Button
1
1
1
1
1
4
1
1
Rail, Shift Shaft
Shift Shaft
Output Shaft, Rear Main
Gear, 33T
Sprocket, 19T
Engagement Dog, 6 Face
Reverse Shaft
Gear, 33T
1
1
1
1
1
2
1
1
-
1
1
1
1
2
1
1
1
-
1
1
Gear, Mid-Output, 47T
Gear, Mid-Output, 60T
Vent Tube
Sprocket, 38T
Gear Set, 10T/31T
Shift Fork w/Pin
Input Shaft, 37/19/15
Cover, Center Drive Bearing
N/A
Silent Chain, 11W/40P
Chain
Switch, 6-Pin Rotary
Seal, Dual Lip
Seal, Triple Lip
O-Ring
O-Ring
O-Ring
N/A
Bracket, Torque Stop
Bracket, Transmission Mount
8
8.17
TRANSMISSION
NOTES
8.18
BRAKES
CHAPTER 9
BRAKES
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
BRAKE SYSTEM SERVICE NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
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 (4X4 CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
EXPLODED VIEW (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
INSPECTION / CABLE TENSION ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
PARKING BRAKE CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
CALIPER DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
NEW BRAKE PAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
PARKING BRAKE DISC SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
FRONT BRAKE PADS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
PAD REMOVAL / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
PAD ASSEMBLY / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
FRONT CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
CALIPER INSPECTION / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
FRONT BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
REAR BRAKE PADS (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
PAD REMOVAL / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
PAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
REAR BRAKE PADS (4X4 CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
PAD INSPECTION / ASSEMBLY / INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
REAR CALIPER SERVICE (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
CALIPER DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
CALIPER ASSEMBLY / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
REAR CALIPER SERVICE (4X4 CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
CALIPER INSPECTION / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.30
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.31
REAR BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.32
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.33
9
9.1
BRAKES
GENERAL SPECIFICATIONS
Item
Front Brake Pad Thickness
Front Brake Disc Thickness
Front Brake Disc Runout
Item
Rear Brake Pad Thickness
Rear Brake Disc Thickness
Park Brake Pad Thickness
Park Brake Disc Thickness
Rear Brake Disc Runout
FRONT BRAKE SYSTEM
Standard
.298 ± .007" / 7.56 ± .178 mm
.158" ( 4.01mm)
-
REAR BRAKE SYSTEM
Standard
.298 ± .007"/ 7.56 ± .178 mm
.188" (4.78 mm)
Inboard - .304” (7.72 mm)
Outboard - .360” (9.14 mm)
0.150” - 0.164” (3.81 - 4.16 mm)
-
Service Limit
.180" (4.6 mm)
.140" (3.56mm)
.010" (.254mm)
Service Limit
.180" (4.6 mm)
.170" (4.32 mm)
.240" (6.1 mm)
.310” (7.87 mm)
.140" (3.56 mm)
.010" (.254 mm)
TORQUE SPECIFICATIONS
Item
Front Caliper Mounting Bolts
Rear Caliper Mounting Bolts
Parking Brake Mounting Bolts
Parking Brake Assembly Bolts
Brake Line Flare Fittings
Brake Line Banjo Bolts
(All)
Front Brake Disc to Hub Bolts
Rear Brake Disc to Hub Bolts
Brake Switch
Master Cylinder Clevis Nut
Torque ft. lbs.
18
25
18
18
12-15
15
18
28
12-15
9-13
Torque
Nm
24
34
24
24
16-20
20
24
38
16-20
12-18
SPECIAL TOOLS
Part Number
2870975
Tool Description
Mity Vac™ Pressure Test Tool
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 (PN 2872113) can be applied to the back of the pads.
Follow directions on the package. This will keep pads in contact with caliper piston(s) to reduce the chance of squeaks caused by dirt or dust.
Possible Cause
Brake Noise Troubleshooting
Dirt, dust, or imbedded material on pads or disc
Remedy
Spray disc and pads with CRC Brakeleen™ or an equivalent non-flammable aerosol brake cleaner. Remove pads and/or disc hub to clean imbedded material from disc or pads.
Pad(s) dragging on disc (noise or premature pad wear) because of improper adjustment
Master cylinder reservoir overfilled
Master cylinder compensating port restricted
Master cylinder piston not returning completely
Caliper piston(s) not returning
Operator error (riding the brake)
Adjust pad stop (front calipers)
Set to proper level
Clean compensating port
Inspect. Repair as necessary
Clean piston(s) seal
Educate operator
Loose wheel hub or bearings
Brake disc warped or excessively worn
Brake disc misaligned or loose
Check wheel and hub for abnormal movement.
Replace disc
Noise is from other source (axle, hub, disc or wheel)
Wrong pad for conditions
Inspect and repair as necessary
If noise does not change when brake is applied check other sources. Inspect and repair as necessary
Change to a softer or harder pad
9
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
6x6
Master Cylinder Top View
Master Cylinder
LH Front
Brake Line
LH Rear Line
LH Rear Caliper
1 2
15 ft. lbs.
(20 Nm)
3
Cross Fitting
1
3
2 1
MC Rear
Brake Line
Brake
Switch
MC Front
Brake Line
RH Rear Caliper RH Rear Line
1
LH Front Caliper
Cross
Fitting
2
2
RH Front Caliper
1
RH Front
Brake Line
1
2
3
Caliper Banjo Style Fittings:
15 ft. lbs. (20 Nm).
All Caliper Bleed Screws:
47 in. lbs. (5.3 Nm)
All Flare Style Fittings:
12-15 ft. lbs. (16-20 Nm)
4x4 CREW
Master Cylinder Top View LH Front Caliper
LH Rear Line
LH Rear Caliper
1
2
15 ft. lbs.
(20 Nm)
3
Cross Fitting
Master Cylinder
LH Front
Brake Line
1
Cross
Fitting
2
2
RH Front Caliper
1
2
RH Rear Caliper
1
3
MC Rear
Brake Line
RH Rear Line
MC Front
Brake Line
Brake
Switch
1
RH Front
Brake Line
1
2
3
Caliper Banjo Style Fittings:
15 ft. lbs. (20 Nm).
All Caliper Bleed Screws:
47 in. lbs. (5.3 Nm)
All Flare Style Fittings:
12-15 ft. lbs. (16-20 Nm)
9.5
9
BRAKES
MASTER CYLINDER
Removal
1.
Open the hood. Locate the master cylinder.
2.
Remove the retaining clip (A) from the clevis pin (B) that attaches the master cylinder to the brake pedal lever.
D
15 ft. lbs.
(20 Nm)
A
B
FOOT BRAKE PEDAL
Pedal Removal
1.
Open the hood. Locate the master cylinder.
2.
Remove the nut, bushing, tube, and bolt from the brake pedal.
Master Cylinder
Bolt
Bushing
Clevis Pin
Tube
Nut
9-13 ft. lbs.
(12-18 Nm)
Bushing
Clip
Brake Pedal
15 ft. lbs.
(20 Nm)
C
3.
Place a container to catch brake fluid under the master cylinder brake line banjo bolts (C).
NOTE: Dispose of brake fluid properly and do not re-use.
CAUTION
Brake fluid will damage finished surfaces.
Do not allow brake fluid to come in contact with finished surfaces.
4.
Loosen the banjo bolts (C) for the brake lines and allow fluid to drain.
NOTE: Make note of front and rear brake line locations to master cylinder.
5.
Remove the two mounting bolts (D) that secure the master cylinder to the frame.
Installation
1.
Reverse Steps 1-5 for master cylinder installation.
Refer to the torque specifications in the illustration.
After installing the foot brake check pedal freeplay. Pedal freeplay should not exceed .090” (2.29 mm).
9.6
3.
Remove the retaining clip and clevis pin from the master cylinder to remove the brake pedal.
Pedal Installation
1.
Reverse Steps 1-3 for foot brake installation. Torque the clevis nut to 9-13 ft. lbs. (12-18 Nm) . After installing the foot brake check pedal freeplay. Pedal freeplay should not exceed .090” (2.29 mm).
Brake Pedal Freeplay:
.090” (2.29 mm)
BRAKES
BRAKE BLEEDING / FLUID CHANGE
NOTE: When bleeding the brakes or replacing the fluid always start with the furthest caliper from the master cylinder.
CAUTION
Always wear safety glasses.
CAUTION
Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact with finished surfaces. This procedure should be used to change fluid or bleed brakes during regular maintenance.
1.
Clean master cylinder reservoir cover thoroughly.
2.
Remove cover from reservoir.
3.
If changing fluid, remove old fluid from reservoir with a
Mity Vac™ pump or similar tool.
6.
Have an assistant slowly pump foot pedal until pressure builds and holds.
7.
Hold brake pedal on to maintain pedal pressure, and open bleeder screw. Close bleeder screw and release foot pedal.
NOTE: Do not release foot pedal before bleeder screw is tight or air may be drawn into master cylinder.
8.
Repeat procedure until clean fluid appears in bleeder hose and all air has been purged. Add fluid as necessary to maintain level in reservoir.
CAUTION
Maintain at least 1/2"(1.27 cm) of brake fluid in the reservoir to prevent air from entering the master cylinder.
9.
Tighten bleeder screw and torque to 47 in. lbs. (5.3 Nm) and remove bleeder hose.
10. Repeat procedure Step 5 through Step 9 for the remaining calipers.
11. Add brake fluid to MAX level inside reservoir.
Mity Vac™ (PN 2870975)
4.
Add brake fluid to the indicated MAX level of reservoir.
Polaris DOT 4 Brake Fluid
(P/N 2872189)
5.
Begin bleeding procedure with the caliper that is farthest from the master cylinder. Install a box end wrench on caliper bleeder screw. Attach a clean, clear hose to fitting and place the other end in a clean container. Be sure the hose fits tightly on fitting.
Maximum
Minimum
9
Bleeder
Screw
Master Cylinder Fluid Level
Between the MIN and MAX line shown on the reservoir.
12. Install master cylinder reservoir cover.
13. Field test machine at low speed before putting into service.
Check for proper braking action and pedal reserve. With pedal firmly applied, pedal reserve should be no less than
1/2"(1.3 cm).
14. Check brake system for fluid leaks.
9.7
BRAKES
PARKING BRAKE
Exploded View (4x4 CREW)
Parking Brake
Lever
Nuts
Washers
Clevis
Pin
Clip
Washer
Screw
Cable
Rear Propshaft w/Parking Brake Disc
Bolts
Clip
Bolt
Clevis
Pin
Parking Brake
Caliper
Nut
Mount Bracket
Nut
Rear Gearcase
9.8
BRAKES
Exploded View (6x6)
Nuts
Clevis
Pin
Washers
Clip
Washer
Middle Gearcase
Parking Brake
Lever
Parking Brake
Caliper
Nut
Clip
Bolt
Mount Bracket
Screw
Cable
Clevis
Pin
Parking Brake Disc
9
9.9
BRAKES
Inspection
1.
Inspect the parking brake cable and brake pads on the caliper assembly located on the rear propshaft.
See “Parking Brake Caliper Service” for brake pad replacement information.
Outboard Pad
Inboard Pad
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.
3.
Locate the parking brake cable adjustment area where the cable attaches to the caliper mount bracket on the rear gearcase.
Front
Parking Brake
Cable Adjustment
Cable Tension Adjustment
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 of operation afterwards to ensure proper cable 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 connector as soon as practicable and adjust the parking brake cable to proper tension.
1.
Pull back on the parking brake lever (located in the dash).
2.
After 2 to 3 clicks the “(P)” brake 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.
3.
If the vehicle moves, adjustment is necessary.
4.
Adjust the parking brake cable where the cable attaches to the caliper mount bracket located on the rear gearcase (mid gearcase on 6x6 models).
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
Brake Caliper
C D
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.
6.
Repeat Step 4 and Step 5 until the proper adjustment is obtained for the parking brake.
NOTE: See Chapter 10 for more information on the parking brake switch.
9.10
PARKING BRAKE CALIPER SERVICE
Exploded View
Pad & Holder
Pad & Holder
18 ft. lbs.
(24 Nm)
Hex Head
Mount Bolt
Sleeve
Thrust Washer
BRAKES
Plain Washer
Hex Nut
Nut
Compression Spring
Shim Pack
(4 Shims)
Spring Pin
Lever
Asm. Bolt
25 ft. lbs.
(34 Nm)
Stationary Actuator
Steel Balls (3)
Figure 9.10
Caliper Removal
NOTE: Do not get oil, grease, or fluid on the parking 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.
2.
If replacing the brake pads, slightly loosen the caliper assembly bolts before removing the complete caliper assembly. This will ease the caliper disassembly procedure later.
9
A
NOTE: Be sure the parking brake is not engaged.
9.11
BRAKES
3.
Loosen the two brake caliper mounting bolts (B) in equal increments.
B
10. Measure the thickness of the rear caliper parking brake pads. Replace assembly or pads as needed. See illustration below for proper readings.
Inboard pad thickness
New .304” (7.72 mm)
Limit: 0.24” (6.1 mm)
Inboard
Pad
Outboard
Pad
4.
Remove the mounting bolts from the mount bracket and lift the parking brake caliper assembly out of the vehicle.
Caliper Disassembly / Inspection
NOTE: The parking brake caliper is replaced as an assembly. Refer to the “Electronic Parts Catalog” for information.
5.
Remove the two caliper assembly nuts (C) that were previously loosened during Step 2 of “Caliper Removal”.
Outboard Pad Thickness
New 0.360” (9.14 mm)
Limit: 0.31” (7.87 mm)
Installed Disc to Park Brake
0.375” (0.953 cm)
New Rotor Disc Thickness
0.150” - 0.164”
(3.81 - 4.16 mm)
C
6.
Slide the brake pads and springs from the assembly.
NOTE: Retain the lever and ball bearings for reassembly.
7.
Inspect the brake pads linings for excessive wear. Replace as needed.
8.
Check the three steel balls for any signs of cracking.
Replace as needed.
9.
Check ball seats in lever and stationary actuator. If excessively worn, replace parts as needed.
9.12
BRAKES
New Brake Pad Installation
NOTE: Parking Brake Pads can be replaced by ordering one of the following kits:
PN 2203148 - Brake Pad and Shim Kit
PN 2203147 - Brake Pad Kit
There may be more parts in the service kit than your brake requires. Check the parts list included with the kit for the exact quantities.
1.
Using the stationary actuator, assemble the caliper components as shown below. Do not install the springs or shims yet. Measure the gap for the brake disc.
Disassemble and add shims between thrust washer and the inside brake pad as needed to close the gap to 0.203”-
0.193” (5.156-4.902 mm). For shim location, see Figure
9.10 on page 11.
Add shims until gap measures 0.203”- 0.193”
(5.156 - 4.902 mm)
Caliper Installation
1.
Install the parking brake assembly into place. Tighten the two mounting bolts in increments for proper installation.
18 ft. lbs.
(24 Nm)
2.
Torque the two mounting bolts to 18 ft. lbs. (24 Nm) .
2.
Once you have determined the correct amount of shims to use, install the assembly bolts through the sleeves. Install the nuts and the correct amount of shims, the inner brake pad, springs, and outer brake pad. Torque the assembly nuts to 25 ft. 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
Parking Brake Caliper - Mounting Bolts:
18 ft. lbs. (24 Nm)
3.
Install the cable, pin, and clip pin. Test the park brake for proper function.
PARKING BRAKE DISC SERVICE
Disc Inspection / Removal
1.
Measure the parking brake disc with a micrometer. If the thickness of the disc is less than specified, replace the rear propshaft / disc assembly.
2.
Follow the appropriate rear prop shaft removal procedure listed in Chapter 7 to remove the rear prop shaft / disc assembly.
New Disc: 0.164” - 0.173” (4.17 - 4.39 mm)
Disc Service Limit: 0.140” (3.56 mm)
Remove Bolts
9
6X6 Shaft Shown
9.13
BRAKES
FRONT BRAKE PADS
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 2-3 turns.
5.
Push mounting bracket inward and slip outer brake pad past edge. Then remove inner pad.
Pad
Adjuster
Pad Inspection
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.
compensating port into master cylinder fluid reservoir when piston is pushed back into caliper.
Remove excess fluid from reservoir as required.
9.14
Measure
Thickness
Front Brake Pad Thickness
New: .298 ± .007” (7.56 ± .178 mm)
Service Limit: .180” (4.6 mm)
BRAKES
Pad Assembly / Installation
1.
Lubricate mounting bracket pins with a light film of
Polaris Premium All Season Grease ( PN 2871423 ), and install rubber dust boots.
5.
Install the pad adjuster set screw and turn clockwise until stationary pad contacts disc, then back off 1/2 turn
(counterclockwise).
1/2 Turn
Pad
Adjuster
2.
Compress mounting bracket and make sure dust boots are fully seated. Install pads with friction material facing each other.
WARNING
If brake pads are contaminated with grease, oil, or liquid soaked do not use the pads.
Use only new, clean pads.
3.
Install caliper onto front hub and torque mounting bolts.
6.
Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap.
Master Cylinder Fluid
Up to MAX line inside reservoir
7.
Install wheel and torque wheel nuts to specification (see
“Chapter 2 - Maintenance”).
18 ft. lbs.
(24 Nm)
Brake Burnishing Procedure
It is required that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise.
Start machine and slowly increase speed to 30 mph. Gradually apply brakes to stop machine. Allow pads and disc to cool sufficiently during the procedure. Do not allow pads or disc to become hot or warping may result. Repeat this procedure 10 times.
9
=
T
Front Caliper Mount Bolt Torque:
18 ft. lbs. (24 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.
9.15
BRAKES
FRONT CALIPER SERVICE
Caliper Exploded View
Apply Polaris DOT 4 Brake Fluid to Component
Apply Polaris All Purpose
Grease
E
C
47 in. lbs.
(5.3 Nm)
B A
F
G
H D
A. Socket Set Screw
B. Bleeder Screw
C. Caliper Assy.
D. Boot
E. Square O-rings
F. Piston
G. Caliper Mount
H. Brake Pads
Caliper Removal
1.
Elevate and safely support the front of the vehicle.
2.
Remove the (4) wheel nuts and the front wheel.
CAUTION
Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur.
3.
Clean caliper area before removal.
4.
Place a container below the caliper to catch brake fluid when removing the line. Remove brake line from caliper.
5.
Loosen brake pad adjustment set screw 2-3 turns to allow brake pad removal after the caliper is removed.
Pad
Adjuster
Remove
Brake Line
9.16
BRAKES
6.
Remove the two caliper mounting bolts and remove the caliper assembly from the front strut.
NOTE: Image shown with brake line attached. Be sure to remove prior to this step.
3.
Remove mounting bracket, pin assembly and dust boot.
Remove
Caliper Disassembly
1.
Push brake pad retainer pin inward and slip brake pads past the edge.
4.
Thoroughly clean the brake caliper before disassembly and prepare a clean work area to disassemble the caliper.
5.
Use low pressure compressed air to remove the pistons from the caliper.
2.
Remove both brake pads from the caliper.
CAUTION
Use caution and always wear safety glasses when working with compressed air.
6.
While holding the caliper and covering the pistons with a shop towel, carefully apply compressed air to the brake line inlet to force the pistons out from the caliper.
IMPORTANT: Do not remove the caliper pistons with a pliers. The piston sealing surfaces will become damaged if a pliers is used.
7.
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.
9
9.17
BRAKES
8.
Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol.
2.
Inspect piston for nicks, scratches, pitting or wear. Measure piston diameter and replace if damaged or worn beyond service limit.
Clean
Components
NOTE: Be sure to clean seal grooves in caliper body.
Caliper Inspection
1.
Inspect caliper body for nicks, scratches, pitting or wear.
Measure bore size and compare to specifications. Replace if damaged or worn beyond service limit.
=
In. / mm.
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.
Caliper Assembly
1.
Install new O-rings in the caliper body. Be sure the grooves are clean and free of residue or brakes may drag upon assembly.
=
In. / mm.
Caliper Piston Bore I.D.:
Std: 1.373” (34.87 mm)
Service Limit: 1.375” (34.93 mm)
Seal
Grooves
New
O-Rings
2.
Coat pistons with clean Polaris DOT 4 Brake Fluid. Install pistons with a twisting motion while pushing inward.
Piston should slide in and out of bore smoothly, with light resistance.
9.18
BRAKES
3.
Lubricate the mounting bracket pins with Polaris Premium
All Season Grease ( PN 2871423 ), and install the rubber dust seal boots.
2.
Install brake line and torque the banjo bolt to the proper torque specification.
15 ft. lbs.
(20 Nm)
4.
Compress the mounting bracket and make sure the dust seal boots are fully seated. Install the brake pads. Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt, oil or grease.
3.
Install the pad adjustment screw and turn until stationary pad contacts disc, then back off 1/2 turn.
1/2 Turn
Caliper Installation
1.
Install caliper and torque mounting bolts to specification.
Pad
Adjuster
18 ft. lbs.
(24 Nm)
4.
Perform brake bleeding procedure as outlined earlier in this chapter.
5.
Install wheel and torque wheel nuts to specification (see
Chapter 2).
NOTE: If new brake pads are installed, brake burnishing is recommended (see “FRONT BRAKE
PADS - Brake Burnishing Procedure”).
9
=
T
Front Caliper Mount Bolt Torque:
18 ft. lbs. (24 Nm)
9.19
BRAKES
FRONT BRAKE DISC
Disc Inspection
1.
Visually inspect disc for scoring, scratches, or gouges.
Replace the disc if any deep scratches are evident.
2.
Use a 0-1” micrometer and measure the disc thickness at eight different points around the pad contact surface.
Replace disc if worn beyond service limit.
Measure
Thickness
Disc Replacement
1.
Remove front brake caliper (see “Front Caliper Service”).
2.
Remove dust cap, 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
Dust
Cap
Front
Disc
Brake Disc Thickness
New .158” (4.01 mm)
Service Limit .140” (3.56 mm)
Washers
Nut
Cotter
Pin
4.
Clean the wheel hub mating surface and install new disc on wheel hub. Torque new bolts to 18 ft. lbs. (24 Nm) .
18 ft. lbs.
(24 Nm)
Brake Disc Thickness Variance
Service Limit: .002” (.051 mm) difference between measurements
3.
Mount dial indicator as shown to measure disc runout.
Slowly rotate the disc and read total runout on the dial indicator. Replace the disc if runout exceeds specification.
60 ft. lbs.
(81 Nm)
Brake Disc Runout
Service Limit .010” (.254 mm)
CAUTION
Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal.
5.
Install wheel hub assembly, washers, and castle nut.
Torque castle nut to 60 ft. lbs. (81 Nm) and install a new cotter pin before installing the dust cap.
6.
Install front brake caliper (see “Front Caliper Service”).
Follow bleeding procedure outlined earlier in this chapter.
7.
Field test unit for proper braking action before putting into service. Inspect for fluid leaks and firm brakes. Make sure the brake is not dragging when pedal is released. If the brake drags, re-check assembly and installation.
9.20
BRAKES
REAR BRAKE PADS (6X6)
Pad Removal
1.
Elevate and support rear of machine.
Pad Inspection
1.
Push caliper piston into caliper bore slowly with pads installed.
CAUTION
Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls.
2.
Remove the rear wheel. Loosen pad adjuster screw 2-3 turns.
Adjuster Screw compensating port into master cylinder fluid reservoir when piston is pushed back into caliper.
Remove excess fluid from reservoir as required.
2.
Remove the brake pads.
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.
3.
Clean the caliper with brake cleaner or alcohol.
4.
Measure the thickness of the pad material. Replace pads if worn beyond the service limit.
Remove Caliper Bolts
Do not bend or kink
Measure
Thickness
Rear Brake Pad Thickness
New .298 + .007” (7.56 + .178 mm)
Service Limit .180” (4.6 mm)
9
9.21
BRAKES
Pad Installation
1.
Install new pads in caliper body.
REAR BRAKE PADS (4X4 CREW)
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 2-3 turns.
2.
Install caliper and torque mounting bolts.
18 ft. lbs. (24 Nm)
Pad
Adjuster
Rear Brake Caliper Mounting Bolt:
Torque 18 ft. lbs. (24 Nm)
3.
Turn adjuster screw back in finger tight using a hex wrench.
4.
Slowly pump the brake pedal until pressure has been built up. Maintain at least 1/2"(12.7 mm) of brake fluid in the reservoir to prevent air from entering the master cylinder.
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.
compensating port into master cylinder fluid reservoir when piston is pushed back into caliper.
Remove excess fluid from reservoir as required.
9.22
BRAKES
5.
Push mounting bracket inward and slip outer brake pad past edge. Then remove inner pad.
Pad Assembly / Installation
1.
Lubricate mounting bracket pins with a light film of
Polaris Premium All Season Grease ( PN 2871423 ), and install rubber dust boots.
Pad Inspection
1.
Measure the thickness of the pad material. Replace pads if worn beyond the service limit.
2.
Compress mounting bracket and make sure dust boots are fully seated. Install pads with friction material facing each other.
WARNING
If brake pads are contaminated with grease, oil, or liquid soaked do not use the pads.
Use only new, clean pads.
3.
Install caliper onto rear hub and torque mounting bolts.
18 ft. lbs.
(24 Nm)
9
Measure
Thickness
Front Brake Pad Thickness
New: .298 ± .007” (7.56 ± .178 mm)
Service Limit: .180” (4.6 mm)
=
T
Front Caliper Mount Bolt Torque:
18 ft. lbs. (24 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.
9.23
BRAKES
5.
Install the adjustment set screw and turn clockwise until stationary pad contacts disc, then back off 1/2 turn
(counterclockwise).
1/2 Turn
Pad
Adjuster
6.
Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap.
Master Cylinder Fluid
Up to MAX line inside reservoir
7.
Install wheel and torque wheel nuts to specification (see
“Chapter 2 - Maintenance”).
Brake Burnishing Procedure
It is required that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise.
Start machine and slowly increase speed to 30 mph. Gradually apply brakes to stop machine. Allow pads and disc to cool sufficiently during the procedure. Do not allow pads or disc to become hot or warping may result. Repeat this procedure 10 times.
9.24
BRAKES
REAR CALIPER SERVICE (6X6)
Rear Caliper Exploded View
Apply Polaris DOT 4 Brake Fluid to Component
Apply Polaris All Purpose
Grease
D
E
F
A
G
H
A. Socket Set Screw
B. Bleeder Screw
C. Caliper Assy.
D. Boot
E. Square O-rings
F. Piston
G. Caliper Mount
H. Brake Pads
B
47 in. lbs.
(5.3 Nm)
Caliper Removal
1.
Safely support the rear of the machine.
C
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 to catch brake fluid draining from brake lines.
Remove Banjo Bolt
E
3.
After the fluid has drained into the container, remove the two caliper mounting bolts and remove caliper.
Remove Caliper Bolts
9
4.
Clean disc, caliper body, and pistons with brake cleaner or alcohol.
9.25
BRAKES
Caliper Disassembly
1.
Remove brake pad adjuster screw (A).
2.
Push upper pad retainer pin inward and slip brake pads past edge, if pads are still installed.
3.
Remove mounting bracket (B) and dust boot (C).
B Pads
C
F D
Caliper Inspection
Inspect caliper body for nicks, scratches or wear. Measure bore size and compare to specifications. Replace if damage is evident or if worn beyond service limit.
E
A
4.
Remove piston (D) and square O-rings (E) from the caliper body (F).
=
In. / mm.
Caliper Piston Bore I.D.:
Std: 1.505” (38.23 mm)
Service Limit: 1.507” (38.28 mm)
6.
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.
Caliper Piston O.D.:
Std: 1.500” (38.10 mm)
Service Limit: 1.498” (38.05 mm)
7.
Inspect the brake disc and pads as outlined for brake pad replacement in this chapter.
9.26
BRAKES
Caliper Assembly
1.
Install new square O-rings (A) in caliper body. Be sure the grooves are clean and free of residue or brakes may drag.
A
Caliper Installation
1.
Install the rear caliper with the mounting bolts. Torque mounting bolts to 18 ft.lbs. (24 Nm).
2.
Install brake line banjo bolt. Torque banjo bolt to 15 ft. lbs.
(20 Nm).
18 ft. lbs.
(24 Nm)
B
15 ft. lbs.
(20 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 smoothly, with light resistance.
3.
Lubricate the mounting bracket pins with Polaris Premium
All Season Grease, and install the rubber dust seal boots.
3.
Install rear wheel and wheel nuts. Carefully lower vehicle.
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 and pads with brake parts cleaner or denatured alcohol to remove any dirt, oil or grease.
9
9.27
BRAKES
REAR CALIPER SERVICE (4X4 CREW)
Rear Caliper Exploded View
Apply Polaris DOT 4 Brake Fluid to Component
Apply Polaris All Purpose
Grease E
E
C
47 in. lbs.
(5.3 Nm)
B
A
F
H
G
D
A. Socket Set Screw
B. Bleeder Screw
C. Caliper Assy.
D. Boot
E. Square O-rings
F. Piston
G. Caliper Mount
H. Brake Pads
Caliper Removal
1.
Elevate and safely support the rear of the vehicle.
2.
Remove the (4) wheel nuts, (4) washers and rear wheel.
CAUTION
Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur.
3.
Clean caliper area before removal.
4.
Place a container below the caliper to catch brake fluid when removing the line. Remove brake line from caliper.
5.
Loosen brake pad adjustment set screw 2-3 turns to allow brake pad removal after the caliper is removed.
Pad
Adjuster
Remove
Brake Line
9.28
BRAKES
6.
Remove the two caliper mounting bolts and remove the caliper assembly from the rear hub.
3.
Remove mounting bracket, pin assembly and dust boot.
Remove
Caliper Disassembly
1.
Push brake pad retainer pin inward and slip brake pads past the edge.
4.
Thoroughly clean the brake caliper before disassembly and prepare a clean work area to disassemble the caliper.
5.
Use low pressure compressed air to remove the pistons from the caliper.
CAUTION
Use caution and always wear safety glasses when working with compressed air.
6.
While holding the caliper and covering the pistons with a shop towel, carefully apply compressed air to the brake line inlet to force the pistons out from the caliper.
IMPORTANT: Do not remove the caliper pistons with a pliers. The piston sealing surfaces will become damaged if a pliers is used.
7.
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.
2.
Remove both brake pads from the caliper.
9
9.29
BRAKES
8.
Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol.
2.
Inspect piston for nicks, scratches, pitting or wear. Measure piston diameter and replace if damaged or worn beyond service limit.
Clean
Components
NOTE: Be sure to clean seal grooves in caliper body.
Caliper Inspection
1.
Inspect caliper body for nicks, scratches, pitting or wear.
Measure bore size and compare to specifications. Replace if damaged or worn beyond service limit.
=
In. / mm.
Caliper Piston O.D.:
Std: 1.186” (30.12 mm)
Service Limit: 1.184” (30.07 mm)
3.
Inspect the brake disc and pads as outlined in this chapter.
Caliper Assembly
1.
Install new O-rings in the caliper body. Be sure the grooves are clean and free of residue or brakes may drag upon assembly.
=
In. / mm.
Caliper Piston Bore I.D.:
Std: 1.192” (30.28 mm)
Service Limit: 1.194” (34.33 mm)
Seal
Grooves
New
O-Rings
2.
Coat pistons with clean Polaris DOT 4 Brake Fluid. Install pistons with a twisting motion while pushing inward.
Piston should slide in and out of bore smoothly, with light resistance.
9.30
BRAKES
3.
Lubricate the mounting bracket pins with Polaris Premium
All Season Grease ( PN 2871423 ), and install the rubber dust seal boots.
2.
Install brake line and tighten securely with a line wrench.
Torque the banjo bolt brake line(s) to the proper torque specification.
15 ft. lbs.
(20 Nm)
4.
Compress the mounting bracket and make sure the dust seal boots are fully seated. Install the brake pads. Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt, oil or grease.
3.
Install the pad adjustment screw and turn until stationary pad contacts disc, then back off 1/2 turn.
1/2 Turn
Caliper Installation
1.
Install caliper and torque mounting bolts to specification.
Pad
Adjuster
18 ft. lbs.
(24 Nm)
4.
Perform brake bleeding procedure as outlined earlier in this chapter.
5.
Install wheel and torque wheel nuts to specification (see
Chapter 2).
NOTE: If new brake pads are installed, brake burnishing is recommended (see “REAR BRAKE
PADS - Brake Burnishing Procedure”).
9
=
T
Rear Caliper Mount Bolt Torque:
18 ft. lbs. (24 Nm)
9.31
BRAKES
REAR BRAKE DISC
Disc Inspection
1.
Visually inspect disc for scoring, scratches, or gouges.
Replace the disc if any deep scratches are evident.
2.
Use a 0-1"micrometer and measure disc thickness at 8 different points around perimeter of disc. Replace disc if worn beyond service limit.
3.
Remove the wheel hub assembly from the vehicle and remove the (4) bolts retaining the disc to the hub.
(4) Bolts
Dust
Cap
Rear
Disc
Washers
Nut
Cotter
Pin
4.
Clean the wheel hub mating surface and install new disc on wheel hub.
5.
Install new bolts and torque to 28 ft. lbs. (38 Nm) .
28 ft. lbs.
(38 Nm)
Measure
Thickness
Brake Disc Thickness
New .188” (4.78 mm)
Service Limit .170” (4.32 mm)
Brake Disc Thickness Variance
Service Limit .002” (.051 mm) difference between measurements
110 ft. lbs.
(150 Nm)
3.
Mount a dial indicator and measure disc runout. Slowly rotate the disc and read total runout on the dial indicator.
Replace the disc if runout exceeds specification.
Brake Disc Runout
Service Limit .010” (.254 mm)
Disc Replacement
1.
Remove rear brake caliper (see “REAR CALIPER
SERVICE”).
2.
Remove dust cap, cotter pin, castle nut and washers.
CAUTION
Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal.
6.
Install wheel hub assembly, washers, and castle nut.
Torque castle nut to 110 ft. lbs. (150 Nm) and install a new cotter pin before installing the dust cap.
7.
Install rear brake caliper (see “REAR CALIPER
SERVICE”). Follow the bleeding procedure outlined earlier in this chapter.
8.
Field test unit for proper braking action before putting into service. Inspect for fluid leaks and firm brakes. Make sure the brake is not dragging when pedal is released. If the brake drags, re-check assembly and installation.
9.32
TROUBLESHOOTING
Brakes Squeal / Poor Brake Performance
• Air in system
• Water in system (brake fluid contaminated)
• Caliper/disc misaligned
• Caliper dirty or damaged
• Brake line damaged or lining ruptured
• Worn disc and/or friction pads
• Incorrectly adjusted stationary pad
• Worn or damaged master cylinder or components
• Damaged break pad noise insulator
Pedal Vibration
• Disc damaged
• Disc worn (runout or thickness variance exceeds service limit)
Caliper Overheats (Brakes Drag)
• Compensating port plugged
• Pad clearance set incorrectly
• Parking brake lever incorrectly adjusted
• Brake pedal binding or unable to return fully
• Parking brake left on
• Residue build up under caliper seals
• Operator riding brakes
Brakes Lock
• Alignment of caliper to disc
• Caliper pistons sticking
• Improper assembly of brake system components
BRAKES
9.33
9
BRAKES
NOTES
9.34
ELECTRICAL
CHAPTER 10
ELECTRICAL
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
UNDER-HOOD COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
SWITCHES / CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
HEADLIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
AWD / 2WD / TURF SWITCH (4X4 CREW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
DIFFERENTIAL SOLENOID (4X4 CREW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
BRAKE LIGHT SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
PARKING BRAKE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
RIDER INFORMATION DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
STANDARD DISPLAY MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
HEADLIGHT HOUSING INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
TAIL LIGHT / BRAKE LIGHT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
COOLING SYSTEM BREAK-OUT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
FAN CONTROL CIRCUIT OPERATION / BYPASS TEST. . . . . . . . . . . . . . . . . . . . . . 10.20
COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
EFI DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
FUEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
RELAYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
FUSES / CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
CHARGING SYSTEM “BREAK EVEN” TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
CHARGING SYSTEM ALTERNATOR TESTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
CHARGING SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
BATTERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
BATTERY TERMINALS / BOLTS / TERMINAL BLOCK. . . . . . . . . . . . . . . . . . . . . . . . 10.26
BATTERY ACTIVATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
BATTERY INSPECTION / REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 10.27
BATTERY TESTING / OCV - OPEN CIRCUIT VOLTAGE TEST. . . . . . . . . . . . . . . . . 10.27
SPECIFIC GRAVITY TEST / LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
OFF SEASON STORAGE / CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 10.28
10
10.1
ELECTRICAL
STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
STARTER MOTOR REMOVAL / DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
BRUSH INSPECTION / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
ARMATURE TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
STARTER REASSEMBLY / INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
STARTER DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
STARTER SOLENOID BENCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
STARTER SOLENOID OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
STARTER EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34
STARTING SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
ELECTRIC BOX LIFT ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36
DIAGNOSIS (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36
ELECTRICAL BREAK-OUT DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37
STARTING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37
KEY-ON POWER CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37
TRANSMISSION SWITCH CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38
AWD CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38
SPEED SENSOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
CHARGING SYSTEM CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
COOLING FAN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.40
FUEL DISPLAY / FUEL PUMP CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.40
10.2
ELECTRICAL
GENERAL INFORMATION
Special Tools
Part Number
PV-43568
2870630
2870836
2460761
2871745
PU-47063
PU-47471
Tool Description
Fluke™ 77 Digital Multimeter
Timing Light
Battery Hydrometer
Hall Sensor Probe Harness
Static Timing Light Harness
Digital Wrench™ Diagnostic Software
Digital Wrench™ SmartLink Module Kit
Electrical Service Notes
Keep the following notes in mind when diagnosing an electrical problem:
• Refer to wiring diagram for stator and electrical component resistance specifications.
• When measuring resistance of a component that has a resistance value under 10 Ohms, remember to subtract meter lead resistance from the reading. Connect the leads together and record the resistance. The resistance of the component is equal to tested value minus the lead resistance.
• Become familiar with the operation of your meter. Be sure leads are in the proper jack for the test being performed (i.e. 10A jack for current readings). Refer to the Owner’s Manual included with your meter for more information.
• Voltage, amperage, and resistance values included in this manual are obtained with a Fluke™ 77 Digital
Multimeter (PV-43568). This meter is used when diagnosing electrical problems. Readings obtained with other meters may differ.
• Pay attention to the prefix on the multimeter reading (K,
M, etc.) and the position of the decimal point.
• For resistance readings, isolate the component to be tested. Disconnect it from the wiring harness or power supply.
Under-Hood Components
The following components can be accessed under the hood.
• Voltage Regulator
• Battery
• Battery Cables
• Terminal Block
• Starter Solenoid
• Starter Diode
• Relays
• Fuses
• Digital Wrench Diagnostic Connector
• Speedometer
• Speedometer Mode Switch
• AWD/2WD/TURF Switch
• Headlight Switch
• 12 VDC Accessory Power Point
• Ignition Switch
• Parking Brake Switch
10
10.3
ELECTRICAL
SWITCHES / CONTROLS
Headlight Switch
1.
Lift the front hood.
2.
The wires are located on the back side of the instrument panel.
3.
Disconnect the headlight switch harness (Brown, Green, and Red/White), by depressing the connector lock and pulling on the connector. Do not pull on the wiring.
4.
Inspect the switch connections and test the switch for continuity at the appropriate pin terminals as shown in the following illustration.
4.
Inspect the switch connections and test the switch for continuity at the appropriate pin terminals as shown in the following illustration.
AWD / 2WD / TURF Switch (4x4 CREW)
1.
Lift the front hood.
2.
The wires are located on the back side of the instrument panel.
3.
Disconnect the switch harness (Grey, Orange/White,
Brown, White/Green), by depressing the connector lock and pulling on the connector. Do not pull on the wiring.
10.4
Differential Solenoid (4x4 CREW)
The differential solenoid is located on the rear gear case. The solenoid actuates an engagement dog, which locks and unlocks the rear carrier. (Refer to Chapter 7 for more information on rear carrier operation.)
Solenoid
ELECTRICAL
Differential Solenoid Circuit Operation
The rear differential solenoid relay is located under the hood.
Power is present at the AWD / 2WD / Turf Switch when the ignition key is turned “ON”.
When the switch is pushed to activate “ Turf ” mode, power is sent from the AWD / 2WD / Turf Switch to the ECU.
Depending on vehicle speed, gear position criteria and parking brake input, the ECU provides a ground path for the Rear Diff
Solenoid Relay allowing it to enable the differential solenoid.
NOTE: The Rear Differential will not unlock if the parking brake is set.
If the rear carrier fails to switch from operational modes:
• Check the connector located under the left rear fender.
Look for loose wires or bad connections.
• Check for power from the connector, to ensure the solenoid has power to be activated.
• Check the AWD / 2WD / TURF Switch wires for loose connections.
• Remove solenoid from carrier and ensure the solenoid plunger is actuating.
Rear Differential Solenoid Circuit
CAUTION
Do not power the solenoid with 12 Volts for more than 1 second, or damage may occur to the solenoid.
Brake Light Switch
1.
The brake light switch is located near the steering gearbox along the frame. The brake pressure switch is installed into this block.
Brake Switch
2.
Disconnect wire harness from switch.
3.
Connect an ohmmeter across switch contacts. Reading should be infinite (OL).
10
4.
Apply foot brake and check for continuity between switch contacts. If there is no continuity or greater than .5 ohms resistance when the brake is applied with slight pressure, first clean the switch contacts and re-test. Replace switch if necessary.
10.5
ELECTRICAL
Parking Brake Switch
The parking brake switch is located within the parking brake lever. Follow the parking brake lever under the dash to locate the internally mounted switch.
Testing The Parking Brake Switch
1.
Disconnect the harness connector at the parking brake switch (Orange/Red and Red/White wires).
2.
Place the ohmmeter leads onto terminal leads A and C. The reading should be infinite (•).
Switch
Contact
Harness
Connector
Switch
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 Speedometer to illuminate the “Park Brake Indicator” 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.
3.
Apply the parking brake. Continuity should now exist between the switch terminals A and C. 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
P
10.6
ELECTRICAL
INSTRUMENT CLUSTER
Overview
The RANGER instrument cluster senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as time, hours of operation and engine RPM.
Speedometer
Rider Information Display
The rider information display is located in the instrument cluster. All segments will light up for 2.5 seconds at start-up.
NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer.
3 4 5 6
7
8
Speedometer
Needle
Park Brake
Indicator
2
Rider
Information
Display
NOTE: In addition to showing vehicle speed, the speedometer needle flashes when a low fuel condition exists.
NOTE: Use the “Mode Button” shown below to toggle between Instrument Cluster display screens.
Instrument
Cluster
Ignition
Switch
Mode
Button
1
1.
Gear Indicator - This indicator displays gear shifter position.
H = High Gear
L = Low Gear
N = Neutral
R = Reverse Gear
2.
AWD Indicator - This indicator illuminates when the
AWD switch is in the AWD position.
3.
Engine Hour Display Indicator
4.
Service Interval / Diagnostic Mode Indicator
5.
Low Battery and Over Voltage - This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged. It may also occur when the engine is at idle and high electrical load (lights, cooling fan, accessories) is applied. Drive at a higher RPM or recharge the battery to clear the warning.
6.
Odometer/Tachometer/Tripmeter/ Hour Meter/Clock
7.
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 will display in the LCD, and the speedometer needle will blink. Refuel immediately.
10
8.
Check Engine Warning Indicator - This indicator serves two purposes. The word HOT displays if the engine overheats. It also appears if an EFI-related fault occurs. Do not operate the vehicle if this warning appears. Serious engine damage could result.
10.7
ELECTRICAL
Standard Display Modes
Use the yellow mode button located under the speedometer to toggle through the mode options.
Odometer Mode
The odometer records the miles traveled by the vehicle.
Trip Meter Mode
The trip meter records the miles 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 odometer displays without a decimal point.
Hour Meter Mode
This mode logs the total hours the engine has been in operation.
Tachometer Mode
The engine RPM is displayed digitally.
NOTE: Small fluctuations in the RPM from day to day may be normal because of changes in humidity, temperature and elevation.
Clock Mode
The clock displays time in a 12-hour format. To reset the clock, see “Clock Screen” in the “Diagnostic Display Mode” section.
Clock Screen
To reset the clock:
1.
Enter the diagnostic mode.
2.
Toggle to the clock screen.
3.
Press and hold the mode button until the hour display flashes. Release the button.
4.
Press and release the mode button once to advance the setting by one hour. Press and hold the mode button to advance the hours quickly.
5.
When the desired hour is displayed, wait approximately four seconds, until the minute display flashes.
6.
When the display stops flashing, the mode has been set.
7.
Use the same procedure to reset the minutes.
Battery Voltage Screen
View this screen to check battery voltage level.
Diagnostic Display Mode
The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any movement of the tires will also cause the gauge to exit the diagnostic mode.
To enter the diagnostics mode:
1.
Turn the key switch off and wait 10 seconds.
2.
Lock the parking brake.
3.
Place the transmission in neutral.
4.
Hold the mode button and turn the key switch to the “ON” position. Release the mode button as soon as the display is activated.
5.
Use the mode button to toggle through the diagnostic screens.
Tachometer Screen
View the tachometer to check engine speed.
10.8
AWD Diagnostic Screen
The gauge indicates whether or not current is flowing through the AWD coil.
ELECTRICAL
NOTE: A 10 - 20% variance from these readings is within normal parameters.
Gear Circuit Diagnostic Screen
This screen displays the resistance value (in ohms) being read at the gear switch input of the gauge.
Programmable Service Interval
When the hours of engine operation equal the programmed 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.
10
10.9
ELECTRICAL
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.
2.
Toggle to the service interval screen.
3.
Press and hold the mode button for 2-3 seconds, until the wrench icon flashes. Release the button.
4.
Press and release the mode button once to advance the setting by one hour. Press and hold the mode button to advance the hours quickly.
NOTE: If you scroll past the intended number, press and hold the button until the hours cycle back to zero.
5.
When the desired setting is displayed, wait until the wrench icon stops flashing. The new service interval is now programmed.
Miles / Kilometers Toggle
The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement.
1.
Enter the diagnostic mode.
2.
Toggle to the screen that displays either kilometers (KM) or miles (MP).
3.
Press and hold the mode button until the letters flash, then press and release the button once. When the display stops flashing, the mode has been set.
Viewing Diagnostic Codes
Use the following procedure to view diagnostic blink codes
(failure codes) from the EFI module:
NOTE: Refer to Chapter 4 “Electronic Fuel Injection” for a complete list of Diagnostic Blink Codes.
1.
Engage the parking brake.
2.
Stop the engine.
3.
Turn the key switch to the ON position.
4.
Turn the key switch off and on three times in less than five seconds, then leave the switch on. The word “Wait” will appear on the screen along with a flashing “Check Engine” light.
10.10
ELECTRICAL
5.
Any blink code numbers stored in the EFI module will display, one at a time, on the screen.
Example below shows a Blink Code of “42”.
2.
Push the instrument cluster out from the back side of the dash panel, while securely holding the panel and rubber mount.
Dash Panel
Push Instrument
Cluster Outward
6.
The number “61” and/or the word “End” displays after all codes have been transmitted.
Rubber Mount
Bezel
Instrument Cluster
NOTE: Do not remove the rubber mount from the dash panel. Only remove the rubber mount if necessary. The bezel is a snap-on assembly and is a serviceable part.
Instrument Cluster Removal
NOTE: Do not allow alcohol or petroleum products to come in contact with the instrument cluster lens.
1.
Lift the hood and disconnect the wire connectors from the back side of the instrument cluster.
Instrument Cluster Installation
1.
Spray a soap and water mixture onto the outer surface area of the instrument cluster. This will help the instrument cluster slide into the rubber mount more easily.
2.
Be sure the rubber mount inside the pod is fully installed and that the indexing key on the rubber mount is lined up with the keyway in the dash panel.
3.
Hold the dash panel securely and insert the instrument cluster into the dash panel. Twist the instrument cluster gently in a clockwise motion to properly seat the instrument cluster into the pod assembly. Apply pressure on the bezel while pressing down on the instrument cluster.
10.11
10
ELECTRICAL
INSTRUMENT CLUSTER TROUBLESHOOTING TESTS
Test 1 - No All Wheel Drive
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10.12
ELECTRICAL
TEST 2 - No Display
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0ROBE (ARNESS 0. OR JUMPER LEADS
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GROUND
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ARE GOOD AND VOLT BATTERY IS IN GOOD CONDITION
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10.13
ELECTRICAL
TEST 4 - No AWD Hub Safety Limiter
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10.14
ELECTRICAL
TEST 5 - Fuel Gauge Display Not Working
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10
10.15
ELECTRICAL
ALL WHEEL DRIVE (AWD) COIL
Operation Overview
• When the AWD switch is “ON”, 12 VDC power is present at the hub coil.
• If the criteria is met, the instrument cluster provides a ground path at pin #16 (Brown/White wire). When this occurs the AWD icon should display in the instrument cluster.
• The AWD system must be grounded to operate.
Diagnosing System Failures
• Verify the AWD switch is functional and that a minimum of 11 volts is present at the hub coil.
• Verify the AWD hub coil is functional. Test the AWD hub coil using an ohm meter. See specifications below:
GEAR POSITION INDICATOR SWITCH
Test Diagram
NOTE: Also see “INSTRUMENT CLUSTER
TROUBLESHOOTING” for switch circuit.
TRANSMISSION SWITCH
High / Low / Neutral / Reverse Switch
High Range
Low Range
Neutral
Reverse
Green/White
Violet
Brown/Red
White/Blue
Blue/Red
7HVW5HVLVWDQFH
5HDGLQJVVKRXOGEH
*<WR%1:+a2KPV
*<WR*URXQG1R&RQQHFWLRQ
AWD Hub Coil Resistance:
24
Ω
± 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
Headlight Adjustment
The headlight beam is adjustable.
1.
Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall.
6.
Adjust the beam to desired position. Repeat the procedure to adjust the other headlight.
WARNING
Due to the nature of light utility vehicles and where they are operated, headlight lenses become dirty. Frequent washing is necessary to maintain lighting quality. Riding with poor lighting can result in severe injury or death.
25 ft.
(7.6 m)
X X
8 in. (20 cm)
2.
Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.
3.
With the machine in Neutral and parking brake applied, start the engine and turn the headlight switch to high beam.
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.
Adjust the beam to the desired position by loosening the adjustment screw (A) and moving the lamp to the appropriate height.
Headlight Bulb Replacement
1.
Open the hood.
2.
Unplug the headlight bulb (A) from the wiring harness. Be sure to pull on the connector, not on the wiring.
3.
Turn the lamp counterclockwise to remove it.
A
A
4.
Insert new bulb. Reinstall the harness assembly into the headlight assembly.
NOTE: Make sure the tab on the lamp locates properly in the housing.
Headlight Housing Removal
1.
Open the hood.
2.
Unplug the headlight from the wiring harness. Be sure to pull on the connector, not on the wiring.
10
10.17
ELECTRICAL
3.
Remove the O-ring (A) from the headlight brackets (both sides).
A
B
TAIL LIGHT / BRAKE LIGHT
Lamp Replacement
Before replacing the tail light, use a digital multi-meter to test the harness to ensure the lamp is receiving 12 volts and that a ground path is present.
If the tail light / brake light does not work the lamp assembly may need to be replaced.
1.
From the rear of the tail light remove two screws holding lens cover in place and remove lens cover. (T-20 Torx)
4.
After the O-rings are removed from the headlight, remove the adjustment screw (B) and pull the headlight from the brackets.
Tail Light Screws
2.
Remove lamp by turning the rubber base 1/4 turn and pulling the bulb out. Replace it with recommended lamp.
Apply Dielectric Grease (PN 2871329).
Headlight Housing Installation
1.
To install the headlight housing, press the headlight tabs back into the brackets.
2.
Secure the headlight housing with the rubber O-rings on each side (A). Install the adjustment screw (B).
A
Tail Light
RD and BN
Brake Light
OG and RD
Replacement Bulbs
PN 4030040
B
3.
Reconnect wire harness or re-insert bulb if previously removed.
4.
Adjust headlights using the “High Beam Headlight
Adjustment” procedure on the previous page.
10.18
3.
Reinstall the lens cover removed in Step 1.
4.
Test the tail light / brake light to see it is working.
COOLING SYSTEM
Cooling System Break-Out Diagram
ELECTRICAL
+EY/N
6OLT0OWER
10.19
10
ELECTRICAL
Fan Control Circuit Operation
Power is supplied to the fan via the Orange/Black wire when the relay is ON. The ground path for the fan motor is through the
Brown harness wire. Refer to “RELAYS” later in this chapter for more information on fan functions.
CAUTION
Keep hands away from fan blades during operation. Serious personal injury could result.
NOTE: The fan may not function or operation may be delayed if coolant level is low or if air is trapped in the cooling system. Be sure cooling system is full and purged of air. Refer to Maintenance Chapter 2 for cooling system information.
Fan Control Circuit Bypass Test
1.
Disconnect harness from coolant temperature sensor on engine.
2.
With the parking brake applied, turn the ignition key (and engine stop switch) “ON”. The fan should start running.
3.
If the fan does not run or runs slowly, check the fan motor wiring, ground, motor condition and mechanical relay for proper operation. Repair or replace as necessary. If the fan runs with the sensor harness disconnected, but will not turn on when the engine is hot, check the coolant temperature sensor and connector terminals.
Coolant Temperature Sensor
The coolant temperature sensor can be tested using an ohmmeter or voltmeter.
1.
With the engine and temperature sensor at room temperature (68
°
F = 20
°
C), disconnect the harness connector.
2.
With the meter in the ohms mode, place the meter leads onto the sensor contacts.
3.
Use the table Temperature / Resistance table to determine if the sensor needs to be replaced.
T EMPERATURE
°
F (
°
C)
68
°
F (20
°
C)
212
°
F (100
°
C)
R ESISTANCE
2.5 k
Ω ± 6%
186
Ω ± 2%
NOTE: If the coolant temperature sensor or circuit malfunctions the radiator fan will default to 'ON'.
EFI DIAGNOSTICS
EFI Component Testing
All EFI component information and diagnostic testing procedures are located in Chapter 4 .
Refer to Chapter 4 “Electronic Fuel Injection System (EFI)” when diagnosing an EFI System.
FUEL SENDER
Testing
1.
Drain the fuel tank and remove it from the chassis.
2.
Set the fuel tank on a flat surface.
3.
Hook up an ohm meter to the fuel sender harness Violet/
White wire (B) and Brown wire (C).
4.
With the sender float in the empty position and compare to specification.
Fuel Sender - Empty: 5
Ω ± 5%
5.
Slowly tilt invert the tank so that gravity moves the sender float to the full position and compare to specification.
Fuel Sender
Empty: 5
Half
Full
Ω ± 5%
: 57Ω ± 5%
: 90Ω ± 5%
Fuel Sender - Full:
90 Ω ± 5%
6.
If the readings are not to specification, or if the reading is erratic or LCD display “sticks”, check the following before replacing the fuel pump assembly.
• Loose float
• Float contact with tank
• Bent Float Rod
If none of the conditions exists, the sender assembly is faulty.
Fuel pump/tank assembly replacement is required.
10.20
RELAYS
Operation
The relays, located under the hood, assist with component operation like the fan, fuel pump, and rear differential.
The differential relay, controlled by the AWD switch and ECU, operates the differential solenoid.
The fan relay, controlled by the ECU and Temp Sensor, operates the fan.
The power relay, controlled by the ECU, turns on power for components such as the fuel pump, injectors, etc.
ELECTRICAL
REAR DIFF SOLENOID RELAY
C
OLOR
F
UNCTION
Red / White
Key-On battery power supply, switched on by key switch, enables power to relay.
Ground path for relay.
Brown
Orange / White
Key-On power supply, switched by relay, provides power to Rear Diff Solenoid.
Brown / White
ECU ground input to connect relay Key-On power to Rear Diff Solenoid output.
+EY/N60OWER
'ROUND
2EAR$IFF0OWER/UPUT
%#5)NPUT
+EY/N60OWER
&AN0OWER/UTPUT
%#5)NPUT
!MP0OWER3UPPLY
FAN RELAY
Red
C OLOR
Red / White
Orange / Black
Yellow / Black
F UNCTION
Key-On battery power supply, switched on by key switch, enables power to relay.
Fused 15-Amp power, switched by relay, provides power to Fan Motor.
ECU input to connect relay Fused 15-Amp power to Fan Motor output.
Fused 15-Amp, constant battery power IN supply for EFI component operation.
!MP0OWER3UPPLY
+EY/N0OWER)NPUT
+EY/N0OWER/UTPUT
%#5)NPUT
C
OLOR
Orange
Red / White
Red / Black
Gray / White
POWER RELAY
F
UNCTION
Fused 15-amp, constant battery power IN supply for EFI component operation.
Key-On battery power supply, switched on by key switch, enables power to relay.
EFI power output. Switched by relay when
ECU sends a signal on the GRY/W wire, closing the relay. Supplies 15-amp power for ECU-controlled operation of EFI components.
ECU input to enable relay. The ECU supplies a ground which closes the relay, supplying power to run the fuel pump, injectors, etc.
10
10.21
ELECTRICAL
FUSES / CIRCUIT BREAKER
Operation
The fuse panel, located under the hood, provides component protection for components such as the Instrument Cluster, ECU, EFI system, Chassis Power and Accessories.
A 15-amp circuit breaker protects the fan motor circuit.
60OWERTO3PEEDOMETER
60OWERTO&AN2ELAY
!CCESSORY0OWER4ERMINAL"LOCK
60OWERTO+EY3WITCH
60OWERTO0OWER2ELAY
!MP0ROTECTIONFOR%#5
60OWERFROM&USIBLE,INK
!MP0ROTECTIONFOR+EY/N0OWER
10.22
ELECTRICAL
CHARGING SYSTEM
Current Draw - Key Off
Charging System “Break Even” Test
CAUTION
Do not connect or disconnect the battery cable or ammeter with the engine running. Damage will occur to electrical components.
Connect an ammeter in series with the negative battery cable.
Check for current draw with the key off. If the draw is excessive, loads should be disconnected from the system one by one until the draw is eliminated. Check component wiring as well as the component for partial shorts to ground to eliminate the draw.
Current Draw Inspection
Key Off
CAUTION
Do not allow the battery cables to become disconnected with the engine running. Follow the steps below as outlined to reduce the chance of damage to electrical components.
The “break even” point of the charging system is the point at which the alternator overcomes all system loads (lights, etc.) and begins to charge the battery. Depending on battery condition and system load, the break even point may vary slightly. The battery should be fully charged before performing this test.
30 Amp
Current Draw - Key Off:
Maximum of .01 DCA (10 mA)
WARNING
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 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.
3.
Shift transmission into neutral with the parking brake 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.
10
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.
10.23
ELECTRICAL
Charging System Alternator Tests
Three tests can be performed using a multi-meter to determine the condition of the stator (alternator).
Y1
Y2
Y3
TEST 1: Resistance Value of Each Stator Leg
1.
Measure the resistance value of each of the three stator legs: Y1 to Y2, Y1 to Y3, and Y2 to Y3.
Each test should measure: 0.19
Ω
± 15%
Test
Battery Charge Coil
Battery Charge Coil
Battery Charge Coil
Connect Meter
Leads To:
Ohms Reading
Y1 to Y2
Y1 to Y3
Y2 to Y3
0.19
Ω
± 15%
0.19
Ω
± 15%
0.19
Ω
± 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)
TEST 3: Measure AC Voltage Output of Each Stator Leg at
Charging RPM
1.
Set the selector dial to measure AC Voltage.
2.
Start the engine and let it idle.
3.
While holding the engine at a specified RPM, separately measure the voltage across each ‘leg’ of the stator by connecting the meter leads to the wires leading from the alternator (Y1 to Y2, Y1 to Y3, Y2 to Y3).
4.
Refer to the following table for approximate AC Voltage readings according to RPM. Test each leg at the specified
RPM in the table.
Example: The alternator current output reading should be approximately 18 VAC at 1300 RPM between each ‘leg’ .
NOTE: If one or more of the stator leg output AC voltage varies significantly from the specified value, the stator may need to be replaced.
RPM Reading
1300
3000
5000
AC Voltage (VAC) Reading
18 VAC ± 25 %
42 VAC ± 25 %
64 VAC ± 25 %
Test
Battery Charge Coil
Connect Meter
Leads To:
Ohms Reading
Y1, Y2, or Y3 to Ground
Open Line
(Infinity)
NOTE: Any measurement other than Infinity (open) will indicate a failed or shorted stator leg.
10.24
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, measure the battery open circuit voltage (See earlier test). It should be 12.4 volts or more.
Is it?
Yes
No
Remove the battery and properly service. Reinstall the fully charged battery or a fully charged shop battery.
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 multitester. Readings should increase to between 13.0 and 14.6 V D.C. Do they?
No
Yes Check Key off Current Draw.
Meter Setting: DC Amps
Perform system
“Break Even Amperage” test outlined in this chapter.
Does charging occur as specified?
No
Yes
Check for owner modification, and discuss operating habits. The battery will continually discharge if operated below the “Break Even” RPM. Continued problems would call for battery inspection.
Ohm stator wires, if bad replace stator, if good, continue with alternator output test.
Meter Setting: AC Volts
Disconnect the Yellow wires from the regulator / rectifier. Using a multitester, perform an
Alternator
Output test.
See test procedure on Page 10.24.
Does output meet specification?
Yes
No
Inspect the wiring harness between the panel and the stator for damage. If no damage is found, remove the recoil and flywheel.
Inspect the flywheel magnets, stator coils and stator wires for damage.
Repair or replace any damaged components.
Meter Setting: DC Volts
Reconnect the alternator wires. Note: Red wire must be connected to harness. Battery voltage must be present on red wire terminal on harness side of voltage regulator connector.
Is voltage present?
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.
No
Check stator, regulator, ground, battery and battery connections. Also check wire connections and wire condition.
Repair or replace faulty wiring or components.
10
10.25
ELECTRICAL
BATTERY SERVICE
Battery Terminals / Bolts
Use Polaris corrosion resistant Nyogel™ grease (PN 2871329) on battery terminal bolts.
Battery Activation
CONVENTIONAL BATTERY
Removable
Caps
Top View
Electrolyte Level
Indicator
Apply
Nyogel™
Side View
Battery Terminal Block
The terminal block is located under the front hood next to the battery. The terminal block provides easy access to the main battery and starting cables. The terminal block also provides easy hookup for accessories.
TERMINAL BLOCK
Orange/White
Black
Orange/White
(Accessories)
Red
Black
(Ground)
Red
(Battery+)
=
T
Terminal Block Nuts:
20-25 in. lbs. (2.3-2.8 Nm)
WARNING
Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote:
External:
Flush with water.
Internal:
Drink large quantities of water or milk.
Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately.
Eyes:
Flush with water for 15 minutes and get prompt medical attention.
Batteries produce explosive gases. Keep sparks, flame, cigarettes etc. away. Ventilate when charging or using in an enclosed space.
Always shield eyes when working near batteries.
KEEP OUT OF REACH OF CHILDREN.
WARNING
The gases given off by a battery are explosive.
Any spark or open flame near a battery can cause an explosion which will spray battery acid on anyone close to it. Should there be contact with battery acid, wash the affected area with large quantities of cool water and seek immediate medical attention.
10.26
ELECTRICAL
To ensure maximum service life and performance from a new battery, perform the following steps. NOTE: Do not service the battery unless it will be put into regular service within 30 days.
After initial service, add only distilled water to the battery.
Never add electrolyte after a battery has been in service.
NOTE: New Battery: Battery must be fully charged before use or battery life will be significantly reduced 10-30% of the battery’s full potential.
To activate a new battery:
1.
Remove vent plug from vent fitting. Remove cell caps.
2.
Fill battery with electrolyte to upper level marks on case.
3.
Set battery aside to allow for acid absorption and stabilization for 30 minutes.
4.
Add electrolyte to bring level back to upper level mark on case.
NOTE: This is the last time that electrolyte should be added. If the level becomes low after this point, add only distilled water.
5.
Charge battery at 1/10 of its amp/hour rating. Examples: 1/
10 of 9 amp battery = .9 amp; 1/10 of 14 amp battery = 1.4
amp; 1/10 of 18 amp battery = 1.8 amp (recommended charging rates).
6.
Check specific gravity of each cell with a hydrometer to assure each has a reading of 1.270 or higher.
Battery Inspection
IMPORTANT: Proper servicing and upkeep of the battery is very important in maintaining long battery life.
The battery is located under the hood.
Inspect the battery fluid level. When the battery fluid nears the lower level, remove the battery and fill with distilled water only to the upper level line. To remove the battery:
Maintain between upper and lower level marks
Battery Removal / Installation
See Chapter 2 “Maintenance” for battery service procedures.
Battery Testing
Whenever a service complaint is related to either the starting or charging systems, the battery should be checked first.
Following are three tests which can easily be made on a battery to determine its condition: OCV Test, Specific Gravity Test and
Load Test.
OCV - Open Circuit Voltage Test
Battery voltage should be checked with a digital multitester.
Readings of 12.6 volts or less require further battery testing and charging. See the following chart and Load Test.
NOTE: Lead-acid batteries should be kept at or near a full charge as possible. Electrolyte level should be kept between the low and full marks. If the battery is stored or used in a partially charged condition, or with low electrolyte levels, hard crystal sulfation will form on the plates, reducing the efficiency and service life of the battery.
State of Charge
100% Charged
OPEN CIRCUIT VOLTAGE
Conventional
Lead-Acid
12.60 V
YuMicron™ Type
12.70 V
75% Charged
50% Charged
25% Charged
12.40 V
12.10 V
12.50 V
12.20 V
0% Charged
11.90 V less than
11.80 V
12.0 V less than
11.9 V
10
10.27
ELECTRICAL
Specific Gravity Test
A tool such as a Battery Hydrometer (PN 2870836) can be used to measure electrolyte strength or specific gravity. As the battery goes through the charge/discharge cycle, the electrolyte goes from a heavy (more acidic) state at full charge to a light (more water) state when discharged. The hydrometer can measure state of charge and differences between cells in a multi-cell battery. Readings of 1.270 or greater should be observed in a fully charged battery. Differences of more than .025 between the lowest and highest cell readings indicate a need to replace the battery.
A battery may indicate a full charge condition in the OCV test and the specific gravity test, but still may not have the storage capacity necessary to properly function in the electrical system.
For this reason, a battery capacity or load test should be conducted whenever poor battery performance is encountered.
To perform this test, hook a multitester to the battery in the same manner as was done in the OCV test. The reading should be 12.6
volts or greater. Engage the starter and observe the battery voltage while cranking the engine. Continue the test for 15 seconds. During cranking the observed voltage should not drop below 9.5 volts. If the beginning voltage is 12.6 volts or higher and the cranking voltage drops below 9.5 volts during the test, replace the battery.
Battery Hydrometer
(PN 2870836)
Detail A
1.10
1.15
1.20
1.25
1.30
State of Charge*
100% Charged
SPECIFIC GRAVITY
Conventional
Lead-Acid
1.265
YuMicron™ Type
1.275
75% Charged
50% Charged
1.210
1.160
1.225
1.175
25% Charged
0% Charged
1.120
less than 1.100
1.135
less than 1.115
* At 80° F
NOTE : Subtract .01 from the specific gravity reading at 40° F.
Load Test
CAUTION
To prevent shock or component damage, remove spark plug high tension leads and connect securely to engine ground before proceeding.
NOTE: This test can only be performed on machines with electric starters. This test cannot be performed with an engine or starting system that is not working properly.
Off Season Storage
See Chapter 2 “Maintenance” for battery service procedures.
Charging Procedure
1.
Remove the battery to prevent damage from leaking or spilled acid during charging.
2.
Charge the battery with a charging output no larger than 1/
10 of the battery’s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater.
3.
Install battery in vehicle with positive terminal toward the front. Coat threads of battery bolt with a corrosion resistant dielectric grease.
Dielectric Grease
(PN 2871329)
4.
Connect battery cables.
WARNING
To avoid the possibility of explosion, connect positive (+) cable first and negative (-) cable last.
5.
After connecting the battery cables, install the cover on the battery and attach the hold down strap.
6.
Install clear battery vent tube from vehicle to battery vent.
WARNING: Vent tube must be free from obstructions and kinks and securely installed. If not, battery gases could accumulate and cause an explosion. Vent should be routed away from frame and body to prevent contact with electrolyte. Avoid skin contact with electrolyte, as severe burns could result. If electrolyte contacts the vehicle frame, corrosion will occur.
7.
Route cables so they are tucked away in front and behind battery.
10.28
STARTER SYSTEM
Troubleshooting
Starter Motor Does Not Run
• Battery discharged - Low specific gravity
• Loose or faulty battery cables or corroded connections
(see Voltage Drop Tests)
• Related wiring loose, disconnected, or corroded
• Poor ground connections at battery cable, starter motor or starter solenoid (see Voltage Drop Tests)
• Faulty key switch
• Faulty Start Diode. Use a digital multi-meter to test diode operation. Unplug the diode from the harness and measure between the Orange and Orange/Green diode connections. Continuity should flow one direction only.
ELECTRICAL
Voltage Drop Test
The Voltage Drop Test is used to test for bad connections. When performing the test, you are testing the amount of voltage drop through the connection. A poor or corroded connection will appear as a high voltage reading. Voltage shown on the meter when testing connections should not exceed .1 VDC per connection or component.
To perform the test, place the meter on DC volts and place the meter leads across the connection to be tested. Refer to the voltage drop tests on the starter system in this chapter.
Voltage should not exceed
.1 DC volts per connection
Starter Motor Removal / Disassembly
NOTE: Use electrical contact cleaner to clean starter motor parts. Some solvents may leave a residue or damage internal parts and insulation.
• Faulty starter solenoid or starter motor
• Engine problem - seized or binding (can engine be rotated easily)
Starter Motor Turns Over Slowly
• Battery discharged - low specific gravity
• Excessive circuit resistance - poor connections (see
Voltage Drop Test)
• Engine problem - seized or binding (can engine be rotated easily)
• Faulty or worn brushes in starter motor
Starter Motor Turns - Engine Does Not Rotate
• Faulty starter drive
• Faulty starter drive gears or starter motor gear
• Faulty flywheel gear or loose flywheel
1.
Remove the starter from the engine.
2.
Remove the two bolts, washers, and sealing O-Rings.
Inspect O-Rings and replace if damaged.
10
10.29
ELECTRICAL
NOTE: Note the alignment marks on both ends of the starter motor casing. These marks must align during reassembly.
3.
Remove the front bracket assembly and the rear bracket assembly. Remove the shims from the armature shaft and inspect the O-rings located on the armature housing.
O-Rings
2.
Measure resistance between insulated brush and starter housing. Reading should be infinite (OL). Inspect insulation on brush wires for damage and repair or replace as necessary.
Shims
reassembly.
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.
3.
Slide positive brush springs to the side, pull brushes out of their guides and remove brush plate. Slide brush end frame off end of starter.
NOTE: The electrical input post must stay with the field coil housing.
4.
Measure resistance between ground brush and brush plate.
Resistance should be .3 ohms or less.
Brush Inspection
1.
Measure length of each carbon brush. Replace brush assembly when worn to 5/16” (8 mm) or less. The brushes must slide freely in their holders.
Brush Length
Limit 5/16” (8 mm)
10.30
ELECTRICAL
Brush Replacement
1.
Remove terminal nut with lock washer, flat washer, large phenolic washer, the small phenolic spacers, and sealing
O-ring. Inspect O-ring and replace if damaged.
4.
Measure the resistance between each commutator segment and the armature shaft. The reading should be infinite (no continuity).
2.
Slide positive brush springs to the side, pull brushes out of their guides and remove brush plate.
CAUTION
Some cleaning solvents may damage the insulation in the starter. Care should be exercised when selecting an appropriate solvent. If the commutator needs cleaning use only electrical contact cleaner.
Armature Testing
1.
Remove armature from starter casing. Note order of shims on drive end for reassembly.
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.
CAUTION
Use care when handling starter housing. Do not drop or strike the housing as magnet damage is possible. If magnets are damaged, starter must be replaced.
Starter Reassembly / Installation
1.
Install brush plate to field magnet housing aligning index tab.
10
2.
Inspect surface of commutator. Replace if excessively 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.
10.31
ELECTRICAL
2.
Install O-ring, two small phenolic spacers, large phenolic washer, flat washer, lock washer, and terminal nut.
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
NOTE: It is important to tighten the bottom starter bolt first (circle), as the bottom hole acts as a pilot hole to properly align the starter drive (bendix) with the flywheel. This helps to prevent binding and starter damage.
Starter Drive
If the garter spring is damaged, the overrun clutch may fail to return properly. Use either of the following methods to remove and install a new garter spring:
6.
Be sure wire insulation is in place around positive brush wire and pushed completely into slot on phenolic plate.
7.
Using Dielectric Grease ( PN 2871329 ), lubricate brush end bushing and install shims.
8.
Align brush plate and install cover and screws.
9.
Lightly grease pinion shaft and install pinion, spring stopper, and snap ring.
A
H
G
F
D
B
A. Gear Assembly
B. Thrust Washer
C. Busing
D. Retaining Ring
E. Thrust Washer
F. Stopper
G. Cover
H. Spring
C
E
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 of the starter bolts. Torque the bottom bolt first to 9 ft.lbs.
(12 Nm).
Then torque the top bolt to the same specification.
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.
10.32
2.
Remove the retaining ring, thrust washer, spring retainers and clutch return spring. Screw the overrun clutch off the end of the pinion shaft. Remove the old spring and install a new one. Lightly grease the pinion shaft and reinstall the clutch, spring, retainers, end washer and lock ring in the reverse order. Make sure the end washer is positioned properly so that it will hold the lock ring in its groove.
Starter Solenoid Bench Test
Test the start solenoid by powering the solenoid using battery voltage for a maximum of 5 seconds. With the solenoid energized, resistance should read about 0.5
Ω
± 10% between terminal (A) and (B). If resistance measurement is out of specification, replace the starter solenoid.
A
Energize
Here
B
Starter Solenoid Operation
To energize the Starter Solenoid the following must occur:
• The brake must be applied to provide a ground path via the Orange / Green wire.
• The key switch must be turned to the “start” position to 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.
ELECTRICAL
10.33
10
ELECTRICAL
Starter Exploded View
*
Indicates
-
Do not reuse.
Replace with new parts.
1. Rubber Ring*
2. Brush Spring
3. Thrust Washer
4. Gear Assembly
5. O-Ring*
6. Brush Complete
7. O-Ring*
8. Thrust Washer
9. Shaft Complete
10. Gear Assembly
11. Through Bolt
12. Cover
13. Stopper
14. Snap Ring
15. Washer
16. Flange Bolt
17. Thrust Washer
18. Flange Bushing
10.34
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 red lead on the battery positive. Reading should be 12.4 V D. C. or greater.
No
Remove battery and properly service. Install fully charged shop battery to continue test.
Yes
Disconnect 2-wire connector at the solenoid.
Using a multi-meter, connect the black meter lead to the Orange/Green harness wire and the red meter lead to the White/Red harness wire. Apply the brake and turn ignition switch to the “start” position. Meter should read battery voltage.
No
Check for voltage at the chassis 20 Amp fuse and then check for voltage entering the ignition switch. Battery voltage should be present. If battery voltage is present at the ignition switch, but not the solenoid, replace the switch. NOTE: The brake MUST be applied when performing these tests.
Yes
Test the start solenoid by powering the solenoid via the 2-wire connection.
With the solenoid energized, resistance should read about 0.5
Ω
± 10% between the two terminals. If resistance measurement is out of specification, replace the starter solenoid (see “Starter Solenoid Bench Test”) Voltage Drop
Testing
Reconnect the solenoid. Connect the tester black lead to the battery positive and the red lead to the solenoid end of the battery-to-solenoid wire. Turn the ignition key to the “start” position. Reading should be less than .1 V D.C.
No Clean the battery-to-solenoid cable ends or replace the cable.
Yes
Connect the black tester lead to solenoid end of battery-to-solenoid cable. Connect red tester lead to solenoid end of solenoid-to-starter cable. Turn the ignition key to the “start” position. Reading should be less than .1 V D.C.
No
Replace the starter solenoid.
Yes
Connect the black tester lead to the solenoid end of the solenoid-to-starter cable. Connect the red tester lead to the starter end of the same cable.
Turn the ignition key to the “start” position. The reading should be less than .1 V D.C.
Yes
No
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.
Clean the solenoid-to-starter cable ends or replace the cable.
10
10.35
ELECTRICAL
ELECTRIC BOX LIFT ACTUATOR
DIAGNOSIS (if equipped)
1. Disconnect the wiring harness to the box lift actuator.
2. Connect a multimeter across the box lift actuator harness connection.
Disconnect Harness
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
YES - (12 Volts at actuator)
(Not 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)
On the main connector behind the dashboard, measure for 12 Volts between RED/BLACK wire terminal and ground.
(12 Volts between wires)
Check the switch. Check the wires between the switch and the actuator motor.
NO
YES
(Not 12 Volts between wires)
Test the accessory and wiring circuit breaker located under the seat.
(Refer to Wiring Schematic)
Test the wiring between the main connector and the circuit breaker.
(12 Volts between wires)
Test wiring between the main connector and the circuit breaker.
10.36
ELECTRICAL BREAK-OUT DIAGRAMS
Starting Circuit
ELECTRICAL
Key-On Power Circuit
10.37
10
ELECTRICAL
Transmission Switch Circuit
AWD Circuit
10.38
Speed Sensor Circuit
Charging System Circuit
ELECTRICAL
10.39
10
ELECTRICAL
Cooling Fan Circuit
Fuel Display / Fuel Pump Circuit
10.40
A
Air Filter Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
Air Intake Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
All Wheel Drive (AWD) Coil . . . . . . . . . . . . . . . . . . . 10.16
AWD Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9
AWD, Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
AWD, Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
B
Ball Joint, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
Battery Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
Battery Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . 10.26
Body Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
Brake Burnishing . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
,
9.24
Brake Caliper Assembly, Front . . . . . . . . . . . . . . 9.16
,
9.18
Brake Caliper Assembly, Rear (4x4 CREW) . . . . 9.28
,
9.30
Brake Caliper Inspection, Front . . . . . . . . . . . . . . . . . . . 9.18
Brake Caliper Inspection, Rear (4x4 CREW) . . . . . . . . 9.30
Brake Caliper Installation, Front . . . . . . . . . . . . . . . . . . 9.19
Brake Caliper Installation, Rear (4x4 CREW) . . . . . . . . 9.31
Brake Caliper Removal, Front . . . . . . . . . . . . . . . . . . . . 9.16
Brake Caliper Removal, Rear (4x4 CREW) . . . . . . . . . . 9.28
Brake Caliper, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
Brake Caliper, Rear (4x4 CREW) . . . . . . . . . . . . . . . . . 9.28
Brake Caliper, Rear (6x6) . . . . . . . . . . . . . . . . . . . . . . . . 9.25
Brake Disc, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
Brake Disc, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.32
Brake Hose and Fitting Inspection . . . . . . . . . . . . . . . . . 2.32
Brake Pad Assembly, Front . . . . . . . . . . . . . . . . . . . . . . 9.15
Brake Pad Assembly, Rear (4x4 CREW) . . . . . . . . . . . . 9.23
Brake Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
Brake Pad Thickness, Front . . . . . . . . . . . . . . . . . . . . . . 9.14
Brake Pad Thickness, Rear (4x4 CREW) . . . . . . . . . . . . 9.23
Brake Pads, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
Brake Pads, Rear (4x4 CREW) . . . . . . . . . . . . . . . . . . . 9.22
Brake Pads, Rear (6x6) . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
Brake Pads, Removal, Front . . . . . . . . . . . . . . . . . . . . . . 9.14
Brake Pads, Removal, Rear (4x4 CREW) . . . . . . . . . . . 9.22
Brake Pedal, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
Brake Pedal, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
Brake System Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2.32
Brake System, Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
Brake System, Exploded View (4x4 CREW) . . . . . . . . . . 9.5
Brake System, Exploded View (6x6, 4x4 CREW) . . . . . . 9.5
Brake System, Operation . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
Brake System, Troubleshooting . . . . . . . . . . . . . . . . . . . 9.33
Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
Breather Hose Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2.14
C
Cab Frame, Assembly / Removal (4x4 CREW) . . . . . . . . 5.9
Cargo Box, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26
Cargo Box, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26
Centralized Hilliard, Exploded View . . . . . . . . . . . . . . . 7.15
Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
Charging System, Alternator Tests . . . . . . . . . . . . . . . . 10.24
Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
Clock, Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
Clutch Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
Coolant Level Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2.22
Coolant Strength and Type . . . . . . . . . . . . . . . . . . . . . . . 2.23
Cooling System Bleeding Procedure . . . . . . . . . . . . . . . . 3.15
Cooling System Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
Cooling System Pressure Test . . . . . . . . . . . . . . . . . . . . . 2.23
Cooling System Specifications . . . . . . . . . . . . . . . . . . . . 3.13
Cooling System, Pressure Test . . . . . . . . . . . . . . . . . . . . 3.14
Cooling System, Troubleshooting . . . . . . . . . . . . . . . . . . 3.59
Crankshaft Gear, Removal . . . . . . . . . . . . . . . . . . . . . . . 3.40
Crankshaft Position Sensor (CPS) . . . . . . . . . . . . . . . . . . 4.16
CV Shaft Boot Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2.25
Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . 3.29
Cylinder Head Assembly Exploded View . . . . . . . . . . . 3.22
Cylinder Honing To De-glaze . . . . . . . . . . . . . . . . . . . . . 3.33
Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
D
Decal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . 1.13
Diagnostic Codes, Instrument Cluster . . . . . . . . . . . . . . 10.10
Diagnostics, AWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9
Diagnostics, Gear Circuit . . . . . . . . . . . . . . . . . . . . . . . . 10.9
Drive Belt, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
Drive Belt, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
Drive Belt, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
Drive Clutch, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
Drive Clutch, Bushing Service . . . . . . . . . . . . . . . . . . . . 6.17
Drive Clutch, Button to Tower Clearance . . . . . . . . . . . . 6.14
Drive Clutch, Cover Bushing Remove/Install . . . . . . . . . 6.18
Drive Clutch, Disassembly . . . . . . . . . . . . . . . . . . . . . . . 6.12
Drive Clutch, Exploded View . . . . . . . . . . . . . . . . . . . . . 6.12
Drive Clutch, Moveable Sheave Inspection . . . . . . . . . . 6.16
Drive Clutch, Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Drive Clutch, Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
Drive Clutch, Shift Weights . . . . . . . . . . . . . . . . . . . . . . 6.11
Drive Clutch, Spider Removal . . . . . . . . . . . . . . . . . . . . 6.13
Drive Clutch, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
Drive Shaft / CV Joint, Handling Tips . . . . . . . . . . . . . . . 7.8
Drive Shaft, Mid Drive (6x6) . . . . . . . . . . . . . . . . . . . . . 7.27
Driven Clutch, Assembly . . . . . . . . . . . . . . . . . . . . . . . . 6.22
Driven Clutch, Disassembly / Inspection . . . . . . . . . . . . 6.20
Driven Clutch, Exploded View . . . . . . . . . . . . . . . . . . . . 6.20
Driven Clutch, Operation . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Driven Clutch, Service . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20
IX.1
IX
E
EFI Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . .4.24
EFI Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . .4.10
EFI Priming / Starting Procedure . . . . . . . . . . . . . . . . . .4.10
EFI Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.23
EFI, Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . .4.22
Electric Box Lift Actuator . . . . . . . . . . . . . . . . . . . . . . .10.36
Electrical Breakout Diagrams (EFI) . . . . . . . . . . . . . . .10.37
Electrical, Cooling System Breakout Diagram . . . . . . .10.19
Electronic Control Unit (ECU) . . . . . . . . . . . . . . . . . . . .4.11
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . 3.13
, 3.14
Engine Designation Number . . . . . . . . . . . . . . . . . . . . . . .1.2
Engine Exploded Views . . . . . . . 3.2
, 3.3
, 3.4
, 3.5
, 3.7
, 3.8
Engine Fastener Torques . . . . . . . . . . . . . . . . . . . . . . . . . .3.9
Engine Flywheel / Stator Removal . . . . . . . . . . . . . . . . .3.36
Engine Installation Notes . . . . . . . . . . . . . . . . . . . . . . . .3.19
Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20
Engine Oil and Filter Change . . . . . . . . . . . . . . . . . . . . .2.15
Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14
Engine Removal / Install Procedure . . . . . . . . . . . . . . . .3.18
Engine Serial Number Location . . . . . . . . . . . . . . . . . . . .1.2
Engine Service Specifications . . . . . . . . . . . . . . . . . . . . .3.11
Engine Speed Display . . . . . . . . . . . . . . . . . . . . . . . . . . .10.8
Engine Temperature Sensor . . . . . . . . . . . . . . . . . . . . . .4.20
Engine Temperature Sensor Replacement . . . . . . . . . . .4.20
Engine Temperature Sensor Test . . . . . . . . . . . . . . . . . .4.20
Engine Torque Specifications . . . . . . . . . . . . . . . . . . . . .3.10
Engine Valve Seal/Spring Service . . . . . . . . . . . . . . . . .3.24
Engine, Accessible Components . . . . . . . . . . . . . . . . . . .3.13
Engine, Balance Shaft Gear Removal . . . . . . . . . . . . . . .3.40
Engine, Balance Shaft Removal . . . . . . . . . . . . . . . . . . .3.44
Engine, Cam Gear Reassembly . . . . . . . . . . . . . . . . . . . .3.39
Engine, Cam Gear Removal . . . . . . . . . . . . . . . . . . . . . .3.38
Engine, Camshaft Inspection . . . . . . . . . . . . . . . . . . . . . .3.44
Engine, Camshaft Installation . . . . . . . . . . . . . . . . . . . . .3.46
Engine, Combustion Chamber . . . . . . . . . . . . . . . . . . . .3.27
Engine, Crankcase Assembly . . . . . . . . . . . . . . . . . . . . .3.45
Engine, Crankshaft Gear Removal . . . . . . . . . . . . . . . . .3.41
Engine, Crankshaft Installation . . . . . . . . . . . . . . . . . . . .3.46
Engine, Cylinder Head Assembly . . . . . . . . . . . . . . . . . .3.29
Engine, Cylinder Head Disassembly . . . . . . . . . . . . . . . .3.25
Engine, Cylinder Head Inspection . . . . . . . . . . . . . . . . . .3.24
Engine, Cylinder Head Removal . . . . . . . . . . . . . . . . . . .3.23
Engine, Cylinder Head Warp . . . . . . . . . . . . . . . . . . . . .3.24
Engine, Cylinder Honing . . . . . . . . . . . . . . . . . . . . . . . . .3.33
Engine, Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . .3.32
Engine, Cylinder Installation . . . . . . . . . . . . . . . . . . . . . .3.47
Engine, Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . .3.30
Engine, Flywheel and Stator Installation . . . . . . . . . . . .3.54
Engine, Flywheel Removal . . . . . . . . . . . . . . . . . . . . . . .3.37
Engine, Gear / Stator Housing Seal Replacement . . . . . .3.51
Engine, Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . .3.49
Engine, Gear(s) Removal . . . . . . . . . . . . . . . . . . . . . . . .3.37
Engine, Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . .3.55
Engine, Oil Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . .3.21
IX.2
Engine, Oil Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . 3.20
Engine, Oil Pump Disassembly . . . . . . . . . . . . . . . . . . . 3.41
Engine, Oil Pump Installation . . . . . . . . . . . . . . . . . . . . 3.48
Engine, Oil Pump Priming . . . . . . . . . . . . . . . . . . . . . . . 3.57
Engine, Oil Pump Reassembly . . . . . . . . . . . . . . . . . . . . 3.42
Engine, Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . 3.41
Engine, Piston Identification . . . . . . . . . . . . . . . . . . . . . 3.13
Engine, Piston Installation . . . . . . . . . . . . . . . . . . . . . . . 3.47
Engine, Piston Removal and Inspection . . . . . . . . . . . . 3.31
Engine, Piston Ring Installed Gap . . . . . . . . . . . . . . . . . 3.35
Engine, Piston to Cylinder Clearance . . . . . . . . . . . . . . 3.34
Engine, Piston to Rod Clearance . . . . . . . . . . . . . . . . . . 3.34
Engine, Pushrod Inspection . . . . . . . . . . . . . . . . . . . . . . 3.23
Engine, Rocker Arm Inspection . . . . . . . . . . . . . . . . . . . 3.23
Engine, Starter Drive Removal . . . . . . . . . . . . . . . . . . . 3.35
Engine, Starter Removal . . . . . . . . . . . . . . . . . . . . . . . . 3.37
Engine, Stator Gear Cover Seal(s) Installation . . . . . . . 3.51
Engine, Stator Installation . . . . . . . . . . . . . . . . . . . . . . . 3.54
Engine, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 3.58
Engine, Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . 3.26
Engine, Valve Lifter Removal and Inspection . . . . . . . . 3.30
Engine, Valve Sealing Test . . . . . . . . . . . . . . . . . . . . . . 3.30
Engine, Valve Seat Reconditioning . . . . . . . . . . . . . . . . 3.27
Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
F
Fan Control Circuit Bypass Test . . . . . . . . . . . . . . . . . 10.20
Fan Control Circuit Operation . . . . . . . . . . . . . . . . . . . 10.20
Flywheel / Stator Removal . . . . . . . . . . . . . . . . . . . . . . . 3.36
Flywheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
Front A-arm, Replacement . . . . . . . . . . . . . . . . . . . . . . . 5.15
Front Caliper, Piston Bore I.D.
. . . . . . . . . . . . . . . . . . . 9.18
Front Drive Shaft, Installation . . . . . . . . . . . . . . . . . . . . 7.11
Front Drive Shaft, Outer CV Joint / Boot Replacement . 7.8
Front Drive Shaft, Removal . . . . . . . . . . . . . . . . . . . . . . . 7.7
Front Gearcase Lubrication . . . . . . . . . . . . . . . . . . . . . . 2.18
Front Gearcase, Assembly . . . . . . . . . . . . . . . . . . . . . . . 7.21
Front Gearcase, Backlash Pad Adjustment . . . . . . . . . . 7.23
Front Gearcase, Centralized Hilliard . . . . . . . . . . . . . . . 7.15
Front Gearcase, Disassembly / Inspection . . . . . . . . . . . 7.19
Front Gearcase, Installation . . . . . . . . . . . . . . . . . . . . . . 7.24
Front Gearcase, Removal . . . . . . . . . . . . . . . . . . . . . . . . 7.18
Front Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Front Propshaft, Removal . . . . . . . . . . . . . . . . . . . . . . . 7.12
Front Propshaft, U-Joint Service . . . . . . . . . . . . . . . . . . 7.13
Front Strut, Cartridge Replacement . . . . . . . . . . . . . . . . 5.17
Front Strut, Exploded View . . . . . . . . . . . . . . . . . . . . . . 5.16
Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
Fuel Injection, Component Locations . . . . . . . . . . . . . . . 4.8
Fuel Injection, Exploded View . . . . . . . . . . . . . . . . . . . . 4.7
Fuel Injection, Service Notes . . . . . . . . . . . . . . . . . . . . . . 4.5
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
Fuel Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
Fuel Pump / Tank Assembly . . . . . . . . . . . . . . . . . . . . . 4.12
Fuel Sender Test . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
, 10.20
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
G
Gear Circuit Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 10.9
Gear Position Indicator Switch Test . . . . . . . . . . . . . . . 10.16
General Specifications, Brakes . . . . . . . . . . . . . . . . . . . . . 9.2
H
Head Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
Hub / Bearing Carrier, Mid Drive (6x6) . . . . . . . . . . . . . 7.24
Hub / Bearing Carrier, Rear (4x4) . . . . . . . . . . . . . . . . . 7.37
I
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
Ignition Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . 4.21
Ignition Coil Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
Indicator, Service Interval . . . . . . . . . . . . . . . . . . . . . . . 10.9
Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
K
Keys, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
Kilometers to Miles Toggle . . . . . . . . . . . . . . . . . . . . . 10.10
L
Leakdown Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
M
Maintenance, Brake System . . . . . . . . . . . . . . . . . . . . . . 2.32
Maintenance, Cooling System . . . . . . . . . . . . . . . . . . . . 2.22
Maintenance, Electrical and Ignition . . . . . . . . . . . . . . . 2.26
Maintenance, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
Maintenance, Final Drive . . . . . . . . . . . . . . . . . . . . . . . . 2.25
Maintenance, Fuel System . . . . . . . . . . . . . . . . . . . . . . . 2.11
Maintenance, General Vehicle Inspection . . . . . . . . . . . 2.10
Maintenance, References . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
Maintenance, Service Products and Lubricants . . . . . . . . 2.7
Maintenance, Steering and Suspension . . . . . . . . . . . . . 2.29
Maintenance, Transmission and Gearcases . . . . . . . . . . 2.17
Master Cylinder, Installation . . . . . . . . . . . . . . . . . . . . . . 9.6
Master Cylinder, Removal . . . . . . . . . . . . . . . . . . . . . . . . 9.6
Mid Axle A-arm, Replacement . . . . . . . . . . . . . . . . . . . 5.18
Mid Drive Gearcase (6x6) . . . . . . . . . . . . . . . . . . . . . . . 7.29
Middle Gearcase Lubrication . . . . . . . . . . . . . . . . . . . . . 2.19
Miles to Kilometers Toggle . . . . . . . . . . . . . . . . . . . . . 10.10
Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
O
Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
Oil Pump Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.57
Oil Pump, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
P
Paint Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
Parking Brake Caliper, Disassembly / Inspection . . . . . 9.12
Parking Brake Caliper, Exploded View . . . . . . . . . . . . . 9.11
Parking Brake Caliper, Installation . . . . . . . . . . . . . . . . 9.13
Parking Brake Caliper, Pad Installation . . . . . . . . . . . . . 9.13
Parking Brake Caliper, Removal . . . . . . . . . . . . . . . . . . . 9.11
Parking Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
Parking Brake Pad Inspection . . . . . . . . . . . . . . . . . . . . . 2.33
Parking Brake, Adjustment . . . . . . . . . . . . . . . . . . 2.32
, 9.10
Parking Brake, Exploded View (4x4) . . . . . . . . . . . . . . . . 9.8
Parking Brake, Exploded View (6x6) . . . . . . . . . . . . . . . . 9.9
Parking Brake, Inspection . . . . . . . . . . . . . . . . . . . . . . . . 9.10
Periodic Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . 2.3
Piston Ring Installed Gap . . . . . . . . . . . . . . . . . . . . . . . . 3.35
Piston to Cylinder Clearance . . . . . . . . . . . . . . . . . . . . . . 3.34
Piston to Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
Pre-Ride / Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . 2.10
Programmable Service Interval . . . . . . . . . . . . . . . . . . . . 10.9
Propshaft, Mid Drive (6x6) . . . . . . . . . . . . . . . . . . . . . . . 7.28
Publication Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
PVT System, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
PVT System, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . 6.5
PVT System, Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 6.3
PVT System, Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
PVT System, Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
PVT Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.24
R
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
Radiator Coolant Level Inspection . . . . . . . . . . . . . . . . . 2.23
Rear A-arm, Replacement . . . . . . . . . . . . . . . . . . . . . . . . 5.19
Rear Axle Service (6x6) . . . . . . . . . . . . . . . . . . . . . . . . . 7.58
Rear Axle, Exploded View (6x6) . . . . . . . . . . . . . . . . . . 5.23
Rear Caliper, Piston Bore I.D. (4x4 CREW) . . . . . . . . . 9.30
Rear Cargo Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
Rear Drive Shaft, CV Joint / Boot Replacement . . . . . . . 7.41
Rear Drive Shaft, Installation . . . . . . . . . . . . . . . . . . . . . 7.47
Rear Drive Shaft, Plunging Joint / Boot Replacement . . 7.44
Rear Drive Shaft, Removal . . . . . . . . . . . . . . . . . . . . . . . 7.41
Rear Gearcase (4x4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.49
Rear Gearcase Lubrication (4x4) . . . . . . . . . . . . . . . . . . 2.20
Rear Gearcase Lubrication (6x6) . . . . . . . . . . . . . . . . . . 2.21
Rear Propshaft Service . . . . . . . . . . . . . . . . . . . . . . . . . . 7.48
Rear Spring Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
Rear Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
Rear Suspension Adjustment (4x4) . . . . . . . . . . . . . . . . . 2.31
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
S
Service Interval Indicator . . . . . . . . . . . . . . . . . . . . . . . . 10.9
Shift Lever, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
Shift Lever, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
Shift Linkage Inspection and Adjustment . . . . . . . . . . . . 2.10
Shift Linkage, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 8.3
Shift Linkage, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
Solenoid, Rear Differential . . . . . . . . . . . . . . . . . . . . . . . 10.4
Spark Plug Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
Special Tool, Cam Gear Installation Kit . . . . . . . . . . . . . 3.39
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
Special Tools, Body/Steering/Suspension . . . . . . . . . . . . . 5.2
Special Tools, Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
IX.3
IX
Special Tools, Clutching . . . . . . . . . . . . . . . . . . . . . . . . . .6.2
Special Tools, EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2
Special Tools, Electrical . . . . . . . . . . . . . . . . . . . . . . . . .10.3
Special Tools, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . .3.13
Special Tools, Final Drive . . . . . . . . . . . . . . . . . . . . . . . . .7.3
Specification, Balance Shaft Gear Bolt Torque . . . . . . .3.50
Specification, Cam Lobe Height . . . . . . . . . . . . . . . . . . .3.44
Specification, Cam Thrust Plate Fastener Torque . . . . . .3.48
Specification, Camshaft Gear Bolt Torque . . . . . . . . . . .3.51
Specification, Coolant Temperature Sensor Resistance 10.20
Specification, Cylinder Head Warp . . . . . . . . . . . . . . . . .3.24
Specification, Cylinder Taper Limit . . . . . . . . . . . . . . . .3.32
Specification, Cylinder Warp Limit . . . . . . . . . . . . . . . .3.32
Specification, Oil Pump Bolt Torque . . . . . . . . . . . . . . .3.49
Specification, Oil Pump Rotor Clearance . . . . . . . . . . . .3.41
Specification, Timing Gear Alignment . . . . . . . . . . . . . .3.37
Specification, Valve Seat Contact Width . . . . . . . . . . . .3.28
Specification, Valve Spring Free Length . . . . . . . . . . . .3.25
Specification, Valve Stem Diameter . . . . . . . . . . . . . . . .3.26
Specification, Valve Stem Guide I.D.
. . . . . . . . . . . . . . .3.26
Specification, Wheel Toe-Out . . . . . . . . . . . . . . . . . . . . .2.29
Specifications, Cam Shaft . . . . . . . . . . . . . . . . . . . . . . . .3.44
Specifications, Cooling System . . . . . . . . . . . . . . . . . . . .3.13
Specifications, Crankcase Fastener Torque . . . . . . . . . . .3.46
Specifications, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2
Specifications, Engine Lubrication . . . . . . . . . . . . . . . . .3.20
Specifications, Engine Oil Pressure . . . . . . . . . . . . . . . .3.20
Specifications, General . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6
Specifications, Oil Baffle Bolt Torque . . . . . . . . . . . . . .3.45
Specifications, Oil Pick-up Bolt Torque . . . . . . . . . . . . .3.45
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.7
Speedometer Troubleshooting Tests . . . . . . . . . . . . . . .10.12
Speedometer, Installation . . . . . . . . . . . . . . . . . . . . . . .10.11
Speedometer, Removal . . . . . . . . . . . . . . . . . . . . . . . . .10.11
Starter Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.32
Starter Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .3.35
Starter Motor Assembly, Exploded View . . . . . . . . . . .10.34
Starter Motor, Armature Testing . . . . . . . . . . . . . . . . . .10.31
Starter Motor, Brush Inspection / Replacement . . . . . .10.30
Starter Motor, Reassembly / Installation . . . . . . . . . . . .10.31
Starter Motor, Removal . . . . . . . . . . . . . . . . . . . . . . . . .10.29
Starter Solenoid, Operation . . . . . . . . . . . . . . . . . . . . . .10.33
Starter Solenoid, Test . . . . . . . . . . . . . . . . . . . . . . . . . .10.33
Starter System, Troubleshooting . . . . . . . . . . . . . . . . . .10.29
Starting System Testing Flow Chart . . . . . . . . . . . . . . .10.35
Stator, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.36
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29
Steering, Exploded View . . . . . . . . . . . . . . . . . . . . . . . . .5.13
Storage Box, Installation . . . . . . . . . . . . . . . . . . . . . . . . .5.27
Storage Box, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .5.27
Swing Arm, Exploded View (6x6) . . . . . . . . . . . . . . . . .5.23
Swing Arm, Installation . . . . . . . . . . . . . . . . . . . . . . . . .5.22
Swing Arm, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .5.22
Switch, AWD / 2WD / TURF (4x4) . . . . . . . . . . . . . . . .10.4
Switch, Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.5
IX.4
Switch, Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
Switch, Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
T
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
Tail Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
Tap/Drill Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
Temperature / Barometric Air Pressure Sensor (T-BAP) 4.17
Throttle Freeplay Adjustment . . . . . . . . . . . . . . . . . . . . 2.12
Throttle Pedal Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2.11
Throttle Position Sensor (TPS) . . . . . . . . . . . . . . . . . . . 4.17
Throttle Position Sensor Initialization . . . . . . . . . . . . . . 4.19
Throttle Position Sensor Replacement . . . . . . . . . . . . . . 4.20
Tie Rod End Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
Timing Gear Mark Alignment . . . . . . . . . . . . . . . . . . . . 3.37
Tire Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
Toe Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
Torque Specifications, Body/Steering/Suspension . . . . . 5.2
Torque Specifications, Brakes . . . . . . . . . . . . . . . . . . . . . 9.2
Torque Specifications, Clutching . . . . . . . . . . . . . . . . . . . 6.2
Torque Specifications, Engine . . . . . . . . . . . . . . . . . . . . 3.10
Torque Specifications, Final Drive . . . . . . . . . . . . . . . . . 7.3
Torque Specifications, Transmission . . . . . . . . . . . . . . . . 8.2
Torque Specifications, Wheel and Hub . . . . . . . . . . . . . 2.25
Transmission I.D. Number Location . . . . . . . . . . . . . . . . 1.3
Transmission Lubrication . . . . . . . . . . . . . . . . . . . . . . . 2.17
Transmission, Assembly . . . . . . . . . . . . . . . . . . . . . . . . 8.10
Transmission, Disassembly . . . . . . . . . . . . . . . . . . . . . . . 8.5
Transmission, Exploded View (4x4) . . . . . . . . . . . . . . . 8.16
Transmission, Installation . . . . . . . . . . . . . . . . . . . . . . . 8.14
Transmission, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
Trip Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
Troubleshooting, Brake Noise . . . . . . . . . . . . . . . . . . . . . 9.3
Troubleshooting, Clutching . . . . . . . . . . . . . . . . . . . . . . 6.23
Troubleshooting, No AWD . . . . . . . . . . . . . . . . . . . . . 10.12
Troubleshooting, No AWD Hub Safety Limiter . . . . . 10.14
Troubleshooting, No Fuel Gauge Display . . . . . . . . . . 10.15
Troubleshooting, No Gear Indicator Display . . . . . . . . 10.15
Troubleshooting, No Instrument Display . . . . . . . . . . . 10.13
Troubleshooting, Transmission . . . . . . . . . . . . . . . . . . . 8.15
Troubleshooting, Wheel Speed Sensor . . . . . . . . . . . . 10.13
V
Valve Seal/Spring Service . . . . . . . . . . . . . . . . . . . . . . . 3.24
Valve Sealing Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30
Valve Seat Reconditioning . . . . . . . . . . . . . . . . . . . . . . . 3.27
Vehicle Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Vent Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
VIN Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VIN Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Voltage Drop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
W
Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
Wheel, Removal / Installation . . . . . . . . . . . . . . . . . . . . 2.25
PN
9921885
Printed in USA
2009 RANGER 700 4X4 CREW (CHASSIS/BOX) PAGE 1 OF 2
WIRE DIAGRAM
WD-1
WIRE DIAGRAM
2009 RANGER 700 4X4 CREW (CHASSIS/BOX) PAGE 2 OF 2
WD-2
2009 RANGER 700 6X6 (CHASSIS) PAGE 1 OF 2
WIRE DIAGRAM
WD-3
WIRE DIAGRAM
2009 RANGER 700 6X6 (CHASSIS) PAGE 2 OF 2
WD-4
2009 RANGER 700 4X4 CREW / 6X6 (DASH)
WIRE DIAGRAM
WD-5
WIRE DIAGRAM
2009 RANGER 700 4X4 CREW / 6X6 (BREAKOUTS)
5$1*(5;&5(:;%5($.2876
WD-6
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