2012 RANGER RZR 570 / INTL

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 p roperly
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 pro cedures ou tlined i n th is man ual re quire a sou nd kn owledge of me chanical t heory, to ol use, and sho p
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you ha ve any doubt as to yo ur ability to perform any of th e procedures outlined in th is Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Publications Question'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.

Publication Printed November 2011 (PN 9923523) Rev. 3

© Copyright 2011 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. Dep ictions an d/or p rocedures in t his pu blication are int ended for re ference use only. N o liability can be accept ed for omissions or inaccura cies. 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.

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 UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS
Throughout this manual, important information is brought to your attention by the following symbols:

WARNING

SAFETY ALERT WARNING ind icates a po tential hazard that may result in severe injury or death to the o perator,
bystander or person(s) inspecting or servicing the vehicle.

CAUTION

SAFETY ALERT CAUTION indicates a potential h azard tha t may r esult in min or personal in jury or damage to th e
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 Pola ris factor y pu blications can be do wnloaded fro m www.polarisindustries.com, pu rchased fr om
www.purepolaris.com or by contacting the nearest Polaris dealer.

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 GENERAL INFORMATION 1

MAINTENANCE 2

ENGINE / COOLING SYSTEM 3

ELECTRONIC FUEL INJECTION 4

BODY / STEERING / SUSPENSION 5

CLUTCHING 6

FINAL DRIVE 7

TRANSMISSION 8

BRAKES 9

ELECTRICAL 10

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 GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION 1
MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE AND ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
2012 RANGER RZR 570 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
2012 RANGER RZR 570 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
2012 RANGER RZR 570 INTL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
2012 RANGER RZR 570 INTL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
STANDARD BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
METRIC BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

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 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 12 VH 57 AD

}
}

}
}
Model Year Emissions & 
Designation Model Option
Basic Chassis 
Designation Engine Designation

Engine Designation Number

1204286..............................................................................Single Cylinder, 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 V H 5 7 A * B P 0 0 0 0 0 0
}

Model
Engine Year Individual Serial No.
Body Style
Emissions Plant No. * This could be either
Powertrain a number or a letter
Check Digit

Vehicle and Engine Serial Number Location

Whenever corresponding about a Pola ris ORV, refe r to the ve hicle identification number (VIN) and the engine serial
number.

The VIN can be found stamped on a portion of the left-hand rear upper frame rail, above the left rear wheel. 
(see Figure 1-1)

The engine model and serial number can be found on a decal applied to the crankcase on the front of the engine. 
(see Figure 1-2)

Engine Serial
Number

Figure 1-1 Figure 1-2

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 GENERAL INFORMATION
VEHICLE INFORMATION
Publication Numbers

Model Model No. Owner’s Manual Parts Manual

1
2012 RANGER RZR 570 R12VH57AD 9923521 9923522
2012 RANGER RZR 570 INTL. R12VH57FX 9923521 9924058

NOTE: When ordering service parts be sure to use the correct parts manual.

NOTE: Polaris fa ctory pu blications c an be fo und at www.pola risindustries.com or p urchased f rom

www.purepolaris.com.

Replacement Keys
Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the
original key and refer to the chart to the right for the proper part number.

Series# Part Number

KEY COVER
20 4010278
P/N 5533534
21 4010278
22 4010321
23 4010321
27 4010321
Key Series
28 4010321
Number
31 4110141
32 4110148
67 4010278
68 4010278

SPECIAL TOOLS
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other
tools maybe su bstituted with a similar to ol, if ava ilable. 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/.

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 GENERAL INFORMATION

GENERAL SPECIFICATIONS

MODEL: 2012 RANGER RZR 570

MODEL NUMBER: R12VH57AD
ENGINE NUMBER: 1204286
Category Dimension / Capacity
Length 107.5 in. / 273.05 cm
Width 50 in. / 127 cm
Height 69 in. / 175.26 cm
Wheel Base 77 in. / 196 cm
Ground Clearance 10 in. / 25.4 cm
Dry Weight 970 lbs. / 440 kg
Front Storage
25 lbs. / 11.3 kg
Capacity
Cargo Box Dimension
20 x 40 x 9" (51 x 102 x 23 cm)
(LxWxH)
Cargo Box Capacity 300 lbs. / 136 kg
740 lbs. / 335.6 kg
Maximum Weight
(Includes rider(s), cargo, accessories
Capacity (Payload)
and trailer tongue weight)
Hitch Towing Capacity 1500 lbs. / 680 kg
Hitch Tongue Capacity 150 lbs. / 68 kg

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 GENERAL INFORMATION
MODEL: 2012 RANGER RZR 570 Drivetrain
Transmission Type Polaris Automatic PVT
MODEL NUMBER: R12VH57AD

1
ENGINE NUMBER: 1204286 Drive Ratio - Front 3.818:1
Drive Ratio - Final 3.70:1
Engine
Shift Type In Line Shift - H / L / N / R / P
Domestic Single Cylinder, Liquid
Platform Front Gearcase Polaris Demand Drive Plus
Cooled, 4-Stroke, DOHC
Fluid Type / Capacity 6.75 oz. (200 ml)
Engine Number 1204286
Transmission: Main Gearcase Polaris AGL Plus
Engine Displacement 567cc
Fluid Type / Capacity 44 oz. (1300 ml)
Number of Cylinders 1
Belt 3211143
Bore & Stroke (mm) 99 x 73.6 mm
Steering / Suspension
Compression Ratio 10:1
Independent Dual A-arm
Compression Pressure 80 - 120 psi (decompression) Front Suspension
w/Anti-Sway Bar
Engine Idle Speed 1200 ± 100 RPM Front Travel 9 in. / 23 cm
Engine Max Operating RPM 7750 RPM Independent Dual A-arm
Rear Suspension
Lubrication Pressurized Wet Sump w/Anti-Sway Bar
Oil Requirements PS-4 Plus Synthetic Rear Travel 9.5 in. / 24 cm
Oil Capacity 2 qts. / 1.9 liters Shock Preload Adjustment Cam Adjustment
Coolant Capacity 4.25 qts. (4 l) Front / Rear Cam Adjustment
Overheat Warning Instrument Cluster Indicator Toe Out 1/8 - 1/4 in. (3 - 6.4 mm)
Exhaust System Single Headpipe / Single Silencer Wheels / Brakes
Fuel System Front Wheel Size 12 x 6 / Steel
Fuel System Type Bosch M17 EFI Front Tire Type / Size Ancla / 25 x 8 R12
Fuel Delivery Electronic Fuel Pump (in tank) Rear Wheel Size 12 x 8 / Steel
Rear Tire Type / Size Ancla / 25 x 10 R12
Fuel Pressure 43-48 psi (296.5 - 331 KPA)
Front: 10 psi (69 kPa)
Fuel Filters In tank, See Chapter 4 Tire Pressure Rear: 12 psi (83 kPa)
7.25 gal. (27.4 liters) Foot Actuated - 4 Wheel
Fuel Capacity / Requirement Brake - Front / Rear
87 Octane (minimum) Hydraulic Disc
Electrical Brake Fluid DOT 4
Alternator Max Output 650 Watts @ 7000 RPM
Headlights 2 - Halogen: Single Beam 55W CLUTCH CHART
Tail / Brake 2 - 6 Watts / 2 - 27 Watts
Shift Drive
Starting System Electric Start Altitude
Weight Spring
Ignition System Bosch M17 (ECU Controlled)
0-1500 25-52 Black
Ignition Timing (Variable) ECU Controlled (0-5000) (5632409) (7043594)
Meters
RG4YCX / .0276” - .0315” (Feet)
Spark plug / Gap 1500-3700 25-48 Black
(.7 - .8 mm)
(5000 - 12000) (5632408) (7043594)
Yuasa YB14-B2 /
Battery (RZR)
14 Amp Hr. / 12 Volt
Instrument Type Multifunction Instrument Cluster
DC Outlet Standard 12 Volt
EFI / Chassis / Fan / Fuel Pump /
Relays
Headlight
Circuit Breaker Fan Motor: 20 Amp
Drive / Fuel Pump: 10 Amp
Fuses (Fuse/Relay Box)
Lights / EFI / Accessory: 20 Amp
EFI: 30 Amp
Fuses (Power Fuse Holder)
Chassis: 30 Amp

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 GENERAL INFORMATION
MODEL: 2012 RANGER RZR 570 INTL
MODEL NUMBER: R12VH57FX
ENGINE NUMBER: 1204286
Category Dimension / Capacity
Length 107.5 in. / 273.05 cm
Width 50 in. / 127 cm
Height 69 in. / 175.26 cm
Wheel Base 77 in. / 196 cm
Ground Clearance 10 in. / 25.4 cm
Dry Weight 1001 lbs. / 454 kg
Front Storage
25 lbs. / 11.3 kg
Capacity
Cargo Box Dimension
20 x 40 x 9" (51 x 102 x 23 cm)
(LxWxH)
Cargo Box Capacity 300 lbs. / 136 kg
740 lbs. / 335.6 kg
Maximum Weight
(Includes rider(s), cargo, accessories
Capacity (Payload)
and trailer tongue weight)
Hitch Towing Capacity 1500 lbs. / 680 kg
Hitch Tongue Capacity 150 lbs. / 68 kg

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 GENERAL INFORMATION
MODEL: 2012 RANGER RZR 570 INTL Drivetrain
Transmission Type Polaris Automatic PVT
MODEL NUMBER: R12VH57FX

1
ENGINE NUMBER: 1204286 Drive Ratio - Front 3.818:1
Drive Ratio - Final 3.70:1
Engine
Shift Type In Line Shift - H / L / N / R / P
Domestic Single Cylinder, Liquid
Platform Front Gearcase Polaris Demand Drive Plus
Cooled, 4-Stroke, DOHC
Fluid Type / Capacity 6.75 oz. (200 ml)
Engine Number 1204286
Polaris AGL Plus
Engine Displacement 567cc Transmission: Main Gearcase
44 oz. (1300 ml)
Number of Cylinders 1 Fluid Type / Capacity
570 INTL: 41 oz. (1200 ml)
Bore & Stroke (mm) 99 x 73.6 mm Belt 3211143
Compression Ratio 10:1 Steering / Suspension
Compression Pressure 80 - 120 psi (decompression) Independent Dual A-arm
Front Suspension
Engine Idle Speed 1200 ± 100 RPM w/Anti-Sway Bar
Engine Max Operating RPM 7750 RPM Front Travel 9 in. / 23 cm
Lubrication Pressurized Wet Sump Independent Dual A-arm
Rear Suspension
Oil Requirements PS-4 Plus Synthetic w/Anti-Sway Bar
Oil Capacity 2 qts. / 1.9 liters Rear Travel 9.5 in. / 24 cm
Coolant Capacity 4.25 qts. (4 l) Shock Preload Adjustment Cam Adjustment
Front / Rear Cam Adjustment
Overheat Warning Instrument Cluster Indicator
Exhaust System Single Headpipe / Single Silencer Toe Out 1/8 - 1/4 in. (3 - 6.4 mm)
Fuel System Wheels / Brakes
Fuel System Type Bosch M17 EFI Front Wheel Size 12 x 6 Aluminum
Front Tire Type / Size Ancla / 25 x 8 R12
Fuel Delivery Electronic Fuel Pump (in tank)
Rear Wheel Size 12 x 8 Aluminum
Fuel Pressure 43-48 psi (296.5 - 331 KPA)
Rear Tire Type / Size Ancla / 25 x 10 R12
Fuel Filters In tank, See Chapter 4
Front: 10 psi (69 kPa)
Tire Pressure Rear: 12 psi (83 kPa)
7.25 gal. (27.4 liters)
Fuel Capacity / Requirement
87 Octane (minimum) Foot Actuated - 4 Wheel
Brake - Front / Rear
Electrical Hydraulic Disc
Alternator Max Output 650 Watts @ 7000 RPM Brake Fluid DOT 4
Headlights (INTL) 2 - Halogen: 55W Low / 60W High Parking Brake Equipped
Tail / Brake 2 - 6 Watts / 2 - 27 Watts
Turn Signals, Rear Diff. Control, CLUTCH CHART
INTL Features
Horn, Lic. Plate Light
Shift Drive
Starting System Electric Start Altitude
Weight Spring
Ignition System Bosch M17 (ECU Controlled)
0-1500 25-52 Black
Ignition Timing (Variable) ECU Controlled (0-5000) (5632409) (7043594)
Meters
RG4YCX / .0276” - .0315” (Feet)
Spark plug / Gap 1500-3700 25-48 Black
(.7 - .8 mm)
(5000 - 12000) (5632408) (7043594)
Yuasa YB14-B2 /
Battery (RZR)
14 Amp Hr. / 12 Volt
Instrument Type Multifunction Instrument Cluster
DC Outlet Standard 12 Volt
EFI / Chassis / Fan / Fuel Pump /
Relays
Headlight
Circuit Breaker Fan Motor: 20 Amp
Drive / Fuel Pump: 10 Amp
Fuses (Fuse/Relay Box)
Lights / EFI / Accessory: 20 Amp
EFI: 30 Amp
Fuses (Power Fuse Holder)
Chassis: 30 Amp

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 GENERAL INFORMATION

MISC. SPECIFICATIONS AND CHARTS

Conversion Table

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

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 GENERAL INFORMATION
Standard Bolt Torque Specification

1
Grade 2 Grade 5 Grade 8

Grade 2 Grade 5 Grade 8

Bolt Size
Ft. Lbs. (Nm) Ft. Lbs. (Nm) Ft. Lbs. (Nm)

1/4-20 5 (7) 8 (11) 12 (16)

1/4-28 6 (8) 10 (14) 14 (19)
5/16-18 11 (15) 17 (23) 25 (35)
5/16-24 12 (16) 19 (26) 29 (40)
3/8-16 20 (27) 30 (40) 45 (62)
3/8-24 23 (32) 35 (48) 50 (69)
7/16-14 30 (40) 50 (69) 70 (97)
7/16-20 35 (48) 55 (76) 80 (110)
1/2-13 50 (69) 75 (104) 110 (152)
1/2-20 55 (76) 90 (124) 120 (166)

Metric Bolt Torque Specification

Grade

Bolt Size 4.6 4.8 8.8 / 8.9 10.9 12.9

Ft. Lbs. (Nm) Dry Threads

M3 .3 (.5) .5 (.7) 1 (1.3) 1.5 (2) 1.5 (2)

M4 .8 (1.1) 1 (1.5) 2 (3) 3 (4.5) 4 (5)
M5 1.5 (2.5) 2 (3) 4.5 (6) 6.5 (9) 7.5 (10)
M6 3 (4) 4 (5.5) 7.5 (10) 11 (15) 13 (18)
M8 7 (9.5) 10 (13) 18 (25) 26 (35) 33 (45)
M10 14 (19) 18 (25) 37 (50) 55 (75) 63 (85)
M12 26 (35) 33 (45) 63 (85) 97 (130) 11 (150)
M14 37 (50) 55 (75) 103 (140) 151 (205) 177 (240)
M16 59 (80) 85 (115) 159 (215) 232 (315) 273 (370)
M18 81 (110) 118 (160) 225 (305) 321 (435) 376 (510)

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 GENERAL INFORMATION
SAE Tap / Drill Sizes Decimal Equivalents

Metric Tap / Drill Sizes

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 MAINTENANCE
CHAPTER 2
MAINTENANCE
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PERIODIC MAINTENANCE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2
BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PRE-RIDE - 25 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
50 - 500 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
GREASE LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
LUBRICANTS / SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 2.10
PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
SHIFT CABLE INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FUEL LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FUEL PUMP / FUEL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
VENT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
THROTTLE PEDAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
THROTTLE FREEPLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
ENGINE AND PVT INTAKE PRE-FILTER SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
ENGINE OIL AND FILTER SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
ENGINE BREATHER HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
ENGINE AND TRANSMISSION MOUNTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
COMPRESSION TEST SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
VALVE CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
EXHAUST - SPARK ARRESTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
TRANSMISSION AND FRONT GEARCASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
SPECIFICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
FRONT GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
COOLING SYSTEM EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
COOLING SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
COOLANT DRAIN / FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
FINAL DRIVE / WHEEL AND TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
WHEEL AND HUB TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
WHEEL REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
WHEEL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
DRIVE SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

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 MAINTENANCE
ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
BATTERY OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
ENGINE TO FRAME GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
STEERING WHEEL FREEPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
TIE ROD END / WHEEL HUB INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
WHEEL TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35
WHEEL TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36
SPRING PRELOAD ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36
BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37
BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37
BRAKE PAD / DISC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37
BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37
PARKING BRAKE CABLE ADJUSTMENT (INTL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38
PARKING BRAKE PAD INSPECTION (INTL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38

SPECIAL TOOLS
SPX Corporation: 1-800-328-6657 or on-line at http://polaris.spx.com/.

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 MAINTENANCE
PERIODIC MAINTENANCE CHART
Periodic Maintenance Overview
Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement
parts, use genuine Pure Polaris parts available from your Polaris dealer. 2
NOTE: Service a nd ad justments are critic al. If y ou’re no t fa miliar w ith sa fe s ervice a nd adjustment
procedures, have a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of
approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the
oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to
rise, discontinue use and determine the cause or see your dealer.

Break-In Period
The break-in period consists of the first 25 hours of operation, or the time it takes to use 14 gallons (53 liters) of fuel.
Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these
components.

• Drive vehicle slowly at first while varying the throttle position. Do not operate at sustained idle.
• Pull only light loads.
• Perform regular checks on fluid levels and other areas outlined on the daily pre-ride inspection checklist.
• Change both the engine oil and filter after 25 hours or one month.
• See “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 p erformed by a n
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.

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Pre-Ride - 25 Hour Maintenance Interval
Maintenance Interval
(whichever comes first)
Item Remarks
Miles
Hours Calendar
(KM)
 Steering - Pre-Ride -
 Front Suspension - Pre-Ride -
 Rear Suspension - Pre-Ride -
Tires - Pre-Ride -
 Brake Fluid Level - Pre-Ride -
Make adjustments as needed. 
 Brake Pedal Travel - Pre-Ride - See Pre-Ride Checklist on Page 2.10.
Brake Systems - Pre-Ride -
Wheels / Fasteners - Pre-Ride -
Frame Fasteners - Pre-Ride -
 Engine Oil Level - Pre-Ride -
E
 Air Filter - Pre-Ride - Inspect; replace as needed
E
Check level daily, change coolant every 2
Coolant Level - Daily -
years
Check operation; apply dielectric grease if
Head Lamp / Tail Lamp - Daily -
replacing
 Air Filter - Weekly - Inspect; replace as needed
E
 Brake Pad Wear 10 H Monthly 100 (160) Inspect periodically

 Brake Pad Wear / Inspect 10 H Monthly 100 (160) Inspect periodically
 Parking Brake Pads (INT’L)
 Parking Brake Cable 25 H - - Inspect; adjust tension after first 25 hours
 Adjustment (INT’L)
Battery 25 H Monthly 250 (400) Check terminals; clean; test
Front Gearcase Oil 
 25 H Monthly 250 (400) Inspect level; change yearly
(Demand Drive Plus)
Transmission - Main
 25 H Monthly 250 (400) Inspect level; change yearly
(AGL Gearcase Lubricant)
 Engine Oil Change 
25 H 1M 250 (400) Perform a break-in oil change at one month
E (Break-In Period)
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.

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 MAINTENANCE
50 - 500 Hour Maintenance Interval
Maintenance Interval
(whichever comes first)
Item Remarks
Miles
Hours Calendar


(KM)
2
Throttle Cable / Throttle Pedal 50 H 6M 300 (500) Inspect; adjust; lubricate; replace if necessary
E
Throttle Body Air Intake Ducts
E 50 H 6M 300 (500) Inspect ducts for proper sealing / air leaks
/ Flange
 General Lubrication 50 H 3M 500 (800) Lubricate all fittings, pivots, cables, etc.
Shift Linkage 50 H 6M 500 (800) Inspect, lubricate, adjust
 Steering 50 H 6M 500 (800) Lubricate
 Front Suspension 50 H 6M 500 (800) Lubricate
 Rear Suspension 50 H 6M 500 (800) Lubricate
Inspect coolant strength seasonally; pressure
Cooling System 50 H 6M 500 (800)
test system yearly
 Check for leaks at fill cap, fuel line / rail, andfuel
Fuel System 100 H 12 M 600 (1000)
E pump. Replace lines every two years.

Spark Plug 100 H 12 M 600 (1000) Inspect; replace as needed
E
Perform a break-in oil change at 25 hours or one

Engine Oil & Filter Change 100 H 6M 1000 (1600) month / always replace oil filter when changing
E
engine oil
 Parking Brake Cable
100 H 6M 1000 (1600) Inspect; adjust tension as needed
 Adjustment (INT’L)
Drive Belt 100 H 12 M 1000 (1600) Inspect; replace as needed
 Radiator / Cooling Hoses 100 H 12 M 1000 (1600) Inspect; clean external surfaces
 Engine Assembly Mounts 100 H 12 M 1000 (1600) Inspect, torque to specification
Exhaust Muffler / Pipe 100 H 12 M 1000 (1600) Inspect
Inspect for wear, routing, security; apply
 Wiring 100 H 12 M 1000 (1600) dielectric grease to connectors subjected to
water, mud, etc.
 Clutches (Drive and Driven) 100 H 12 M 1000 (1600) Inspect; clean; replace worn parts
 Front Wheel Bearings 100 H 12 M 1000 (1600) Inspect; replace as needed
 Shocks 100 H - - Visually inspect shock seals
 Brake Fluid 200 H 24 M 2000 (3200) Change every two years (DOT 4)
Spark Arrestor 300 H 36 M 3000 (4800) Clean out

Shocks 500 H 12 M - Change shock oil and seals


Valve Clearance Check 500 H - 5000 (8050) Inspect / Adjust as needed
E
Inspect periodically; adjust when parts are
 Toe Adjustment -
replaced
Headlight Aim - 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.

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 MAINTENANCE
Maintenance Quick Reference

III. # Item Lube Rec. Method Frequency*

Change after 1st month or first
25 hours of operation, 100 hours
Polaris PS-4 Plus
Add oil to proper level on thereafter; Change more often
1 Engine Oil Performance Synthetic 
dipstick (25 hours) in severe duty
4-Cycle Engine Oil
conditions or short trip cold
weather operation
Maintain coolant level in Check level daily, change
2 Engine Coolant Polaris 60/40 Coolant
coolant reservoir bottle coolant every 2 years
Maintain fluid level between Check level during pre-ride
3 Brake Fluid Polaris DOT 4 Brake Fluid “MAX and “MIN” lines on the inspection; change fluid every
master cylinder reservoir two years

* More often under severe use, such as operated in water or under severe loads.

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 MAINTENANCE
Maintenance Quick Reference

III. # Item Lube Rec. Method Frequency*

Add lubricant until it is visible Check level every 25 hours;
4 Front Gearcase Polaris Demand Drive Plus
2
at the fill hole threads change fluid yearly
Polaris AGL Plus Add lubricant until it is visible Check level every 25 hours;
5 Transmission
Gearcase Lubricant at the fill hole threads change lubricant yearly

* More often under severe use, such as operated in water or under severe loads.

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 MAINTENANCE
Grease Lubrication Points
There are greasefittings at each A-arms pivot point, each front or rear stabilizer bushing, and on the front propshaft yoke.
Apply grease until all traces of water have been purged out at each of these areas.

Item Recommended Lube Method Frequency

Front Propshaft Yoke(s) Grease before long periods
Grease fittings every 500 of storage, and after
A-arm Pivot Bushings Polaris Premium U-Joint Grease
miles (800 km). thoroughly washing or
Stabilizer Bar Bushings submerging the vehicle.

Prop Shaft

Rear Stabilizer Bar

Front Suspension

Front Stabilizer Bar

Rear Suspension

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 MAINTENANCE
LUBRICANTS / SERVICE PRODUCTS NOTE: Each item c an b e pu rchased se parately at
your local Polaris dealer.
Polaris Lubricants, Maintenance and Service
Products Part No. Description
Additives / Sealants / Thread Locking Agents / Misc.
Part No. Description
2871950
Loctite™ Threadlock 242  2
Engine Lubricant (6 ml.) (12 count)
2870791 Fogging Oil (12 oz. Aerosol) Premium Carbon Clean 
2871326
PS-4 Plus Synthetic 4-Cycle Engine Oil (12 oz.) (12 count)
2876244
(Quart) 2870652 Fuel Stabilizer (16 oz.) (12 count)
PS-4 Plus Synthetic 4-Cycle Engine Oil 2872189 DOT 4 Brake Fluid (12 count)
2876245
(Gallon)
2871557 Crankcase Sealant, 3-Bond 1215 (5 oz.)
Gearcase / Transmission Lubricants
AGL Plus Gearcase Lubricant NOTE: The nu mber co unt indicated by each part
2878068 number in th e t able above ind icates t he numbe r of
(1 Qt.) (12 Count)
units that are shipped with each order.
AGL Plus Gearcase Lubricant
2878069
(1 Gal.) (4 Count)
AGL Plus Gearcase Lubricant
2878070
(2.5 Gal.) (2 Count)
Demand Drive Plus 
2877922
(Quart)
Demand Drive Plus
2877923
(2.5 Gallon)
2870465 Oil Pump for 1 Gallon Jug
Grease / Specialized Lubricants
2871312 Grease Gun Kit
Premium All Season Grease 
2871322
(3 oz. cartridge) (24 Count)
Premium All Season Grease 
2871423
(14 oz. cartridge) (10 Count)
2871460 Starter Drive Grease (12 Count)
2871515 Premium U-Joint Lube (3 oz.) (24 Count)
2871551 Premium U-Joint Lube (14 oz.) (10 Count)
2871329 Dielectric Grease (Nyogel™)
Coolant
2871323 60/40 Coolant (Gallon) (6 Count)
2871534 60/40 Coolant (Quart) (12 Count)

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GENERAL VEHICLE INSPECTION AND MAINTENANCE

Pre-Ride / Daily Inspection Shift Cable Inspection / Adjustment
Perform the following pre-ride inspection daily, and when Shift c able a djustment m ay be ne cessary if sy mptoms
servicing the vehicle at each scheduled maintenance. include:

• Tires - check condition and pressures • No AWD or gear position display on instrument
cluster
• Fuel tank - fill to proper level
• Ratcheting noise on deceleration
• All brakes - check operation and adjustment
• Inability to engage into a gear
• Throttle - check for free operation and closing
• Excessive gear clash (noise)
• Headlights/Taillights/Brakelights - also check
operation of all indicator lights and switches • Gear selector moving out of desired range

• Ignition switch - check for proper function 1. Locate th e shift ca ble in th e r ear r ight-hand whe el
well area.
• Wheels - check for tightness of wheel nuts and
axle nuts; check to be sure axle nuts are secured
by cotter pins Shift Cable
Mount
• Air cleaner element - check for dirt; replace if
necessary.
Clevis Pin
• 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 Dust Boot Shift Cable

• Check all front and rear suspension components

for wear or damage. 2. Inspect shift cable, clevis pin, pivot bushings, and dust
boot. Replace if worn or damaged.

Frame, Nuts, Bolts, and Fasteners 3. If adjustment is required: Loosen jam nut (A), pull the
cable out of the mount and rotate jam nut (B).
Periodically inspect the tor que of all fasten ers in
accordance with the maintenance schedule. Check that all
cotter pins are in place. Refer to specific fastener torques
listed in each chapter.

Jam Nut (B)

Jam Nut (A)

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 MAINTENANCE
4. Adjust the shift cable so there is the same amount of Fuel Line
cable travel when shifting slightly past the detents of
HIGH (H) gear and PARK (P). 1. Check the quick-connect fu el line from th e en gine
fuel rail conn ection to th e fu el ta nk connection for
5. Thread jam nut (A) or (B) as required to obtain proper signs of wear, de terioration, da mage or leakag e.
Replace if necessary.
2
cable adjustment.

NOTE: This procedure may require a few attempts to Fuel Line

obtain the proper adjustment.

6. Once the p roper ad justment is obtained, place the

shift cable and jam nut (B) into the mount. Tighten jam
nut (A) against the mount.

7. Start engine and shift through all gears to ensure the

shift cable is properly adjusted. If transmission still
ratchets after cable adjustment, the transmission will
require service.

FUEL SYSTEM AND AIR INTAKE

2. Be sure fuel line is routed and retained properly.
Fuel System
IMPORTANT: Make sure line is not kinked or pinched.
WARNING 3. Replace fuel line every two years.

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 in loss of consciousness or
death in a short time.
Never drain the fuel when the engine is hot.
Severe burns may result.

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 MAINTENANCE
Fuel Pump / Fuel Filters Vent Lines
The RZR 57 0 e ngine u ses a se rviceable, hi gh-volume, 1. Check fuel tan k, fr ont gearcase an d transmission
high-pressure, fuel pump that includes a preliminary filter vent lines for signs of wear, deterioration, damage or
and a n in ternal fine filter located be fore th e p ump leakage. Replace every two years.
regulator.
2. Be sure vent lines are routed and secured properly.

Fuel Pump Asm IMPORTANT: Ensure lines are not kinked or pinched.

Throttle Pedal Inspection

If the throttle pedal has excessive play due to cable stretch
or cab le misadju stment, it wil l cause a dela y 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
Fuel Line the idle speed may be erratic.

NOTE: Neither f ilter is se rvicable individua lly. Mu st

replace the fuel pump as an assembly.

Throttle Pedal

Check the throttle pedal play periodically in accor dance

with the Periodic Maintenance Chart and adjust the play if
necessary.

NOTE: Refer to Chapter 4 for fuel pump replacement

and all other information related to the EFI System.

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 MAINTENANCE
Throttle Freeplay Adjustment 4. Re-tighten the jam nut after final adjustment is made.

Inspection 5. Apply a small am ount of grease to the inside of the

boot and slide it over the cable adjuster to its original
1. Place the transmission in the P (Park) position. position.

2
2. Start the engine, and warm it up thoroughly. 6. Reinstall the cargo box access panel.
3. Measure the distance the throttle pedal moves before
the en gine be gins to increase in RPM . Freeplay
should be 1/16” - 1/8” (1.5 - 3 mm). Engine and PVT Intake Pre-Filter Service
It is r ecommended that the e ngine and PVT intake pre-
Adjustment filter b e in spected daily. T he filter sho uld be inspe cted
1. Remove the car go box a ccess panel to ac cess the using the following procedure:
throttle body area.
NOTE: The engine and PVT inta ke pr e-filter is locate d
just above the left-rear wheel fender.

1. Press “IN” on the intak e grill cover tabs and remove

the pre-filter cover to access the pre-filters.

Pre-filter Cover

Throttle Body
Press In Tabs

2. Locate thro ttle ca ble o n the le ft-hand side o f the

throttle body. Slide back the cable adjuster boot.

B
2. Remove and insp ect the p re-filters. If ne cessary,
clean with soapy water and dry with compressed air.

Pre-Filters

Boot

3. Using an o pen-end wrench, lo osen the a djustment

jam nut (A). Using another open-end wrench, move
the cable adjuster (B) until 1/16” to 1/8” (1.5 - 3 mm)
of freeplay is achieved at the throttle pedal.

NOTE: While adj usting, li ghtly move th e t hrottle

3. Reinstall the dry pre-filter s an d inst all the pr e-filter
pedal in and out.
cover.

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 MAINTENANCE
Air Filter Service 4. Inspect the air filter element and replace if necessary.
Do not attempt to clean the air filter.
It is recommended that the air filter be inspected as part of
pre-ride inspection. In extremely dusty conditions, air filter NOTE: If the filter has been soaked with fuel or oil it
replacement will be required more often. must be replaced.

The filter shou ld be inspected using the following NOTE: Service more frequently if vehicle is operated
procedure: in wet cond itions o r at hig h th rottle ope ration f or
extended periods.

Installation

1. Clean the air box and air box cover thoroughly.

2. Place the filter into the air box with the air filter pleats
facing UP, as shown.

Removal

NOTE: The air box is located underneath the cargo box

access panel.

1. Thoroughly clean the air box area to remove dirt and 3. Carefully install air box cover and secure with the (6)
debris. clips.
2. Loosen hose clamp (A) and remove the intake hose
from the air box cover.
3. Unlatch the (6) clips and carefully remove the air box
Install Hose
cover. Be sure not to let the air box cover contact the
air filter element during removal.

Remove Hose
A

4. Reinstall the clea n intake h ose a nd tigh ten ho se

clamp (A).
5. Reinstall the cargo box access cover.

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 MAINTENANCE
Air Box / Air Filter Exploded View

Air Intake Duct

Clamp
Air Box Cover Clamp

2
Remove Hose From Air Box
Cover for Filter Removal

Engine Pre-filter

Air Filter

Clip (6)
Boot

PVT Pre-filter
Intake Baffle Box
Air Intake
Box Clamp

Grommets Drain

Mount Clamps

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 MAINTENANCE

ENGINE 8. Unscrew and remove dipstick and verify the oil level
is in the SAFE (XX) range. Add oil as indicated by the
level on the dips tick. D o not overfill (see N OTE
Engine Oil Level below!).
This single cylinder engine is a wet-sump engine, meaning
the o il is co ntained in t he bo ttom of th e cr ankcase. To
check the oil level follow the procedure listed below:

IMPORTANT: Thoroughly clean engine around the oil

drain plug, oil filte r and oil dip stick to prevent Maintain Oil Level In SAFE Range
contamination from entering the engine.
DO NOT Overfill the Engine
1. Position vehicle on a level surface.

2. Place the transmission in Park (P).

NOTE: A rising oil level bet ween ch ecks in cool
3. Be sure engine OFF has not been run for at lease 3 weather driving can indicate contaminants suc h as
minutes. gas or moisture collecting in the crankcase. If the oil
level is ov er t he f ull mar k, cha nge t he o il
IMPORTANT: Do not run the machine and then immediately.
immediately check the oil level.
9. Reinstall the dipstick and hand tighten.
4. Locate the engine oil dipstick:

• RZR 570 - Located on the right-hand side of the

Engine Oil and Filter Service
engine case; accessible through the right- Always change engine oil and filter at the intervals outlined
hand rear wheel well area. in the Periodic Maintenance Chart. Always change the oil
filter whenever changing the engine oil.

IMPORTANT: Thoroughly clean engine around the oil

drain plug, oil f ilter an d oil dipst ick t o prev ent
contamination from entering the engine.

WARNING

Personal injury can occur when handling used

oil. Hot oil can cause burns or skin damage.

Recommended Engine Oil:

PS-4 Plus Synthetic 4-Cycle Engine Oil

5. Thoroughly clean the engine around dipstick area.
(PN 2876244) (Quart)
6. Unscrew / remove dipstick and wipe dry with a clean
cloth.
1. Position vehicle on a level surface.
7. Reinstall the dipstick completely. 2. Place the transmission in PARK (P).
NOTE: Make certain th e dipst ick is thr eaded all the
way into the engine case.

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 MAINTENANCE
3. If needed, start the engine and allow it to idle for three 11. Lubricate O-ring on n ew filter with a film o f fre sh
minutes until warm. Stop the engine. engine oil. Check to make sure the O-ring is in good
condition.
4. Place a d rain pa n b eneath e ngine cr ankcase a nd
remove the drain plug. 12. Install new filter an d tur n b y hand u ntil filter gasket
contacts the sealing surface, then turn an additional
NOTE: Drain plug is accessed
through the skid plate.
1/2 turn.
13. Remove the engine o il dipstick (see “Eng ine Oil
2
Level”).
14. Using a long funnel, fill the sump with 2 qts. (1.9 l) of
PS-4 Plus Synthetic Engine Oil (2876244).

Drain Plug
=T
Crankcase Drain Plug Torque:
12 ft. lbs. (16 Nm)

Oil Filter Torque:

Turn by hand until filter gasket contacts sealing
CAUTION surface, then turn an additional 1/2 turn

Oil Filter Wrench:

Oil may be hot. Do not allow hot oil to come into
PU-50105: 2.5” (64 mm)
contact with skin, as serious burns may result.

5. Allow oil to drain completely. 15. Verify the transmission is still positioned in PARK (P).

6. Replace sealing washer on drain plug. 16. Start the engine and let it idle for two minutes.

NOTE: The sealing surface on the drain plug should 17. Stop the engine and inspect for leaks.
be clean and free of burrs, nicks or scratches. 18. Re-check the oil level on the dipstick and add oil as
7. Reinstall drain plug and torque to 12 ft. lbs. (16 Nm). necessary to bring the level to the upper mark on the
dipstick.
8. Place a drain pan under vehicle below the oil filter.
19. Dispose of used oil and oil filter properly.
9. Place shop towels beneath oil filter. U sing Oil Filter
Wrench (PU-50105) and a 3/8” extension, turn the oil
filter counter-clockwise to remove it.

Oil Filter

10. Using a clean dry cloth, clean filter sealing surface on

the crankcase.

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 MAINTENANCE
Engine Breather Hose Inspection Valve Clearance Inspection
The engine is equipped with a breather hose. Inspect the IMPORTANT: Valve cl earance i nspection should be
breather hose fo r po ssible kinks or we ar. The hose is performed on a cold engine, at room temperature.
form fitted for a proper fit. Follow the breather hose from 1. Remove the seats and disconn ect th e ne gative ( -)
the engine crankcase to the a ir intake baffle box on the battery cable. 
left-hand rear fender panel.
2. Remove the cargo box access panel.
Breather 3. Remove the spar k plug wire from the en gine an d
Hose
remove the spark plug. Place a clean shop towel into
the spark plug tube to prevent debris from entering the
combustion chamber.

4. Remove the (3) T40 bolts retaining the valve cover.

5. Remove the valve cover from the engine out of the

right-hand rear wheel well area.

NOTE: Make sure line is not kinked or pinched.

Engine and Transmission Mounts

Periodically inspect engine and transmission mounts for
cracks or damage.

Refer to Chapter 3 “Engine Assembly and Installation” for

mounting fastener torque values.

Compression Test Specification 6. Remove the outer PVT cover and drive belt as shown
in chapter 6.
NOTE: This en gine does ha ve decompression
components.

A smooth idle generally indicates good compression. Low

engine compression is rarely a factor in running condition
problems above idle speed.

Cylinder Compression:
80 - 120 psi (decompression)

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 MAINTENANCE
7. Rotate th e drive clu tch co unter-clockwise until the 9. If the valve clearance is out of specification, proceed
cam chain sprocket timing marks are aligned with the to “Valve Clearance Adjustment” (see Chapter 3).
gasket sur face as sho wn (see Ch apter 3 for mo re
TDC setting procedures).
IMPORTANT: Intake ca m s procket sh ould ha ve “I” = In. / mm.
marks aligned with ga sket surface a nd the ex haust
cam spr ocket shou ld hav e “E” ma rks aligned with 2
gasket surface. Intake Valve Clearance (cold):
.005-.007 in. (0.125-0.175 mm)

Image for Reference Only

= In. / mm.

Exhaust Valve Clearance (cold):

I E E .008-.010 in. (0.152-0.254 mm)
I

10. Repeat steps 8- 9 u ntil all (4) valves h ave b een

inspected.

11. Inspect the valve cover seal and replace if necessary.

12. Install the valve cover and spark plug as outlined in

Chapter 3.
8. Measure the valve clearance of each valve using a
thickness (feeler) gauge. Record the measurement if 13. Install d rive b elt an d o uter clu tch cover a nd ( 8)
clearance is out of specification. retaining screws (see Chapter 6)

=T
Outer Clutch Cover Screws:
45-50 in. lbs. (5 Nm)

14. Connect the negative (-) battery cable to the battery.

15. Start the engine to ensure proper operation.

16. Reinstall the cargo box access panel and seats (see
Chapter 5).

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 MAINTENANCE
Exhaust - Spark Arrestor

WARNING

Do not clean spark arrestor immediately after the

engine has been run, as the exhaust system
becomes very hot. Serious burns could result from
contact with the exhaust components. Allow
components to cool sufficiently before proceeding.
Wear eye protection and gloves.
Never run the engine in an enclosed area. Exhaust
contains poisonous carbon monoxide gas that can
cause loss of consciousness or death in a very
short time.

Periodically clean spark arrestor to remove accumulated carbon.

1. Allow engine and exhaust system to completely cool.

2. Remove the retaining screw, washer and spark arrestor from the end of the silencer.

3. Use a non-synthetic brush to clean the arrestor screen.

4. Inspect the screen for wear and damage. Replace if needed.

5. Reinstall the arrestor and torque the screw to 40 in. lbs. (4.5 Nm).

40 in. lbs.
(4.5 Nm)

Gaskets and Seals -

Replace Each Time Component is Removed

18 ft. lbs. 18 ft. lbs.

(24.5 Nm) (24.5 Nm)

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 MAINTENANCE
TRANSMISSION AND FRONT GEARCASE
Specification Chart

Gearcase Lubricant Capacity Fill / Drain Plug Torque

Transmission AGL Plus Gearcase Lubricant 44 oz. (1300 ml) 10-14 ft. lbs. (14-19 Nm) 2
Transmission (INTL) AGL Plus Gearcase Lubricant 41 oz. (1200 ml) 10-14 ft. lbs. (14-19 Nm)
Front Gearcase Demand Drive Plus 6.75 oz. (200 ml) 8-10 ft. lbs. (11-14 Nm)

Transmission Lubrication
NOTE: It is important to f ollow t he t ransmission 3. If lubricant level is not even with the bottom threads,
maintenance inte rvals de scribed in the Periodic add the r ecommended lu bricant a s needed. Do n ot
Maintenance Chart . Regular lu bricant leve l overfill.
inspections should be performed as well.
4. Reinstall the fill plug and torque to specification.
The transmission lubricant level shou ld be che cked and
changed in accordance with the maintenance schedule.
=T
• Be sur e ve hicle is po sitioned on a level su rface
when checking or changing the lubricant. Fill / Drain Plug Torque:
• Check vent hose to be sure it is routed properly 10-14 ft. lbs. (14-19 Nm)
and unobstructed.

Transmission Lubricant Level Check

The fill plug is located on the rear portion of the
transmission gearcase. Access the fill plug at the rear of
the vehicle. Maintain lubricant level even with the bottom
of the fill plug hole.

1. Position vehicle on a level surface.

2. Remove the fill plug and check the lubricant level.

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 MAINTENANCE
Transmission Lubricant Change 6. Add the r ecommended am ount of lub ricant thro ugh
the fill plug hole. Maintain the lubricant level at the
The drain plug is located on the bottom of the transmission
bottom of the fill plug hole w hen filling the
gearcase. Access the drain plug through the drain hole in
transmission. Do not overfill.
the skid plate.

1. Remove the fill plug (refer to “Transmission Lubricant

Level Check”). =
2. Place a drain pan under the transmission drain plug. Recommended Transmission Lubricant:
AGL Plus Gearcase Lubricant
3. Remove d rain p lug and allo w lub ricant to dr ain
(PN 2878068) (Quart)
completely.
Capacity: 44 oz. (1300 ml)

Capacity (INTL): 41 oz. (1200 ml)

7. Reinstall fill plug with a new O-r ing a nd tor que to

specification.

=T
Fill / Drain Plug Torque:
10-14 ft. lbs. (14-19 Nm)

8. Check for leaks. Dispose of used lubricant properly.

4. Clean the drain plug magnetic surface.

5. Reinstall drain plug with a new O-ring and torque to

specification.

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 MAINTENANCE
Front Gearcase Lubrication 4. Reinstall the fill plug and torque to specification.

NOTE: It is important to fo llow the fro nt gea rcase

maintenance inte rvals de scribed in the Periodic =T
Maintenance Chart . Regular fluid leve l ins pections
should be performed as well.
2
Fill / Drain Plug Torque:
8-10 ft. lbs. (11-14 Nm)
The fron t gearcase fluid le vel should be checked and
changed in accordance with the maintenance schedule.
Front Gearcase Fluid Change:
• Be sur e ve hicle is po sitioned on a level su rface
when checking or changing the fluid. The d rain pl ug is locate d on th e bo ttom of th e fro nt
• Check vent hose to be sure it is routed properly gearcase. Access the drain plug through the access hole
and unobstructed. in the frame underneath the front gearcase.

1. Remove the fill plug (refer to “Front Gearcase Fluid

Front Gearcase Fluid Level Check Level Check”).
The fill plug is located on the bottom right side of the front 2. Place a drain pan under the front gearcase drain plug.
gearcase. Access the fill plug through the right front wheel
well. Maintain fluid level even with the bottom of the fill plug 3. Remove th e dr ain plug and allo w fl uid to drain
hole. completely.
1. Position vehicle on a level surface.

2. Remove the fill plug and check the fluid level.

4. Clean the drain plug magnetic surface.

5. Reinstall drain plug with a new O-ring and torque to

specification.

3. If fluid level is not even with the bottom threads, add

the recommended fluid as needed. Do not overfill.

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 MAINTENANCE
6. Add the recommended amount of fluid through the fill
hole. Maintain the fluid le vel ev en wit h t he b ottom
threads of the fill plug hole.

Recommended Front Gearcase Fluid:

Polaris Demand Drive Plus
(PN 2877922) (Quart)

Capacity: 6.75 oz. (200 ml)

7. Reinstall fill plug with a new O- ring an d tor que to

specification.

=T
Fill / Drain Plug Torque:
8-10 ft. lbs. (11-14 Nm)

8. Check for leaks. Dispose of used fluid properly.

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 MAINTENANCE
COOLING SYSTEM
Cooling System Exploded View

Upper Engine Hose

2
Water Pump

Bypass Hose

Upper Radiator
Hose

Lower Engine Cooling Fan

Hose

Recovery
Bottle

Radiator

Pressure Cap

Filler Neck

Hoses

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 MAINTENANCE
Cooling System Overview 4. If the coolant level is below the MIN line, inspect the
coolant level in the radiator.
The engine coolant level is controlled, or maintained, by
the recovery system. The re covery syst em components NOTE: If o verheating is e vident, allow system to
are the recovery bo ttle, radiator filler neck, radiator cool comp letely and ch eck coolant leve l in th e
pressure cap and connecting hose. radiator and inspe ct f or s igns of trapped a ir in
system.
As coola nt op erating tem perature in creases, the
expanding ( heated) excess coola nt is for ced o ut of the WARNING
radiator past the pressure cap and into the recovery bottle.
As engine coolant temperature decreases the contracting
Never remove the pressure cap when the
(cooled) coolant is drawn back up from the tank past the
engine is warm or hot. Escaping steam can
pressure cap and into the radiator.
cause severe burns. The engine must be cool
NOTE: Some coolant level drop on new machines is before removing the pressure cap.
normal as the system is purging itself of trapped air.
5. Remove the pr essure ca p. Using a funnel, ad d
Observe coolan t lev els of ten during the brea k-in
coolant to the top of the filler neck.
period.
6. Reinstall the pressure cap.
NOTE: Overheating of engine could oc cur if air is
not fully purged from system. NOTE: Use of a non-standard pressure cap will not
allow the recovery system to function properly.
Polaris Premium 60/40 is already premixed and ready to 7. Remove recovery bottle cap and add coolant using a
use. Do not dilute with water. funnel.

Coolant Level Inspection 8. Fill recov ery bottle to M AX level w ith Polaris 60/40
premix Anti Freeze/Coolant or 50/50 or 60/40 mixture
The pressure cap and recovery bottle are located under of antifreeze and distilled water as required for freeze
the front hood of the vehicle. The coolant level must be protection in your area.
maintained be tween th e min imum and ma ximum le vels
9. Reinstall the recovery bottle cap.
indicated on the recovery bottle.
10. If co olant was re quired, sta rt eng ine an d check for
leaks. Ma ke su re radiator fins ar e clea n to pre vent
Recovery Bottle overheating.

Pressure Cap Cooling System Pressure Test

Refer to Ch apter 3 fo r co oling sy stem pressure tes t
procedure.

With the en gine at o perating temp erature, the coolant

level should be between the upper and lower marks on the
coolant re covery bo ttle. If no t, per form the fo llowing
procedure:

1. Position the vehicle on a level surface.

2. Remove the hood from the front cab.
3. View the coolant level in the recovery bottle.

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 MAINTENANCE
Coolant Strength / Type Coolant Drain / Fill
Test th e str ength of the co olant u sing a n an tifreeze Coolant Drain
hydrometer.
1. Remove the hood from the front cab.

WARNING 2
Antifreeze Hydrometer
Never drain the coolant when the engine and
radiator are warm or hot. Hot coolant can cause
• A 50/50 or 60/40 mixture of antifreeze and distilled severe burns. Allow engine and radiator to cool.
water will provide the optimum c ooling, corrosion
protection, and antifreeze protection.
2. Slowly remove the pressure cap to relieve any cooling
• Do n ot use t ap water , stra ight a ntifreeze, or system pressure.
straight water in th e system. T ap water co ntains
3. Place a su itable drain pan underneath the rad iator
minerals an d impu rities wh ich build up in the
fitting on the front right-hand side of the vehicle.
system.

• Straight water or antifreeze may cause the system 4. Drain the coolant from the radiator by rem oving the
lower co olant ho se fro m the ra diator a s shown.
to freeze, corrode, or overheat.
Properly dispose of the coolant.

Polaris Premium Antifreeze

2871534 - Quart
2871323 - Gallon

Cooling System
1. Inspect a ll ho ses fo r cracks, d eterioration, a brasion
or leaks. Replace if necessary.

Drain Here
CAUTION

Do not over-tighten hose clamps at radiator,

or radiator fitting may distort, causing a 5. Allow coolant to completely drain.
restriction to coolant flow.
Radiator hose clamp torque is 36 in. lbs. (4 Nm). 6. Place a su itable d rain pan underneath t he lo wer
engine hose on the right-hand rear side of the vehicle.
2. Check tightness of all hose clamps.

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 MAINTENANCE
7. Remove the h ose and completely drain the engine. FINAL DRIVE / WHEEL AND TIRE
Reinstall the lower coolant hose.
8. Properly dispose of the coolant. Wheel and Hub Torque Table
9. Remove the pressure cap. Using a funnel, add the
recommended coolant to the top of the filler neck and
fill the recovery bottle to the MAX level. =T
10. Refer to Chapter 3 for the “Cooling System Bleeding
Wheel Nuts:
Procedure”.
Steel Wheels: 27 ft. lbs. (37 Nm)
Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn)
Polaris Premium Antifreeze
2871534 - Quart
2871323 - Gallon =T
Hub Retaining Nuts:
80 ft. lbs. (108 Nm)

NOTE: Do not lubricate the stud or the lug nut.

Wheel Removal
1. Position the vehicle on a level surface.

2. Place the tra nsmission in PARK (P) and stop th e

engine.

3. Loosen the wheel nuts slightly. If wheel hub removal

is required, remove the cotter pin and loosen the hub
nut slightly.

4. Elevate the appropriate side of the vehicle by placing

a suitable stand under the frame.

5. Remove the wheel nuts and remove the wheel.

6. If hub removal is re quired, remove the hub nut and

washers.

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 MAINTENANCE
Wheel Installation Tire Inspection
1. Verify the transmission is still in PARK (P). • Improper tire inflation may affect vehicle
maneuverability.
2. Install th e wh eel hub, washe rs, an d hub n ut, if
previously removed. • When replacing a tire always use original

3. Place the wheel in the correct position on the wheel

equipment size and type. 2
hub. Be sure the valve stem is toward the outside and • The use of non-standard size or type tires may
rotation arrows on the t ire point towa rd fo rward affect vehicle handling.
rotation.

4. Attach the wheel nuts and finger tighten them. WARNING

5. Carefully lower the vehicle to the ground. Operating with worn tires will increase the
6. Torque the whee l nuts and/or hub nut to the proper possibility of the vehicle skidding easily with
torque specification listed in th e tor que table at the possible loss of control.
beginning of this section.
7. If hub nut was removed, install a new cotter pin after Worn tires can cause an accident.
the hub nut has been tightened.
Always replace tires when the tread depth
Use a new measures 1/8", (.3 cm) or less.
Note cotter pin
Tire Rotation
(RZR Only) Tire Tread Depth
Replace tires when tread depth is worn to 1/8" (3 mm) or
less.
Hub Nut

Tread
Depth 1/8" (3 mm)

Valve stem
Wheel Nuts (4) facing outward

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.

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 MAINTENANCE
Tire Pressure ELECTRICAL AND IGNITION SYSTEM
CAUTION Battery Maintenance
Keep battery terminals and connections free of corrosion.
Maintain proper tire pressure. If cleaning is necessary, remove the corrosion with a stiff
Refer to the warning tire pressure decal wire brush. Wash with a solution of one tablespoon baking
applied to the vehicle. soda and one cup water. Rinse well with tap water and dry
off with c lean shop towels . Coat the terminals with
dielectric grease or petroleum jelly.
Tire Pressure Inspection (Cold)
Front Rear
10 psi (55 kPa) 12 psi (55 kPa) WARNING

Drive Shaft Boot Inspection CALIFORNIA PROPOSITION 65 WARNING:

Batteries, battery posts, terminals and related
Inspect the drive shaft boots for damage, tears, wear or accessories contain lead and lead compounds,
leaking grease. If the boots exhibit any of these symptoms, and other chemicals known to the State of
they should be replaced. Refer to Chapter 7 for drive shaft California to cause cancer and birth defects or
boot replacement. other reproductive harm.
WASH HANDS AFTER HANDLING.
Front Boots
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.
Rear Boots
NOTE: Batteries must be fully charged before use or
battery life will b e re duced by 10 -30% of fu ll
potential. Ch arge battery acc ording t o “Charging
Procedure” provided in Cha pter 1 0. Do not u se the
vehicle’s stator/alternator to charge a new battery.

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 MAINTENANCE
Battery Removal Battery Installation
1. Remove the driver’s seat to access the battery. IMPORTANT: Using a new battery that has not been
fully charged can damage the battery and result in a
shorter life . It can a lso hinder v ehicle pe rformance.
Follow the battery charging procedure in Chapter 10
“Electrical” before installing the battery. 2
1. Ensure the battery is fully charged.

2. Place the battery in the battery holder and secure with

hold-down strap.

3. Coat the terminals with dielectric grease or petroleum

jelly.

4. Connect and tighten the (2) red (positive) cables first.

2. Disconnect the (2) black (negative) battery cables. 5. Connect a nd tighten the ( 2) black ( negative) cable
last.
3. Disconnect the (2) red (positive) battery cables.

4. Remove the hold-down strap and lift th e battery out

of the vehicle.

CAUTION

To reduce the chance of sparks: Whenever

removing the battery, disconnect the black
(negative) cable first. When reinstalling the
battery, install the black (negative) cable last.

6. Verify that cables are properly routed and reinstall the

driver’s seat.

Battery Off Season Storage

Refer to Chap ter 10 “Electrical” for o ff sea son stor age
procedures.

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 MAINTENANCE
Spark Plug Service 8. Measure gap with a wire gauge. Adjust gap if
necessary by carefully bending the side electrode.
1. Remove the dr iver’s sea t a nd d isconnect th e ( -)
negative battery cable from the battery. Spark Plug Gap
2. Remove cargo box access panel.

WARNING

A hot exhaust system and engine can cause Gap - .0276 - .0315" (0.7 - 0.8 mm)
serious burns. Allow engine to cool or wear
protective gloves when removing the spark plugs.
9. If n ecessary, r eplace spa rk p lug with p roper type.
CAUTION: Severe engine damage may occur if the
3. Clean top of engine to remove all dirt and debris.
incorrect spark plug is used.
4. Remove the spark plug wire from the engine.
10. Apply Anti-seize compound to the spark plug threads.
11. Install spark plugs and torque to specification.

Recommended Spark Plug:

Champion RG4YCX

Spark Plug Torque:

7 ft. lbs. (10 Nm)
Apply Anti-seize

Note for
12. Install spark plug wire into spark plug / engine.
reassembly
13. Reinstall cargo box access panel.
5. Remove spark plug. 14. Reinstall the (- ) negative b attery cab le a nd driver’s
seat.
6. 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

7. Clean with electrical contact cleaner only.

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 MAINTENANCE
Engine To Frame Ground STEERING
Inspect ground cable connections. Be sure they are clean
Steering Inspection
and tight.
The steering components should be checked periodically
The engine ground cable runs from the upper starter motor
2
for lo ose fa steners, wor n tie ro d e nds, b all jo ints, and
mounting bolt to the chassis ground terminal. damage. Also ch eck to make sure all co tter pin s ar e in
place. If cotte r p ins are re moved, they mu st no t be re–
The Chassis ground is located under the drivers seat, near
used. Always use new cotter pins.
the starter solenoid.
Replace any wor n or da maged steer ing com ponents.
Steering should move freely through the entire range of
travel without binding. Check routing of all cables, hoses,
and wirin g to b e sur e the steer ing mech anism i s n ot
restricted or limited.

NOTE: Whenever s teering c omponents are

replaced, check front end alignment.

WARNING
Engine
Ground Cable Due to the critical nature of the procedures
outlined in this chapter, Polaris recommends
steering component repair and adjustment be
performed by an authorized Polaris
MSD certified technician.
Use only genuine Polaris replacement parts.
Chassis
Ground Terminal

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 MAINTENANCE
Steering Wheel Freeplay Tie Rod End / Wheel Hub Inspection
Check t he st eering wh eel f or specified freeplay and • To check for play in the tie rod end, grasp the
operation. steering tie rod, pull in all directions feeling for
movement.
1. Position the vehicle on level ground.
2. Lightly turn the steering wheel left and right.
3. There should be 0.8”-1.0” (20-25 mm) of freeplay.
4. If there is exce ssive fr eeplay or the stee ring feels
rough, inspect the following components.
• Tie Rod Ends
• Steering Shaft U-Joints
• Steering Gearbox

U-Joints
Tie Rod

Tie Rod
Gearbox • Replace any worn steering components. Steering
should move freely through entire range of travel
without binding.

• Elevate fr ont end of mach ine so front wh eels ar e

off the ground. Che ck fo r a ny lo oseness in fr ont
hub/wheel assembly by g rasping 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.

Check for Loose Wheel or Hub

• If abnormal movement is detected, inspect the hub

and whe el assemb ly to deter mine the cau se
(loose wheel nuts or loose front hub nut).

• Refer to Chap ter 7 “ Final Drive” for fro nt hu b

service procedures.

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 MAINTENANCE
Wheel Toe Alignment Inspection Wheel Toe Adjustment
1. Place ma chine o n a smooth le vel su rface and set If to e alig nment is inco rrect, mea sure th e dist ance
steering wh eel in a str aight ah ead position . Se cure between vehicle center and each wheel. This will tell you
the steering wheel in this position. which tie rod needs adjusting.

2. Place a chalk mark on the center line of the front tires

approximately 10” (25.4 cm) from the floor or as close
2
to the hub/axle center line as possible.

NOTE: It is impor tant t he h eight of b oth mark s be

equally positioned to get an accurate measurement.

3. Measure the distance between the marks and record

the measurement. Call this measurement “A”.
NOTE: Be sure st eering wheel is st raight ahead
4. Rotate the tires 180 ° by moving the vehicle forward.
before determining which tie rod needs adjustment.
Position chalk marks facing rearward, even with the
hub/axle center line.
CAUTION
5. Again measure the distance between the marks and
record. Call t his m easurement “ B”. Su btract
measurement “ B” from me asurement “ A”. The During tie rod adjustment, it is very important that
difference between measurements “A” and “B” is the the following precautions be taken when
vehicle toe alignment. The recommended vehicle toe tightening tie rod end jam nuts.
tolerance is 1/ 8”, t o 1/4”, ( .3 to .6 cm) toe out. This If the rod end is positioned incorrectly it will not
means the measurement at the front of the tire (A) is pivot, and may break.
1/8”, to 1/4”, (.3 to .6 cm) wider than the measurement
at the rear (B).

= In. / mm.

Wheel Toe-Out:
(A) - (B) = 1/8 - 1/4" (.3 to .6 cm)

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 MAINTENANCE
To adjust toe alignment: SUSPENSION
• Hold tie rod end to keep it from rotating.
Spring Preload Adjustment
• Loosen jam nuts at both end of the tie rod.
The front and rear shock absorber springs are adjustable
• Shorten or lengthen the tie rod until alignment is as by rotating the adjustment cam to change spring tension
required to achieve the pr oper toe settin g as preload.
specified in “Wheel Toe Alignment”.

• IMPORTANT: When tightening the tie rod end jam WARNING

nuts, the rod ends must be held parallel to prevent
rod e nd da mage and p remature wear. Dama ge Uneven adjustment may cause poor handling of the
may not be immed iately app arent if done vehicle, which could result in an accident and
incorrectly. serious injury or death. Always adjust both the left
and right spring preloads equally.
• After alignment is complete, torque jam nuts to
specification. Suspension Spring Adjustment
1. Position the vehicle on a lev el surface and stop the
=T engine.

Tie Rod Jam Nut Torque: 2. Raise and safely su pport th e fr ont or rear of th e
12-14 ft. lbs. (16-19 Nm) vehicle off the ground to allow the suspension to fully
extend.

NOTE: The tires should not be touching the ground.

3. To adjust the suspension, rotate the adjustment cam

clockwise to incr ease spr ing ten sion or counter-
clockwise to decrease spring tension.

Increase
Preload
Cam

Decrease
Preload

Shock Spanner Wrench

(PN 2871095)

4. Each notch of the adjustment will add 6% - 8% more

preload to the spring over the primary position.

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 MAINTENANCE
BRAKE SYSTEM Brake Pad / Disc Inspection
1. Check the br ake pa ds for wear, dam age, or
Brake Fluid Inspection
looseness.
Always check the brake pedal travel and inspect the brake
2. Inspect th e br ake p ad we ar su rface for e xcessive
2
fluid reservoir level before each operation. If the fluid level
is low, add DOT 4 brake fluid only. wear.

Brake fluid should be changed every two years. The fluid 3. Pads should be changed when the friction material is
should also be chan ged anytime th e fluid becomes worn to .040” (1 mm).
contaminated, the fluid level is below the minimum level,
or if th e type and br and of th e flu id in the reservoir is
unknown.

The brake fluid master cylinder reservoir can be accessed

through the left front wheel well.

1. Position the vehicle on a level surface.

2. Place the transmission in PARK (P). Measure Pad Material

Thickness Service Limit:
3. View the brake fluid level in the reservoir. The level .040" (1 mm)
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. 4. Check surface condition of the brake discs.

5. Install th e re servoir ca p and apply the br ake pe dal 5. Measure the th ickness o f the front an d re ar bra ke
forcefully fo r a fe w se conds a nd ch eck for fluid discs.
leakage ar ound the master cylind er fittings an d the
brake caliper fittings. 6. The disc(s) should be replaced if thickness is less than
.170” (4.32 mm).

Measure Brake Disc Thickness

Maximum
Minimum
Rear Front
Master Cylinder Disc Disc

Service Limit:
.170" (4.32 mm)

Brake Hose and Fitting Inspection

Check b rake system hoses and fitting s for cracks,
deterioration, ab rasion, an d leaks. Tighten an y loo se
fittings and replace any worn or damaged parts.

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 MAINTENANCE
Parking Brake Cable Adjustment (INTL) Parking Brake Pad Inspection (INTL)
When the parking brake is fully engaged and “BRAKE” is Inspect t he p arking br ake ca liper br ake p ad thickness.
displayed on the instrument clu ster, en gine spe ed is Replace brake pads if damaged or worn beyond service
limited to 1500 RPM while ingear. If throttle is applied, this limit. Replac e caliper ass embly if damage or excessive
limiting fea ture pr events op eration, wh ich pr otects the wear is found. Refer to the following image for brake pad
parking brake pads from excessive wear. specifications.

NOTE: Inspect the parking brake cable tension after

the first 25 hours of operation and every 100 hours Outboard Inboard
of operation af terwards to ens ure prop er cab le Pad Pad
tension.

Loss of tension in the p arking brake cable will caus e

illumination of the parking brake indicator and activationof
the limiting feature. If this occurs, inspect an d a djust
parking brake cable tension. If p erforming this service is
difficult due to conditions o r location , temporarily
disconnect the parking brake switch electrical connector.
Reconnect th e co nnector as so on as practicable an d
adjust the parking brake cable to proper tension.

1. Pull back on the parking brake lever (located in dash).

2. After 3 t o 4 clic ks “BRAKE ” should display on the
instrument cl uster a nd th e whe els of the vehicle
should not rotate when turning by hand. After 8 full Outboard Pad Thickness Inboard Pad Thickness
clicks of lever travel, the vehicle should not roll while New 0.250” (6.35 mm) New 0.300” (7.62 mm)
Limit: 0.190” (4.83 mm) Limit: 0.240” (6.10 mm)
parked.
3. If the vehicle moves, adjustment is necessary.
4. Adjust the pa rking brake cable wh ere th e ca ble
attaches to the caliper mount / shift cablebracket. The
mount bracket is located on the right-hand side of the
transmission.

Adjustment Procedure: Refer to Chapter 9 “Brakes”

for complete adjustment procedure.

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 ENGINE / COOLING SYSTEM
CHAPTER 3
ENGINE / COOLING SYSTEM
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
ENGINE OIL FLOW CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
ENGINE SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6

3
ENGINE SPECIFICATIONS - 1204286 RZR570HO-11 . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
ENGINE DETAIL - TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES . . . . . . . . 3.8
MAIN ENGINE COMPONENTS - TORQUE SPECIFICATION AND SEQUENCE . . . . . 3.8
CRANKCASE / TIMING CHAIN GUIDES / OIL PICKUP / REGULATOR VALVE . . . . . . 3.9
CYLINDER / OIL FILTER / OIL PUMP / BREATHER. . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / IDLER GEARS / STATOR COVER. 3.11
SPARK PLUGS / STARTER / THROTTLE BODY / VALVE COVER . . . . . . . . . . . . . . . 3.12
PISTON / CRANKSHAFT / BALANCE SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
COOLING SYSTEM EXPLODED VIEW AND COOLANT FLOW DIAGRAM. . . . . . . . . 3.14
COOLING SYSTEM SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
PRESSURE CAP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
COOLANT DRAIN / RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
THERMOSTAT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
COOLING SYSTEM BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
WATER PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
WATER PUMP COVER AND IMPELLER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
WATER PUMP MECHANICAL SEAL / OIL SEAL REPLACEMENT . . . . . . . . . . . . . . . 3.21
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
ACCESSIBLE ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
TOP-END SERVICE (ENGINE IN CHASSIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
ENGINE BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
ENGINE MOUNTING AND TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35
ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35
SETTING TDC (TOP-DEAD-CENTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
ENGINE DISASSEMBLY / INSPECTION - TOP END . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37
VALVE COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37
CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37
CAMSHAFT SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39
CAMSHAFT / CAMSHAFT BORE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39
EXHAUST CAMSHAFT DECOMPRESSION MECHANISM . . . . . . . . . . . . . . . . . . . . . 3.41
CAM CHAIN AND GUIDE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
CYLINDER HEAD WARP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
COMBUSTION CHAMBER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46
CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48
CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48
PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.49
PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50
PISTON / ROD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50

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 ENGINE / COOLING SYSTEM
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.51
HONING TO OVERSIZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.52
CYLINDER HONE SELECTION / HONING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . 3.52
CLEANING THE CYLINDER AFTER HONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.52
ENGINE ASSEMBLY - TOP END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53
PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53
PISTON / CONNECTING ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.54
CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.55
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.56
VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.57
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.58
VALVE CLEARANCE CHECK / ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59
INTAKE VALVE LASH - SHIM SELECTION MATRIX . . . . . . . . . . . . . . . . . . . . . . . . . . 3.61
EXHAUST VALVE LASH - SHIM SELECTION MATRIX . . . . . . . . . . . . . . . . . . . . . . . . 3.62
CAMSHAFT INSTALLATION / TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.63
CAMSHAFT TIMING - QUICK REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.66
VALVE COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.67
ENGINE DISASSEMBLY / INSPECTION - LOWER END. . . . . . . . . . . . . . . . . . . . . . . . 3.68
CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.68
FLYWHEEL / STATOR HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.68
STARTER ONE-WAY CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.69
STARTER ONE-WAY CLUTCH INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.70
FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.71
STATOR REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.72
STATOR / STATOR COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.73
OIL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.73
OIL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.75
CRANKCASE BREATHER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.76
CRANKCASE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.76
BALANCE SHAFT REMOVAL / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.77
CRANKSHAFT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.78
CRANKSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.78
PTO SIDE CRANKCASE BEARING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.79
MAG SIDE CRANKCASE BEARING SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.80
OIL PICKUP ASSEMBLY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.81
OIL PRESSURE REGULATOR (BYPASS) VALVE INSPECTION . . . . . . . . . . . . . . . . 3.81
CRANKCASE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.81
ENGINE ASSEMBLY - LOWER END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.82
CRANKCASE ASSEMBLY - PTO SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.82
BALANCE SHAFT INSTALLATION / TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.84
FINAL CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.84
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.86
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.86
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.87

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 ENGINE / COOLING SYSTEM
GENERAL INFORMATION
Special Tools

Tool Description Part Number

Bench Mount Engine Stand Adapter PW-47053
Clutch Center Distance Tool PU-50658
Crankshaft Removal / Installation Tool Kit PU-50784
Cylinder Holding & Camshaft Timing Plate PU-50563
Engine Stand (2” Bore) PU-50624 3
Engine Stand Adapter (Mounts To The Engine) PU-50824
Engine Stand Sleeve Adapter (Use With 2” Bore Stand) PU-50625
Engine Stand Sleeve Adapter (Use With 2.375” Bore Stand) PW-47054
Flywheel Puller PA-49316
Oil Filter Wrench PU-50105
Oil Pressure Gauge PV-43531
Oil Pressure Gauge Adapter PU-50569
Stator Cover Removal Handles PA-49317
Valve Spring Compressor PV-1253 or PV-4019 (Quick Release)
Valve Spring Compressor Adapter PV-43513-A
Water Pump Mechanical / Oil Seal Installation Kit PU-50689

SPX Corporation - 1-800-328-6657

http://polaris.spx.com/.

Engine Lubrication Specifications

Oil Capacity Approx. 2 Quarts (1.9 L)

Oil Filter Wrench PU-50105 or 2.5” (64 mm)
Polaris PS-4 Plus
Oil Type
Synthetic Engine Oil

Oil Pressure 10 PSI @ 1200 RPM

Minimum Specification (Minimum)
(using Polaris PS-4 Plus 40 PSI @ 7000 RPM
at operating temperature) (Minimum)

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 ENGINE / COOLING SYSTEM
Oil Pressure Test
1. Attach the Oil Pr essure Gauge Adapter (PU-50569)
to the Oil Pressure Gauge (PV-43531).
=
PU-50569
Oil Capacity Approx. 2 Quarts (1.9 L)
Oil Filter Wrench PU-50105 or 2.5” (64 mm)
Polaris PS-4 Plus
Oil Type
Synthetic Engine Oil

Oil Pressure 10 PSI @ 1200 RPM

Minimum Specification (Minimum)
(using Polaris PS-4 Plus 40 PSI @ 7000 RPM
PV-43531 at operating temperature) (Minimum)

6. Upon assembly, torque the crankcase gallery plug to

specification.

Oil Pressure Gauge Adapter: PU-50569

Oil Pressure Gauge: PV-43531 =T
Oil Gallery Plug:
2. Remove the seats and engine service panel.
11 ft. lbs. (15 Nm)
3. Clean the area around the main oil gallery plug (A),
located on the oil filter adapter housing.

4. Remove the plu g ( A) and in sert the oil pressure

adapter.

Image for Reference Only

5. Start engine an d a llow it to r each op erating

temperature, monitoring gauge indication.

NOTE: Test results ar e bas ed on the us e of the

recommended engine oil (Pola ris PS- 4 Plus) at
operating temperature, and may vary considerably if
any ot her oil is used or if engine is not up to
temperature.

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 ENGINE / COOLING SYSTEM
Engine Oil Flow Chart

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 ENGINE / COOLING SYSTEM
ENGINE SERVICE SPECIFICATIONS
Engine Specifications - 1204286 RZR570HO-11

CAMSHAFT / CYLINDER HEAD / CYLINDER (IN. / MM)

Cam Lobe Height - Intake 1.5704" ± 0.0038" (39.89 ± 0.097 mm)
Cam Lobe Height - Exhaust 1.5405" ± 0.0038" (39.13 ± 0.097 mm)
Camshaft Journal O.D. - All (Standard) 0.9029" - 0.9037 " (22.933 - 22.954 mm)
Camshaft Journal O.D. - All (Service Limit) 0.9025" (22.923 mm)
Camshaft Journal Bore I.D. - All (Standard) 0.9055" - 0.9063" (23.000 - 23.021 mm)
Camshaft
Camshaft Journal Bore I.D. - All (Service Limit) 0.9072" (23.044 mm)
Camshaft Oil Clearance (Standard) 0.0018" - 0.0034" (0.046 - 0.088 mm)
Camshaft Oil Clearance (Service Limit) 0.0047" (0.121 mm)
Camshaft End Play (Standard) 0.0069" - 0.0128" (0.175 - 0.325 mm)
Camshaft End Play (Service Limit) 0.0157" (0.4 mm)
Cylinder Head - Surface Warp Limit 0.0024" (0.060 mm)
Cylinder Head
Cylinder Head - Standard Height 4.745" ± 0.0020" (120.53 ± 0.05 mm)
Valve Seat - Contacting Width - Intake (Standard) 0.0393" ± 0.0039" (1.0 ± 0.10 mm)
Valve Seat - Contacting Width - Intake (Service
0.0551" (1.4 mm)
Limit)
Valve Seat Valve Seat - Contacting Width - Exhaust (Standard) 0.0590" ± 0.0039" (1.5 ± 0.10 mm)
Valve Seat - Contacting Width - Exhaust (Service
0.0748" (1.9 mm)
Limit)
Valve Seat Angles 30.0° ± 1.5° / 45.0° ± 0.5° / 60.0° ± 1.5°
Valve Guide Valve Guide Inner Diameter 0.2165" - 0.2171" (5.500 - 5.515 mm)
Valve Lash (Cold) - Intake 0.005" - 0.007" (0.125 - 0.175 mm)
Valve Lash (Cold) - Exhaust 0.006" - 0.010" (0.152 - 0.254 mm)
Valve Stem Diameter - Intake 0.2155" - 0.2161" (5.475 - 5.490 mm)
Valve Stem Diameter - Exhaust 0.2147" - 0.2153" (5.455 - 5.470 mm)
Valve
Valve Stem Oil Clearance - Intake 0.0003" - 0.0015" (0.010 - 0.040 mm)
Valve Stem Oil Clearance - Exhaust 0.0011" - 0.0023" (0.030 - 0.060 mm)
Valve Stem Overall Length - Intake 3.7704" (95.77 mm)
Valve Stem Overall Length - Exhaust 3.7964" (96.43 mm)
Valve Spring Free Length (Standard) 1.7263" (43.85 mm)
Valve Spring
Valve Spring Free Length (Service Limit) 1.683" (42.75 mm)
Cylinder - Surface Warp Limit
0.00098" (0.025 mm)
(mating with cylinder head)
Cylinder Bore - Standard 3.8976" ± 0.0003" (99.0 mm ± 0.008 mm)
Cylinder
Cylinder Out of Round Limit 0.001" (0.025 mm)
Cylinder Taper Limit 0.001" (0.025 mm)
Cylinder to Piston Clearance 0.00019" - 0.00216" (.005 - .055 mm)

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 ENGINE / COOLING SYSTEM

PISTON / RINGS / CONNECTING ROD / CRANKSHAFT / BALANCE SHAFT (IN. / MM)

Piston - Standard O.D. - Measured 90 degrees to
3.8957” - 3.8968” (98.953 - 98.980 mm)
pin, 0.47 in. (12 mm) up from piston skirt. See text.
Piston
Piston Pin Bore I.D. (Standard) 0.8662” - 0.8665” (22.004 - 22.010 mm)
Piston Pin Bore I.D. (Service Limit) 0.8677" (22.042 mm)
Piston Pin O.D. (Standard) 0.8659" - 0.8661" (21.995 - 22.000 mm)
Piston Pin
Piston Pin O.D. (Service Limit) 0.8651" (21.975 mm)
Top Ring (Standard) 0.0059" - 0.0122" (0.15 - 0.31 mm)
Top Ring (Service Limit) 0.0137" (0.35 mm) 3
Installed Second Ring (Standard) 0.0094" - 0.0196" (0.24 - 0.50 mm)
Gap Second Ring (Service Limit) 0.0220" (0.56 mm)
Oil Control Rails (Standard) 0.0098" - 0.0401" (0.25 - 1.02 mm)
Piston Ring
Oil Control Rails (Service Limit) 0.0480" (1.22 mm)
Top Ring (Standard) 0.0011" - 0.0037" (0.030 - 0.095 mm)
Ring to Top Ring (Service Limit) 0.0042" (0.108 mm)
Groove
Clearance Second Ring (Standard) 0.0007" - 0.0029" (0.020 - 0.076 mm)
Second Ring (Service Limit) 0.0035" (0.089 mm)
Connecting Rod Small End I.D. (Standard) 0.8665" - 0.8670" (22.010 - 22.023 mm)
Connecting
Connecting Rod Small End I.D. (Service Limit) 0.8682" (22.053 mm)
Rod
Connecting Rod Big End I.D. See Service Procedure Listed In This Chapter
Main Journal O.D. (Service Limit) 1.6137" (40.990 mm)
Crankshaft
Crankshaft Runout Limit (PTO and MAG) See Service Procedure Listed In This Chapter
Balance Shaft Bearing Journal O.D. (Standard) 1.1798” - 1.1802" (29.969 - 29.979 mm)

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 ENGINE / COOLING SYSTEM
ENGINE DETAIL - TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES
Main Engine Components - Torque Specification and Sequence

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 ENGINE / COOLING SYSTEM
Crankcase / Timing Chain Guides / Oil Pickup / Regulator Valve
Replace Bolts if
Loosened or Removed

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 ENGINE / COOLING SYSTEM
Cylinder / Oil Filter / Oil Pump / Breather

Replace Bolts if
Loosened or Removed

Apply Loctite® 272™

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 ENGINE / COOLING SYSTEM
Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover

Replace Bolts if
Loosened or Removed

Replace Gasket if
Loosened or Removed

Replace Nut if
Loosened or Removed

Apply Loctite® 272™

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 ENGINE / COOLING SYSTEM
Spark Plugs / Starter / Throttle Body / Valve Cover

Apply Anti-seize

Replace Bolts if
Loosened or Removed

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 ENGINE / COOLING SYSTEM
Piston / Crankshaft / Balance Shaft

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 ENGINE / COOLING SYSTEM
ENGINE COOLING SYSTEM
Cooling System Exploded View and Coolant Flow Diagram

Upper Engine Hose

Water Pump

Bypass Hose

Upper Radiator
Hose

Lower Engine Cooling Fan

Hose

Recovery
Bottle

Radiator

Pressure Cap

Filler Neck

Hoses

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 ENGINE / COOLING SYSTEM
Cooling System Specifications Cooling System Pressure Test
1. Remove the hood from the front cab.
Condition Coolant Temperature °F (°C)

Room Temperature 68° F (20° C) WARNING

Thermostat Open 180° F (82° C)
Never remove pressure cap when engine is
Fan Off 192° F (89° C) warm or hot. The cooling system is under
Fan On 198° F (92° C) pressure and serious burns may result.
Allow the engine to cool before servicing.
Thermostat Full Open
203° F (95° C)
Lift
Engine Temperature
2. Remove pressure cap and pressure test the cooling
system using a commercially available pressure
3
233° F (112° C) tester.
Overheat Indicator
Engine Protection
236° F (113° C)
Ignition Misfire
Engine Protection
257° F (125° C)
Shutdown

Item Specification

Cooling System Capacity 4.25 qts. (4 l)

Pressure Cap Relief 13 PSI

Polaris Premium Antifreeze

2871534 - Quart
2871323 - Gallon Test Here

Recommended Coolant
Use only high quality antif reeze/coolant m ixed 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 he at dissip ation, r esulting in p ossible engine 3. The system must maintain 10 psi for five minutes or
damage. Pola ris Pre mium 60 /40 An tifreeze/Coolant is longer. If pressure loss is evident within five minutes,
recommended for use in all cooling systems and comes check the filler neck, radiator, hoses, clamps and
pre-mixed, ready to use. water pump weep hole for leakage.

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 ENGINE / COOLING SYSTEM
Pressure Cap Test Radiator
1. Remove th e ho od fro m th e fro nt cab (see 1. Check ra diator (A) air passages for r estrictions or
“WARNING” under “Cooling System Pressure Test”). damage.

2. Remove pressure cap (A) and test using a pressure

cap tester (commercially available).

Flush radiator fins

in this direction

3. The pressure cap r elief pressure is 13 psi. Re place 2. Carefully straighten any bent radiator fins.
cap if it does not meet this specification.
3. Remove any obstructions with compressed air or low
pressure water.

CAUTION

Washing the vehicle with a high-pressure

washer could damage the radiator fins and
impair the radiators effectiveness. Use of a high-
pressure washer is not recommended.

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 ENGINE / COOLING SYSTEM
Coolant Drain / Radiator Removal Radiator Removal

Coolant Drain 1. Remove the front bumper (see Chapter 5).

1. Remove the hood from the front cab. 2. Remove the upper engine outlet hose and recovery
hose from the top of the radiator.

WARNING 3. Remove the (2) upper radiator retaining bolts and the
(4) bolts retaining the lo wer radiator mount bracket.
Never drain the coolant when the engine and Remove the bracket from the frame.
radiator are warm or hot. Hot coolant can cause
severe burns. Allow engine and radiator to cool.

2. Slowly remove the pressure cap to relieve any cooling 3

system pressure.

3. Place a suitab le drain p an underneath the r adiator

fitting on the front right-hand side of the vehicle.

4. Drain the coolant from the radiator by removing the

lower coo lant hose from the r adiator as sho wn.
Properly dispose of the coolant.

4. Disconnect th e fa n mo tor an d re move the radiator

from the vehicle. Take care not to damage the cooling
fins.

5. Reverse procedure for installation.

Fan Motor Asm.

Recovery
Hose
Inserts
Drain Here

Radiator
Engine
5. Allow coolant to completely drain. T-Fitting Outlet Hose

6. Place a s uitable drain p an u nderneath th e lower

Screws
engine hose on the right-hand rear side of the vehicle.

Grommets
Engine
Inlet Hose

7. Remove the hose and completely drain the engine.

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 ENGINE / COOLING SYSTEM
Thermostat Replacement Cooling System Bleeding Procedure
1. Remove the hood from the front cab.
WARNING
WARNING
Always wear safety glasses and proper shop
clothing when performing the procedures in this
The cooling system is under pressure and
manual. Failing to do so may lead to possible
serious burns may result.
injury or death.
Allow the engine to cool before servicing.

2. Remove the pr essure cap to reliev e any sys tem CAUTION

pressure (see “Pressure Cap Test”).
Use caution when performing these procedures.
3. Drain coolant to a level below the thermostat housing. Coolant may be hot and may cause
severe injury or burns.
4. Remove the cargo box access panel.
NOTE: If the coolant level is LOW in the radiator, or
5. Remove the spark plug wire from the engine.
if there are leaks in th e system, the coolant system
6. Remove th e (2 ) bo lts (X) retai ning the th ermostat will not draw coolant from the reservoir tank.
cover.
NOTE: It may be necessary to safely raise the front
of the vehicle 1 2” ( 30 c m) to blee d the c ooling
system.
X
1. Allow engine and cooling system to completely cool.

CAUTION

Be sure the engine has cooled and no pressure

is built up in the cooling system before removing
the pressure cap. The coolant may be hot and
could cause severe injury or burns.

2. Remove the hood.

3. Remove the recovery bottle cap (A) and fill the bottle
7. Lift the co ver from th e en gine a nd r emove the to the MAX line.
thermostat.
A
8. Reverse th is p rocedure for in stallation. Re place
thermostat seal if wor n or da maged. T orque B
thermostat cover bolts to specification.

MAX Line
=T
Thermostat Cover Bolts:
7.5 ft. lbs. (10 Nm)

9. Be sure to properly fill and bleed cool ing system as

outlined in this chapter.

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 ENGINE / COOLING SYSTEM
4. Remove the pressure cap (B) and add the necessary 13. Tighten the b leed scr ew to sp ecification, to p off
amount of Polaris Premium Antifreeze to the radiator coolant and properly install the pressure cap.
filler neck.

5. Remove the cargo box access cover to gain access =T

to th e coola nt bleed screw that is on top of the
thermostat housing. Coolant Bleed Screw:
6 ft. lbs. (8 Nm)
6. Open the bleed screw (C) to allow any trapped air to
escape. 14. Fill the recovery bottle to the MAX line.
7. Fill the radiator until asteady stream of coolant begins
3
15. Reinstall the hood.
to drain out of the bleed screw (C).
16. Reinstall cargo box access cover.
C

8. Tighten the b leed scr ew to sp ecification, to p o ff

coolant and properly install the pressure cap.

=T
Coolant Bleed Screw:
6 ft. lbs. (8 Nm)

9. Start the en gine and allow it to idle until the coolant

fan has cycled.

10. Allow engine and cooling system to completely cool

down (see CAUTION).

11. Remove the pressure cap. Add the necessary amount

of P olaris Premium Antifree ze to the radiator filler
neck.

12. Open th e ble ed scre w to allo w any tr apped air to

escape. Close the bleed screw once a steady stream
of coolant begins to drain out.

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 ENGINE / COOLING SYSTEM
WATER PUMP SERVICE 11. Using an 8 mm socket, r emove th e water pum p
impeller (D).
Water Pump Cover and Impeller Service
NOTE: The wa ter pump impe ller (D) use s rev erse
(Stator Cover Remains on Engine) (LH) threads.
NOTE: The wate r pu mp cov er, ga sket and impe ller
can be serviced with the stator cover installed on the A B C
engine.
D
1. Allow engine and cooling system to completely cool.

CAUTION

Be sure the engine has cooled and no pressure 9 ft. lbs.

(12 Nm)
is built up in the cooling system before removing
the pressure cap. The coolant may be hot and Finger Tighten
could cause severe injury or burns. (Reverse Threads)

2. Remove both seats and the engine service panel.

12. Inspect the water pum p co ver an d impe ller for
3. Disconnect the (-) negative battery cable. damage. Replace as necessary.

4. Remove all debris and thoroughly clean water pump 13. Follow this pro cedure in reverse to asse mble th e
area and right-hand side of engine block. water pump impeller and cover. Always use a new
water p ump co ver g asket. To rque a ll fa steners in
5. Remove the hood. sequence to specification.
6. Remove the pressure cap from the filler neck.

7. Completely dr ain co oling syste m and engine as 9 ft. lbs.

outlined in this chapter. (12 Nm)

8. Raise a nd sa fely su pport the ve hicle. Rem ove the

right-hand rear wheel.

9. Remove th e (8 ) b olts (A) a ttaching th e wa ter pu mp

cover to the stator cover.

10. Remove the water pump cover (B) and water pump
cover gasket (C). Discard the water pump gasket (C).

=T
Water Pump Cover Fastener Torque:
9 ft. lbs. (12 Nm)

14. Fill and bleed cooling s ystem as outlined in this

chapter.

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 ENGINE / COOLING SYSTEM
Water Pump Mechanical Seal / Oil Seal 10. Remove the CPS sensor from the stator cover on the
Replacement right-hand side of the engine. Inspect CPS O-ring and
replace if needed.
NOTE: The s tator cov er must be re moved f rom t he
engine t o s ervice the wa ter pump drive sh aft, oil
seal, mechanical seal and bearing.

1. Allow engine and cooling system to completely cool.

CAUTION

Be sure the engine has cooled and no pressure

is built up in the cooling system before removing 3
the pressure cap. The coolant may be hot and
could cause severe injury or burns.

2. Remove both seats and the engine service panel.

3. Disconnect the (-) negative battery cable. 11. Remove the oil dipstick.
4. Remove all debris and thoroughly clean water pump 12. Remove the ( 8) bolts (A) r etaining the water pump
area and right-hand side of engine block. cover to the stator cover.
5. Remove the hood. 13. Remove the water pump cover (B) and water pump
cover gasket (C). Discard the water pump gasket (C).
6. Remove the pressure cap from the filler neck.

7. Completely drain c ooling syst em and engine as A B C

outlined in this chapter.
D
8. Raise an d s afely s upport the ve hicle. Rem ove the
right-hand rear wheel.

9. Disconnect the stator wire connector and cut the tie

strap s ecuring th e w iring t o t he fr ont e ngine mount
bracket.

14. Remove the water pump impeller (D).

NOTE: The water pump impeller (D) uses reverse

(LH) threads.

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 ENGINE / COOLING SYSTEM
15. Remove the (13) bolts securing the stator cover to the 18. Bring the sta tor cover assemb ly to a clea n work
engine. bench.

16. If needed, install the stator cover removal handle tool 19. Using a b rass dr ift, re move th e water pum p dr ive
(PA-49317) to the water pump cover bolt holes to aid shaft. Be sur e not to da mage the thr eads. Inspe ct
in stator cover removal. shaft for wear or damage, replace if necessary.

PA-49317

CAUTION
20. Extract the mechanical seal (E) and the oil seal (F)
The flywheel contains powerful magnets. Use
from the stator cover.
caution when removing the stator cover.
DO NOT place fingers between cover and
crankcase at any time during the removal E
process or injury could result.
F
17. Remove and discard the stator cover gasket.

21. Press out the water pump drive shaft bearing (G) from
the sta tor cover. Disca rd bea ring an d r eplace with
new.

CAUTION

Be sure engine coolant does not contaminate the

engine oil during stator cover service.

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 ENGINE / COOLING SYSTEM
Water Pump Assembly
1. Thoroughly clean the stator cover. PU-50869
2. Press in a new water pump drive shaft bearing (G)
until it is fully seated in the cover.

Item #1 Item #2 Item #3 3

5. Install the water pump drive shaft ho lding tool ( Item

#1) in kit PU-50869. Hold the tool in position and flip
the as sembly u p-side-down so the spe cial tool PU-
50869 is supporting the assembly.

CAUTION
PU-50869
Be sure bearing is fully seated in cover orsevere Item #1
engine damage may result.

3. Clean and de-grease the water pump drive shaft (H).

4. Press in th e wa ter pu mp dr ive shaft (H) into the

bearing using PU-50869 Item #1.

PU-50869
Item #1

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 ENGINE / COOLING SYSTEM
6. Lubricate the new wa ter p ump oil se al w ith c lean 10. Align the water pump drive slot as shown below.
engine oil.

7. Use the water pump oil seal installation tool in kit

PU-50869 to fully install the new water pump oil seal
(I).

PU-50869
Item #2
I

11. Align th e water p ump dr ive sh aft b lade as sh own

below.

12. Apply a small amount of crankcase sealant to the area

indicated below (A).

CAUTION A

Be sure the oil seal is fully seated in cover or

severe engine damage may result

8. Use the water pump mechanical seal installation tool

in kit PU-50869 to fully install the new water pump
mechanical seal (J) until itis fully seated in the cover.

PU-50869
Item #3

Water Pump Alignment Detail View

Crankshaft Oil Seal

Impeller

9. Install a new stator cover gasket onto the engine. Mechanical

Drive Shaft Seal

13. If needed, install the stator cover removal handles tool

PA-49317 to the water cover bolt holes to aid in stator
cover installation.

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 ENGINE / COOLING SYSTEM
14. While installing the stator cover to the engine, slightly
rotate the water pump impeller to verify the crankshaft
slot and the water pump drive shaft blade are properly =T
engaged. Verify the stator cover is laying flat on the
engine case. Stator Cover and Water Pump Cover
9 ft. lbs. (12 Nm)

PA-49317 16. Measure the installed height of the new mechanical

seal a s sh own b elow. If not within sp ecification,
remove and discard the mechanical seal and properly
install new mechanical s eal as outlined in this

3
chapter.

Water Pump Drive Shaft

Mechanical Seal

Stator Cover

CAUTION

The flywheel contains powerful magnets. Use

caution when installing the stator cover.
DO NOT place fingers between cover and
crankcase at any time during the removal and
installation process or injury could result.

CAUTION
= In. / mm.
If the water pump drive shaft blade and slot in the
crank shaft are not in alignment during the Mechanical Water Pump Seal Installed Height:
installation process, severe engine damage may 0.280” - 0.287” (7.2 +/- 0.1 mm)
result.
17. Install the water pu mp impeller (K). Finger tighten
15. Install and to rque the stator cover fa steners in only.
sequence to specification.
NOTE: The water pump impeller (K) uses reverse
(LH) threads.

9 ft. lbs.
(12 Nm)
Finger Tighten
(Reverse Threads)

18. Install a new water pump cover gasket.

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 ENGINE / COOLING SYSTEM
19. Install th e water pu mp co ver to the stator cover. ENGINE SERVICE
Torque all fasteners in sequence to specification.
Accessible Engine Components
9 ft. lbs.
(12 Nm) The followin g com ponents can b e serviced or re moved
with the engine installed:

• Camshaft
• Camshaft Sprockets
• Cylinder Head and Gaskets
• Cylinder and Gaskets
• Piston and Rings
• Flywheel
• Starter Motor / Idler Gear Asm
20. Install the oil dipstick. • Stator (Alternator)
• Thermostat
21. Install the coolant hose to the water pump cover and
tighten hose clamp. • Valve Cover

22. Connect the stator wire connector and install a new • Water P
ump
tie strap securing the wiring to the front engine mount • Camshaft Timing Chain and Guides
bracket.
• Crankshaft Seal (PTO)
23. Install the CPS sen sor into the stator cover. Inspect • Oil Pump / Oil Pump Sprocket or Chain
CPS O-ring and replace if needed.
The following c omponents require e ngine re moval for
24. Install the right-hand rear wheel and torque the wheel service:
nuts to specification. Safely lower vehicle.
• Counterbalance Shaft and Bearings

=T • Crankshaft and Bearings

• Crankcase
Wheel Nuts:
Steel Wheels: 27 ft. lbs. (37 Nm) • Oil Pressure Regulator
Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn) • Oil Pump Pickup Assembly

25. Install both seats and the engine service panel.

Top-End Service (Engine in Chassis)
26. Connect the (-) negative battery cable.
ALL of th e top-end engine components can be serviced
27. If the engine oil was contaminated during this service while the engine is mounted in the chassis.
procedure, perform an engine oil change as outlined
in Chapter 2. DO NOT run the engine until coolant has
been added to the cooling system.

28. Fill cooling system with recommend coolant and bleed

the system of air as outlined in this chapter.

29. Check for leaks.

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 ENGINE / COOLING SYSTEM
Engine Removal 3. Drain the engine oil and engine coolant prior to engine
removal (see Chapter 2).
IMPORTANT: Some engine repair procedures can be
performed with out removing the engine as sembly
from th e ve hicle. Re fer to “Acc essible Engine
Components” for further information.

NOTE: The use of an overhead or port able engine

hoist is the only recommended method for removing
and installing the engine.

NOTE: Have an a ssistant help gu ide the eng ine in

and out of the vehicle while using an engine hoist to
prevent pe rsonal injur y or dama ge to vehicle
3
components.

CAUTION
4. Remove the sea ts an d en gine service pan el (see
Correct Drive Clutch Puller P/N PA-48595 Chapter 5).

5. Disconnect th e ( -) neg ative ba ttery ca ble fr om the

battery.

6. Remove th e r ear bu mper and cargo b ox as a n

assembly (see Chapter 5).

7. Loosen the (3) clam ps se curing th e int ake ba ffle

assembly to the air bo x lid, inn er clutch cover and
engine crankcase vent. Remove the air intake baffle
/ intake ho ses / engine cran kcase vent tube an
assembly as shown below.

Spring Style
WARNING Clamp

Always wear safety glasses and proper shop

clothing when performing the procedures in
this Service Manual.
Failing to do so may lead to possible injury.

1. If vehicle was recently operated, allow it to cool down

before attempting to perform any work.

2. Thoroughly clean the engine and chassis.

8. Elevate the rear of the vehicle off the ground using a
suitable lift and remove the left rear wheel.

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 ENGINE / COOLING SYSTEM
9. Remove the outer clutch cover, drive belt, drive clutch, 12. Disconnect the IAC valve (A), TPS (B), T-MAP sensor
driven clutch and inner clutch cover (see Chapter 6). (C), harness leads from the throttle body.
Make note of hose and wire routings for reassembly.
A C
IMPORTANT: Be sure to use the correct Drive Clutch
Puller (PA-48595) to prevent damage to crankshaft.

10. Disconnect the stator wire connector and cut the tie
strap secur ing the wir ing to th e fro nt eng ine mou nt
bracket. Replace tie strap for engine installation.

13. Disconnect the fuel injector harness lead (D) from the
fuel injector.

14. Properly relieve fuel pressure from the fuel rail.

15. Place a shop to beneath the fuel line quick connector

to catch any excess fuel. Disconnect the fuel line (E)
from the fuel rail by pressing in on the quick connector
11. Remove the CPS sensor from the stator cover on the tabs.
right-hand sid e of the en gine. Plug CPS h ole with
clean shop towel. Inspect CPS O-ring and replace if 16. Move fue l line to th e left-h and sid e of th e en gine
needed. compartment. Make note of line routing for
installation.

17. Disconnect the ignition coil har ness co nnector an d

remove the spark plug wire from the engine.

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 ENGINE / COOLING SYSTEM
18. Remove t he ( 8) fa steners securing t he ( 2) b olt in 22. Loosen the hose clamp (F) securing the throttle body
braces to the veh icle main fra me. Ma neuver the to the air box. L ift air box up and rea rward a s an
braces for engine removal clearance. Note the routing assembly to disengage it from the throttle body.
of the transmission breather hose and wire harness.
23. Loosen the hose clamp (G) securing the throttle body
to the engine intake boot. Remove throttle body from
the engine and wrap it with a clean shop towel. Place
throttle body on the left-hand side frame rail area.

3
G

19. Remove (+) positive cable from the starter motor.

20. If desired, remov e the re maining s tarter motor bolt

and remove the starter motor from the engine.
IMPORTANT: Be sure dirt and debris do not enter the
21. Remove (-) negative cable from the starter mounting engine, a ir box or t hrottle bod y. Use clean sho p
bolt. towels to plug engine and air box intake holes.

24. Disconnect the upper en gine coo lant h ose ( H),

bypass hose (I) and ECT (J) harness connector.

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 ENGINE / COOLING SYSTEM
25. Remove the (3 ) he x bolts (K) secur ing th e exha ust 30. Remove the ( 8) b olts (N) securing th e cou pler
head pipe to the eng ine. Remo ve th e (3 ) r ubber brackets to the engine and transmission.
exhaust hangers (L) securing the exhaust system to
the main frame. Discard the exhaust seal and replace 31. Loosen the (2) bolts and nuts (O) so the engine mount
with new for reassembly. bracket can be slightly tilted away from engine.

L O

Discard

N
L M

26. Maneuver the exhaust system towards the right-hand 32. With the h elp of an assista nt an d the en gine ho ist,
side of the vehicle to gain engine removal clearance. raise the engine vertically out of the vehicle frame.
Removal of the exhaust system from the chassis is not
needed. NOTE: Have a n ass istant help guide t he e ngine in
and out of the vehicle while using an engine hoist to
27. Place a s upport in -between th e main fra me and prevent per sonal injury or dama ge t o th e ve hicle
transmission case. Do not pinch brake line. components.

33. Install the engine stand adapter (PU-50824) onto the

engine PTO side mounting ears as shown below.

Bolts From The

Center Outward

28. Use an overhead or portable engine hoist and suitable PU- 50824
engine s traps t o s ecure the engine in its cu rrent
position.
34. Select th e pr oper eng ine stan d slee ve ada pter an d
29. Remove the (4) bolts and nuts (M) securing the engine install it onto the engine stand adapter.
to the front motor mount bracket.
• Sleeve adapter for a 2” bore engine stand: 
(PU-50625)
• Sleeve adapter for a 2.375” bore engine stand: 
(PW-47054)

35. Place engine onto the engine stand (PU- 50624) for
service.

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 ENGINE / COOLING SYSTEM
Engine Installation 6. Install the Clutch Ce nter Distance To ol (PU-5 0658)
onto th e cr ankshaft and tr ansmission in put shaft t o
Use the following pr ocedure to re install th e eng ine properly position the clutch center distance. 
assembly. 
The pictures below show the tool (PU-50658) properly
1. Attach en gine with suit able lift ing str aps t o a n installed.
overhead or portable engine hoist.

2. Remove the engine stand adapter plate.

3. Use the ove rhead or p ortable engine ho ist a nd

suitable e ngine straps to lower the en gine in to the
vehicle frame. PU-50658 3
NOTE: Have an a ssistant help gu ide the eng ine in
and out of the vehicle while using an engine hoist to
prevent pe rsonal injur y or dama ge to vehicle
components.

4. By hand, install the (4) front engine mount bolts and

Drive Clutch Bolt Installed
nuts (A). Do not tighten at this time.

5. Instal the (4) engine to transmission coupler plates (B)

and instal the ( 8) bo lts and washe rs ( C). Do no t
tighten fasteners at this time.

C
Tool Fully Seated Inward
B

IMPORTANT: DO NOT torque fasteners at this time.

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 ENGINE / COOLING SYSTEM
7. In seq uence, to rque the (8 ) e ngine cou pler br acket 10. Remove the lifting str aps a nd over head or po rtable
fasteners to specification. engine hoist an d r emove th e sup port pr eviously
installed under the tra nsmission case du ring th e
55 ft. lbs engine removal process.
(74.5 Nm)
11. Reposition th e e xhaust system a nd insta ll the (3)
rubber exhaust hangers, new exhaust seal and the (3)
head p ipe bo lts. To rque he ad pipe b olts to
specification.

18 ft. lbs.
(24.5 Nm)

New

=T
Rear Engine Coupler Fastener (In Sequence):
55 ft. lbs. (74.5 Nm)

8. In a criss-cross pattern, torque the (4 ) fro nt eng ine

mount fasteners to specification.
=T
=T Exhaust Head Pipe Bolts:
18 ft. lbs. (24.5 Nm)
Front Engine Mount Fasteners:
40 ft. lbs. (54 Nm) 12. Install the (3) coolant hoses onto the engine.

9. Torque th e (2) front center iso lator bolts to 13. Install the throttle body and air box. Tighten the hose
specification. clamps that secure the throttle body to the intake boot
and air box.

14. Install the lower stater motor bolt through the lower
40 ft. lbs. starter motor mounting boss.
(54 Nm)
15. Instal the starter motor onto the engine.

16. Install the starter motor and battery cables as outlined

in Chapter 10.

=T
40 ft. lbs.
(54 Nm)
Starter Motor Fastener:
7 ft. lbs. (10 Nm)

=T
Isolator Center Bolt:
40 ft. lbs. (54 Nm)

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 ENGINE / COOLING SYSTEM
17. Connect the harness leads to the IAC valve (D), TPS 20. Install the (8) fasteners securing the (2) bolt in braces
(E), T-MAP sensor (F). Verify routing is correct. to th e ve hicle m ain frame. Torque fas teners to
specification. Be sure the routing of the transmission
D F breather hose and wire harness is correct.
17 ft. lbs.
(23 Nm)

40 ft. lbs.
(54 Nm)
3
E

18. Connect the fuel injector harness lead (G) to the fuel
injector.
=T
19. Connect the fuel line (H) to the fuel rail.
Rear Bolt in Brace Fastener Torque:
H 17 ft. lbs. (23 Nm)

Front Bolt in Brace Fastener Torque:

40 ft. lbs. (54 Nm)

21. Connect the ignition coil harness connector and install

the spark plug wire.
G
22. Install the CPS and mounting bolt into the stator cover
and torque to specification.

=T
CPS Fastener Torque:
9 ft. lbs. (12 Nm)

23. Connect the stator wire connector and install a new

tie strap to secure the wiring to the front engine mount
bracket.

24. Install the inner clutch cover as outlined in chapter 6.

25. Install the dr ive clutch, driven clutch, belt and outer
clutch cover as outlined in Chapter 6. Be sure all hose
and wire routings are correct. Torque all fasteners to
specification as outlined in Chapter 6.

26. Install the in take ba ffle as sembly. Se cure the 3

clamps that attach the a ssembly to the crankc ase
vent, air box lid and inner clutch cover.

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 ENGINE / COOLING SYSTEM
27. Install the rear bumper and cargo box assembly as Engine Break-In Period
outlined in Chapter 5.
The break-in period con sists o f the first 25 h ours o f
28. Install the left-hand rear wheel and torque wheel nuts operation, or the time it takes to use 15 gallons (57 liters)
to specification. of fuel. Careful treatment of a ne w e ngine a nd d rive
components will result in more efficient performance and
longer life for these components.
=T
Wheel Nuts: CAUTION
Steel Wheels: 27 ft. lbs. (37 Nm)
Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn) Use only Polaris PS-4 PLUS
Synthetic Engine Oil.
29. Remove the pressure cap and fill the cooling system Never substitute or mix oil brands.
through the filler neck with properly mixed anti-freeze Serious engine damage and voiding of
/ coolant. warranty can result.
Do not operate at full throttle or high speeds for
30. If the e ngine o il wa s com pletely d rained, a dd extended periods during the first three hours of
approximately 2 quarts (1.9 L) of Polaris PS-4 Plus use. Excessive heat can build up and cause
Synthetic Engine Oil into the crankcase. damage to close fitted engine parts.

31. Install a new oil filter. Lubricate the seal with engine 1. Fill fuel tank with unleaded fuel which has a minimum
oil prior to installation (see Chapter 2 “Maintenance”). pump octane number of 87 = (R+ M)/2.
32. Connect the (-) negative battery cable to the battery. 2. Refer to Chapter 2, “Engine Oil Level”. Check oil level
indicated on oil tank dipstick. Add oil if necessary.
33. Install the engine service panel and seats.
3. Drive slo wly at first to g radually b ring en gine up to
34. Follow the “Cooling System Bleeding Procedure” as
operating temperature.
outlined in this chapter.
4. Vary throttle positions. Do not operate at sustained
35. Start engine and check for any oil or coolant leaks.
idle or sustained high speed.
36. Check the engine oil level (see Chapter 2).
5. Perform regular checks on fluid le vels, controls and
37. Refer customer to “En gine Bre ak-In Peri od” up on all important bolt torques.
returning vehicle to customer.
6. Change oil an d oil filter a fter br eak-in pe riod at 25
hours.

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 ENGINE / COOLING SYSTEM
Engine Mounting and Torque Values
25 ft. lbs. See Engine Installation For 40 in. lbs.
(34 Nm) Critical Torque Procedure (4.5 Nm)

Coupler Brackets

Gasket 18 ft. lbs.

(24.5 Nm)

40 ft. lbs. Seal

3
(54 Nm)

Exhaust System

55 ft. lbs. 40 ft. lbs.

(74.5 Nm) (54 Nm)
See Torque Sequence

40 ft. lbs. Isolator Mount

(54 Nm)
25 ft. lbs.
40 ft. lbs. (34 Nm)
(54 Nm) Front Engine Mount

Engine Lubrication Specifications

=
Oil Capacity Approx. 2 Quarts (1.9 L)
Oil Filter Wrench PU-50105 or 2.5” (64 mm)
Polaris PS-4 Plus
Oil Type
Synthetic Engine Oil

Oil Pressure 10 PSI @ 1200 RPM

Minimum Specification (Minimum)
(using Polaris PS-4 Plus at
40 PSI @ 7000 RPM
operating temperature)
(Minimum)

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 ENGINE / COOLING SYSTEM
SETTING TDC (TOP-DEAD-CENTER) IMPORTANT: Intake c am spr ocket shou ld h ave “I”
marks a ligned wit h g asket su rface and t he e xhaust
There ar e thre e ways to en sure the pisto n is at TDC. cam s procket sh ould ha ve “E” mark s a ligned wit h
Remove the outer clutch cover to access the drive clutch gasket surface.
to aid in engine ro tation (m anually tu rn the drive clu tch
counter clockwise).
Image for Reference Only
1. With the CPS sensor removed, rotate the engine until
the “V” mar ked o n the flywhee l is a ligned with the
CPS mounting ho le. This will se t TDC, but not
necessarily TDC o f t he compression st roke.
View the timing marks on the camshaft sprockets to I E E
ensure the e ngine is at TDC o f the co mpression I
stroke.

3. With the stator cover and flywheel removed, rotate the

engine and position the piston at TDC by aligning the
timing ho le in cra nk case with a timing hole in th e
crankshaft. 

Insert a 1 /4” dr ive socket exte nsion through th e
crankcase and into the crankshaft locating hole. This
will s et TDC, but n ot necessarily TDC of the
compression stroke. View the timing marks on the
cam shaft sprockets to ensure the engine is at TDC
2. With t he v alve cover a nd thermostat h ousing of the compression stroke.
removed, ro tate th e en gine so the cam lobe s a re
facing ou tward a nd th e Cylin der Hold ing a nd Alignment Hole
Camshaft Timing Plate (PU-50563) can be installed
into the slots of the camshafts as shown below. This
will set TDC of the compression stroke.

1/4” Drive Extension

PU-50563

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 ENGINE / COOLING SYSTEM
ENGINE DISASSEMBLY / INSPECTION - TOP END
Valve Cover Removal Camshaft Removal
NOTE: The valve cover, camshafts, cy linder hea d, NOTE: The c amshafts c an be removed wit h the
cylinder and piston can be se rviced with the engine engine installed in the chassis.
installed in the chassis.
1. Rotate the engine so the piston is at Top Dead Center
1. If needed, rem ove th e sp ark plu g wir e fr om the (TDC) on the compression stroke.
engine.

2. Remove dirt and debris from valve cover area.

3. Remove the ( 3) valve cover shou lder b olts ( A) a nd 3

isolators (B) using a T40 driver.

4. Carefully lift valve cover from the engine and remove Lobes should face out
it out of the right-hand rear wheel well area.

A NOTE: To verify TD C, see the “S ETTING TDC”

section in this chapter.

2. Remove the hydraulic cam chain tensioner (E) from

the cylin der. Repla ce the se aling washer (F ) u pon
reassembly.

5. Replace isolators (B) and valve co ver seal (C) if oil

leaks are evident.

6. Remove the spark plug (D). Stuff spark plug hole with
a shop towel to prevent anything from falling into the
combustion chamber (if further engine disassembly is
required).
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 ENGINE / COOLING SYSTEM
3. Remove the (2 ) bo lts r etaining th e fixed cam ch ain 6. Mark the intake ( I) an d exha ust (J) camsh afts to
guide (G) and remove the assembly from the engine. ensure proper assembly.
Inspect the guide for wear and replace if necessary.
7. Lift up ward on the intake ca mshaft wh ile r otating it
counter-clockwise. W alk t he timing chain off of th e
sprocket. Carefully remove the intake camshaft from
the engine.
G
I J

4. Remove th e re maining (6 ) b olts t hat r etain th e

camshaft carrier (H) and carefully lift the carrier off the
camshafts.
8. Remove the cam chain fro m the exha ust ca mshaft
sprocket (J) and remove the exhaust camshaft from
the engine.

NOTE: The crankcase has a lower guide t o prevent

the chain from falling off the crankshaft.

5. Attach a hoo k or other tool to the camshaft chain to

prevent it from dropping down into the engine.

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 ENGINE / COOLING SYSTEM
Camshaft Sprocket Inspection Camshaft / Camshaft Bore Inspection
NOTE: Camshaft sprocket removal is not necessary Inspect a ll main journals a nd cam lo bes as de scribed
unless the replacement of the sprockets is required. below and compare to specifications. Replace camshafts
or cylinde r he ad if wo rn beyond s ervice limit or if any
Inspect cam sprocket teeth for wear or damage. Replace surface is pitted or damaged.
timing chain and sprockets as a set if worn or damaged.
1. Visually inspect each cam lobe for wear or damage.
Inspect
Sprocket Teeth 2. Measure the height of each cam lob e from the base
circle to highest point on the lobe using a micrometer.
Compare to specification.
3

Replace if
Worn or Damaged

IMPORTANT: Replace camshaft sprocket bolts if they NOTE: Replace camshafts if damaged or if any part
are loosened or removed. is worn past the service limit.

=T = In. / mm.
Camshaft Sprocket Bolts:
15 ft. lbs. (20 Nm) Camshaft Lobe Height:

Intake: 1.5704" ± 0.0038" (39.89 ± 0.097 mm)

Exhaust: 1.5405" ± 0.0038" (39.13 ± 0.097 mm)

3. Visually insp ect each camsha ft journal for sco ring,

wear or damage.

4. Measure the diameter of the camshaft journals using

a micrometer. Compare to specification.

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 ENGINE / COOLING SYSTEM
NOTE: Replace camshafts if damaged or if any part 6. If the camshaft journal bo re is found to be ou t of
is worn past the service limit. specification, re placement o f th e cylin der head
assembly is required.

= In. / mm.

Camshaft Journal O.D. Standard:

0.9029” - 0.9037” (22.933 - 22.954 mm)

Service Limit:
0.9025” (22.923 mm)

5. Temporarily install the camshaft carriers to measure

the camsha ft b ore. To rque b olts in sequence to
specification.
NOTE: Replace cy linder he ad if camshaft jour nal
bores are damaged or if worn past the service limit.

= In. / mm.

Camshaft Journal Bore I.D. Standard:

0.9055" - 0.9063" (23.000 - 23.021 mm)

Service Limit: 0.9072" (23.044 mm)

7. Calculate o il cle arance by su btracting ca mshaft

journal O.D.s fro m camshaft car rier bor e I.D.s.
Compare to specification.

=T
Camshaft Carrier Bolts:
= In. / mm.
7.5 ft. lbs. (10 Nm)
Calculated Camshaft Oil Clearance:
0.0018" - 0.0034" (.046 - .088 mm)

Service Limit: .0047" (.121 mm)

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 ENGINE / COOLING SYSTEM
Exhaust Camshaft Decompression Cam Chain and Guide Service
Mechanism NOTE: The cra nkcase has a remov able lowe r cam
chain g uide t hat pre vents th e ch ain f rom
NOTE: Removal of t he d ecompression mec hanism
disengaging the crankshaft during engine service.
is not necessary unless replacement is required.

1. Thoroughly cle an an d inspe ct the de compression NOTE: The c am c hain, ca m cha in guide s a nd c am
mechanism located on the exhaust camshaft. chain tensioner ca n b e re placed wit h t he eng ine
installed in the vehicle.
2. Replace th e decom pression assemb ly if any
excessive wear or binding is evident. 1. If no t a lready pe rformed, re move th e va lve cov er,
stator cover , flywhe el, cam chain tensioner, cam
Retaining Ring
carrier and camshafts as outlined in this chapter.
3
2. Remove the (2) fasteners that secure the cam chain
guides to the crankcase.
Pivot
3. Remove the (2) fasteners that secure the lower cam
chain guide to the crankcase.

4. Inspect all cam chain guides and replace if excessive

wear is evident.

5. Upon installation, torque all fasteners to specification

Return Spring and reassemble engine and vehicle as outlined in this
Decomp. Cam and Pin chapter.

3. Be sure th e de compression me chanism fu nctions

smoothly and easily returns under spring pressure to
the resting position against gravity.

9 ft. lbs
(12 Nm)

=T
Tension Blade and Guides:
9 ft. lbs. (12 Nm)

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 ENGINE / COOLING SYSTEM
Cylinder Head Removal Cylinder Head Disassembly
NOTE: The cy linder hea d ca n be se rviced with the
engine installed in the chassis. WARNING
IMPORTANT: Do not rotate hea d assembly up side-
Wear eye protection during cylinder head
down unt il the valve buck ets and shims hav e been
disassembly and reassembly or when working
removed.
with the valve springs.
1. Remove and discard the (2) outer M6 bolts (A) that
IMPORTANT: Keep mated parts together and in order
retain the cylinder head (B) and the cylinder.
with respect to their location in the cylinder head for
2. Loosen the (4) cylinder head bolts (C) evenly 1/8 turn assembly purposes. It is important to install cylinder
(60 degrees) at a time until all are loose. head components b ack in the same lo cation. M ark
each component or place them in an organized rack
3. Remove an d d iscard the cylin der h ead bo lts ( C). as you remove them.
Replace with new upon assembly.
1. Remove the valve bu cket ( F) an d a djustment shim
4. Tap cyl inder he ad lightly with a so ft faced hammer (G) from the cylinder head.
until loose. Tap only in reinforced areas or on thick
parts of the cylinder head casting.
G
5. Remove the cylinder head (B) and head gasket (D).

C
F
A

2. Compress the valve spring by hand using valve spring

compressor adapter (PV-43513-A).

PV-43513-A

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 ENGINE / COOLING SYSTEM
3. Push down on the spring and remove the split keepers 9. Measure the free length of each valve spring with a
(H). Vernier caliper and compare to specification.

H
I

J Top

K
L

Bottom
3

= In. / mm.

Valve Spring Free Length:

M Standard: 1.7263" (43.85 mm)
Service Limit: 1.6830" (42.75 mm)

4. Slowly release valve spring pressure and remove the

compressor adapter.

5. Remove the valve retainer (I), valve spring (J), valve

stem seal (K) and valve spring seat (L). Discard the
valve seal.

NOTE: Replace valve seals whenever cylinder head

is disa ssembled. Harde ned, cr acked or worn s eals
will cause excessive oil consumption.

6. Lift up the cylinder head and push the valve (M) out,
keeping it in order for reassembly in th e same valve
guide.

7. Repeat the previous steps to re move the re maining

valves.

8. Clean the co mbustion ch amber and he ad g asket

surface.

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 ENGINE / COOLING SYSTEM
Cylinder Head Inspection Valve Inspection
Thoroughly clea n cylinde r h ead sur face to r emove a ll 1. Remove all carbon from valves with a soft wire wheel
traces of gasket material and carbon. or brush.

2. Check va lve face fo r exce ssive runout, pit ting, a nd

CAUTION burnt spots.

Use care not to damage gasket sealing surface. 3. To chec k for bent v alve st ems, mo unt va lve in “V ”
All gasket surfaces must be clean, dry and free blocks and measure with a dial indicator.
of any oil or grease upon assembly. Clean
sealing surfaces with rubbing alcohol or
electrical contact cleaner. Do not touch sealing
surfaces of the new head gasket.

Cylinder Head Warp Inspection

1. Lay a s traight ed ge ( E) ac ross the s urface of th e
cylinder head 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.

4. Check the e nd of the valve stem fo r flaring, pitting,

wear or damage.

= In. / mm.

Cylinder Head Warp Limit: 5. Inspect split keeper groove for wear or flaring in the
.0024" (0.06 mm) keeper seat area.

NOTE: The valves can be re-faced or end ground, if

necessary. T hey mu st be re placed if e xtensively
worn, burnt, bent or damaged.

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 ENGINE / COOLING SYSTEM
6. Measure diameter of valve stem with a micrometer in Combustion Chamber Cleaning
three places, then rotate 90° and measure again (take
six measurements total). Compare to specifications.
WARNING

Wear eye protection during combustion

chamber cleaning.

1. Clean a ll accumulated car bon dep osits fro m

combustion chambers and valve seat area.

Combustion Area
3

= In. / mm.

Valve Stem Diameter:

Intake: 0.2155" - 0.2161" (5.475 - 5.490 mm)
Exhaust: 0.2147" - 0.2153" (5.455 - 5.470 mm)

7. Measure valve guide inside diameter at the top middle

and end of the guide using a small hole gauge and a NOTE: Carbon Clean Fu el Tre atment (2 871326) ca n
micrometer. Measure in two directions. be used to help remove carbon deposits.

IMPORTANT: Do not u se a met al scr aper, a co arse

wire brush or abrasive cleaners to clean the cylinder
head. Damage may result.

2. Visually inspe ct cylinde r head g asket su rface and

combustion chamber for cracks or damage. Pay close
attention to th e ar eas a round sp ark p lug and va lve
seats.

= In. / mm.

Valve Guide I.D.:

0.2165" - 0.2171" (5.500 - 5.515 mm)

8. Be su re to mea sure each guide a nd valve

combination individually.

NOTE: The valve guides cannot be replaced.

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 ENGINE / COOLING SYSTEM
Valve Seat Reconditioning * If the contact area is less than 75% of the circumference
of the seat, rotate the pilot 180° and make another light cut.
Valve se at reconditioning should be pe rformed by a
technician pr oficient in cylinder hea d reco nditioning * If the cutter now contacts the uncut portion of the seat,
techniques. Reconditioning techniques vary, so follow the check the pilot. Look for burrs, nicks, or runout. If the pilot
instructions pr ovided by the valve reco nditioning is bent it must be replaced.
equipment m anufacturer. D o not grind seats m ore t han
* If the contact area of the cutter is in the same place, the
necessary t o provide p roper seat su rface, w idth, and
valve guide is distorted from improper installation.
contact point on valve face.
* 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
WARNING seat surface is evident.

Wear eye protection or a face shield during NOTE: Remove on ly t he a mount o f material
cylinder head disassembly and reassembly. necessary to repair the seat surface.

5. To ch eck the con tact area o f the seat on the valve

Valve Seat Inspection
face, apply a thin coating of Prussian Blue paste to the
Inspect valve seat in cylinder head for pitting, burnt spots, valve seat. If using an interference angle (46°) apply
roughness, a nd u neven sur face. If a ny of the a bove black permanent marker to the entire valve face (A).
conditions exist, the valve seat must be reconditioned. If
the valve seat is cracked the cylinder head must be
replaced.

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 isuneven, compression leakage will result. If the A
seat is too wide, seat pressure is reduced, causing carbon
accumulation and possible compression loss. Ifthe seat is
too n arrow, he at tr ansfer fr om va lve to se at is r educed.
The valve may over heat an d warp , r esulting in burnt
6. Insert valve into guide and tap valve lightly into place
valves.
a few times.

7. Remove valve an d check where the Pru ssian Blu e

indicates seat contact o n the valve face . The valve
seat should co ntact th e middle of th e 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 lo w, use the 60° cu tter to raise th e se at. When

contact area is centered on the valve face, measure seat
width.

Renewing Valve Seats * If the seat is toowide or uneven, use both topand bottom
cutters to narrow the seat.
1. Install pilot into valve guide.
* If the seat is too narrow, widen using the 45° cutter and
2. Apply cutting oil to valve seat and cutter. re-check contact point on the valve face and seat width
after each cut.
3. Place 46° cutter on the pilot and make a light cut.

4. Inspect the cut area of the seat:

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 ENGINE / COOLING SYSTEM
NOTE: When us ing a n int erference a ngle, t he seat Exhaust Seat Cutter Diameter: 1.364 in. (34.65 mm)
contact point on the valve will be very narrow, and is
a normal condition. Look for an even and continuous EXHAUST
contact point all the way around the valve face (A).

30°
3
Proper Seat Contact
on Valve Face 45°
Seat Width 60°
Intake Seat Cutter Diameter: 1.567 in. (39.80 mm) .059” (1.50 mm)

INTAKE

= In. / mm.

Valve Seat Width:

Intake: .0393" (1.00 mm)
Service Limit: .0551" (1.4 mm)

Exhaust: .0590” (1.50 mm)

Service Limit: .0758" (1.9 mm)
30°

45° 8. Clean all filings from the area with hot s oapy water.
Seat Width Rinse and dry with compressed air.
60° .039” (1.00 mm)
9. Lubricate valve guides with clean engine oil and apply
oil or water based lapping compound to the face ofthe
valve.

NOTE: Lapping is no t req uired if an interference

angle reconditioning method is used.

10. Insert the valve into its respective guide and lap using
a lapping tool or a section of fuel line connected to the
valve stem.

11. Rotate the valve rapidly back and forth until the cut
sounds smooth. Lift the valve slightly off of the seat,
rotate 1/4 turn, and repeat the lapping process. Do this
four to f ive times until t he valve is fully seated, and
repeat process for the other valves.

12. Thoroughly clean cylinder head and valves.

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 ENGINE / COOLING SYSTEM
Cylinder Removal Cylinder Inspection
1. Remove and discard the head gasket. 1. Remove all gasket material from the cylinder sealing
surfaces.
2. Position the cam chain and guides vertically.
2. Inspect th e top of the cylin der for war page using a
3. Tap cylin der lig htly with a p lastic h ammer in th e straight edge and feeler gauge.
reinforced areas only until loose.

4. Rock cylinder forward and backward and lift it from the

crankcase, supporting piston and connecting rod.

5. Remove the cylinder from the engine.

Cylinder Warpage:
.00098” (.025 mm)

3. Inspect cylinder for wear, scratches, or damage.

6. Remove and discard cylinder base gasket.

1/2” Down From Top of Cylinder

X Y

Y
X

Y
X

1/2” Up From Bottom

4. Inspect cylinder for ta per an d ou t o f r ound 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).

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 ENGINE / COOLING SYSTEM
5. Record measurements taken in Step 4. If cy linder is Piston Removal
tapered, or out of r ound beyond .001, cylinder must
be re-bored oversize, or replaced. 1. Note pis ton dir ectional indicator “EX” po sitioned
toward the exhaust side of engine.

Cylinder Taper 2. Remove p iston circlip and pu sh piston p in o ut of

Limit: .001 Max. (0.025 mm) piston. If necessar y, he at th e cr own of the piston
slightly with a heat gun.
Cylinder Out of Round 
Limit: .001 Max. (.025 mm) CAUTION: Do not apply heat to the piston rings, they
may lose radial tension.

Standard Bore Size: 3. Remove top ring.

3
3.8976 +/- 0.0003” (99.0 +/- 0.008 mm) *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.

*By hand: Placing both thumbs as shown, spread the ring

open and push up on the opposite side.

4. Repeat procedure for second ring.

5. Remove oil control ring top rail first, then bottom rail.

6. Remove oil control ring expander.

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 ENGINE / COOLING SYSTEM
Piston-to-Cylinder Clearance Piston / Rod Inspection
1. Measure the ou tside dia meter of the pisto n 1 2 mm 1. Measure piston pin bore.
from the skirt and at a rig ht angle to the direction of
the piston pin.

12 mm

Piston Pin Bore:

Standard.:
Piston Piston Pin
0.8662” - 0.8665” (22.004 - 22.010 mm)

Service Limit:
2. Subtract t his m easurement fr om th e ma ximum
0.8651” (21.975 mm)
cylinder size measurement from cylinder inspection.

Piston to Cylinder Clearance: 2. Measure piston pin O.D. Replace piston and/or piston
.00019” - .00216” (.005 - .055 mm) pin if out of tolerance.

Piston O.D.:
3.8957 - 3.8968” (98.953 - 98.980 mm)

Piston Pin O.D.:

Standard.:
0.8659” - 0.8661” (21.995 - 22.0 mm)

Service Limit:
0.8651” (21.975 mm)

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 ENGINE / COOLING SYSTEM
3. Measure connecting rod small end ID. Inspect bearing Piston Ring Installed Gap
surface for damage.
1. Place each piston ring inside cylinder. Use a pis ton
to push the ring sq uarely into p lace 1” (2 5.4 mm)
down from the cylinder head gasket surface.

2. Measure installed gap with a feeler gauge at location

(A).
Cylinder Head
Gasket Surface

1” A
3
Piston Pin Degree of Fit

Pin should be a push-fit by hand with piston Piston Ring

at room temperature or warmed slightly

Connecting Rod Small End ID:

Standard:
0.8665” - 0.8670” (22.010 - 22.023 mm)

4. Measure piston ring to groove clearance by p lacing Piston Ring Installed Gap
the rin g in th e r ing la nd and mea suring with a
thickness gauge. Replace piston and rings if ring-to- Top Ring
groove clearance exceeds service limits. Std: 0.0059” - 0.0122" (0.15 - 0.31 mm)
Limit: 0.0137" (0.35 mm)
Piston
Ring Second Ring
Std: 0.0094” - 0.0196" (0.24 - 0.50 mm)
Limit: 0.022" (0.56 mm)

Oil Ring Rails

Std: 0.0098” - 0.0401" (0.25 - 1.02 mm)
Feeler Gauge
Limit: 0.0480" (1.22 mm)

NOTE: Always check piston ring installed gap after

Piston Ring-to-Groove Clearance
re-boring a cylinder or when installing new rings.
Top Ring Standard:
0.0011” - 0.0037" (0.030 - 0.095 mm)
Service Limit: 0.0042" (0.108 mm)

Second Ring Standard:

0.0007” - 0.0029" (.020 - 0.076 mm)
Service Limit: 0.0035" (0.89 mm)

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 ENGINE / COOLING SYSTEM
Honing to Oversize Cylinder Hone Selection / Honing Procedure

CAUTION CAUTION

If cylinder wear or damage is excessive, it willbe Selecting a hone which will straighten as well as
necessary to oversize the cylinder using a new remove material from the cylinder is very
oversized piston and rings. This may be important. Using a common spring loaded finger
accomplished by either boring the cylinder and type glaze breaker for honing is never advised.
then finish honing to the final bore size, or by Polaris recommends using a rigid hone or arbor
rough honing followed by finish honing. honing machine which also has the
capability of oversizing.

CAUTION Cylinders may be wet or dry honed depending upon the

hone m anufacturer’s re commendations. W et ho ning
removes more material faster and leaves a more distinct
For oversize honing always wet hone using
pattern in the bore.
honing oil anda coarse roughing stone. Measure
piston (see piston measurement) and calculate
finished bore size. Always leave .002 - .003" (.05
Cleaning the Cylinder After Honing
- .07 mm) for finish bore sizing with a fine stone.
It is very important that the cylinder be thoroughly cleaned
A finished cylinder should have a 45 degree cross-hatch after honing to remove all grit material. Wash the cylinder
pattern to ensure piston ring seating, aid in oil re tention in a solvent, then in hot, soapy water. Pay close attention
and reduce r ing vibr ation during initial break-in. Ho ne to areas where the cylinder sleeve meets the aluminum
cylinder according to hone manufacturer’s instructions, or casting. Use electrical contact clea ner if ne cessary to
these guidelines: clean these areas. Rinse thoroughly, dry with compressed
air, and oil the bore immediately with engine oil.
• Use a mo tor sp eed of a pproximately 300-500
RPM, r un the hon e in and out of the cylinder
rapidly until cutting tension decreases. Remember
to keep the hone drive shaft centered (or cylinder
centered on ar bor) an d to br ing the sto ne
approximately 1/2" (1.3 cm) beyond the bore at the
end of each stroke.

• Release the hone at regular intervals and inspect

the bore to determine if it has been cleared, and to
check piston fit. NOTE: Do not allow cylinder to
heat up during honing.

Example:
Cross Hatch
pattern

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 ENGINE / COOLING SYSTEM
ENGINE ASSEMBLY - TOP END 3. Install upper rail with end gap positioned as shown.
Spring Expander
Piston Ring Installation Ill. 1 Gap Position

NOTE: Apply clean eng ine oil t o all ring surfaces

and ring land s upo n in stallation. Always che ck
piston ring installed gap before rings are installed on
piston (s ee “Pis ton Ring Installed Ga p”). Clean
accumulated ca rbon fro m pist on ring grooves and
oil ring lube holes if piston has been in service. PTO
SIDE

Top Ring
Marking
Up
3
Marking
Up Upper Rail
Second Ring Gap Position Lower Rail
Gap Position

4. Install second ring with marking facing top of piston.

Upper Rail Rotate ring to position the end gap toward intake side
of piston as shown below.

Spring Expander 5. Install top ring with mark facing top of piston. Ro tate
ring to position the end gap toward exhaust side of
piston as shown below.
Lower Rail
Second Ring Top Ring
Gap Position Gap Position
1. Place oil co ntrol ring expa nder in oil ring groove.
Rotate expander in groove until butt ends are on PTO
side of piston (see illustration 1).

IMPORTANT: Ends must butt squarely together and

must not overlap.

2. Install lower rail with end gap positioned as shown in

illustration 1.

6. Be sure top a nd second rings rota te fr eely in their

grooves and do not bind when compressed by hand.

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 ENGINE / COOLING SYSTEM
Piston / Connecting Rod Assembly 4. Place piston (A) on connecting rod (B). Push p iston
pin (C) through rod and piston until it seats against the
1. Lubricate connecting rod small end, piston pin bore installed circlip.
and piston pin with engine oil.
IMPORTANT: Do not tap on pin or cause any sideways
CAUTION force to c onnecting r od. War m pist on crown with a
heat gun if pin cannot be installed by hand, or use a
Do not re-usecirclips. Circlips become deformed piston pin installation tool.
during the removal process.
Do not compress the new clip more than CAUTION
necessary to prevent loss of radial tension.
Severe engine damage may result if circlips are DO NOT apply heat to piston rings or a loss of
re-used or deformed during installation. radial tension could result.

2. Install a new circlip on one side of piston with gap at

the top (12:00 position) or bottom (6:00 position).
A
IMPORTANT: Never re-use a piston pin circlip.

3. When Installing the piston, be sure the piston marking

“EX” is po sitioned towar ds the e xhaust side of the
engine.

C B
D

5. Install th e re maining cir clip ( D) with ga p at the top

(12:00 position) or bottom (6:00 position). Push the
piston pin in both directions to make sure the clips are
properly seated in the groove.

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 ENGINE / COOLING SYSTEM
Cylinder Installation 7. Remove support block and ring compressor.

1. Clean b ase g asket se aling su rface on c ylinder and 8. Push cylinder downwa rd un til fu lly se ated on base
crankcase to remove all oil, grease, or old sealant. gasket.

2. Install a new base gasket.

NOTE: Base gasket and s urfaces must be DRY and

oil free. Use care upon assembly to keep oil away.

3. Slide a commercially available Piston Support Block

under piston skirt as shown to support piston during
cylinder installation.
Image for Reference Only
3

9. Hold the cylinder in place and rotate the engine and

position the piston at TDC.

NOTE: If cam c hain a nd fl ywheel a re installed (top

end work only is be ing pe rformed) hold c am ch ain
tight wh ile r otating the en gine t o a void d amage t o
the chain, drive sprocket teeth, or tensioner blade.

4. Apply clean eng ine oil to cylin der bor e an d bo ttom

tapered portion of cylinder sleeve.

5. Verify all ring end gaps are correctly located on piston.

Place cam chain and guides in alignment with chain
room.

6. Carefully compress rings with fingers or commercially

available spring compression tool and install cylinder
with a slight front to back rocking motion until all rings
are captive in cylinder and past the taper of the sleeve.

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 ENGINE / COOLING SYSTEM
Cylinder Head Assembly 7. Install th e valve spr ing (D) with tigh tly spa ced coils
facing down toward the cylinder head.
NOTE: Assemble t he v alves on e at a t ime to
maintain proper order.

WARNING Top

Wear eye protection during cylinder head

disassembly and reassembly or when working Paint Mark
with the valve springs.
Bottom
1. Apply engine oil to valve guides and seats.

2. Lubricate the valve stems with clean engine oil.

3. Install the valve (A) in the cylinder head, through the NOTE: Valve s prings to be ins talled with the pa int
guide. mark facing up.

8. Place the valve retainer (E) on the spring.

F 9. Compress the valve spring by hand using valve spring

E compressor adapter (PV-43513-A). Compress spring
D only enough to allow split keeper installation.

B PV-43513-A
C

NOTE: To prevent damage to the valve seals, do not

compress the va lve sp ring more tha n ne cessary t o
install the keepers.
4. Carefully install a new va lve seal ( B) o n the val ve
guide with a rotating motion. Push firmly until seated 10. Install split keepers (F) with gap even on both sides.
in retaining groove and square with the guide
11. Repeat this procedure for remaining valves.
5. Dip the seat (C), valve spring (D) and retainer (E) in
clean engine oil. 12. Exercise each valve th rough its tr avel to ensure the
valve keepers are seated correctly.
6. Install the valve spring seat (C).

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 ENGINE / COOLING SYSTEM
13. Install the valve adjustment shim (G) and valve bucket Valve Sealing Test
(H) for each valve in the order they were removed.
1. Clean and dry the combustion chamber area (A).

2. Pour a small amount of clean solvent into each intake

port (B) and check for leakage around the valves. The
valve seats should hold fluid with no seepage.

G 3. Repeat for exhaust valves by pouring fluid into each

exhaust port (C).

3
B

NOTE: Shim 240 is shown for reference only. Refer

to “ Valve C learance Ad justment” procedure f or C
proper shim selection.

IMPORTANT: If a ny va lve tr ain compo nents were

replaced, refer to “Valve Clea rance Adjust ment”
procedure prior to “Camsh aft Inst allation / Timin g”
procedure.

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 ENGINE / COOLING SYSTEM
Cylinder Head Installation
NOTE: Head gasket and surfaces must be DRY and
oil f ree. Use ca re during a ssembly t o keep oil and
finger prints off of gasket.

1. Prepare cylin der h ead ga sket sea ling surfa ces by

cleaning thoroughly to remove all residue. The new
head gasket must be insta lled clean an d dr y, fr ee
from oil or grease.

NOTE: Do not to uch s ealing s urfaces of the new

head gasket.

2. Guide cam chain (D) through a new head gasket (E)

and install the gasket on the cylinder, locating it on the
alignment pins.

3. Carefully set th e cylin der he ad (F) in pla ce on

alignment pins.
G
IMPORTANT: Install new cylinder head bolts.
4. Install an d fing er tig hten the (4 ) new cylin der he ad
H
bolts (G) evenly.

5. Install and finger tighten the (2) new outer M6 bolts

(H) evenly.

6. Torque the new cylinder head bolts in sequence to

specification.

=T
Cylinder Head Torque Procedure:

Step 1: Torque the (4) M11 Bolts in Sequence

21 ft. lbs. (28 Nm)
F
Step 2: Torque the (4) M11 Bolts in Sequence
26 ft. lbs. (35 Nm)
D
Step 3: Torque the (4) M11 Bolts in Sequence
Additional 180° (1/2 turn)
E
Step 4: Torque the Outer M6 Head Bolts
89 ± 9 in. lbs. (10 ± 1 Nm)

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 ENGINE / COOLING SYSTEM
Valve Clearance Check / Adjustment 6. Install the upper cam chain guide and the (8) bolts that
retain the camshaft carrier.
IMPORTANT: Always inspect valve clearance prior to
camshaft installation or final engine assembly.

1. Install the cam ch ain g uides and ca m chain be fore

camshaft installation (if removed) as outlined in this
chapter.

2. Reference the camshaft intake and exhaust markings

made during disassembly. If installing new camshafts
or if camshafts were not marked, you can reference

3
the part number stamped on the end of the shafts.
Exhaust Cam
INTAKE
Intake Cam EXHAUST
(decompression)
Part Number Part Number

7. Torque the camshaft ca rrier bolts in se quence to

specification.

3. Lubricate the camshaft bearing journal surfaces with

Polaris PS-4 Plus engine oil prior to installation.

4. Carefully install the camshafts into the cylinder head.

The camshaft lobes should face out.

=T
Camshaft Carrier Bolts:
7.5 ft. lbs. (10 Nm)

8. Install the Cy linder Holding and Camsha ft Timing

Plate (PU-50563) into the end of camshafts as shown
below. The thermostat housing must be removed to
install the timing plate PU-50563.

5. Carefully insta ll the camshaft carrier onto the

camshafts.

PU-50563

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 ENGINE / COOLING SYSTEM
9. Measure the valve clearance of each valve using a 12. Record the 3 digit adjustment shim number (B).
thickness (feeler) gauge. Record the measurement if
clearance is out of specification.

= In. / mm.
B
Intake Valve Clearance (cold):
.005-.007 in. (0.125-0.175 mm)

= In. / mm.

Exhaust Valve Clearance (cold):

.006-.010 in. (0.152-0.254 mm) NOTE: Shim 240 is shown for reference only.

10. If any of the valve clearance measurements are out 13. Reference the valve clearance m easurement
of specification, re move th e ca mshaft carrier an d recorded fo r th at valve, alon g with the 3- digit sh im
camshafts and proceed with this procedure. number.

NOTE: If a ll valve clear ance meas urements are 14. Refer to the appropriate shim selection matrix (Intake
within s pecification, remov e t he ca mshaft ca rriers or Exha ust) on the fo llowing pag es an d se lect th e
and proceed to “Camshaft Installation / Timing”. proper shim.

11. Remove the valve bucket from a valve that was out of 15. Install the new adjustment shim and valve bucket.
specification.
NOTE: Lubricate th e out er portion of the va lve
bucket upon installation.

16. Repeat steps until all ne cessary valves ha ve been

adjusted.

17. Reinstall th e ca mshafts an d ca mshaft carriers and

tighten the bolts evenly to specification.

=T
Camshaft Carrier Bolts:
7.5 in. lbs. (10 Nm)

18. Measure and co nfirm t hat v alve clearance is now

IMPORTANT: Keep mated parts together and in order within specification for each valve.
with respect to their location in the cylinder head for
assembly purposes. Mark each component or place 19. If valve cle arance is not within specifica tion, r epeat
them in an organized rack as you remove them. this procedure.

20. If all valve clearance measurements are now within

CAUTION specification, rem ove the cam shaft car riers an d
proceed to “Camshaft Installation / Timing”.
If performing this procedure with the cylinder
head installed on the engine, cover the spark
plug holes and the cam chain opening to prevent
a valve adjustment shim from falling into the
cylinder or crankcase.

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 ENGINE / COOLING SYSTEM
Intake Valve Lash - Shim Selection Matrix
Example: = In. / mm.
• Installed shim is 240
• Measured clearance is 0.002 in. (0.06 mm) Intake Valve Clearance (cold):
0.005 - 0.007 in. (0.125 - 0.175 mm)
• Replace 240 shim with 232 shim
Shim Thickness: Exa mple 240 equals thickness of 2.40
mm. Part Number : 3022173-XXX (X s represent 3 digit s
on shim)

Existing Valve Lash Shim Marking (3 digits on shim)

190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248
Correct Valve Lash Shim Marking (3 digits on shim)
250 252 255 258 260 262 265 268 270 272 275 278 280 3
0.000-0.024 178 180 182 185 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268
0.025-0.049 180 182 185 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270
0.050-0.074 182 185 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272
0.075-0.099 185 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275
0.100-0.124 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278
0.125-0.175
(Standard)
0.176-0.200 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282
0.201-0.225 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285
0.226-0.250 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288
0.251-0.275 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290
0.276-0.300 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292
0.301-0.325 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295
0.326-0.350 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298
0.351-0.375 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.376-0.400 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.401-0.425 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.426-0.450 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.451-0.475 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
Intake Valve Clearance Before Adjusting (mm)

0.476-0.500 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.501-0.525 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.526-0.550 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.551-0.575 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.576-0.600 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.601-0.625 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.626-0.650 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.651-0.675 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.676-0.700 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.701-0.725 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.726-0.750 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.751-0.775 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.776-0.800 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.801-0.825 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.826-0.850 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.851-0.875 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.876-0.900 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.901-0.925 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.926-0.950 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.951-0.975 270 272 275 278 280 282 285 288 290 292 295 298 300
0.976-1.000 272 275 278 280 282 285 288 290 292 295 298 300
1.001-1.025 275 278 280 282 285 288 290 292 295 298 300
1.026-1.050 278 280 282 285 288 290 292 295 298 300
1.051-1.075 280 282 285 288 290 292 295 298 300
1.076-1.100 282 285 288 290 292 295 298 300
1.101-1.125 285 288 290 292 295 298 300
1.126-1.150 288 290 292 295 298 300
1.151-1.175 290 292 295 298 300
1.176-1.200 292 295 298 300
1.201-1.225 295 298 300
1.226-1.250 298 300
1.251-1.275 300

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 ENGINE / COOLING SYSTEM

Exhaust Valve Lash - Shim Selection Matrix

Example: = In. / mm.
• Installed shim is 240
• Measured clearance is 0.006 in. (0.16 mm) Exhaust Valve Clearance (cold):
.006-.010 in. (0.152-0.254 mm)
• Replace 240 shim with 232 shim
Shim Thickness: Example 240 equals thickness of 2.40
mm. Part Number : 3022173-XXX (Xs represent 3 digit s
on shim)

Existing Valve Lash Shim Marking (3 digits on shim)

190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280
Correct Valve Lash Shim Marking (3 digits on shim)
0.000-0.025 170 172 175 178 180 182 185 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258
0.026-0.050 170 172 175 178 180 182 185 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260
0.051-0.075 172 175 178 180 182 185 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262
0.076-0.100 175 178 180 182 185 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265
0.101-0.125 178 180 182 185 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268
0.126-0.150 180 182 185 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270
0.151-0.175 182 185 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272
0.176-0.200 185 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275
0.201-0.225 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278
0.226-0.275
(Standard)
0.276-0.300 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282
0.301-0.325 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285
0.326-0.350 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288
0.351-0.375 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290
0.376-0.400 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292
0.401-0.425 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295
0.426-0.450 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298
0.451-0.475 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.476-0.500 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.501-0.525 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
Exhaust Valve Clearance Before Adjusting (mm)

0.526-0.550 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.551-0.575 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.576-0.600 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.601-0.625 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.626-0.650 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.651-0.675 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.676-0.700 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.701-0.725 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.726-0.750 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.751-0.775 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.776-0.800 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.801-0.825 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.826-0.850 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.851-0.875 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.876-0.900 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.901-0.925 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.926-0.950 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.951-0.975 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.976-1.000 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
1.001-1.025 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
1.026-1.050 268 270 272 275 278 280 282 285 288 290 292 295 298 300
1.051-1.075 270 272 275 278 280 282 285 288 290 292 295 298 300
1.076-1.100 272 275 278 280 282 285 288 290 292 295 298 300
1.101-1.125 275 278 280 282 285 288 290 292
295 298 300
1.126-1.150 278 280 282 285 288 290 292 295 298 300
1.151-1.175 280 282 285 288 290 292 295 298 300
1.176-1.200 282 285 288 290 292 295 298 300
1.201-1.225 285 288 290 292 295 298 300
1.226-1.250 288 290 292 295 298 300
1.251-1.275 290 292 295 298 300
1.276-1.300 292 295 298 300
1.301-1.325 295 298 300
1.326-1.350 298 300
1.351-1.375 300

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 ENGINE / COOLING SYSTEM
Camshaft Installation / Timing 6. Carefully install the intake cam at an angle to allow for
cam c hain installation. Ro ll the cam shaft into its
IMPORTANT: If a ny va lve tr ain compo nents were bearing pockets and verify that the timing marks are
replaced, refer to “Valve Clea rance Adjust ment” in alignment as shown below.
procedure prior to “Camshaft Installation / Timing”.

1. Rotate the engine and position the piston at TDC.

2. Reference th e in take and ex haust ma rkings m ade

during disassembly.
Exhaust Cam
INTAKE
Intake Cam EXHAUST
3
(decompression)
Part Number Part Number

3. Lubricate a ll camsha ft lo bes a nd be aring jo urnal

surfaces with Pola ris PS- 4 Plus en gine oil pr ior to
installation.

4. Place the exha ust cam in to th e cylin der he ad and

align the timing marks as shown below.

IMPORTANT: Intake c am spr ocket s hould h ave “I”

marks aligne d wit h g asket su rface and th e e xhaust
cam s procket sh ould ha ve “E” mark s a ligned wit h
gasket surface.
E E

5. Wrap the camchain around the exhaust cam sprocket

and hold the exhaust cam in its current position.

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 ENGINE / COOLING SYSTEM
7. Carefully insta ll the camshaf t ca rrier onto the 10. Verify cam timing is correct and the piston is a TDC.
camshafts.

8. Install the upper cam chain guide and the (8) bolts that
retain the camshaft carrier. Tighten the bolts evenly
until snug. Do not torque at this time.

9. Install th e Cylind er Holding an d Ca mshaft Timing

Plate (PU-50563) into the end of camshafts as shown.

11. If timing marks are not aligned:

• Remove the Camshaft Timing Plate (PU-50563)

from the end of the camshafts.

PU-50563 • Remove the cam carrier bolt and cam carrier.

• Correct the camshaft timing as needed.

• Reinstall the cam carrier.

• Re-check cam timing.

12. Remove the Cylin der Ho lding & Camsha ft Timin g

Plate (PU-50563) from the end of the camshafts.

13. If needed, install the camshaft carrier and bolts.

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 ENGINE / COOLING SYSTEM
14. Torque the camshaft car rier bolts in seq uence to
specification.

=T
Camshaft Carrier Bolts:
7.5 ft. lbs. (10 ± 1 Nm)

15. Insure the new sealing washer (G) is in place.

16. Install the hydraulic cam chain tensioner (H) into the
cylinder and torque to specification.

=T
Cam Chain Tensioner:
30 ft. lbs. (40 Nm)

17. Rotate crankshaft through two revolutions and verify

camshaft timing is correct.

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 ENGINE / COOLING SYSTEM
Camshaft Timing - Quick Reference
Intake Cam TOP END
Exhaust Cam

I E E
I

Align Marks Align Marks

with Surface with Surface

Cam Lobes
Facing Out
PU-50563
Installed

Flywheel Key
Faces Down

Stator Cover / Flywheel Installed

Alignment Hole “V” Marking on

1/4 “ Drive Extension
Flywheel
Stator Cover / Flywheel Removed

BOTTOM END CPS Mounting

Bolt Hole

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 ENGINE / COOLING SYSTEM
Valve Cover Installation 6. Torque valve cover bolts to specification.

1. Apply An ti-seize a nd install th e sp ark plu g (A ) an d

torque to specification. =T
Valve Cover Bolts:
=T 9 ft. lbs. (12 Nm)
Spark Plug:
7 ft. lbs. (10 Nm) Apply Anti-seize

2. Prepare va lve cover se aling sur faces by clean ing

thoroughly to remove all residue.
3
3. Apply a sm all am ount of crankcase sealant to the
cylinder head half-moon cutouts (E) as shown.

Crankcase Sealant: 2871557

4. Install a new valve cover seal (B).

5. Install th e ( 3) va lve co ver sh oulder bo lts (C) an d

isolators (D) using a T40 driver.
A

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 ENGINE / COOLING SYSTEM
ENGINE DISASSEMBLY / INSPECTION - LOWER END
Crankcase Disassembly 3. Hold flywheel with a com mercially a vailable stra p
NOTE: The en gine t op e nd, st arter motor, s tator wrench and remove flywheel nut and washer. Discard
cover, st arter drive , flywhee l, st ator, cam chain, oil the flywheel nut and replace for assembly.
pump and sprockets can be serviced with the engine
NOTE: The flywheel nut has standard rotation (right
installed in the vehicle.
hand) threads.
Flywheel / Stator Housing Removal 4. Back the cen ter screw of flywh eel pu ller PA-49316
1. Remove the sta tor cover as ou tlined in the ” Water completely ou t and screw puller onto flywheel
Pump Mecha nical Seal / Oil Seal Replacement” completely.
procedure” in this chapter.
PA-49316
CAUTION

The flywheel contains powerful magnets.

Use caution when removing the stator cover.
DO NOT place fingers between cover and
crankcase at any time during the removal
process or injury could result.

CAUTION

Be sure engine coolant does not contaminate

the engine oil during stator cover service. 5. Tighten cen ter b olt of too l PA-49 316 an d r emove
flywheel.
2. Remove star ter drive ge ar and sha ft. Inspect ge ar
teeth for damage. Inspect fit of shaft inside gear and
replace ge ar a ssembly if clea rance is e xcessive.
Inspect shaft and shaft bearing surfaces in case and
stator housing for wear.

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 ENGINE / COOLING SYSTEM
Starter One-Way Clutch Inspection 6. Remove starter gear from the flywheel assembly.

1. Remove flywheel as outlined in this chapter.

2. Place flywheel on work bench. Grasp gear and rotate

clockwise. It should turn smoothly without binding.

3. Rotate ge ar co unterclockwise. T he g ear sh ould

immediately lock in position and not slip.

4. Inspect inside of hub (A) for wear, galling, or uneven

surface.

A 3
7. Remove the (3) one-way clutch retaining bolts.

5. Inspect cra nkshaft be aring su rface fo r a bnormal

wear.

8. Remove clutch and inspect both sides of drive rollers

(B) and roller contact surface (C) inside hub for wear,
damage, or uneven surface.

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 ENGINE / COOLING SYSTEM
9. Inspect drive surface of starter gear (D) and bearing Starter One-Way Clutch Installation
surface (E) for wear, damage, or uneven surface. If
any star ter clutch com ponent is wor n or d amaged, 1. Install one-way clutch in clutch hu b with fla nge of
replace clutch, clutch hub, and starter gear. clutch (F) engaged in recess.
Correct
E D F Installation

IMPORTANT: The one -way clutch can be in stalled

into t he hub inc orrectly. This will ca use eng ine
cranking issues.

2. Clean screw threads in flywheel to remove all oil or

grease.

3. Apply Loctite® 272™ on the (3) bolts. Place hub on

flywheel and install (3) bolts.

4. Torque screws to specification.

=T
One Way Clutch Retaining Bolts:
9 ft. lbs. (12 Nm)
Apply Loctite® 272™

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 ENGINE / COOLING SYSTEM
Flywheel Installation 4. Rotate crankshaft so the flyw heel key (A) is facing
upward.
1. Clean the threads, ta per a nd flat of cr ankshaft to
remove all oil or grease. 5. Fully install starter gear onto the crankshaft as shown.

3
A

2. Clean flywheel taper to remove all oil or grease. 6. Align the flywheel ke yway with flywhe el key on the
crankshaft.

7. By ha nd, ligh tly pr ess th e flywhe el inwa rd while

rotating th e star ter ge ar counter clock-wise. Fully
install the flywh eel until seated o n the cr ankshaft
taper.

3. Apply a small amount of PS4 Plus engine oil to the flat

area (A) on the MAG side crankshaft. DO NOT apply
engine oil to the crankshaft taper.

8. Install the flywheel washer.

9. Hold fly wheel with comm ercially availab le strap

wrench.

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 ENGINE / COOLING SYSTEM
10. Torque new flywheel nut (B) to specification. Stator Removal
NOTE: Test stator wire continuity before removing it
C
from the housing.
1. Remove the stator cover as o utlined in the ”Water
Pump Me chanical Seal / Oil Se al Re placement”
procedure” in this chapter.

CAUTION

The flywheel contains powerful magnets.

Use caution when removing the stator cover.
B
DO NOT place fingers between cover and
crankcase at any time during the removal
process or injury could result.
=T
2. Remove and discard the stator cover gasket.
Flywheel Retaining Nut:
133 ft. lbs. (180 Nm)
CAUTION
11. Install starter idler gear and shaft (C).
Be sure engine coolant does not contaminate
the engine oil during stator cover service.

3. Remove the 3 bolts (C) that secure the stator to the

stator cover.

4. Remove the 2 bolts that secure the stator wire routing

bracket (D) to the stator cover.

5. Remove the stator (E) from the stator cover.

C
D
E

Apply Crankcase
Sealant
6 ft. lbs.
9 ft. lbs. (8 Nm)
Apply Loctite
(12 Nm)
Apply Loctite

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 ENGINE / COOLING SYSTEM
Stator / Stator Cover Installation Oil Pump Removal
1. Clean a nd de grease screws an d threads in stator Replace if Loosened or Removed
9 ft. lbs
housing. (12 Nm) Gerotor

2. Clean mounting surfaces of stator and housing. Drive Shaft

Chain
3. Apply crankcase se alant to e dges of ru bber stator Spacer
grommet as shown below.

4. Set the stator in housing and press wire grommet into

slot on housing.

5. Apply Lo ctite® 242™ to en d ( 8-10 thr eads) o f ( 3)

7.5 ft. lbs Cover
Drive Pin 3
stator scr ews (C) an d the (2) wi re ro uting br acket (10 Nm)
screws (D). Washer

6. Install all (5) screws and torque to specification. 1. Rotate the crankshaft to TDC position by aligning the
timing hole in crankcase with a timing hole in the
C crankshaft. Insert a 1/4” drive so cket extension
D through th e cra nkcase an d in to the cr ankshaft
E
locating hole.

2. Remove the (2) oil pump sprocket bolts and washers.

Discard the bolts and replace with new for assembly.
Apply Crankcase
Remove the sprockets and chain from the engine.
Sealant
6 ft. lbs.
9 ft. lbs. (8 Nm)
Apply Loctite
(12 Nm)
Apply Loctite

=T
Stator to Cover Retaining Bolts (C):
9 ft. lbs. (12 Nm) Apply Loctite® 242™

=T
Stator Wire routing Bolts (D):
6 ft. lbs. (9 Nm) Apply Loctite® 242™

7. Install a new stator cover gasket into the engine.

8. Install the stator cover as outlined in this chapter.

CAUTION

The flywheel contains powerful magnets.

Use caution when installing the stator cover.
DO NOT place fingers between cover and
crankcase at any time during the removal
process or injury could result.

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 ENGINE / COOLING SYSTEM
3. Inspect the oil pump chain for worn or missing rollers 6. Grasp the oil pump shaft and pull it outward to remove
or damage. Chain should be replaced as a set with the shaft, oil pump cover and inner oil pump geroter.
sprockets if sprocket teeth are worn. This will prevent the oil pumpdrive pin from falling out
and into the crankcase.

Larger Sprocket
(Upper)

Smaller Sprocket
(Lower)

NOTE: The larger oil pu mp sp rocket moun ts to th e

balance s haft e xtension, t he s maller oil pump IMPORTANT: The gerotor set has (2) orientation dots
sprocket mounts to the oil pump shaft. that must be installed inward upon assembly 
(Figure 1 on the next page).
4. Remove the upper oil pump sprocket spacer.
7. Remove the center geroter, pin and shaft from the oil
pump cover.

NOTE: There is a spacer in be tween t he inne r oil

pump geroter and the oil pump cover.

8. Remove the oil pump geroter that is in the engine case

(if needed).

9. Clean the geroters to remove oil.

10. Inspect su rfaces of pum p ca vity in cr ankcase and

surface of pump cover for scoring or wear.

5. Remove the (3) bolts securing the oil pump cover to

the crankcase.

Spacer

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 ENGINE / COOLING SYSTEM
11. Inspect gerotor for scoring or other damage. Replace 7. Grasp the complete oil pu mp assembly by the drive
parts as a set if damaged. shaft and install the assembly into the crankcase.

3
Figure 1

Oil Pump Assembly 8. Install the ( 3) oil pump cover bo lts and torque to
specification.
1. Clean an d dr y all pa rts thoroughly. Ap ply cle an
engine oil to all parts. Do not use gasket sealer on the
pump cover mating surfaces. =T
2. Align the gerotor according to the orientation dots. Oil Pump Cover Bolt:
7.5 ft. lbs. (10 Nm)
3. Place the d rive p in (A) th rough the o il pu mp drive
shaft. 9. Install the upper oil pump sprocket spacer.
4. Slide the gerotor (B) onto the drive shaft and lock them 10. Install the oil pump sprockets, chain, washer and new
into position on the drive pin. bolts. Oil pump sprockets must be installed in the
correct position, with the word “OUT” facing out.
5. Install the washer (C) onto the drive shaft.
11. Torque sprocket bolts to specification.
6. Install the oil pump cover (D) onto the shaft assembly.

B =T
D
Oil Pump Sprocket Bolt:
9 ft. lbs. (12 Nm)

=
A
Oil Capacity Approx. 2 Quarts (1.9 L)
C
Oil Filter Wrench PU-50105 or 2.5” (64 mm)
Polaris PS-4 Plus
Oil Type
Synthetic Engine Oil

Oil Pressure 10 PSI @ 1200 RPM

Minimum Specification (Minimum)
(using Polaris PS-4 Plus 40 PSI @ 7000 RPM
at operating temperature) (Minimum)

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 ENGINE / COOLING SYSTEM
Crankcase Breather Service Crankcase Separation
NOTE: Th e cran kcase breather is se rviceable with NOTE: Before th e cr ankcase ca n be sep arated, b e
the e ngine as sembled and in stalled in t he v ehicle sure the entire top en d and oil pump ass embly ar e
chassis. removed from the engine as outlined in this chapter.

1. Remove th e cr ankcase vent tu be (if no t alr eady 1. Rotate the e ngine on the e ngine stand so the
performed). magneto side is facing upward.

2. Remove th e (2 ) fa steners s ecuring th e e ngine 2. Remove the oil filter and the (3) fasteners that secure
breather cover to the engine. oil filter adapter (A) to the crankcase. Discard O-rings
and through clean the adaptor for reassembly.
3. Remove the b reather cove r g asket a nd replace if
damaged.
A
4. For reassembly, thoroughly clean the crankcase and
breather cover mating surfaces. Install a new gasket
and torque the (2) fasteners to specification. Apply Loctite® 272™

9 ft. lbs.
(12 Nm)

20 ft. lbs.
(28 Nm)

3. Remove and discar d the ( 15) flan ge bolts fro m

To Intake
Baffle Box magneto side cr ankcase evenly in a cr iss-cross
pattern.

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 ENGINE / COOLING SYSTEM
4. Separate cr ankcase by ta pping wi th a soft faced 3. Inspect drive gear for broken or damaged teeth.
hammer in reinforced areas and lift MAG cr ankcase
off PTO case. 4. Inspect bearing surfaces for scoring or signs of wear.

5. Inspect / replace the balance shaft bearings in both

Balance Shaft Removal / Inspection crankcase halves. Se e “ Crankcase Be aring
Inspection / Removal” procedure in this chapter.
1. Rotate crankshaft to align the timing marks as shown
below. NOTE: Due to ext remely clos e t olerances an d
minimal wear , counterbalance shaft ba ll be arings
must be insp ected v isually an d by f eel. Loo k fo r
signs of discoloration, sc oring or gallin g. Turn the
inner race of each bearing. The bearings should turn
smoothly and quietly. The outer race of each bearing
should f it tightly in th e cra nkcase bore. The inner
race shou ld be firm wit h minimal side to side
movement and no detectable up and down ( radial)
movement.

2. Pull upward on the balance shaft and remove it from

the crankcase.

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 ENGINE / COOLING SYSTEM
Crankshaft Removal Crankshaft Inspection
1. Remove the engine from the engine stand and place IMPORTANT: The c onnecting rod u ses plain
the assembly on a sturdy work bench. bearings. The co nnecting rod be arings a re not
serviceable. If ANY exc essive we ar or mov ement is
2. Remove the ( 2) bolts secur ing the bearing r etainer present or if the rod does not rotate on the crankshaft
plate to the crankcase. Remove the bearing plate. freely, the crankshaft assembly must be replaced.

3. Install the crankshaft removal / installation tool 1. Use a feeler gauge to measure the connecting rod big
PU-50784 on to the PTO side crank case. end side clearance (A).

• Install plate “A” over adapter “B”.

• Evenly attach the assembly onto the PTO side

crankcase using the (4) bolts as shown below.

• Thread the crankshaft removal screw “C” into A

adapter “B”.
PU- 50784
X4
B

A Connecting Rod Big End Side Clearance:

0.00590-.01771” (.15 - .45mm)

C 2. Measure the connecting rod small end I.D. (B).

B
B

A
Small End I.D. Standard:
0.8665” - 0.8670” (22.010 - 22.023 mm)
Service Limit: 0.08682” (22.053 mm)
4. With the help of an assistant holding the crankshaft,
slowly t ighten th e screw “C ” unt il the crankcase is
completely separated from the crankshaft.

5. Remove all special tools from the crankcase.

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 ENGINE / COOLING SYSTEM
3. Place the crankshaft in a truing stand or V-blocks and PTO Side Crankcase Bearing Service
measure the runout where indicated below with a dial
indicator. Bearing Removal
NOTE: Due to ext remely clos e t olerances an d
minimal wea r, the be arings mu st be inspected
visually, and by feel. Look for signs of discoloration,
scoring or g alling. T urn t he inn er ra ce of each
C C bearing. T he be arings sho uld turn smoot hly an d
quietly. Th e out er ra ce of ea ch be aring s hould f it
tightly in the cra nkcase. The inne r ra ce s hould be
firm with minimal side to side mo vement and n o
detectable up and down movement.
3
NOTE: Bearings are st ressed during the remov al
process and must not be re-used!

1. Remove and discard the PTO side cra nkshaft seal.

Replace with new for assembly.

2. If not already performed, remove the (2) screws that

secure the bearing retainer to the case.

3. Remove the retaining ring.

D D
4. Support the crankcase and drive, press, or extract the
(3) bearings with a blind bearing remover.

Maximum Runout:

Inner (C) - 0.00118” (0.03 mm)

Outer (D) - 0.00590” (0.15 mm)

IMPORTANT: The MAG side crankshaft plain bearing Bearing Seal

is not s erviceable. Cra nkcase re placement is Retainer
required if the bearing is damaged or has excessive
wear. The cra nkshaft is reusable if it meets Spacer
specifications an d M AG si de b earing s urface i s n ot
groved, pitted, damaged or excessively worn.

Retaining
Ring

8 ft. lbs.
(11 Nm) Bearing
Apply Loctite® 272™

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 ENGINE / COOLING SYSTEM
Installation MAG Side Crankcase Bearing Service
NOTE: To ea se bea ring installation, warm t he Bearing Removal
crankcase evenly with a heat gun or place in an oven
and he at to 220 -250° F. Pla ce bea rings in clean 1. Support the cr ankcase a nd dr ive, pr ess, or extra ct
plastic wrap and set in a freezer for 10-20 minutes. the bala nce shaft bea ring with a blind bea ring
remover.
1. Clean a ll b earing bo res and in spect for excessi ve
wear. IMPORTANT: The MAG side crankshaft plain bearing
is not ser viceable. Crank case rep lacement is
2. Lubricate all bearing bores with clean engine oil. required if the bearing is damaged or has excessive
wear. The c rankshaft is re usable if it me ets
3. Fully se at the new ba lance shaft be aring un til specifications and M AG side b earing surf ace is not
bottomed in the bearing bore. groved, pitted, damaged or excessively worn.

4. Install the retaining ring for the crankshaft bearings.

5. Fully seat the new outer PTO crankshaft bearing until

bottomed against the retaining ring.

6. Install the bearing spacer.

7. Press in the new inner PTO bearing until it is bottomed

against the bearing spacer.

8. Apply Loctite® 272™ to the (2) bearing retainer bolts.

9. Install the bearing retainer and torque the fastener to

specification.

Non Serviceable
=T MAG Side Plain Bearing

Bearing Retainer Fastener:

8 ft. lbs. (11 Nm)
Apply Loctite® 272™

Balance
Shaft
Bearing

NOTE: Due to e xtremely cl ose to lerances an d

minimal wear, t he be arings must b e inspected
visually, and by feel. Look for signs of discoloration,
scoring or g alling. T urn t he inner r ace of eac h
bearing. The be arings sho uld tur n smoot hly a nd
quietly. Th e out er ra ce of ea ch be aring should f it
tightly in the cra nkcase. The inn er ra ce s hould b e
firm wit h min imal s ide t o side move ment and no
detectable up and down movement.

NOTE: Bearings are st ressed during the remo val

process and must not be re-used!

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 ENGINE / COOLING SYSTEM
Installation Oil Pressure Regulator (Bypass) Valve
Inspection
1. Clean a ll b earing bo res and in spect for excessive
wear. The oil pressure regulator (bypass) valve is located in the
MAG side crankcase (B).
2. Lubricate all bearing bores with clean engine oil.
1. Use a br ass drift to press out th e oil pr essure valve
3. Fully se at th e new ba lance shaft be aring un til from the crankcase.
bottomed in the bearing bore.
2. Replace the o il pr essure valve if the inner p lunger
Oil Pickup Assembly Inspection binds, sticks or does not operate smoothly.

The o il picku p a ssembly is located

crankcase (A).
in the M AG side 3. Remove and discard the O-ring.
3
4. Thoroughly clean the valve.

5. Replace the O-ring and lubricate with clean engine oil.

B
6. Press the oil pressure valve into the crankcase until
fully seated.

B
A

1. Pull and twist to remove the oil pickup assembly from

the crankcase. A

2. Inspect the assembly for cracks and excessive wear.

Replace if necessary.

3. Remove and discard the O-ring. Crankcase Inspection

4. Thoroughly clean the pickup assembly. 1. Remove a ll traces of gasket se aler fr om the
crankcase mat ing surfaces . Inspect the surfaces
5. Replace the o-ring and lubricate with clean engine oil. closely for nicks, burrs or damage.
6. Press th e p ickup a ssembly into the crankcase unt il 2. Be sure alignment pins are in place where used.
fully seated.
3. Be sur e oil p assages are clean an d fr ee of a ny
cleaning solvent.

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 ENGINE / COOLING SYSTEM
ENGINE ASSEMBLY - LOWER END
PU- 50784
Crankcase Assembly - PTO Side X4
B
1. Lubricate a ll cran kcase be arings with e ngine o il.
Clean sealing surface to remove all old sealant.
D
2. Place crankcase on a sturdy work bench.

3. Carefully set the PTO cran kcase onto the PTO side
of the crankshaft. A
4. Align the connecting rod with the cylinder area if the
crankcase.
C
5. Install the crankshaft removal / installation tool 
PU-50784 on to the PTO side crankcase.

• Install plate “A” over adapter “B”. Nut and

Washer D
• Evenly attach the assembly onto the PTO side
crankcase using the 4 bolts as shown below.

• Place the nut and large washer onto the

crankshaft installation screw “D”.

• Insert the crankshaft installation screw “D” through B

the threaded portion of the adaptor “B”.
A
• Fully thread the crankshaft installation screw “D”
into the clutch bolt threads of the crankshaft.

• With the help of an assistant holding the 6. With the help of an assistan t, slowly tighten the nut
crankshaft, firmly hold the crankshaft installation until th e crankshaft is co mpletely seated into the
screw “D” with a wrench while tightening the large crankcase bearings.
nut against the adaptor “B”.
7. Remove the crankshaft removal / installation tool 
PU- 50784 from the crankcase.

8. Be su re crankshaft is fully se ated and r otates

smoothly.

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 ENGINE / COOLING SYSTEM
IMPORTANT: The c rankshaft s eal c an be replaced 11. Drive seal until flush with seal bore.
with the engine installed in the chassis. The engine
does not have to be removed and the crankcase does
not ha ve to b e se parated t o re place the cra nkshaft
seal.

9. Lubricate a new crankshaft seal and slide it over the

PTO end of the crankshaft. with numbers facing OUT.
Be sure seal lip does not fold back when moving over
the crankshaft flange.

10. Use the crankshaft removal / installation tool 

PU-50784 to properly drive the cran kshaft seal into
the crankcase.
3
• Center plate “A” over the crankshaft so it is resting
on the crankshaft seal.
12. Turn PTO crankcase over and support with crankshaft
• Center adaptor “B” over the crankshaft end. upright.

• Place the nut and large washer onto the

crankshaft installation screw “D”.

• Insert the crankshaft installation screw “D” through

the threaded portion of the adaptor “B”.

• Fully thread the crankshaft installation screw “D”

into the clutch bolt threads of the crankshaft.

• Firmly hold the crankshaft installation screw “D”

with a wrench while tightening the large nut
against the adaptor “B”.

B Nut and
Washer

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 ENGINE / COOLING SYSTEM
Balance Shaft Installation / Timing Final Crankcase Assembly
1. Position balance shaft in the crankcase. 1. Prepare MAG side crankcase by clean ing se aling
surface. Be sure the oil pickup and oil pressure valve
2. Rotate crankshaft to alig n the tim ing marks ( A) as are fully installed.
shown below.

3. Fully seat the balance shaft into the crankcase and

verify timing marks are correct.

2. Apply a thin film of Crankcase Sealant (PN 2871557)

evenly to a clean and oil-free MAG crankcase mating
surface as indicate d below. Be sure alignment pins
(A) are in place.

Crankcase Sealant: 2871557

3. Assemble MAG crankca se to PTO crankc ase

immediately. Do not allow sealant to dry.

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 ENGINE / COOLING SYSTEM
4. Tap crankcase evenly until fu lly se ated with a soft 8. Install the engine stand adapter (PU-50824) onto the
sided hammer. engine PTO side mounting ears as shown below.

Bolts From The

Center Outward

3
PU- 50824

5. Install th e (1 5) new crankcase bo lts fin ger tig ht in

9. Select th e pr oper eng ine stan d slee ve ada pter and
MAG side crankcase.
install it onto the engine stand adapter.
6. Tighten all bolts evenly until snug.
• Sleeve adapter for a 2” bore engine stand: 
7. Torque th e new crankcase bolt s to in sequenc e to (PU-50625)
specification. • Sleeve adapter for a 2.375” bore engine stand: 
(PW-47054)

10. Place engine onto the engine stand (PU- 50624) for
top end engine assembly as outlined in this chapter.

=T
Crankcase Bolts (In Sequence):
22 ft. lbs. (30 Nm)

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 ENGINE / COOLING SYSTEM
TROUBLESHOOTING Engine Idles But Will Not Accelerate
• Spark plug fouled/weak spark
Engine
• Broken throttle cable
Spark Plug Fouling
• Obstruction in air intake
• Spark plug cap loose or faulty
• Air box removed (reinstall all intake components)
• Incorrect spark plug heat range or gap
• Incorrect flywheel installation or sheared flywheel
• PVT system calibrated incorrectly/ components key.
worn or mis-adjusted
• Restricted exhaust system
• Fuel quality poor (old) or octane too high
• Cam worn excessively
• Low compression
Engine Has Low Power
• Restricted exhaust
• Spark plug fouled
• Weak ignition (loose coil ground, faulty coil, or
stator) • Cylinder, piston, ring, or valve wear or damage
(check compression)
• Restricted air filter (main or pre-cleaner) or
breather system • PVT not operating properly

• Improperly assembled air intake system • Restricted exhaust muffler

• Restricted engine breather system • Cam worn excessively

• Oil contaminated with fuel Piston Failure - Scoring

Engine Turns Over But Fails To Start • Lack of lubrication

• No fuel • Dirt entering engine through cracks in air filter or

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

Engine Does Not Turn Over Piston Failure - Scoring

• Lack of lubrication
• Dead battery
• Dirt entering engine through cracks in air filter or
• Starter motor does not turn ducts
• Engine seized, rusted, or mechanical failure • Engine oil dirty or contaminated
Engine Runs But Will Not Idle Slow Engine Cranking
• Restricted fuel supply
• Weak battery
• Low compression
• Loose Electrical connections
• Crankcase breather restricted
• Decompression Mechanism not functioning
properly.

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 ENGINE / COOLING SYSTEM
Excessive Smoke and Carbon Buildup Cooling System
• Excessive piston-to-cylinder clearance Overheating
• Wet sumping due to over-full crankcase • Low coolant level
• Worn rings, piston, or cylinder • Air in cooling system
• Worn valve guides or seals • Wrong type/mix of coolant
• Restricted breather • Faulty pressure cap or system leaks
• Air filter dirty or contaminated • Restricted system (mud or debris in radiator fins
Low Compression causing restriction to air flow, passages blocked in

• Cylinder head gasket leak

radiator, lines, pump, or water jacket, accident
damage)
3
• No valve clearance (cam wear) • Lean mixture (vents, fuel pump or fuel valve)
• Cylinder or piston worn
• Fuel pump output weak
• Piston rings worn, leaking, broken, or sticking
• Electrical malfunction
• Bent valve or stuck valve
• Water pump failure/ Loose impeller
• Valve spring broken or weak
• Thermistor failure
• Valve not seating properly (bent or carbon
• Cooling fan inoperative or turning too slowly
accumulated on sealing surface)
(perform current draw test)
• Rocker arm sticking
• Low oil level
Backfiring • Spark plug incorrect heat range
• Fouled spark plug or incorrect plug or plug gap • Faulty hot light circuit
• Exhaust system air leaks • Thermostat stuck closed or not opening
completely
• Valve sticking
• Radiator is missing its internal diverter plate not
• Ignition system faulty: 
allowing coolant to flow through entire radiator
Spark plug cap cracked / broken
Temperature Too Low
Ignition coil faulty
• Thermostat stuck open
Ignition or kill switch circuit faulty
Poor connections in ignition system Leak at Water Pump Weep Hole
Ignition timing incorrect • Faulty water pump mechanical seal (coolant leak)

Sheared flywheel key • Faulty pump shaft oil seal (oil leak)

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 ENGINE / COOLING SYSTEM

NOTES

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 ELECTRONIC FUEL INJECTION
CHAPTER 4
ELECTRONIC FUEL INJECTION
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
ELECTRONIC FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
PRINCIPAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
EFI OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
INITIAL PRIMING / STARTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
ELECTRONIC CONTROL UNIT (ECU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
ECU SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
ECU REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12

4
ECU REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
TEMP / MANIFOLD ABSOLUTEPRESSURE SENSOR (T-MAP). . . . . . . . . . . . . . . . . . 4.13
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
T-MAP SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
T-MAP SENSOR REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
CRANKSHAFT POSITION SENSOR (CPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
FUEL INJECTOR TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
FUEL INJECTOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
FUEL INJECTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
FUEL SENDER TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
FUEL PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
FUEL PUMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
FUEL TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24
FUEL TANK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27
IDLE AIR CONTROL (IAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27
THROTTLE POSITION SENSOR (TPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.28
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.28
TPS RESISTANCE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29
TPS TESTER / REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29
TPS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29
ENGINE COOLANT TEMPERATURE SENSOR (ECT) . . . . . . . . . . . . . . . . . . . . . . . . . 4.31
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.31
ECT SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.31
ECT SENSOR REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.32
IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.32
EFI DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.34
DIGITAL WRENCH™ OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.38
EFI SYSTEM ELECTRICAL DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.47

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 ELECTRONIC FUEL INJECTION
GENERAL INFORMATION Fuel Pressure Gauge Kit - PU-43506-A

IMPORTANT: The EFI fuel system remains under high

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

Special Tools

PART Disconnect here and connect

TOOL DESCRIPTION in-line w/fuel pump outlet
NUMBER
PU-43506-A Fuel Pressure Gauge Kit
PV-48656 Fuel Pressure Gauge Adaptor
Digital Wrench™ Diagnostic Software
(Includes most recent version of software
PU-47063-B
w/serial number, standard interface cable
and SmartLink Module Kit)
Digital Wrench™ SmartLink Module Kit Digital Wrench™ Diagnostic Software - PU-47063-A
PU-47471
(PU-47470, PU-47469, PU-47468)
This de aler-only sof tware inst alls on laptop co mputers
Digital Wrench™ equipped with a CD drive and serial port connection, and
PU-47470
PC Interface Cable is designed to re place multiple shop tools often used to
Digital Wrench™ test EF I comp onents. It also includ es step-by-step
PU-47469 diagnostic pr ocedures to a id techn ician r epair an d
Vehicle Interface Cable
troubleshooting.
Digital Wrench™
PU-47468
SmartLink Module IMPORTANT: If the PC you are using is not equipped
with a 9-pin serial port, a USB to serial port adaptor
SPX Corporation: 1-800-328-6657or http://polaris.spx.com/. will be necessary. A USB to serial port adaptor can be
purchased through DSA at: www.diagsys.com

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 ELECTRONIC FUEL INJECTION
Digital Wrench™ SmartLink Module Kit - PU-47471 Digital Wrench™ - Download Website
This module kit contains the ne cessary cab les a nd Located at: www.polaris.diagsys.com
hardware to communicate between the vehicle ECU and
the Digital Wrench™ diagnostic software. Polaris dealers
can als o or der th e follo wing kit co mponents separately:
SmartLink Module PU-47468, Vehicle Interface Cable
PU-47469 and PC Int erface Cab le PU-4 7470. This
module kit is used on all 8 pin connector-based Polaris EFI
systems. This kit is available to Polaris dealers through our
tool supplier SPX at (1-800-328-6657) or http://
polaris.spx.com

PU-47469

4
Download Digital Wrench™ Updates:

PU-47468
PU-47470

Digital Wrench™ - Diagnostic Connector

Located under the dash connected to a sealed plug.

IMPORTANT: For th e most recent info rmation on

Digital Wren ch™ software an d update downloads
please visit the website: www.polaris.diagsys.com

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 ELECTRONIC FUEL INJECTION
Service Notes • Do not allow the battery cables to touch opposing
terminals. W hen connecting b attery ca bles attach
• For m ore co nvenient a nd a ccurate testing of EF I the positiv e (red) cable to posit ive (+) batt ery
components, it is recommended dealers utilize the terminal first, followed by negative (black) cable to
Digital W rench™ Diag nostic Sof tware ( dealer negative (-) battery terminal.
only), or testing may b e done manually using the
procedures provided. • Never start the engine when the cables are loose
or poorly connected to the battery terminals.
• 80% o f al l EF I pro blems a re c aused by wi ring
harness connections. • Never disconnect battery while engine is running.

• For the purpose of troubleshooting difficult running • Never use a battery boost-pack to start the engine.
issues, a kn own-good ECU fr om an other
• Do not charge battery with key switch "on."
RANGER RZR 5 70 of the same model a nd year
may be used without damaging system or engine • Always disconnect negative (-) battery cable lead
components. before charging battery.
• Never at tempt to serv ice any fuel sys tem • Always unplug ECU fr om the wire harness before
component while en gine is r unning or ig nition performing any welding on the unit.
switch is "on."
• Cleanliness is essential and must be maintained at
all tim es when ser vicing or working o n th e EFI
system. Dirt , even in sm all qu antities, can cause
significant problems.
• Do not use comp ressed air if the system is open.
Cover any p arts r emoved a nd wra p a ny op en
joints w ith plas tic if th ey 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 ever y pr ecaution has b een t aken to
prevent wa ter intru sion fa ilure, avoid dir ect water
or spray contact with system components.
• Do not disconnect or reconnect the wiring harness
connector to th e c ontrol u nit or an y in dividual
components with the ignition "on." This can send a
damaging voltage spike through the ECU.

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 ELECTRONIC FUEL INJECTION
EFI System Exploded View
1. Electronic Control Unit (ECU) 13. Spark Plug Wire
2. Temperature / Manifold Absolute Pressure Sensor (T-MAP) 14. Idle Air Control (IAC)
3. Crankshaft Position Sensor (CPS)
4. Fuel Injector
5. Fuel Filter
6. Fuel Pump / Regulator / Fuel Level Sender (located in fuel tank)
7. Fuel Rail / Regulator
8. Engine Coolant Sensor (ECT)
9. Throttle Position Sensor (TPS)
10. Throttle Body
11. Ignition Coil
12. Spark Plug

1 4
11 6

13 5

12 4

10
14
2

9
3

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 ELECTRONIC FUEL INJECTION
EFI System Component Locations 4. Fuel Injectors / Fuel Rail / Regulator
- Attached to the fuel rail located in the intake track of
1. Electronic Control Unit (ECU) the cylinder head.
- Located behind the driver’s seat.
Fuel Rail

Fuel Injector

ECU

5. Fuel Pump / Regulator / Fu el Ga uge Sender

2. Temperature and Manifold Ab solute Pr essure Assembly
Sensor (T-MAP) - Located under the passenger seat.
- Lo cated in the r ubber in take b oot b etween the
throttle body and the cylinder head. Located in Fuel Tank

T-MAP
Fuel Line
Connection

Regulator

Pump / Sending Unit Fuel Pump

Connection

Preliminary Filter
3. Crankshaft Position Sensor (CPS)
- Located in the magneto cover on the right-hand side
of the Engine.

CPS

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 ELECTRONIC FUEL INJECTION
6. Throttle Body 9. Engine Coolant Temperature Sensor (ECT)
- Located between the rubber air box boot and rubber - Lo cated in the cylinder h ead und erneath the
cylinder he ad ad aptor un der th e ca rgo bo x access thermostat housing. The sensor can be accessed with
panel. the rear service p anel, cargo box access panel and
the clutch outlet hose removed.
7. Throttle Position Sensor (TPS)
- Located on the right-hand side of the throttle body
below the IAC motor. ECT

8. Idle Air Control Motor (IAC)

- Located on the upper right-hand side of the throttle
body above the TPS.

4
10. Ignition Coil
- Located in the LH rear wheel well area, behind the
PVT inlet hose.

IAC

Ignition Coil

PVT Inlet Hose

Throttle Body TPS

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 ELECTRONIC FUEL INJECTION
FUEL TANK
Exploded View

Fuel Flow
Fuel Rail Fuel Injector

Fuel Tank

Pressure Regulator

Fuel Filters Fuel Pump Assembly Quick Connect Fuel Line

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 ELECTRONIC FUEL INJECTION
Fuel Lines - Quick Connect
To Fuel Rail

Formed Fuel Line

Fuel Tank

1. Place a shop towel around the fuel line to catch any

dripping fuel. Sq ueeze the c onnector ta bs t ogether
4
and push the locking slide back.

Squeeze Connector Tabs

2. Pull on the fuel line for removal.

3. To install the line(s), verify the connections are clean
and free of debris.
4. Snap the fuel line back over the nipple and slide the
locking me chanism ba ck into p lace. Ve rify the
connector tabs snap back into place.

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 ELECTRONIC FUEL INJECTION
ELECTRONIC FUEL INJECTION The ECU con trols the amount of fuel being injected and
the ig nition timing by m onitoring the primary sensor
Principal Components signals for int ake air temperature, mani fold absol ute
pressure (load), engine temperature, speed (RPM), and
The Electronic Fuel Injection (EFI) system is a complete throttle position. These primary signals are compared to
engine fuel and ignition management design. This system the programming in the ECU computer chip, and the ECU
includes the following principal components: adjusts the fuel delivery and ignition timing to match the
values.
• Fuel P ump
• Fuel Rail During operation, the EC U ha s the ability to re-adjus t
• Fuel Line temporarily; providing compensation for chan ges in
overall engine condition and operating environment, so it
• Fuel Filter(s)
will be able to maintain the ideal air/fuel ratio.
• Fuel Injector
• Pressure Regulators During certain operating periods such ascold starts, warm
• Throttle Body / lntake Manifold up, acceler ation, e tc., a richer air / fue l ratio is
• Engine Control Unit (ECU) automatically calculated by the ECU.
• Ignition Coils
• Engine Coolant Temperature Sensor (ECT) Initial Priming / Starting Procedure
• Throttle Position Sensor (TPS) NOTE: The in jection system must be purg ed of all
• Crankshaft Position Sensor (CPS) air prior t o the initial st art up, and / or any time the
• Temperature and Manifold Absolute Pressure system has been disassembled.
Sensor (T-MAP)
If the EFI system is completely empty of fuel or has been
• Idle Air Control Motor (IAC)
disassembled and repaired:
• Wire Harness Assembly
• Check Engine Light 1. Cycle the key switch from “OFF” to “ ON” 6 time s,
waiting for app roximately 3 secon ds at ea ch “ON”
EFI Operation Overview cycle to allow the fuel pump to cycle and shut down.

The EFI system is design ed to p rovide pe ak eng ine 2. Once step 1 is c ompleted, t urn the key sw itch to
performance with optimum fuel ef ficiency an d lowest “START” un til the en gine starts or 5 seconds h as
possible em issions. The ig nition a nd inje ction fu nctions passed.
are ele ctronically contr olled, mo nitored an d co ntinually
corrected during operation to maintain peak performance. 3. If the engine failed to start, repeat step 1 for 2 more
cycles and attempt to start the engine.
The ce ntral comp onent of the system is th e Bosch
Electronic Control Unit (ECU) which manages sys tem If the engine fails to s tart, a problem may still exist, and
operation, deter mining th e best co mbination of fuel should be diagnosed.
mixture a nd ig nition tim ing for the cu rrent op erating
conditions. NOTE: Accurate te sting of EF I c omponents is
recommended utilizing t he Digit al Wrench™
An in-tank electric fuel pump is used to move fuel from the Diagnostic Software (dealer only).
tank through the fuel line, to the fuel rail. The in-tank fuel
pressure regulator maintains a system operating pressure
and returns any excess f uel back in to th e t ank. At th e
engine, fuel is fed thr ough the fue l ra il an d in to the
injectors, which inject into the intake po rts. Th e ECU
controls the amount of fuel b y varying the length of time
that the injectors are "on." This range can vary depending
on fuel requirements. The controlled injection of the fuel
occurs every other crankshaft revolution, or once for each
4-stroke cycle. The total amount of fuel n eeded for one
firing of a cylinder is injected during each cycle. When the
intake valve opens, the fuel/air mixture is drawn into the
combustion chamber, ignited and burned.

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 ELECTRONIC FUEL INJECTION
ELECTRONIC CONTROL UNIT (ECU) RANGER RZR 570 EFI RPM Limit:
Max RPM Limit - Injector and ignition suppression.
Operation Overview
• RZR 570: 7750 RPM (All Gears)
The ECU is the brain or central processing computer of the
entire EF I fu el/ignition ma nagement system. Dur ing
operation, sensors continu ously g ather data which is ECU Service
relayed through the wiring harness to input circuits within
the ECU. Sign als to the ECU include: ig nition (on/off), Never attempt to disassemble t he EC U. It is sealed t o
crankshaft position and sp eed (RPM), th rottle po sition, prevent damage to internal components. Warranty is void
engine coolant temperature, intake air temperature, intake if the case is opened or tampered with in any way.
manifold absolute pressure and battery voltage. The ECU
All operating and control functions within the ECU are pre-
compares the input signals to the programmed maps in its
set. No internal servic ing or re adjustment may b e
memory and determines the a ppropriate fuel a nd spark
performed. If a pr oblem is enco untered, a nd you
requirements for the immediate operating conditions. The
determine the ECU to be faulty, contact the Polaris Service
ECU then sends output signals to set the injector duration

4
Department for specific h andling instructions. Do not
and ignition timing.
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 kn own-good ECU

from an other Polaris RANGER RZR 57 0 of the same
model may be used without system or engine component
damage.
ECU

During operation, the ECU contin ually per forms 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 fa ult memo ry. De pending 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” ligh t by re ferencing the
“Instrument Cluster Trouble Co de Display” a nd
“Diagnostic T rouble Cod e T able” or by using Digit al
Wrench™. The ECU requires a minimum of 7.0 volt s to
operate. T he memory in the ECU is operational the
moment the battery cables are connected.

To p revent en gine ove r-speed an d p ossible fa ilure, an

RPM limiting feature is programmed into the ECU. If the
maximum RPM limitis exceeded, the ECU suppresses the
injection signals, cutting off the fuel flow and retards the
ignition timin g. This process r epeats it self in ra pid
succession, limiting operation to the preset maximum.

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 ELECTRONIC FUEL INJECTION
ECU Replacement 4. To in stall, r everse the pr ocedure an d tig hten the
mounting screws to specification.
Although the ne ed for ECU r eplacement is u nlikely, a
specific replacement procedure is required to ensure that NOTE: Upon ins talling t he ECU c onnector, y ou
all essentia l da ta con tained within the original ECU is should hea r a “click” when t he conn ector is f ully
transferred to the replacement ECU. closed.

IMPORTANT: Refer to this proc edure and ca refully

follow all instructions provided in Digital Wrench™. =T
1. Carefully follow the ECU replacement instru ctions ECU Retaining Screws
provided in D igital Wr ench™ to en sure th at all 10 in. lbs. (1.1 Nm)
essential dat a cont ained within the original E CU is
transferred to the replacement ECU.
ECU Replacement
2. Remove the black plastic cover by lifting up on the tab.
1. Remove the (2) retaining screws holding the ECU.
Remove the retaining screw that attaches the ECU to
the left rear fender well. 2. With the ig nition turn ed off, disconnect the wir e
harness from the ECU.
Lift Tab Remove
3. To install, reverse the procedure and tighten screws
to specification.

=T
ECU Retaining Screws
10 in. lbs. (1.1 Nm)

Remove

3. With the ign ition turned off, d isconnect the wire

harness from the ECU. Lift the connector locking lever
and rotate it up u ntil the connector is free fro m the
ECU.

NOTE: Upon remov ing th e ECU c onnector, you

should he ar a “clic k” whe n t he c onnector is f ully
open.

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 ELECTRONIC FUEL INJECTION
TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP)
Operation Overview 6. Install the sensor by inserting it with a twisting motion
to properly seat the grommet.
Mounted on the throttle body intake manifold, the T-MAP
sensor performs two functions in one unit.
T-MAP
Bolt
T-MAP

Intake Boot

4
7. Install the retaining bolt and torque to specification.

Air passing through the intake is measured by the T-MAP

and r elayed to the ECU. Th ese signa ls, comp rised of =T
separate air temperature and manifold absolute pressure
readings, are processed by the ECU and compared to its T-MAP Retaining Bolt Torque:
programming for determining th e fu el an d ign ition 24 in. lbs. (2.8 Nm)
requirements d uring o peration. The T -MAP se nsor
provides the ECU with engine load data.

T-MAP Sensor Test

The T-MAP sensor is a non-serviceable item. If it is faulty,
it must be replaced.

IMPORTANT: This sensor should only be tested using

the Dig ital Wrench™ Diag nostic So ftware (de aler
only).

T-MAP Sensor Replacement

1. Remove the drivers seat and disconnect the negative
(-) battery cable.

2. Remove the cargo box access panel.

3. Disconnect vehicle harness from T-MAP sensor.

4. Remove the r etaining bolt a nd r emove the se nsor

from the intake boot.

5. Use a light coating of soapy water on the grommet to

aid installation of the new sensor.

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 ELECTRONIC FUEL INJECTION
CRANKSHAFT POSITION SENSOR (CPS)
Operation Overview CPS Test
Mounted on top of the stator cover, the crankshaft position The CPS is a sealed, non-serviceable assembly. If fault
sensor is es sential to engine op eration, co nstantly code diagnosis indicates a problem with this sensor, test
monitoring the rotational speed (RPM) and position of the as follows:
crankshaft.
1. The CPS is accessible through the r ight-hand r ear
wheel well area.
CPS
2. Disconnect CPS harness connector.

CPS
Location

CPS
Connector
A ferromagnetic 35-tooth encoder ring with a missing tooth
is built onto the flywheel. The inductive speed sensor is
mounted 1.0 ± 0.26 mm (0.059 ± 0.010 in.) away from the
encoder rin g. During ro tation, a n AC pu lse is cr eated
within the se nsor for each p assing to oth. Th e ECU 3. Connect an ohmmeter between the CPSpin terminals
calculates en gine speed from th e tim e inte rval be tween shown below. A resistance value of 1000 Ohm ± 10%
the consecutive pulses. at room temperature should be obtained.
CPS Connector
The encoder ring missing tooth creates an “interrupt” input
signal, corresponding to specific crankshaft position. This
signal serves as a r eference for the con trol of ig nition
timing by the ECU. Synch ronization o f the CPS a nd
crankshaft po sition t akes place d uring the first two
revolutions each time the engine is started. This sensor
must be properly connected at all times. If the sensor fails
or becomes disconnected for any reason, the engine will
stop running.

1000 ± 10%

CPS Resistance Specification:

1000 Ohms ± 10%

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 ELECTRONIC FUEL INJECTION
4. If the resistance is correct: FUEL INJECTORS
• Test the ma in harness circuit between the sensor Operation Overview
connector te rminals and the co rresponding pin
terminals at the ECU (see wiring diagram). The fuel injector is mountedinto the cylinder head, with the
fuel rail retaining it from the top end. O-rings on both ends
• Check th e sensor mou nting, air gap , flywh eel of the injector prevent external fuel leaks and also insulate
encoder ring for da mage or ru nout, and flywheel the injectors from heat and vibration.
key. Follow the “CPS Replacement” procedure to
inspect CPS an d flywh eel en coder r ing for Fuel Rail
damage.

5. If th e re sistance is incorrect, follow the “CPS Fuel Injector

Replacement” procedure.

CPS Replacement
1. If no t done already; disconnect the CPS ha rness
4
connector (see “CPS Test”).

2. Using an 8mm socket, remove the CPS retaining bolt

and remove the sensor from the stator cover.

3. Install new sensor using a light coating of oil on the When the key switch is on, the fuel rail is pressurized, and
O-ring to aid installation. the EFI r elay pr ovides volt age to the in jectors. During
engine operation, the ECU completes the ground circuit,
4. Torque the CPS an d he at sh ield r etaining b olts ( if
energizing the injectors. The valve needle in each injector
equipped) to specification.
is opened electromagnetically, and the pressure in the fuel
rail forces fuel down th rough th e in side. T he “director
=T plate” at the tip of the inje ctor contains a se ries of
calibrated openings which directs the fuel into the intake
CPS Retaining Bolt Torque: port in a cone-shaped spray pattern.
9 ft. lbs. (12 Nm)
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 depending on the speed and
load requirements of the engine.

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 ELECTRONIC FUEL INJECTION
Fuel Injector Troubleshooting Fuel Injector Test
Injector pr oblems typically fall into th ree g eneral The fuel injector is non-serviceable. If diagnosis indicates
categories- electrical, d irty / clogg ed, or leakage. An a problem with the injector, test the resistance of the fuel
electrical pr oblem u sually causes o ne o r b oth of the injector by measuring between the two pin terminals:
injectors to sto p fu nctioning. Several methods may be
used to check if the injectors are operating. Disconnect
and test here
• 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 Air Box
injector noise or vibration.

NOTE: Do not apply vo ltage d irectly t o t he fuel

injector. Excessive voltage will burn out the injector. Fuel Injector Resistance Specification:
Do not gro und the inject or with t he ignition o n. 11.4 - 12.6 Ohms
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 inrare instances it can

be internal (past the tip of th e valve n eedle), or external
(weeping around the injector body). The loss of system
pressure from the leakage can cause hot restart problems
and longer cranking times.

Injector problems due to dirt or clogging are unlikely due

to the design of the injectors, the high fuel pressure, the
use of filters and the detergent additives in the gasoline.
Symptoms that could be caused by dirty/clogged injectors
include rough idle, hesitation/stumble during acceleration,
or triggering of fault codes related 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 p attern. Some contributing fact ors t o injector
clogging includ e; dir ty a ir filters, hig her than nor mal
operating t emperatures, sh ort o perating intervals an d
dirty, incorrect, or poor quality fuel. Cleaning of clogg ed
injectors is n ot recommended; they should be replaced.
Additives an d hig her gr ades o f fuel can be used as a
preventative measure if clogging has been a problem.

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 ELECTRONIC FUEL INJECTION
Fuel Injector Replacement 8. Carefully pull up on the fuel rail and injector to remove
them from the engine as an assembly. If the injector
1. Remove the cargo box access panel. stays in the cylinder head, grab the injector with your
fingers and gently pull and twist the injector unit it can
2. Be sure the engine has cooled enough to work on.
be removed from the cylinder head. Take care not to
damage the fuel injector ends during removal.
3. Remove the driver’s seat and disconnect the negative
battery cable.
9. Gently pull and twist to free the injector from the fuel
4. Thoroughly clean the fuel injector area if a ll dirt and rail.
debris.

5. Disconnect the fuel injector harness lead.

10. Upon in stallation o f the new fuel injector, lightly

lubricate the injector O-rings to aid installation.

11. Install the new inje ctor into the fuel rail. Be sure to
6. Hold a shop towel over the fuel line fittings and remove
align boss in the injector with the slot in the fuel rail.
the fuel supply line from the fuel rail.

7. Remove the (2) screws that mount the fuel rail to the
cylinder head.

Align
Boss

12. Thoroughly clean the area around the fuel injector port
on the cylinder head.

13. Lightly lubricate the injector O-rings and reinstall the

fuel rail / injector assembly into the cylinder head.

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 ELECTRONIC FUEL INJECTION
14. Install th e fu el rail mo unting screws and torque to FUEL PUMP
specification.
Operation Overview
=T An electric fuel pump assembly is used to transfer fuel to
the EFI system from inside the fuel tank. This assembly
Fuel Rail Mounting Screws: includes th e fue l pu mp, fuel filters, r egulator a nd fu el
7 ft. lbs. (10 Nm) gauge sender. The pump is rated for a minimum output of
25 liter s pe r ho ur at 43 - 48 p si an d ha s two non-
15. Reinstall the fuel line to the fuel rail. serviceable fuel filters.

16. Connect the harness lead to the fuel injector. When the key switch is turned to "ON", the ECU activates
the fuel pump, which pressurizes the system for start-up.
17. Reconnect the negative battery cable and reinstall the
driver’s seat.
Fuel Pump Assembly
18. Start the engine briefly and inspect the fuel rail and
injector for fuel leaks.

19. Reinstall the cargo box access panel.

Located in Fuel Tank

Fuel Line
Connection
Pump / Sending Unit
Connection

Fuel Pump

Regulator

Preliminary Filter

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 ELECTRONIC FUEL INJECTION
The ECU switches off the pump preventing the continued Fuel Pump Test
delivery of fuel in these instances:
If a fuel delivery problem is suspected, make certain the
• If the key switch is not promptly turned to the fuel pump filters are not plugged, that the pump is being
"start" position. activated through the ECU, all electrical connections are
• If the engine fails to start. properly secured, the fuses are good, and a minimum of
7.0 volts is being supplied. If d uring starting the battery
• If the engine is stopped with the key switch "on" voltage drops below 7.0 volts, the ECU will fail to operate
(as in the case of an accident). the system.
In these situations, the “check engine” light will go on, but
will turn off after 4 cranking revolutions if system function WARNING
is OK. Once the engine is running, the fuel pump remains
on. Fuel is extremely flammable and may cause
severe burns, injury, or death.
Do not use any device that produces a flame or
Fuel Sender Test
If the fuel gauge reading on the instrument cluster is not
electrical devices that may spark around
fuel or fuel vapors. 4
working, o r if the displ ay re ading differs in lar ge
comparison to the fuel in the tank, perform a resistance 1. Remove the passenger seat from the vehicle.
test on the fuel sender.
2. Cover the fuel line connection at the fuel tank with a
Disconnect the fuel p ump / sending unit connection and shop towel and disconnect the line from the fuel pump
measure the resistance. If out of specification, replace the outlet.
fuel pump assembly.
3. Install the Fuel Pressure Gauge Adaptor (PV-48656)
in-line between the fuel pump outlet and fuel line.

4. Connect the hose from the Fuel Pressure Gauge Kit

(PU-43506-A) to the test valve on the Fuel Pressure
Gauge Adaptor (PV-48656). Route the clear hose into
a portable ga soline container or the ve hicle’s fu el
tank.

Fuel Sender Resistance Specifications:

Full: 6 ± 1 Ohms
Empty: 90 ± 4.5 Ohms PU-43506-A

PV-48656

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 ELECTRONIC FUEL INJECTION
5. Turn on the key switch toactivate the pump and check 8. If voltage at the plug was within the specified range,
the system pressure on the gauge. If system pressure and there was continuity across the pump terminals,
of 43 - 48 psi is ob served, the ig nition switch, ECU, reconnect the plug to the fuel pump, making sure you
fuel pump, an d pr essure regulator are working have a clean connection. Turn on the key switch and
properly. Tu rn th e k ey s witch of f an d de press th e listen for the pump to activate.
valve bu tton on th e te ster to relieve the system
pressure. NOTE: If the pump starts, repeat steps 3, 4 and 5 to
verify correct pressure.

Normal Fuel Pressure: 9. If the pump still does not operate, check for correc t
43-48 psi (296.5 - 331 KPA) ECU operation by plugging in a known-good ECU of
the same model.

NOTE: If t he f uel p ressure is out o f specification, NOTE: If the pump still does not operate, replace the
replace the fuel pump assembly. fuel pump assembly.

6. If the pump did not activate (Step 5), disconnect the

harness connector from the fuel pump. Connect a DC
voltmeter across terminals “3” and “4” in the plug on
the vehicle fuel pump harness. Turn on the key switch
and observe voltage to ensure a minimum of 7 volts
is present.

NOTE: If t he volt age was be low 7 VDC, t est the

battery, ignition switch, relay(s), wiring har ness and
ECU.

7. If th e r eading is between 7 a nd 14 vo lts, tu rn key

switch off an d co nnect an ohmmeter b etween
terminals “3” and “4”' at the white fuel pump connector
to check for continuity within the fuel pump.

NOTE: If there was no continuity between the pump

terminals, replace the fuel pump assembly.

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 ELECTRONIC FUEL INJECTION
Fuel Pump Replacement 6. Be sure the top of the fuel tank is clean. If it requires
cleaning, hand wash the top of the tank to ensure no
debris will enter the fuel sy stem when the fuel pump
WARNING is removed.

Always wear safety goggles when working with

Clean this area
high pressure or flammable fluids. Failure to do
so could result in serious injury or complications.

1. Remove the driver and passenger seat to access the

fuel pump.

2. Disconnect the battery (-) negative cable.

3. Ensure that static has been discharged from you by

touching a ground so urce su ch as th e en gine or
frame.

4. Disconnect the fuel pump electrical harness.

4
CAUTION
Pump Harness
Fuel Line Connector
Failure to clean area around fuel pump may lead
to debris entering the fuel tank during service.
Excessive debris in fuel tank may cause
premature wear of fuel pump and/or clogging
of internal fuel filters.

7. Place the Fuel Pump Service Tool (PU-50326) over

the fuel pump PFA nut. Using a 1/2” drive ratchet or
breaker bar, loosen and remove the PFA nut. Discard
the PFA nut.

5. While holding a shop towel ov er the fuel line PU-50326

connector, disconnect the quick connect fuel line from
the fuel pump.

CAUTION

It is possible for pressurized fuel to be present

when disconnecting the fuel line.
It is recommended to allow the vehicle to sit for
a period of one hour after shutting off the engine PFA Nut
before servicing the fuel pump. This allows the
exhaust to cool and fuel pressure to drop.

NOTE: A small amount of fuel may come out of the NOTE: Apply down ward for ce o n the fue l p ump
fuel line or tank. Prop erly dra in fuel in to a su itable flange while removing the fuel pump PFA nut.
container.

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 ELECTRONIC FUEL INJECTION
8. Carefully lift the fuel pump out of the fuel tank. As the 11. Remove new fuel pu mp assembly, gasket and PFA
fuel pump assembly is bein g removed, be a ware of nut from packaging. Use care not to bend float arm
float arm and pump pre-filter. Hold the float arm to the during un-packaging. Do not lift or ca rry fuel pum p
pump body as you lift and tilt the pump to ensure that assembly by the float arm.
the float arm is not bent when removed from the tank.
12. Use cle aning wip es provided to clean fuel ta nk
surface and threads. Remove all debris, grease and
oil. Allow surfaces to dry completely.

13. Install new PFA g asket onto fue l pu mp a ssembly

using care not to damage gasket or bend float arm.

9. Transfer old fuel pump to a suitable container capable

of safely holding fuel. The fuel pump will retain some
fuel.

10. Inspect the in side o f the fuel tank for debris (m ay

require flashlight and mirror). If debris like mud or sand
is present, fuel tank should be flushed and cleaned out
prior to installation of new fuel pump assembly.

IMPORTANT: It is r ecommended to r emove the fu el

tank from the vehicle and rinse it with a small amount
of clean fuel. Do not use water or any other chemicals
to remove debris.

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 ELECTRONIC FUEL INJECTION
14. Install fuel pu mp into fuel tank, hold float arm to the
pump body and tilt assembly to ensure float arm does
not get caught or bent during installation.

15. Gently pu sh down on fuel p ump fla nge ensu ring

flange is centered.

16. Roughly align orientation mark on fuel pump between

the orientation marks on fuel tank to ensure float arm
does not get bent or snagged.

CAUTION

Failure to align the orientation marks may lead

to interferences with the fuel level float arm
and cause incorrect function.

17. While maintaining down ward pr essure, th read n ew

PFA nut o nto fuel tan k and h and tighten . Use care
when starting PFA nut, ensuring threads are properly
aligned. Verify orientation marks are still aligned
between fuel pump and fuel tank.

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 ELECTRONIC FUEL INJECTION
18. Torque PFA nut to specification using the Fuel Pump Fuel Tank Removal
Service Too l (PU-5 0326) and a calib rated torq ue
wrench. IMPORTANT: Syphon as muc h fuel from the tank as
possible before at tempting to remo ve it from th e
vehicle.
70 ± 5 ft. lbs.
(95 ± 7 Nm)
WARNING

Always wear safety goggles when working with

high pressure or flammable fluids. Failure to do so
could result in serious injury or complications.

1. Remove the dr iver and passenger seats along with

the rear service panel.

2. Disconnect the negative battery cable from the battery

located under the driver’s seat.

3. While h olding a sho p towel over th e fu el lin e

=T connector, disconnect the quick connect fuel line from
the fuel pump. Move the fu el line out of the way for
Fuel Pump PFA Nut: tank removal.
70 ± 5 ft. lbs. (95 ± 7 Nm)

19. Verify al ignment of fuel pum p and ta nk orientation

marks.

20. Connect the fuel line to the fuel pump outlet.

Press in retainer
to engage the tabs

NOTE: A small amount of fuel may c ome out of the

fuel li ne o r t ank. P roperly drain f uel into a suitable
container.

IMPORTANT: Be sure to engage the retainer on fuel

line until it snaps into place. Pull on fuel line lightly to
confirm connection.

21. Connect the fuel pump electrical harness.

22. Connect battery.

23. Install the driver and passenger seat.

24. Test the fuel pump by turning on the key and listening
for the pump to activate. Cycle the key several times
to prime the system.

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 ELECTRONIC FUEL INJECTION
4. Disconnect the fuel pump electrical harness. 8. Remove the push rivets and screws retaining the RH
rocker panel and remove panel from the vehicle (see
Disconnect Chapter 5).
Here

Remove
RH Rocker Panel

5. Remove the fuel tank vent hose clamp with a suitable

pliers an d re move th e v ent lin e f rom t he ta nk ve nt
4
fitting. 9. Remove the lower bolt retaining the se at b elt
mechanism near the rear RH portion of the fuel tank.
Once r emoved, place the mechanism in the r ear
cargo box to keep it out of the way.

6. Remove the rear seat base assembly from the vehicle

by removing the (2) fasteners retaining the rear seat
base.
10. Remove th e ( 3) Tor x fa steners fr om th e r ear RH
fender well an d re move th e fender we ll fr om the
vehicle (see chapter 5).

7. Remove the sh ift knob and center console from the

vehicle.

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 ELECTRONIC FUEL INJECTION
11. Remove the (3) shift lever support bracket bolts and 13. Lift the rear of the fuel tank up first and carefully pull
place the bracket out of the way of the fuel tank, but it up and out from the vehicle.
do not remove or cut the plastic wire harness retainer.

1 2

Set bracket by
shift lever

Do not cut
plastic strap

12. Remove the (2) tank bracket fasteners that retain the
fuel tank in the chassis. Swing the tank brackets clear
of the fuel tank for removal.

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 ELECTRONIC FUEL INJECTION
Fuel Tank Installation IDLE AIR CONTROL (IAC)
1. Carefully reinstall the fuel tank assembly.
Operation Overview
2. Reinstall the (2) fuel tank brackets and fasteners. The Idle Air Control (IAC) is used to stabilize the idle
quality of the engine at cold start-up and after warm-up
3. Reinstall the (3) shift lever support bracket fasteners.
operations.
4. Reinstall the rear R H fender well and secure with
fasteners . IAC

5. Reinstall the se at belt me chanism an d se cure the

lower bolt.

6. Reinstall the RH ro cker pa nel a nd all p reviously

removed fasteners.

7. Reinstall the rear seat base / su pport assembly and

secure with the fasteners. 4
8. Reinstall the center console and shift knob.
Throttle Body TPS
9. Install the fuel line, vent hose and clamp. Verify they
are secure.
Mounted on the throttle body, the IAC contains 1 stepper
10. Reconnect the fuel pump electrical harness. motor which receives varying voltage signal pulses from
the ECU. These pulses determine the IAC plunger setting,
11. Reconnect the n egative battery cable. Test th e fuel thereby controlling the amount of air bypassing the closed
pump by turning the ignition key on and listening for throttle body for idle control. If the IAC is disconnected or
the pump to activate. Check for leaks. inoperative, it will remain at it’s last operated position.

12. Finally, install the re ar ser vice panel a long with the
seats. IAC Test
The IAC is a non-serviceable item. If it is faulty, it must be
replaced. It can be ‘bench teste d’ u sing the following
method:

Set your meter to read Ohms. Check the resistance values

at each of the following pin locations of the IAC. If any of
the readings are out of specification, replace the IAC.
IAC Valve Connector

4 5 6

1 2 3

IAC Resistance Readings

Pins Resistance Pins Resistance
1-2 30  ± 1.2  4-5 30  ± 1.2 
2-3 30  ± 1.2  5-6 30  ± 1.2 
1-3 60  ± 2.4  4-6 60  ± 2.4 

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 ELECTRONIC FUEL INJECTION
IAC Replacement THROTTLE POSITION SENSOR (TPS)
1. Remove the drivers seat and disconnect the negative
Operation Overview
(-) battery cable.
The th rottle po sition senso r ( TPS) is used to ind icate
2. Remove the cargo box access panel. throttle plate angle to the ECU. Mo unted on the throttle
body and operated directly off the end of the throttle shaft,
3. Disconnect the vehicle harness from the IAC motor.
the TPS works like a rheostat, varying the voltage signal
4. Remove the (3) Phillips-he ad mounting screws and to the ECU in direct correlation to the angle of the throttle
remove the IAC from the throttle body. T he screws plate. This signal is processed by the ECU and compared
can a lso be acc essed fr om th e R H re ar wh eel well to the internal pre-programmed “maps” to determine the
area. required fuel and ignition settings for the amount of engine
load.

IAC

TPS

5. Install the new IAC and torque the mounting screws

to specification.
Stop Screw
(Factory Calibrated)
=T DO NOT ADJUST

IAC Mounting Screw Torque:

17.7 in. lbs. (2 ± 0.5 Nm)

6. Reconnect the vehicle harness to the IAC motor.

7. Reinstall the cargo box acce ss pa nel, conn ect the

negative (-) battery cable and install the drivers seat.

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.

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 ELECTRONIC FUEL INJECTION
TPS Resistance Tests TPS Replacement
The TPS is a non-serviceable item. If it is faulty, it must be NOTE: The correct position of the TPS angle on the
replaced. It can be tested using the following method: throttle body is e stablished and set at the factory. If
the TPS is replaced or has been loosened it must be
With the te st lea ds co nnected an d th e me ter set to th e repositioned to obtain the proper voltage reading.
ohms sca le, obser ve th e re ading at th e fo llowing pin
locations of the TPS: 1. Remove the drivers seat and disconnect the negative
(-) battery cable.
TPS Connector
2. Remove the carg o box a ccess p anel. Th e T PS
sensor scr ews can a lso be a ccessed thro ugh the
right-hand rear wheel well area.
1 2 3
3. Disconnect the vehicle harness from the TPS.

4
TPS Resistance Readings
Pins Throttle Position Resistance
2 - GND ----- 
1-2 Closed 4k - 5k(reference)
1-2 Open 1150 - 1250(reference)
1-3 ----- 4k6k
TPS
TPS Tester / Regulator
The TPS r eading must be ch ecked by using Digital 4. Remove the (2) Phillips -head mounting s crews and
Wrench™ Diagnostic Software. replace th e TPS . Reconnect the vehicle ha rness to
the TPS.

NOTE: If re placing t he TPS o r thr ottle bod y, you

must set the TPS voltage to specification.

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 ELECTRONIC FUEL INJECTION
TPS Adjustment Using Digital Wrench™: 4. Rotate the TPS un til your d isplay r eading is within
specification.
1. Assemble Sma rtLink M odule a nd co nnect the
diagnostic interface ca ble to the veh icle to allo w
Digital W rench™ us e (see “Digital Wrench™ -
Diagnostic Connector”).

2. Select the appropriate ve hicle an d op en the da ta

display grid. C lick on the meter ic on next to “TPS
Volts”.

TPS Output Reading (Digital Wrench™):

0.46 ± 0.03 Vdc

5. Retighten the TPS mo unting scre ws a nd torque to

specification.

3. Loosen the TPS mounting screws. =T

TPS Mounting Screws:
17.7 in. lbs. (2 Nm)

6. Verify volta ge reading did n ot cha nge. If voltage

reading is now out of specification, repeat steps 3 - 5.
7. Reinstall item s that wer e r emoved to access TPS
sensor.

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 ELECTRONIC FUEL INJECTION
ENGINE COOLANT TEMPERATURE SENSOR (ECT)
Operation Overview ECT Sensor Test
Mounted on the cylind er hea d, th e en gine te mperature To quickly rule out other components and wiring related to
sensor me asures coola nt temp erature. The eng ine the ECT, disconnect the harness from the ECT sensor and
temperature sensor is a Negative Temperature Coefficient start the engine. After a few seconds, the fan should turn
(NTC) typ e se nsor, as the temperature increases the on and the “Check Engine” indicator should display on the
resistance decreases. instrument cluster. This indicates all other components are
working properly.

ECT

ECT Sensor
4
Refer to Chapter 10 foradditional ECT sensor information.
Polaris dealers can test th e se nsor b y using the Digital
PVT Outlet Hose Removed Wrench™ Diagnostic Software (dealer only).

ECT Sensor Resistance Readings

Coolant passes thr ough the cylin der and by the sensor
probe, varying a resistance reading which is relayed to the Temperature F (C) Resistance
ECU. This signal is processed by the ECU and compared
to its pr ogramming for determining th e fu el an d ign ition 68 F (20 C) 2.5 k ± 6%
requirements during operation. The ECU also uses th is 86 F (30 C) 1.7 k ± 6%
signal to deter mine when to a ctivate the fan during
operation. 104 F (40 C) 1.2 k ± 6%
122 F (50 C) 834  ± 6%
140 F (60 C) 596  ± 6%
158 F (70 C) 435  ± 6%
176 F (80 C) 323  ± 6%
194 F (90 C) 243  ± 6%
212 F (100 C) 186  ± 6%

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ECT Sensor Replacement IGNITION COIL
1. Remove the cargo box access panel.
Operation Overview
2. Loosen the hose clamp that attaches the PVT outlet
The ignition coil is used to provide high voltage to fire the
duct.
spark plug. When th e ign ition key is on , DC volt age is
present in primary side of the ignition coil windings. During
engine r otation, an AC pulse is created within th e
crankshaft position sensor for each passing tooth on the
flywheel. The two -tooth gap creates an “interrupt” in put
signal, corresponding to specific crankshaft position. This
signal serves as a r eference for th e co ntrol of ignition
timing. The ECU then calculates the time interval between
the consecutive pulses, and determines when to trig ger
the voltage spike that induces the voltage from the primary
to the secondary coil windings to fire the spark plug.

Ignition Coil

3. Remove the driver and passenger seats.

4. Remove the re ar service pa nel to access the ECT
sensor.
5. Remove the PVT outlet hose.
6. Drain coolant to level below sensor.

7. Disconnect sensor from engine harness.

8. Using a wrench, re move a nd r eplace th e sensor , Outer PVT Cover

applying a ligh t coatin g o f thread seala nt to aid
installation.

9. Torque the sensor to 17 ft. lbs. (23 Nm).

=T
ECT Torque:
17 ft. lbs. (23 Nm)

10. Add the r equired amount of coo lant and p roperly

bleed the cooling system (see Chapter 3).

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Ignition Coil Tests Ignition Coil and HT Lead Replacement
The ignition coil can be tested by using an Ohmmeter. Use 1. Remove th e drivers s ear and disconnect th e (- )
the following specification table and illustrations to test the negative battery cable.
ignition coil.
2. Loosen ho se clamp and disengage th e PVT intake
Ignition Coil Resistance Readings hose from the duct.

Test Pin Connection Resistance

Between
Primary 0.5 Ohms ± 10%
(Battery +) & (Coil -)
Between Coil - and + at
Primary
the Coil Connection 0.5 Ohms
Test

Secondary
Test
Between High Tension
Lead Caps
7.0 k Ohms ±5% 4
Primary Test
3. Disconnect the harness connection to the ignition coil.
4. Remove the hig h tension lead cap fr om the spa rk
plug.
Measure Between
Connector Pins 5. Remove the fasteners retaining the ignition coil and
0.5  remove the coil assembly from the vehicle.

6. Install the new igni tion co il asse mbly an d tighten

fasteners to specification.

NOTE: Be sure to re install th e coil mount ing

spacers upon assembly (if equipped).
Battery +
Coil -
=T
Secondary Tests
Ignition Coil Retaining Bolt Torque:
75 in. lbs. (8.5 Nm)

7. Connect the harness connection to the ignition coil.

8. Reinstall the PVT intake hose and tighten hose clamp.

9. Reconnect the ba ttery cable an d insta ll th e dr ivers
seat.

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 ELECTRONIC FUEL INJECTION
EFI DIAGNOSTICS 3. A set of three numbers will appear in the information
area.
Instrument Cluster Trouble Code Display • The first number (located far left) can range from 0
NOTE: The diagno stic mode is accessible on ly to 9. Th is n umber re presents th e t otal nu mber o f
when the check engine MIL has been activated. trouble code present (example: 2 means there are
3 codes present).
Use the following procedure to display diagnostic trouble • The second number (located top right) can be 2 to
codes that wer e a ctivated du ring cur rent ignitio n cycle 6 dig its in leng th. This num ber equates to th e
causing the MIL toilluminate. Diagnostic trouble codes will suspected area of fault (SPN).
remain stored in the gauge (even if MIL turns off) until the
• The third number (located bottom right) can be 1 to
key is turned off.
2 digits in length. This number equates to the fault
NOTE: If t here is a diagno stic prob lem with t he mode (FMI).
power st eering s ystem, t he power s teering MIL will
illuminate and blink in place of the check engine MIL.

1. If t he tro uble co de(s) ar e not dis played, use th e

MODE button t o to ggle un til “C K ENG” dis plays on
the information display area.

4. If more than one code exists, press the MODE button

to advance to the next trouble code.
5. To exit the dia gnostic mode, press and ho ld th e
2. Press an d ho ld th e MODE bu tton to en ter the
MODE button or turn the ignition key OFF once the
diagnostics code menu.
codes are recorded.













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 ELECTRONIC FUEL INJECTION
DIAGNOSTIC TROUBLE CODE TABLE
Digital Wrench™
Component Condition SPN FMI
P-Code
Voltage Too High 3 P0123
Throttle Position Sensor (TPS) 51
Voltage Too Low 4 P0122
Data Erratic or Intermittent (or missing) 2 P0503
Vehicle Speed Signal 84
Received Vehicle Speed Has Error 2 C1069

Manifold Absolute Pressure Sensor Voltage Too High 3 P0108

102
(T-MAP) Voltage Too Low 4 P0107
Voltage Too High 3 P0113
Intake Air Temperature (T-MAP) 105
Voltage Too Low 4 P0112
Voltage Too High
Voltage Too Low
3
4
P0118
P0117
4
Engine Temperature Sensor (ECT) 110
Temperature Too High 16 P0217
Engine Overheat Shutdown 0 P1217
P0563
Voltage Too High 3
System Power C1063
168
(Battery Potential / Power Input) P0562
Voltage Too Low 4
C1064
Received Engine Speed Has Error 0 C1059
Engine Speed 190
Engine Speed Too High 0 C1066
Gear Sensor Signal Voltage Too Low 523 4 P0916
ECU Memory EEPROM: Read/Write Failure 628 12 C1073
Calibration Checksum / CRC Error 630 12 C1073
Crankshaft Position Sensor (CPS) Plausibility Fault 636 2 P0335
Driver Circuit Open / Grounded 5 P0261
Injector 1 (MAG) Driver Circuit Short to B+ 651 3 P0262
Driver Circuit Grounded 4 P1262
Driver Circuit Open / Grounded 5 P1691

Rear Differential Output (INTL) Driver Circuit Short to B+ 746 3 P1692

Driver Circuit Grounded 4 P1693

Driver Circuit Open / Grounded 5 P1481

Fan Relay Driver Circuit Driver Circuit Short to B+ 1071 3 P1482
Driver Circuit Grounded 4 P1483
Ignition Coil Primary Driver 1 (MAG) Driver Circuit Short to B+ 1268 3 P1353
Driver Circuit Open / Grounded 5 P0230
Fuel Pump Driver Circuit Driver Circuit Short to B+ 1347 3 P0232
Driver Circuit Grounded 4 P0231

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 ELECTRONIC FUEL INJECTION
DIAGNOSTIC TROUBLE CODE TABLE
Digital Wrench™
Component Condition SPN FMI
P-Code
Voltage Too High 3 P16A2
ECU Output Supply Voltage 1 3597
Voltage Too Low 4 P16A1
Voltage Too High 3 P16A9
ECU Output Supply Voltage 2 3598
Voltage Too Low 4 P16A8
Driver Circuit Open / Grounded 5 P1836
All Wheel Drive Control Circuit
Driver Circuit Short to B+ 520207 3 P1835
(AWD)
Driver Circuit Grounded 4 P1834
Driver Circuit Open / Grounded 5 P1505
Idle Air Control Valve (IAC)
Driver Circuit Short to B+ 520271 3 P1509
M17; IAC Stepper Pin 1
Driver Circuit Grounded 4 P1508
Driver Circuit Open / Grounded 5 P1515
Idle Air Control Valve (IAC)
Driver Circuit Short to B+ 520268 3 P1519
M17; IAC Stepper Pin 3
Driver Circuit Grounded 4 P1518
Driver Circuit Open / Grounded 5 P1525
Idle Air Control Valve (IAC)
Driver Circuit Short to B+ 520269 3 P1529
M17; IAC Stepper Pin 4
Driver Circuit Grounded 4 P1528
Driver Circuit Open / Grounded 5 P1535
Idle Air Control Valve (IAC)
Driver Circuit Short to B+ 520270 3 P1539
M17; IAC Stepper Pin 6
Driver Circuit Grounded 4 P1538

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 ELECTRONIC FUEL INJECTION
EFI Troubleshooting Poor Idle
Symptom: Idle Too High (If greater than 1300 RPM when
Fuel Starvation / Lean Mixture engine is warm).
Symptoms: Hard start or no start, bog, backfire, popping
• Throttle stop screw set incorrect
through int ake / exh aust, hesitation, de tonation, low
power, spark plug erosion, engine runs hot, surging, high • Throttle cable sticking, improperly adjusted, routed
idle, idle speed erratic. incorrectly

• No fuel in tank Symptom: Id le Too L ow ( if less than 9 00 RPM when

engine is warm).
• Restricted tank vent, or routed improperly
• Fuel lines or fuel injectors restricted • Plugged air filter

• Fuel filter plugged • Leaking injector (rich condition)

• Fuel pump inoperative • Belt dragging

• Air leak in system • Throttle stop screw tampering

4
• Intake air leak (throttle shaft, intake ducts, airbox Symptom: Erratic Idle.
or air cleaner cover)
• Throttle cable incorrectly adjusted
• Incorrect throttle stop screw adjustment • Air Leaks, dirty injector
Rich Mixture • TPS damaged or adjusted
Symptoms: Fou ls spark p lugs, black, soo ty exha ust • Tight valves
smoke, rough idle, poor fuel economy, engine runs rough/
• Ignition timing incorrect
misses, poor performance, bog, engine loads up, backfire.
• Belt dragging
• Air intake restricted (inspect intake duct)
• Dirty air cleaner
• Air filter dirty/plugged
• Engine w
orn
• Poor fuel quality (old fuel)
• Spark Plug fouled
• Fouled spark plug
• Throttle stop screw set incorrectly (out of sync with
• TPS setting incorrect ECU)
• Injector failure

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 ELECTRONIC FUEL INJECTION
DIGITAL WRENCH™ OPERATION
Digital Wrench™ Diagnostic Software Overview
IMPORTANT: Refer to Section 2, 3 and 4 in the Instruction Manual provided in the Digital Wrench™ Diagnostic
Kit to install the Polaris Digital Wrench™ diagnostic software on your computer.

The Digital Wrench™ diagnostic software allows the technician to perform the following tests and observations:
• View or clear trouble codes • Perform guided diagnostic procedures
• Analyze real-time engine data • Create customer service account records
• Reflash ECU calibration files • Perform output state control tests (on some
models)

Special Tools (also refer to page 4.2)

DIGITAL WRENCH™ DIAGNOSTIC SOFTWARE PART NUMBER

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

Diagnostic Software Version In addition, guided diagnostics are also available for many
other electrical sub systems.
Always use the mos t curren t vers ion of the Digit al
Wrench™ software to ensure you have the latest updates Diagnostic procedures are added to subsequent versions
or enhancements. New reprogramming files and guided of Digital Wrench™ as they become available. Check your
diagnostic procedures are added to these updates as they release version often and upgrade when available to be
become available. For information on how to determine if sure you are using the most current software available.
you have th e latest up date avai lable, re fer to “Digital
Wrench™ Version and Update ID”.

ECU Replacement
Although the ne ed for ECU r eplacement is u nlikely, a
specific replacement procedure is required to ensure that
all essentia l da ta con tained within the original ECU is
transferred to the replacement ECU.

Refer to pro cedure and car efully follow all instruc tions
provided in Digital Wrench™.

Guided Diagnostic Available

Guided diagnostics are available within Digital Wrench™
for all supported Trouble Codes (that is, any fault that will
turn on the ‘Check Engine’ indicator).

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 ELECTRONIC FUEL INJECTION
Digital Wrench™ Communication Errors Digital Wrench™ - Diagnostic Connector
If you experience problems connecting to a vehicle or any Located under the dash connected to a sealed plug.
Digital Wrench™ related problem, vis it the Digit al
Wrench™ Knowledge Base for the most current
troubleshooting in formation, F AQs, d ownloads a nd
software updates at: http://polaris.diagsys.com/.

4
Follow these steps to con nect the d iagnostic interface
cable to the vehicle to allow Digital Wrench™ use:

1. Assemble the SmartLink Module and attach the PC

Interface Cable to your laptop (see page 4.3).

2. Remove the protective cap from the Digital Wrench™

connector.

3. Connect the Veh icle In terface Cab le to the Dig ital

Wrench™ diagnostic connector.

4. Turn the ignition key to the ‘ON’ position, selec t the

appropriate vehicle and wait for the status to display
‘Connected’ in the lower left corner of the screen.

5. Once connected, pr oceed wit h us ing Digital

Wrench™.

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 ELECTRONIC FUEL INJECTION
Digital Wrench™ Serial Number Location IMPORTANT: Always operate with the latest update.

Open the configuration screen by clicking on the wrench Digital Wrench™ Updates
icon. The serial number is located on the right side of the
screen. Updates are released for Digital Wrench™ via the Internet
at: http://polaris.diagsys.com. T he Digital W rench™
website can also be accessed through the dealer website
at: www.polarisdealers.com.

NOTE: Only aut horized Polaris de alers and

distributors can access the dealer website.

1. Log on to www.polarisdealers.com.

2. Locate th e “Service a nd War ranty” dr op-down

Digital Wrench™ Version and Update ID menu.
Knowing what Digit al W rench™ ver sion a nd up date is
installed will help determine which updates are required. 3. Click on “Digital Wrench Updates”.

NOTE: Versions and updates are subject to change.

1. Open the Dig ital Wrench™ so ftware. Locate the

version ID shown on the lower right side of the Digital
Wrench™ start-up screen.

Version
4. The Digital Wrench™ portal website should appear in
a new web browser.

5. Click on “Digital Wrench Version Updates”.

2. Proceed to http://polaris.diagsys.com to se e if a
newer update is available.

Digital Wrench Update

IMPORTANT: You must alrea dy hav e the cur rent

version inst alled be fore ad ding an upda te. Upda tes
will not install if you are using an older version loaded
on your PC.

3. If a n ewer update is a vailable, it should be

downloaded be fore us ing Dig ital Wr ench™ (see
“Digital Wrench™ Updates”).
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 ELECTRONIC FUEL INJECTION
6. If the update file date listed is newer than your current 8. When the update is complete, the version shown on
version an d upd ate (se e “Digital Wre nch™ Version the right side of the Digital Wrench™ start-up screen
and Update ID”), download the file. should match the update you just downloaded.

Digital Wrench Update

7. Click on the link shown above, save the file to y our 4

hard disk and then double-click the icon to start the
update process.

NOTE: Do n ot "run" or "o pen" the f ile from wh ere

they are. Selec t "sa ve" a nd download t hem t o your
PC before running the install.

Version

NOTE: Versions and updates are subject to change.

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 ELECTRONIC FUEL INJECTION
Digital Wrench™ Feature Map

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 ELECTRONIC FUEL INJECTION
Engine Controller Reprogramming (Reflash) • CLOSE NON-ESSENTIAL PROGRAMS : Polaris
recommends that yo u DO NOT inst all n on-
Process Overview essential pr ograms o n a Ser vice De partment
laptop. Ca mera detection sof tware, V irus
The reprogramming feature is in the Special Tests menu Scanners, Tool Ba rs, et c. m ay clo g up m emory if
on the Digit al W rench™ scre en. Start Dig ital W rench™ running in the background and make it h arder for
and click on the Special Tests menu icon (red tool box). A the diagnostic software to operate.
technician should be familiar with the proc ess and w ith
computer op eration in g eneral be fore attemp ting to • KNOW THE PROCESS: If you are not familiar with
reprogram an ECU. the en tire r eprogramming pr ocess, re view the
HELP se ction of the d iagnostic so ftware be fore
The Digital Wrench™ Engine Controller Reprogramming you attempt reprogramming. Click on the ? on the
(or “Reflash”) feature allows reprogramming of the ECU tool bar or pr ess F11. The infor mation in th e on-
fuel and ignition map. To successfully reprogram the ECU, line help is the mos t current a nd complete
an Autho rization Key must be obt ained by en tering a information ava ilable. This shou ld b e you r first
Request Cod e in the bo x provided o n the Reflash step until you are familiar with the process.
Authorization site. The Request Co de is autom atically
generated by Digital Wrench™ during the reprogramming • COMMUNICATION PROBLEMS: If you ha ve had 4
process. The Reflash Authorization site is located under problems comm unicating with a vehicle while
the “ Service and W arranty” d rop down menu on the performing dia gnostic f unctions, do no t a ttempt
dealer website at: www.polarisdealers.com. reprogramming until the cause has been identified
and fixe d. Check all con nections, an d be sure
IMPORTANT: Failure to follow t he repr ogramming battery voltage is as specified. 
instructions completely and correctly can result in an 
engine t hat does not ru n! Replac ement ECUs are Proceed to http://polaris.diagsys.com for
programmed as “no- start” an d require a reflash for specific information an d F AQs on ho w to
them to work. troubleshoot communication problems.

Reprogramming (Reflash) Tips:

• BATTERY VOL TAGE: The majority of problems

with reprogramming ca n be attributed to a low
battery. Be sure the battery voltage (no load) is a t
least 13 volts and at lea st 12.5 volts with the key
‘ON’. Connect a battery cha rger if ne cessary to
bring volt age le vel ab ove min imum. F ully ch arge
the battery before you attempt to reprogram.

• DEDICATED LAPT OP: Best result s are obt ained

using a lap top com puter tha t is “ dedicated to
Digital W rench™”. A la ptop th at is u sed b y a
variety of pe ople and in sever al ap plications
around th e dea lership is mo re likely to cause a
reprogramming pr oblem than one de dicated to
Digital Wrench™ diagnostics only.

• OBTAINING THE LA TEST UPD ATE:

Reprogramming updates are provided periodically
and contain th e most recent ca librations (see • DON’T DISTURB THE PC : While r eprogramming
“Digital Wrench™ Updates”). is in pr ogress, d on’t mo ve th e mo use an d do n’t
touch the keyboard. The process only takes a few
minutes, and is best left alone until complete.

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 ELECTRONIC FUEL INJECTION
Reprogramming (Reflash) Procedure: 5. Select the “Special Tests” icon.

If you are not familiar with th e reprogramming process,

review the “ Reprogramming ( Reflash) T ips” before you
begin. Follow the on-screen instructions as you progress
through the steps. If yo u en counter a p roblem, always
check the On-Line help for current tips and information.

1. Verify the most current update has been downloaded

and lo aded in to Di gital Wre nch™. See “Digital
Wrench™ Version and Update ID” on page 4.40.

2. Connect the SmartLink Module cables to the PC and

vehicle. See “Digital Wrench™ - Diagnostic Connector”
on page 4.39.

6. Select “Engine Controller Reprogramming”.

7. Select the file you want toload into the ECU then click
3. Open the Digital Wrench™ program. the “Continue” icon to proceed to the Integrity Check.

4. Select the mo del year , pr oduct line and vehicle

description by sele cting the “Ch ange Ve hicle T ype”
icon.

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 ELECTRONIC FUEL INJECTION
8. Follow the o n screen instructions and connect a 9 V 10. Go t o www.polarisdealers.com an d click on
battery to the reflash battery connector located off the “ReFlash Au thorization” fro m the “ Service and
main diagnostic connector. Click the “Continue” icon Warranty” drop-down menu.
to obtain a Request Code.

“Service and Warranty” “Reflash Authorization”

11. Enter or paste (CTRL+V) the Request Code into the 4

box.
9. Copy (CTRL+C) the Request Code that will be
required on th e dealer website in th e next step. DO
NOT CLOSE Digital Wrench™ or the Request Code
will be invalid. NOTE: All c haracters a re letters;
there are no numbers in a request code.

Enter the
Authorization Key goes here after “Request Code”
obtained from the dealer website

Copy Request Code to

obtain Authorization Key
12. Select the same file type from the list that you selected
previously while in Digital Wrench™. Enter the VIN
along with the customer’s name and address. When
completed, click th e Autho rize bu tton once to
proceed.
NOTE: Request Codes and Authorization Keys must
be entered EXACTLY as they appear on the screen.

Enter ALL the information and

click on the “Authorize” button

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 ELECTRONIC FUEL INJECTION
13. An “Authorization Key” will appear in the upper left 15. At this point the reflash proc ess will begin. Do not
corner of the screen. Copy (CTRL+C) this key exactly touch the vehicle or PC during the process.
as it appears.

“Authorization Key”

16. Once the ECU re programming pr ocedure is

14. Enter or paste (CTRL+C) the Authorization Key in the
complete, clic k the ‘Finish’ button on the scre en.
box located on the Digital Wrench™ screen. Click the
Verify th e r eflash was a success by sta rting th e
‘Continue’ button and follow instructions provided on
vehicle.
the screen to complete the re programming
procedure.

Enter the
“Authorization Key”

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 ELECTRONIC FUEL INJECTION
EFI SYSTEM ELECTRICAL DIAGRAM

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 ELECTRONIC FUEL INJECTION

NOTES

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 BODY / STEERING / SUSPENSION
CHAPTER 5
BODY / STEERING / SUSPENSION
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
CAB FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
ASSEMBLY / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
BODY EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
SIDE SAFETY NETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
DASH INSTRUMENTS / CONTROLS / GLOVEBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
HOOD / FRONT BODY WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
FRONT BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
REAR BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
SEAT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
SEAT BELTS / MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
FLOOR / ROCKER PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
REAR CARGO BOX / FENDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
CHASSIS / MAIN FRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
BODY COMPONENT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
REAR SERVICE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
FRONT BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
5
REAR BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
HOOD AND FRONT BODY WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
REAR FENDER FLAIR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
CARGO BOX ASSEMBLY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
ROCKER PANELS, CONSOLE AND FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
STEERING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
STEERING WHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
STEERING SHAFT BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
FRONT A-ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
REMOVAL / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
BALL JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
FRONT STABILIZER BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
STABILIZER BAR LINKAGE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
STABILIZER BAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23
REAR A-ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
REAR STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26
REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26
SHOCKS / SPRINGS / FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
SHOCK REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
SHOCK REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.28
DECAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.28

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 BODY / STEERING / SUSPENSION
TORQUE SPECIFICATIONS SPECIAL TOOLS

ITEM TORQUE VALUE

TOOL DESCRIPTION PART NUMBER
Front LH/RH Upper / Lower
Shock Spanner Wrench 2871095
A-Arm Bolt 39 ft. lbs. (53 Nm)
Rear LH/RH Upper / Lower Shock Spring Compressor Tool 2870623
A-Arm Bolt 39 ft. lbs. (53 Nm) Multi-Function Pliers 2876389
Lower LH/RH
Rear Bearing Carrier 40 ft. lbs. (54 Nm) Multi-Function Pliers
Upper LH/RH Included in the tool kit, the multi-function pliers is designed
Rear Bearing Carrier 40 ft. lbs. (54 Nm) to re move th e p lastic push rivets u sed to fasten bo dy
components.
Outer Tie Rod to
42.5 ft. lbs. (58 Nm)
Bearing Carrier Housing
Front Ball Joint Pinch Bolts 23 ft. lbs. (31 Nm)

Shock Mounting Bolts

37 ft. lbs. (50 Nm)
Wheel Hub Castle Nuts 80 ft. lbs. (108 Nm)
Wheel Nuts (Cast Rims) 90 ft. lbs. (122 Nm)
Wheel Nuts (Steel Rims) 27 ft. lbs. (37 Nm)
Tie Rod End Jam Nut 13 ft. lbs. (18 Nm)
Seat Belt to Seat Base 40 ft. lbs. (54 Nm)
Tilt Shock Upper Fastener 7 ft. lbs. (10 Nm)
Tilt Shock Lower Fastener 12 ft. lbs. (16 Nm)
Steering Pivot Tube Fasteners 23 ft. lbs. (31 Nm)
Steering Wheel to Shaft 42 ft. lbs. (57 Nm)
Lower Steering Shaft to Box 30 ft. lbs. (41 Nm)
Steering Gear Box 17 ft. lbs. (23 Nm)

SPECIAL TOOLS
SPX: 1-800-328-6657 or on-line at http://polaris.spx.com/

Pliers

Push Rivet

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CAB FRAME Fasten the two se lf-tapping screws to the rear inner
portion of the bracket on each side. Tighten screws to
Assembly / Removal 15 ft. lbs. (20 Nm).

NOTE: Finger tight en all co mponents until cab 3. Place the stra ps fro m the sa fety ne t over th e fro nt
frame is c ompletely ass embled on veh icle, t hen coupler posts.
tighten to specifications listed. 4. Fasten the front of the cab frame to the base brackets
and secure with four (3/8-16 x 1 1/4) screws and (3/
1. Assemble the rear cab frame and the front cab frame 8-16 Nyloc) nuts. Tighten screws to 25-28 ft. lbs. (34-
at the coupler joints and secure with four (3/8-16 x 1 38 Nm).
1/4) screws and (3/8-16 Nyloc) nuts. Tighten screws
5. Attach side bars to cab frame using M6 screws and
to 25-28 ft. lbs. (34-38 Nm).
nuts on top and M8 screws and nuts on the bottom.
2. Place the assembled cab frame onto the vehicle and Tighten to 8-10 ft. lbs. (10.8-13.5 Nm).
align the rear mount holes. Fasten the rear cab frame
brackets to vehicle with four (5/16-18) bolts and (5/16- 6. To r emove the ca b fra me, r everse th e a ssembly
18) nuts. Tighten bolts to 16-18 ft. lb s. (22-24 Nm). procedure (steps 1-5).

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 BODY / STEERING / SUSPENSION
BODY EXPLODED VIEWS
Side Safety Nets

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 BODY / STEERING / SUSPENSION
Dash Instruments / Controls / Glovebox

D 5

B A
C
F E

A. Instrument Cluster / Speedo

B. AWD / 2WD / TURF Switch 


C. Headlight Switch or Hazard Switch (INT’L)

D. 12 Volt Accessory Receptacle

E. Key Switch / Headlight Switch


F. Switch; Turn, Lights, Horn (INT’L)

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 BODY / STEERING / SUSPENSION
Hood / Front Body Work

1/4 Turn Latch Center Access Hood

Washer

Grommet
T25 Screws

Push Rivets

Hood / Dash

Front LH
Fender Flair
Front RH
Fender Flair
T27 Screws

Push Rivets

Front Bumper

Winch Pocket Cover

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 BODY / STEERING / SUSPENSION
Front Bumper
Front Bumper Support
T30
Screws

Radiator Front Bumper

Screen

O-Ring

Bulb

T25
Screw

T27
Screw
5
Headlight
Winch Pocket
Cover

Rear Bumper
LH Tail Light

T27
Screws
RH Tail Light

Rear Bumper

Speed
Nuts

T27
Screws

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 BODY / STEERING / SUSPENSION
Seat Assembly
Seat Back

Seat
Hoop Tube

48 in. lbs.
(5.4 Nm)

Seat Bottom

Latch Body Nuts

Lever
Spring Seat Base Asm.
Plate
Cap

41-57 in. lbs. 41-57 in. lbs.

(4.6-6.4 Nm) (4.6-6.4 Nm) Grommets

Seat Belts / Mounting

Driver
3 Point Seat
Seat Belt
Passenger
Seat

Rear
40 ft. lbs. Seat Base
(54 Nm)

Latch
Plunger
40 ft. lbs.
(54 Nm)

40 ft. lbs.
(54 Nm)

40 ft. lbs. 17 ft. lbs.

(54 Nm) (23 Nm)

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 BODY / STEERING / SUSPENSION
Floor / Rocker Panels

Self-Tapping
Screw
Rear LH Rocker
Support Bracket
Push Rivets

Block Off
Flap
Upper Floor

T27
Console Cover
Front
Screws
T27 5
Support Bracket Screw
Rear
Support Bracket

Self-Tapping T27
Screw Screws T27
Screws
Push Rivets
U-Type
Nuts
Torx Close Off
Screws Panel
T27
Plastic Dart Screws

Self-Tapping Front
Screws Support Bracket

RH Rocker

Lower Floor

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 BODY / STEERING / SUSPENSION
Rear Cargo Box / Fenders

Cargo Box
Access Panel
Intake Grill

Rear Cargo Box

LR fender

LH Panel
RR Fender Divider
Grommet

1/4 Turn
Latch

Heat Shield Seal

(Mounts Under Box)

Cover

Engine Service
Panel
INTL
Units

Heat Shield

LH Panel
Divider

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 BODY / STEERING / SUSPENSION
Chassis / Main Frame
40 ft. lbs.
(54 Nm)

Bolt-In Brace 17 ft. lbs.

Rear Cross Member (23 Nm)

Bolt-In Brace
Front Cross Member

Rear Bumper
Support
Shield

Plug
5

17 ft. lbs.
(23 Nm)

Main Frame

Skid Plate

Washer
6-8 ft. lbs.
(8-11 Nm)

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 BODY / STEERING / SUSPENSION
BODY COMPONENT REMOVAL Front Bumper
1. Remove the (4) push rivets from the sides of the front
Seats
bumper.
1. To remove any of the seats, lift upward on the latch
lever located behind the seat bottom.
Push
Rivets

Latch
Lever

Torx
Screws

2. Remove th e (6 ) Torx scr ews re taining the upper,

middle and lower portion of the bumper.
2. Lift upward and forward on the seat while lifting up on
the latch lever and remove the seat from the vehicle.
3. Disconnect the fro nt h ead la mp connectors and
remove the front bumper from the vehicle.
Rear Service Panel
1. Remove driver and passenger seats.
Rear Bumper
2. Turn both latches 1/4 turn to disengage the panel. 1. Disconnect the harness connectors at the tail lights.
2. Remove the (10) T-27 Torx screws retaining the rear
bumper to the re ar bumper supp ort a nd re ar cargo
box.
3. Remove the rear bumper from the vehicle.

3. Lift the p anel up ward an d towar ds the fr ont of the

vehicle to remove it.

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 BODY / STEERING / SUSPENSION
Hood and Front Body Work 4. Remove the push rivets that attach the dash assembly
to the rocker panels on each side.
Hood Removal
1. To remove the hood, turn both latches to disengage
the rear portion of the hood.

5. Remove the (2) Torx screws and (2) push rivets that
retain the fron t an d r ear p ortions of the da sh
assembly.

Push
Rivets
5

2. Tilt the ho od back to dise ngage the fro nt tab s a nd

remove the hood from the vehicle. Torx
Screws
Front Body / Dash Removal
1. Remove the hood as previously described. 6. Disconnect all electrical dash components noting their
location and wire routing.
2. Remove the front bumper (see “BODY COMPONENT
7. Remove the dash assembly from the vehicle.
REMOVAL - Front Bumper”).

3. Remove the front portion of the cab frame assembly

to allow dash removal. Refer to appropriate “CAB
FRAME - Asse mbly / Remo val” p rocedure for
assembly torque specifications.

Remove

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 BODY / STEERING / SUSPENSION
Front Fender Flair Removal Cargo Box Assembly Removal
1. If d ash is installed, re move th e ( 2) pu sh rive ts tha t 1. Remove the seats and the engine service panel.
attach the lo wer po rtion of th e fend er flair to the
rocker panels. 2. Disconnect the harness connectors at the tail lights.
3. Disengage th e tail lig ht ha rness from the r outing
2. Remove the (6) push rivets and remove fender flairs features molded into the rear box on both sides.
from the dash assembly.
4. Remove the cargo box access panel.

5. Remove t he (10) T -27 Torx s crews r etaining rear

bumper to the rear bumper support and storage box
(See Rear Bumper Removal).

Rear Fender Flair Removal

1. Remove the rear bumper (see “BODY COMPONENT
REMOVAL - Rear Bumper”).

2. Remove the (4) push rivets that secure the rear fender 6. Remove the (6) T-27 Torx screws (A) from the middle
flair and remove the fender flair from the vehicle. of the cargo box.
7. Remove the (4) T-27 Torx Screws (B) from the front
of the cargo box.
8. Remove the (6) T-27 Torx Screws (C) from both sides
of the cargo box / rocker panels.
9. Remove the (2) push pins (D) from both sides of the
cargo box / rocker panels.

A
D
C

B
C

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 BODY / STEERING / SUSPENSION
10. Remove intake grill and foam filters from the LH side Console and Lower Floor Removal
of the rear storage box.
1. Remove both seats and rocker panels (see “Rocker
11. Remove the (7) T-25 Torx screws (E) securing intake Panel Removal”).
baffle to the rear storage box.
2. Remove the T27 screws retaining the console to the
NOTE: Do not remove the baffle box along with the floor.
rear storage box. The baffle box will remain with the
vehicle when the storage box is removed to prevent 3. Remove the shift handle knob and r emove the
damage to the crankcase vent tube. console.

Baffle Box

5
12. With the aid of an assistant, carefully lift and guide the
cargo box assembly up and off of the vehicle frame.
Make note of wire and hose routings for reassembly.

Rocker Panels, Console and Floor

Rocker Panel Removal 4. Remove the Torx screws retaining the upper floor to
the lower floor.
1. Remove the p ush ri vets an d To rx scr ews r etaining
the rocker panel and remove panel from the vehicle. 5. Remove the Torx screws retaining the rear portion of
the floor and remove the lower floor from the vehicle.

Push
Rivets

Screws

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 BODY / STEERING / SUSPENSION
STEERING ASSEMBLY
Exploded View

Cap
Spacer INTL ONLY
Thick Collar
Steering Wheel Thin Washer
42 ft. lbs. Washer
(57 Nm) Thin
Washer Screw
Thick
Washers Steering
Lock
Thin
Washer Pivot Tube

Steering Shaft
Pivot Tube
Spacer

Bearing

7 ft. lbs. Bushing 42.5 ft. lbs.

(10 Nm) (58 Nm)
23 ft. lbs.
(31 Nm)
27-33 ft. lbs.
(37-45 Nm)
Bushing
23 ft. lbs.
(31 Nm) LH Boot 12-14 ft. lbs.
Oil Locking Bearing
Gear Box (16-19 Nm)
Shock Asm.
Asm.
12 ft. lbs. RH Boot
(16 Nm)

42.5 ft. lbs.

(58 Nm)

Boot 17 ft. lbs.

(23 Nm) 17 ft. lbs.
(23 Nm)
12-14 ft. lbs.
(16-19 Nm)

Nut Tie Rod

Cotter Pin

Rod End

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 BODY / STEERING / SUSPENSION
Steering Wheel Removal

Thick
CAUTION Washers
Spacer
This procedure should NOT be used on EPS Pivot Tube
models. Using this procedure on an EPS model Cap
can permanently damage the EPS unit and
Nut
cause a Power Steering Fault.
Bearing Spacer
1. Remove the steering wheel cap. Thin
Washer
Thick
2. Loosen the nut and back it half way off the ste ering Washers
shaft.

3. With a glove on your hand, place it under the steering Bearing Thin
wheel. Lift upward on the inner portion of the steering Washers
wheel while u sing a ham mer to str ike th e ste ering
shaft nut. NOTE: Be sure the lower w ashers an d s pacers a re
still on the steering shaft.
IMPORTANT: If the steering wheel will not pop loose,
proceed to “Steering Shaft Removal”. 8. Apply Loctite® 271™ (Red) to the outer circumference
of the new upper bearing race. Slide the ne w upper 5
4. Once th e st eering wheel p ops lo ose, completely bearing onto the steering shaft and press it into the
remove the nut andlift the steering wheel off the shaft. pivot tube by hand.

Steering Shaft Bearing Replacement NOTE: Use ca re no t t o allow an y of the Loc tite® to
get in the bearing.
IMPORTANT: Replacement pivo t tu be as sembly
comes with new upper and lower bearings installed. NOTE: Bearings will be seated in the pivot housing
Use this procedure if replacing just the bearings only. upon tightening the steering wheel nut in step 14.

1. Perform the “Steering Shaft Removal” procedure. 9. Reinstall the upper washers and spacers in the order
in which they were removed.
2. Remove the steering wheel cap and retaining nut.
10. Install the steering wheel and hand tighten the nut.
3. Press steering sh aft ou t o f th e s teering wh eel an d
pivot tube. 11. Reinstall the steering shaft assembly in th e vehicle.
Install the lower portion of the steering shaft onto the
4. Note the ord er and location of the wa shers and steering gear box assembly (see Figure 5-16). Torque
spacers between the steering wheel and pivot tube. the lower pinch bolt to 30 ft. lbs. (41 Nm).

5. Drive the bearings out of th e pivot tube using a drift 12. Install the (2) fasteners that retain the pivot tube (see
punch. Figure 5-17). Torque fasteners to 23 ft. lbs. (31 Nm).

6. Inspect the pivo t tube bearing sur faces for signs o f 13. Install the fastener retaining the upper portion of the
excessive wear or damage. steering wheel tilt shock to the pivot tube (see Figure
5-17). Torque fastener to 7 ft. lbs. (10 Nm).
7. Apply Loctite® 271™ (Red) to the outer circumference
of the new lower bearing race. Slide the new lower 14. Be sure the front wheels are facing straight forward.
bearing onto the steering shaft and install the steering Remove the steering wh eel a nd ali gn as ne eded.
shaft through the pivot tube. Torque the steering wheel nut to 42 ft. lbs. (57 Nm).

NOTE: Use car e not to a llow any of t he L octite® to 15. Wipe the pivot tube clean of any excess Loctite.®
get in the bearing.
16. Install steer ing wh eel cap and fie ld test steering
operation.

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 BODY / STEERING / SUSPENSION
FRONT A-ARMS 13. Attach shock to A-arm with spacer (D) or washer (G)
and fa stener (A). To rque lowe r shock bolt to
Removal / Replacement specification.

The following pro cedure details up per and lower A-a rm 14. Remove lower ba ll jo int pin ch b olt ( E) fr om bearing
removal and replacement on one side of the vehicle. carrier.
15. Using a soft face hammer, tap on bearing carrier to
1. Elevate and safely support the front of the vehicle and loosen the lower A-arm ball joint end while pushing
remove the front wheel. downward on the lower A-a rm. Com pletely r emove
2. Remove lower shock fastener (A) from the upper A- the ball joint end from the bearing carrier.
arm. 16. Loosen an d re move the lower A-ar m thro ugh-bolt
3. Remove upper ball joint pinch bolt (B) from bearing fastener (F ) a nd re move the lo wer A-arm fr om the
carrier. vehicle.

4. Using a soft face hammer, tap on bearing carrier to 17. Examine A-arm bushin gs and pivot tube (se e
loosen the upp er A- arm ba ll joint en d while lifting “Exploded View”). Replace if worn. Discard hardware.
upward on the upper A-arm. Completely remove the 18. If not replacing the A-arm, thoroughly clean the A-arm
ball joint end from the bearing carrier. and pivot tube.
5. Remove the front bumper toallow A-arm bolt removal. 19. Install new ball j oint into A-arm. Refer to “Ball Joint
6. Loosen an d remove th e u pper A-arm th rough-bolt Replacement” section.
fastener ( C) a nd r emove the upp er A-ar m fro m the 20. Insert new A-arm bushings and pivot tube into new A-
vehicle. arm.
7. Examine A-a rm b ushings and p ivot tube (see 21. Install new lower A-arm assembly onto vehicle frame.
“Exploded View”). Replace if worn. Discard hardware. Torque new bolt to specification.

WARNING C
The locking agent on the existing bolts was
destroyed during removal. DO NOT reuse old
hardware. Serious injury or death could result if
fasteners come loose during operation. A
G
8. If not replacing the A-arm, thoroughly clean the A-arm D
and pivot tube.
F
9. Install new ball joint into A-arm. Refer to “Ball Joint
Replacement” section.
10. Insert new A-arm bushings and pivot tube into new A-
arm. B

11. Install new upper A-arm assembly onto vehicle frame.

Torque new bolt to specification.
12. Insert u pper A-arm ball jo int e nd into the b earing
carrier. Install upper ball jo int pinch bolt (B) into the E
bearing carrier and torque bolt to specification.

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 BODY / STEERING / SUSPENSION
22. Insert lower A-ar m b all jo int en d into the be aring Exploded View
carrier. Install low er ball joint pinch bolt (E) into the
bearing carrier and torque bolt to specification.

WARNING Upper Fastener

Upon A-arm installation completion, test vehicle
at low speeds before putting into service.
Pivot Tube

=T Upper
A-arm
Front Upper / Lower A-arm Bolts:
39 ft. lbs. (53 Nm) Ball Joint

=T
Grease Zerk
Front Ball Joint Pinch Bolts: Bushings
23 ft. lbs. (31 Nm)
Lower Fastener

5
Pivot Tube
=T
Bearing
Shock Mounting Bolts: Carrier
37 ft. lbs. (41 Nm)
Lower
A-arm
=T
Wheel Nuts:
Steel Wheels: 27 ft. lbs. (37 Nm) Grease
Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn) Zerk Bushing
Pinch
Bolts

Ball Joint

CV Shield
Screws

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 BODY / STEERING / SUSPENSION
BALL JOINT SERVICE 4. Use a press and correct size driver to remove the ball
joint from the A-arm.
Removal Correct
IMPORTANT: Do not reuse a ball joint if it has been Driver Placement
removed for any reason. If removed, it must be
replaced. Use t his removal p rocedure o nly when
replacing the ball joint.

1. The A-ar m must be removed to perform th is

procedure (see “FRONT A-ARMS - Re moval /
Replacement”).

The driver must fit the

Ball Joint inside diameter of the
A-arm end.

Upper A-Arm Shown Standard RZR Shown

NOTE: The driv er must fit th e ball joint housing in

Upper A-arm the A-arm. This will allow the ball joint to be properly
pressed out of the A-arm witho ut da maging th e A-
arm.
Retaining Ring
Press out of the A-arm
in this direction
Standard RZR Shown

2. Remove the retaining ring from the ball joint.

Upper A-Arm Shown
3. A driver must be used for the removal of the ball joint.
Use the dimensions below to fabricate or locate the
correct size driver to use in the following process.

Driver Dimensions Place driver HERE

to support A-arm
1.375 in.
(3.49 cm)

3 in.
(7.62 cm)

1.75 in.
(4.45 cm)

- Outside diameter of driver cannot be any

larger than 1.75 in. (4.45 cm).
- Inside diameter cannot be any smaller than
1.375 in. (3.49 cm).
- Driver must be at least 3 in. (7.62 cm) tall.

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 BODY / STEERING / SUSPENSION
Installation FRONT STABILIZER BAR
1. Place the A-arm in the correct position for ball joint
installation. Face the A-a rm e nd flat on to p of the Stabilizer Bar Linkage Removal
driver. Carefully drive the ball joint into place until the
1. Elevate and safely support the front of the vehicle.
ball joint is properly seated.
2. Remove the lower shock mounting fastener from the
Press into the A-arm upper A-a rm on ea ch side of the vehicle (see
in this direction “Exploded View”).

3. Remove the up per portion of the linkage from the

stabilizer bar on each s ide of the v ehicle (see
“Exploded View”):

4. Inspect the linkage assemblies for signs of excessive

wear or da mage. Re place lin kage a ssembly if
Place driver HERE damaged.
to support A-arm
5. Reverse th e procedure fo r in stallation. To rque the
Upper A-Arm Shown linkage fasten ers to spe cification ( see “Exploded
View”).
2. After the new ball joint is installed into the A-arm,
Stabilizer Bar Removal
5
install a NEW retaining ring.
1. If stabilizer bar linkages are installed, remove the nut
and linkage bushings (see “Exploded View”).
Ball Joint 2. Remove the hood and fro nt b umper ( see “ BODY
COMPONENT REMOVAL”).

3. Remove the (4) T30 Torx fasteners retaining the front

bumper support to the frame.

Main T30
Frame Screws
Upper A-arm
Nuts

NEW
Retaining Ring

Standard RZR Shown

3. Reinstall the A-arm (see “FRONT A-ARMS - Removal Bumper

Support
/ Replacement”).

4. Repeat the b all jo int ser vice procedure for an y NOTE: Properly support th e bumpe r support an d
additional A-arm ball joint replacements. wires that are attached.

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 BODY / STEERING / SUSPENSION
4. Remove the (2) upper radiator retaining bolts (A) and 8. Lift up on the stabilizer bar and remov e it from the
remove the (4) bolts (B) retaining the lo wer radiator vehicle.
mount bracket and remove the bracket from the frame

5. Allow radiator to sag down to allow access to recovery

bottle retaining screws an d filler neck retaining
screws.

6. Remove re taining scr ews fro m recovery bo ttle an d 9. Inspect the stabilizer bar for straightness. Inspect the
filler neck. Allow the recovery bottle and filler neck to bushings and replace if needed.
hang down to access the (4) bolts retaining the upper
radiator mount bracket. 10. Reverse the pro cedure for installatio n. Torque th e
linkage fasten ers to spe cification ( see “Exploded
View”).

Recovery
Bottle
Filler
Neck

7. Remove th e ( 4) bo lts re taining t he up per ra diator

mount br acket an d r emove the br acket fr om th e
frame.

Main
Frame

Mount
Bracket

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 BODY / STEERING / SUSPENSION
Exploded View

Grease
Zerk

T30
Screws

5
Stabilizer
Bar

30 ft. lbs. Bushings

(40.5 Nm)

Linkage

Linkage
Bushings

Linkage

37 ft. lbs. (50 Nm)

Spacer
Washer

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 BODY / STEERING / SUSPENSION
REAR A-ARMS Lower A-arm Removal

1. Disengage the rear brake line from the routing clip on

Removal
the lower A-arm.
The following pro cedure details up per and lower A-a rm 2. Remove the fastener (C) retaining the lower portion of
removal an d r eplacement on one side of th e veh icle. the shock and stabilizer linkage to the lower A-arm.
Repeat the followin g steps to remove the A-arm(s) from 3. Remove the fastener (D) attaching the lower A-arm to
the opposite side. the bearing carrier.
NOTE: Use the exp loded v iew in t his se ction as a 4. Remove the (2) fasteners (E) attaching the lower A-
reference during the procedure. arm to the frame and remove the lowerA-arm from the
vehicle (see previous illustration).
1. Elevate and safely support the rear of the vehicle off
the ground.
2. Remove the wheel nuts, and rear wheel.
E
Upper A-arm Removal C
1. Remove the fastene r (A) attaching the u pper A-arm
to the bearing carrier.
2. Remove the (2) fastener (B) attaching the upper A-
arm to the frame and remove the upper A-arm from
the vehicle.

D
5. Examine bushin gs an d p ivot tub es (se e “Explo ded
View”). Replace if worn. Discard hardware.
6. If not replacing the A-arm, thoroughly clean the A-arm
and pivot tubes.
A
WARNING
The locking agent on the existing bolts was
3. Examine bushings and pivot tubes. Replace if worn. destroyed during removal. DO NOT reuse old
Discard hardware. hardware. Serious injury or death could result if
4. If not replacing the A-arm, thoroughly clean the a-arm fasteners come loose during operation.
and pivot tubes.
7. Insert new A-arm bushings and pivot tubes into new
A-arm.
WARNING
The locking agent on the existing bolts was
destroyed during removal. DO NOT reuse old
hardware. Serious injury or death could result if
fasteners come loose during operation.
5. Insert new A-arm bushings and pivot tubes into new
A-arm.

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 BODY / STEERING / SUSPENSION
Installation Exploded View
1. Install lo wer A- arm as sembly o nto ve hicle f rame.
Torque new fasteners to specification. Upper Bushings
A-arm
2. Attach lower A-a rm to be aring carr ier. Torque ne w
Upper Fastener
fastener to specification.
3. Route brake line on top of th e lower A-arm and into
the routing clip.
4. Reinstall the lower portion of the shock and stabilizer
bar to the lower A-arm. Tor que sh ock fastener to
Pivot Tube
specification.
5. Install upper A-a rm a ssembly o nto vehicle frame.
Torque new fastener to specification.
6. Attach upper A-a rm to be aring carr ier. Torque ne w Upper
fastener to specification. Fastener
7. Install wheel and torque wheel nuts to specification. Bushings
Grease
Zerk
WARNING

Upon A-arm installation completion, test vehicle Lower

5
at low speeds before putting into service. Fastener
Bearing
Carrier
=T
Rear Upper / Lower A-arm Bolts:
39 ft. lbs. (53 Nm)

=T
Pivot
Shock Mounting Bolts: Tube
37 ft. lbs. (50 Nm) Lower
Fastener Lower
A-arm
=T
Upper and Lower Bearing Carrier Bolts:
40 ft. lbs. (54 Nm)

=T
Wheel Nuts:
Steel Wheels: 27 ft. lbs. (37 Nm)
Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn)

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 BODY / STEERING / SUSPENSION
REAR STABILIZER BAR
Removal / Installation 18 ft. lbs.
(24 Nm) 30 ft. lbs.
1. Remove the cargo box access panel. (40.5 Nm)
2. Remove the bushing retaining nut (A) from the upper
portion of the stabilizer bar linkage on each side of the
vehicle.
3. Remove the (4) fasteners (B) retaining the s tabilizer Bracket
bar bracket to the frame. Remove the bushing and
bushing brackets from the vehicle.

Bushing

Linkage
B

37 ft. lbs.
(50 Nm)
C

4. Remove the stabilizer bar from the vehicle.

NOTE: Rotate th e st abilize b ar 18 0 de grees s o th e
linkage hole (C) is facing rearward to aid in stabilizer
bar removal.

5. Inspect the stabilizer bar for straightness. Inspect the

bushings and replace if needed.

6. Inspect the r ubber bushings on the linkage rod and

replace if needed.

7. Reverse the procedure for installation.

8. Torque the stabilizer mo unting nuts (B) to
specification.

=T
Stabilizer Mounting Bolt Torque:
18 ft. lbs. (24 Nm)

9. Torque th e bu shing re taining nu t ( A) o n the upp er

portion of the stabilizer bar linkage to specification.

=T
Stabilizer Bushing Retaining Nut Torque:
30 ft. lbs. (40.5 Nm)

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 BODY / STEERING / SUSPENSION
SHOCKS / SPRINGS / FASTENERS Shock Removal / Installation
1. Elevate the ve hicle off the g round to r elieve the
Exploded View
suspension load.
Front Shock Mounting Retainer gap
2. Remove the stabilizer ba r upper link age bushings /
should be 180°
from spring end nut from both sides. Rotate the stabilizer bar upward.
37 ft. lbs.
(50 Nm)
3. Remove the upper and lower fasteners retaining the
Spring shock and remove the shock from the vehicle.

NOTE: It may be necessary to use a commercially

available swivel socket to remove and install the LR
upper shock bolt.

4. Reverse the procedure to reinstall the shock. Torque

new fasteners to spe cification ( refer to explo ded
views).

Adjusting Cam
5
37 ft. lbs.
(50 Nm) Front of Vehicle

Rear Shock Mounting Retainer gap

should be 180°
from spring end
37 ft. lbs.
(50 Nm)

Spring

Adjusting Cam

37 ft. lbs.
(50 Nm) Front of Vehicle

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 BODY / STEERING / SUSPENSION
Shock Replacement DECAL REPLACEMENT
1. Using a spr ing comp ressor, co mpress the shock
spring far enough to remove the spring retainer.
WARNING
Shock Spring
Compressor Tool
The following procedure involves the use of an
2870623
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.

WARNING

Do not flame treat components that are installed

2. Remove the spr ing and ad justing cam fro m the on the vehicle. Remove the component from the
existing shock and install components onto the new vehicle before flame treating.
shock.
The side p anels, front a nd rear fen der ca bs a re pla stic
3. Compress the shock s pring and inst all t he spring polyethylene m aterial. The refore, they must be “flam e
retainer. treated” prior to ins talling a dec al to ensure good
adhesion. A bonus of the flame treating procedure is it can
IMPORTANT: The spring retainer gap should be 180° be used to r educe or eliminate the whitish stress marks
from the end of the spring upon installation. that are sometimes left after a fender or cab is bent, flexed,
or damaged.
4. Reinstall the shock onto the vehicle and torque new
fasteners to specification (refer to exploded views).
CAUTION

Do not flame treat painted plastic components.

Painted plastic surfaces should only be wiped
clean prior to decal adhesion.

To flame treat the decal area:

1. Pass the fla me o f a pr opane tor ch ba ck a nd for th
quickly over the area where the decal is to be applied
until the surface appears slightly glossy. This should
occur after just a fe w seconds of flame treating. Do
not hold the torch too close to the surface (2-3 inches
from the flame tip is recommended). Keep the torch
moving to prevent damage.

2. Apply the de cal on on e e dge first. Slowly lay do wn

remainder of the decal while rubbing lightly over the
decal surface to eliminate any air bubbles during the
application.

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 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
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 COVERS AND DUCTING COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
PVT DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
PVT ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
PVT BREAK-IN (DRIVE BELT / CLUTCHES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9

6
CLUTCH CENTER DISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
DRIVE CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12
DRIVE CLUTCH EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12
CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
DRIVE CLUTCH SPRING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
SHIFT WEIGHT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
SPIDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
ROLLER, PIN, AND THRUST WASHER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . 6.16
BUTTON TO TOWER CLEARANCE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
BEARING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
BUSHING SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20
DRIVEN CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21
CLUTCH DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21
CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.24
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.25

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 CLUTCHING
SPECIAL TOOLS AND SUPPLIES PVT SYSTEM OVERVIEW
TOOL DESCRIPTION PART NUMBER CLUTCH CHART
Drive Clutch Puller (Short) PA-48595 Shift Drive
Altitude
Weight Spring
Clutch Holding Wrench 9314177
0-1500 25-52 Black
Clutch Holding Fixture 2871358-A (0-5000) (5632409) (7043594)
Meters
Drive Clutch Spider Removal and (Feet) 1500-3700 25-48 Black
2870341
Installation Tool (5000 - 12000) (5632408) (7043594)

Roller Pin Tool 2870910

Clutch Bushing Replacement
2871226 General Operation
Tool K it
Piston Pin Puller 2870386
Universal Clutch Compressor Tool PU-50518 WARNING
Clutch Bushing Replacement All PVT maintenance or repairs should be performed by
2871025
Tool K it a certified Polaris Master Service Dealer (MSD)
technician who has received the proper training and
SPECIAL SUPPLIES PART NUMBER understands the procedures outlined in this manual.
Because of the critical nature and precision balance
Loctite™ 609 N/A incorporated into the PVT components, it is
RTV Silicone Sealer 8560054 absolutely essential that no disassembly or repair
be made without factory authorized special tools
SPX Corporation: and service procedures.
1-800-328-6657 or http://polaris.spx.com/.
The Polaris Variable Transmission (PVT) consists of three
major assemblies:

TORQUE SPECIFICATIONS 1) The Drive Clutch

PVT System Fastener Torques 2) The Driven Clutch

3) The Drive Belt
ITEM TORQUE VALUE
The inte rnal comp onents of the dr ive clutch an d d riven
Drive Clutch Retaining Bolt 47 ft. lbs. (63.5 Nm) clutch contr ol e ngagement ( initial veh icle mo vement),
Driven Clutch Retaining Bolt 36 ft. lbs. (48.5 Nm) clutch upshift and ba ckshift. Du ring the d evelopment of
the Polaris vehicle, the PVT system is matched first to the
PVT Inner Cover Bolts 12 ft. lbs. (16 Nm) engine power curve; then to average riding conditions and
PVT Outer Cover Bolts 45-50 in. lbs (5 Nm) the vehicle’s intended usage. Therefore, modifications or
variations of components at ra ndom ar e ne ver
Drive Clutch Spider 200 ft. lbs. (271 Nm) recommended. Proper clutch setup and careful inspection
Drive Clutch Cover Plate 100 in. lbs. (12 Nm) of e xisting comp onents m ust be the primary ob jective
when troubleshooting and tuning.

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 CLUTCHING
Drive Clutch Operation PVT Break-In (Drive Belt / Clutches)
Drive clutches primarily sense engine RPM. Th e two A proper break-in of the clutches and drive belt will ensure
major components which co ntrol its shifting function are a longer life and better performance. Break in the clutches
the shift weigh ts and the coil spr ing. When ever eng ine and drive belt by operating at slower speeds during the 10
hours as recommended (see Chapter 3 “Engine Break-In
RPM is in creased, ce ntrifugal for ce is cr eated, ca using
Period” for break-in example). Pull only light loads. Avoid
the shift weights to push against rollers on the moveable aggressive acceleration and high speed operation during
sheave, which is held open by coil spring preload. When the break-in period.
this force becomes higher than the preload in the spring,
the ou ter she ave moves inw ard an d co ntacts th e drive Maintenance / Inspection
belt. This motion pinches the drive belt between the spin-
ning shea ves and cause s it to ro tate, wh ich in tu rn Under normal use the PVT system will provide years of
trouble fr ee operation. Pe riodic inspection and
rotates the driven clutch.
maintenance is required to keep the system operating at
At lower RPM, the drive belt rotates low in the drive clutch peak performance. The following list of items should be
sheaves. As engine R PM in creases, centrifugal force inspected and ma intained to e nsure maximu m
causes the drive belt to be forced upward on drive clutch performance and service life of PVT components. Refer to
sheaves. the troubleshooting checklist at the end of this chapter for
more information.
Driven Clutch Operation
1. Belt Inspection.
Driven clutches pr imarily sense to rque, ope ning and
closing according to the forces applied to it from the drive 2. Drive an d Driv en Clutch But tons a nd Bush ings,
belt and the transmission input shaft. If the torque resis- Drive Clutch Shift Weights and Pins, Drive Clutch

6
tance at the transmission input shaft is gr eater than the Spider Rollers and Roller Pins, Drive and Driven
Clutch Springs.
load from the drive belt, the drive belt is kept at the outer
diameter of the driven clutch sheaves. 3. Sheave Faces. Clean and inspect for wear.
As engine RPM and horsepower increase, the load from
the drive belt increases, resulting in the belt rotating up 4. PVT Syst em Sealing. Re fer to the ap propriate
toward the outer diameter of the drive clutch sheaves and illustration(s) on the following pages. The PVT system
downward in to the sheaves of the driven clutch. Th is is air coole d by fins on the drive clutch sta tionary
action, which increases the driven clutch speed, is called sheave. T he fins create a lo w pr essure ar ea in th e
upshifting. crankcase cast ing, drawing air int o the syst em
through an in take du ct. The ope ning for th is in take
Should the throttle settin g re main th e sa me a nd the duct is located at a high point on the vehicle (location
vehicle is subjected to a heavier load, the drive belt rotates varies by mo del). T he in take du ct d raws fr esh a ir
back up toward the outer diameter of the driven clutch and through a vented cover. All connecting air ducts (as
downward into the sheaves of the drive clutch. This action, well as the inner and outer covers) must be properly
which d ecreases the dr iven clutch speed, is ca lled sealed to ensure clean air is being used for cooling the
backshifting. PVT system an d also to prevent wa ter an d other
In situations where loads vary (such as uphill and downhill) contaminants from ente ring the PVT a rea. This is
and th rottle s ettings ar e co nstant, the drive and dr iven especially critical on units subjected to frequent water
clutches ar e con tinually shif ting to main tain o ptimum forging.
engine RPM. At full thrott le a perfectly matched P VT
system should hold engine RPM at the peak of the power
curve. This RPM should be ma intained dur ing clu tch
upshift and backshift. In this respect, the PVT system is
similar to a power g overnor. Rath er than var y throttle
position, as a conventional gove rnor doe s, th e PVT
system ch anges e ngine lo ad r equirements by e ither
upshifting or backshifting.

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 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 th rough the ducts will significantly increase PVT system operating
temperatures. The vehicle should be operated in Low when plowing or pulling heavy load s, or if extended low s peed
operation is anticipated.

CLUTCH DRIVE BELT & COVER RELATED ISSUES: DIAGNOSIS

Possible Causes Solutions / What to do
Loading the vehicle into a truck or tall
Shift transmission to Low during loading of the vehicle to prevent belt burning.
trailer when in high range.
Starting out going up a steep incline from When starting out on an incline, use Low gear. Shift transmission to Low
a stopped position. during loading of the vehicle to prevent belt burning.
Driving at low RPM or low ground speed Drive at higher speed or use Low. The use of Low is highly recommended for
(at approximately 3-7 MPH). cooler PVT operating temperatures and longer component life.
Warm engine at least 5 min., then with transmission in neutral, advance
Insufficient engine warm-up when
throttle to approx. 1/8 throttle in short bursts, 5 to 7 times. The belt will
exposed to low ambient temperatures.
become more flexible and prevent belt burning.
Slow and easy clutch engagement. Fast, effective use of the throttle for efficient engagement.
Towing/Pushing at low RPM or low
Use Low only.
ground speed.
Plowing snow, dirt, etc./utility use. Use Low only.
Shift the transmission to Low, carefully use fast, aggressive throttle
Stuck in mud or snow. application to engage clutch. WARNING: Excessive throttle may cause loss
of control and vehicle overturn.
Shift the transmission to Low, carefully use fast, aggressive, brief throttle
Climbing over large objects from a
application to engage clutch. WARNING: Excessive throttle may cause loss
stopped position.
of control and vehicle overturn.
Shift the transmission to neutral. Using the throttle, vary the engine rpm from
Belt slippage from water or snow idle to full throttle. Repeat several times as required. During this procedure,
ingestion into the PVT system. the throttle should not be held at the full position for more than 10 seconds.
Clutch seals should be inspected for damage if repeated leaking occurs.
Clutch component inspection should be performed by a Polaris MSD certified
Clutch malfunction.
technician.
Fouled spark plugs, foreign material in fuel tank, restricted fuel lines, or faulty
Poor engine performance.
fuel pump may cause symptoms similar to clutching malfunction.
Low: Heavy pulling, basic operational speeds less than 7 MPH, riding
GENERAL RANGE OPERATION
through rough terrain (swamps, mountains, ect.), or low ground speeds.
GUIDELINES:
High: High ground speeds, or speeds above 7 MPH.

Operating in Low Gear

Low gear s hould be used when pulling heavy loads, riding through rough terrai n, or when basic operational ground
speeds are less than 7 MPH. Use High gear when basic operational ground speeds are more than 7 MPH.
IMPORTANT: Using High gear for heavy loads, hilly terrain, or in wet, muddy conditions will increase the chance
of drive belt burning.

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 CLUTCHING
PVT SYSTEM SERVICE

PVT Covers and Ducting Components

Clutch Intake Filter
Box

Clutch Clamp
Intake Hose
Outlet Duct

Inner
Clutch Cover

Outer
Bolt & Cover Seal
Washer Drain
12 ft. lbs.
(16 Nm)

Cover
Screws
45-50 in. lbs.
(5 Nm)
6

Outer
Drain Clutch Cover

PVT Disassembly 1. Remove the seats an d en gine service pan el (see

chapter 5).

CAUTION 2. Disconnect the (-) negative battery terminal.

3. Place transmission in neutral.

Correct Drive Clutch Puller P/N PA-48595
4. Raise and support the vehicle.

CAUTION

Serious injury may result if machine tips or falls.

Be sure machine is secure before beginning this
service procedure.

5. Remove the left rear wheel.

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 CLUTCHING
6. Remove the (8) clutch cover screws and remove the 11. Loosen hose clamp attaching the PVT inlet duct to the
outer clutch cover from the vehicle. inner c lutch co ver. D isengage ho se fr om t he in ner
clutch cover.

7. Mark the drive belt direction of rotation and remove

drive belt (see “DRIVE BELT - Belt Removal”).
12. Loosen the hose clamp (A) that attach the clutch outlet
8. Remove the d riven clutch r etaining b olt and dri ven duct to th e inn er clutch cover . Diseng age th e ho se
clutch. from the cover.

9. Install the Drive Clutch Holder PN 9314177. 13. Remove the (8) bolts that retain the inner clutch cover
to the engine and transmission. Remove inner clutch
10. Remove the dr ive clutch r etaining b olt an d r emove cover. Make note of ca ble and hose routings for
drive clutch using the Drive Clutch Puller PA-48595. assembly.

A A

Drive Clutch Puller PA-48595

Drive Clutch Holder 9314177

IMPORTANT: Be sure to use the correct Drive Clutch

Puller (PA- 48595) to prevent damage to crankshaft.

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 CLUTCHING
PVT Assembly 10. Install the dr iven clutch, washer a nd re taining bolt.
Torque to specification.
1. Inspect inne r clu tch cover. Repla ce if cracked or
damaged.
=T
2. Inspect th e se al on the tra nsmission inpu t shaft.
Replace if damaged. Driven Clutch Retaining Bolt:
36 ft. lbs. (48.5 Nm)
3. Remove silic one sealant from the engine case and
inner PVT cover.
11. Clean the end of the taper on the crankshaft and the
4. Apply R TV silicone sealant to the bac k side of the tapered bore inside the drive clutch.
inner clutch cover to ensure a water tight fit between
12. Install d rive clutch onto the en gine an d tor que
the engine and inner clutch cover. Both surfaces must
retaining bolt to specification.
be clean to ensure adhesion of the silicone sealant.
Apply RTV Silicone Here
=T
9

Drive Clutch Retaining Bolt:

47 ft. lbs. (63.5 Nm)

13. Install th e dr ive b elt no ting dir ection of be lt r otation

(see “DRIVE BELT - Belt Installation”). If a new belt is
installed, install so numbers can be easily read.

14. Install a new outer clutch cover seal with the colored
stripe facing the inner clutch cover. 6
15. Reinstall outer clutch cover and secure with screws.
Torque screws to specification.
5. Install an d p roperly align th e in ner clu tch cov er. Be
sure the cables and hose routings are correct.
=T
6. Install the (4) inner clutch cover bolts and washers that
retain the cover to the transmission. Torque bolts to
Outer Clutch Cover Retaining Screws:
specification.
45-50 in. lbs. (5 Nm)
7. Install the (4) inner clutch cover bolts and washers that
retain th e cover to the en gine. Tor que bo lts to 16. Install the clutch inlet and outlet ducts and tighten the
specification. hose clamps.

=T =T

Inner Clutch Cover Bolts: Wheel Nuts:

12 ft. lbs. (16 Nm) Steel Wheels: 27 ft. lbs. (37 Nm)
Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn)
8. Clean the splines inside the driven clutch and on the
transmission input shaft. 17. Reconnect the battery cable.
18. Install engine service panel and both seats.
9. Apply a light film of grease to the splines on the shaft.

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 CLUTCHING
DRIVE BELT 5. Lift up ward a nd outward on belt a nd ro tate d riven
clutch clockwis e to walk the be lt off of the driven
Belt Removal clutch.

IMPORTANT: Inspect t he entire c lutch out let duct

when replacing a drive belt. Remove any debris found
in the outlet duct.

6. Walk the belt out of the driven clutch and drive clutch.
Inspect / Remove Debris Remove the belt from the vehicle.

1. Remove th e (8 ) sc rews th at retain the ou ter clu tch

cover. Belt Inspection
1. Inspect belt for hour glassing (extreme circular wear
2. Maneuver the outer clutch cover outward as shown in at lea st one spo t and on b oth side s of the be lt).
below to access the drive belt. Hour glassing occurs when the drive train does not
3. Mark the drive belt direction of rotation so that it can move and the drive clutch engages the belt.
be installed in the same direction.
4. Push downward o n be lt to op en the dr iven clutch 2. Inspect belt for loose cor ds, missing cogs, cracks,
sheaves. abrasions, thin spot s, or excessiv e wear. C ompare
belt measurements with a new dr ive belt. Replace if
necessary.
Press downward on Belt
3. Belts with th in sp ots, burn marks, etc., sho uld be
replaced to eliminate noise, vibration, or erratic PVT
operation. See the Troubleshooting Chart at the end
of this chapter for possible causes.

NOTE: Removal of left rear wheel is NOT necessary

for belt replacement.

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 CLUTCHING
Belt Installation PVT Break-In (Drive Belt / Clutches)
NOTE: Be su re t o install be lt in th e s ame d irection A proper break-in of the clutches and drive belt will ensure
as it was removed. a longer life and better performance. Break in the clutches
and drive belt by operating at slower speeds during the 10
1. Loop be lt over th e d rive clu tch an d o ver th e d riven hour break-in p eriod as r ecommended ( see Chapter 3
sheave. “Engine Break-In Period” for break-in example). Pull only
light loads. Avoid aggressive acceleration and high speed
operation during the break-in period.

2. Rotate th e dr iven clu tch a nd wa lk th e be lt into the

clutch.

3. Rotate / spin the driven clutch and belt approximately

5-7 times to properly seat the belt in the driven clutch. 6
4. Install the outer clutch cover and (8) screws. Torque
screws to specification.

=T
Outer Clutch Cover Retaining Screws:
45-50 in. lbs. (5 Nm)

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 CLUTCHING
CLUTCH CENTER DISTANCE Adjustment
1. Remove the Clutch Cen ter Distance tool from th e
Inspection
engine and transmission.
1. Remove the outer PVT cover, drive belt, drive clutch 2. Remove the inner PVT Cover.
and driven clutch as outlined in this chapter. 3. Loosen the (8) engine to transmission coupler bolts
(A).
NOTE: The in ner PVT cover do es not nee d t o be
removed to ch eck t he clutch center t o c enter
distance.

2. Install the Clutch Center Distance Too l (PU-50658)

onto the crankshaft and transmission input shaft. The
pictures b elow show the too l (PU-50658) p roperly
A
installed.

4. Loosen th e (2 ) fasteners ( B) se curing the re ar

transmission isolator to the vehicle frame.

Drive Clutch Bolt Installed

5. With the engine and transmission mounting fasteners

loose, ins tall the Clutch Center Dista nce T ool (PU-
50658) as shown in the inspection process.
Tool Fully Seated Inward

3. If the tool fits as shown above, the clutch center to

center distance is correct.

4. If the tool does not fit as shown above, adjustment is

needed.

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 CLUTCHING
6. With the too l n ow p roperly installed, in sequence
torque the (8) engine to transmission coupler bolts to
specification.

55 ft. lbs
(74.5 Nm)

=T
Engine To Trans Coupler Bolts:
55 ft. lbs. (75 Nm)

7. Torque the (2) rear transmission isolator fasteners (B)

to specification
6
B

8. Remove the Clu tch Ce nter Distan ce tool a nd

reassemble the P VT system as out lined in t his
chapter.

=T
Rear Trans. Isolator Bolts:
25 ft. lbs. (34 Nm)

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 CLUTCHING
DRIVE CLUTCH SERVICE

Drive Clutch Exploded View

Clutch Bolt
Replace If Removed
47 ft. lbs. (63.5 Nm)
Lock
Washer
Flat
Washer
Limiter Spacer

Bushing
Spring
Spider
210 ft. lbs. (284 Nm)

Bushing
Non-Braking Bushing
Bearing

Spacer
Cover
Button Screws
Pin 100 in. lbs. (12Nm)
Roller

Washers

Button

Nut
Washers Bolt Shift 25 in. lbs. (2.8 Nm)
Weight

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 CLUTCHING
Clutch Disassembly 5. Remove and insp ect the clu tch spring. See “ Drive
Clutch Spring Specifications” for spring inspection.
1. Using a permanent marker, mark the cover, spider,
and moveable and stationary sheaves for reference, Inspect Shaft
as the cast in X's may no t h ave be en in align ment
before disassembly.

6. Remove the limiter spacer (B) and inspect for wear.

Replace if excessive wear is evident.
7. Inspect area on shaft ( C) whe re bu shing rid es for
wear, galling, nic ks, or scratches . Replace clutc h
2. Mark the stationary sheave and clutch shaft to verify
assembly if worn or damaged.
the shaft has not turned in the sheave after tightening
the spider during clutch assembly. B
3. Remove the (6) cover bolts evenly in a cross pattern
and remove cover plate. C 6
4. Inspect cover bushing (A). The outer cover bushing is
manufactured with a Te flon coa ting. We ar is
determined by the amount of Teflon remaining on the
bushing.

CAUTION

DO NOT reassemble the drive clutch without the

limiter spacer (B). Belt life will be greatly reduced.

Cover Bushing Inspection:

Replace the cover bushing if more
brass than Teflon is visible on
the bushing. Refer to bushing
replacement in this chapter.

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 CLUTCHING
Drive Clutch Spring Inspection Shift Weight Inspection
1. Remove shift weight bolts and weights . Inspec t the
CAUTION contact surface of the weight. The surface should be
smooth and free of dents or gall marks. Inspect the
Never shim a drive clutch spring to increase its weight pivot bore and bolts for wear or galling. If
compression rate. This may result in complete weights or bolts are worn or broken, replace in sets of
stacking of the coils and subsequent clutch three with new bolts and nuts.
cover failure.
Inspect for
excessive wear
The d rive clu tch sp ring is on e of the most critical
components of t he PVT system. It is also one of t he
easiest to service. Due to the severe relaxation the spring
is su bject to du ring op eration, it sh ould alw ays be
inspected for tolerance limits during any clutch operation Nut
diagnosis or repair.

With the spring resting on a flat surface, measure its free

length from the outer coil surfaces. Also check to see that Shift Weight
spring coils a re parallel to one another. Distortion of the
spring indicates stress fatigue, requiring replacement.
Inspect for
excessive wear
Bolt

Inspect for
excessive wear

WARNING

The clutch assembly is a precisely balanced

unit. Never replace parts with used parts from
another clutch assembly!

NOTE: A damaged shift weight is usually caused by

Drive Clutch Spring Specifications
a da maged or st uck rolle r in the spider assembly.
Color Black See “Roller, Pin and Thrust Washer Inspection”.

Free Length 2.8” (71.12mm)

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 CLUTCHING
Spider Removal NOTE: It is impo rtant t hat t he sa me numb er an d
thickness of wa shers a re r einstalled b eneath the
1. Install clutch in ho lding fixture (PN 2871358-A) and spider during assembly. Be sure to note the number
loosen th e spider (cou nterclockwise) using Clu tch and thickness of these washers.
Spider Removal Tool (PN 2870341).
To main tain p roper clutch ba lance
and be lt-to-sheave clea rance, be
sure to reinst all original
quantity an d th ickness

2870341

2871358-A

Moveable Sheave Bushing Inspection

Clutch Holding Fixture:
(PN 2871358-A) 2. Inspect the Teflon™ coating on the moveable sheave
bushing.
Spider Removal Tool:
(PN 2870341)
6

TeflonTM

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.

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 CLUTCHING
Roller, Pin, and Thrust Washer Inspection Button To Tower Clearance Inspection
1. Inspect all rollers, bushings and roller pins by pulling 1. Inspect fo r a ny cle arance between sp ider bu tton to
a flat metal rod across the roller. Turn roller with your tower. If clearance exists, re place all button s and
finger. If you notice resistance, galling, or flat spots , inspect su rface of towers. See “Sp ider Removal”
replace r ollers, p ins an d thr ust washer s in sets of procedure.
three. Also inspe ct to see if ro ller a nd b ushing ar e
separating. Bushing must fit tightly in roller. Use the
Roller Pin T ool (PN 2870910) to replace rollers and
pins. T ake car e n ot to d amage r oller b ushing or
bearing surface of the new pin during installation.

Button to Tower Clearance:

.000-.010”

2. Inspect sheave surfaces. Replace the entire clutch if

2. Rubber backed buttons can be used in all RANGER worn, damaged or cracked.
clutches if the hollow roller pin is changed to the solid
roller pin.
Bearing Inspection
NOTE: The rubbe r side of the but ton is positioned 1. Rotate the clutch be aring in bo th clockwise and
toward the solid roller pin. counter-clockwise directions. Th e n on-braking
bearing should rotate in 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 continue with disassembly.

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 CLUTCHING
Clutch Inspection 4. Inspect sur face of shaft for p itting, gr ooves, or
damage. Measure the outside diameter and compare
NOTE: Remove cov er, spring, and spider following to specifications. Replace the drive clutch assembly
instructions for drive c lutch remov al, t hen proc eed if shaft is worn or damaged.
as follows:

1. Remove the movea ble sh eave spacer slee ve (A) .

Inspect for damage and wear.

= In. / mm.
2. Remove the moveable clutch sheave (B). Inspect for
damage and wear. Shaft Diameter:

B
Standard: 1.3745” - 1.375” (34.91 - 34.93 mm)
Service Limit: 1.3730” (34.87 mm) 6
5. Visually inspect PT FE th rust washer s fo r da mage.
Measure the thickness and compare to specification.
Replace if worn or damaged.

= In. / mm.

PTFE Washer Thickness

Standard: .030” (.76 mm)
Service Limit: .025” (.64 mm)
3. Lift bearing (C) an d th rust wa shers (D) off shaft.
Replace as a n assembly if wor n, d amaged, o r if
problems were noted.

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 CLUTCHING
Bushing Service
IMPORTANT: Special Tools Required CAUTION

EBS Clutch Bushing Tool Kit - 2201379 Clutch components will be hot! In order to avoid
serious burns, wear insulated gloves during the
Item Qty. Part Description Part # removal process.
A, B 1 EBS Puller Tool 5132027
C 1 EBS Puller Nut 5132501 Moveable Sheave - Bushing Removal
D 1 EBS Main Adapter 5132029 1. Remove clutch as outlined previously in this chapter.
E 1 EBS Bushing Removal 5132028
2. Install ha ndle en d of the Piston Pin Pu ller (PN
-- 1 Instructions 9915111
2870386) securely into bench vise and lightly grease
puller threads.
Additional Special Tools
Qty. Part Description Part # Piston Pin Puller (PN 2870386)
1 Clutch Bushing Replacement Tool 2871226
1 Piston Pin Puller 2870386
3. Remove nut from puller rod and set aside.
*Clutch Bushing Replacement Tool Kit (PN 2871226)
Piston Pin Puller
#2 #3 (PN 2870386)
#5

Main Puller Adaptor (#8)

(PN 5020632)

#9
#10
4. Install puller adapter (Item 10 from kit PN 2871226).
#8
5. Install main adapter (Item D) onto puller.
Item Qty. Part Description Part #
P-90 Drive/Driven Clutch Puller Tool (A,B) Nut (C)
#2 1 5020628 Side “A” toward
Bushing Install Tool
sheave
Drive Clutch Cover
Bushing Removal/
#3 1 5020629
Installation Tool (all
clutches)
P-90 Driven Clutch Cover
#5 1 5020631
Bushing Removal Tool
#8 1 Main Puller Adapter 5020632
#9 1 Adapter Reducer 5010279 Puller
Adapter (10)
Number Two Puller
#10 1 5020633
Adapter Main Piston Pin
Adapter (D) Puller
NOTE: Bushings ar e inst alled at th e fa ctory us ing
Loctiteä 609. In ord er to re move bu shings it wi ll be 6. With tower s pointing to ward th e vise, slide sh eave
necessary to apply he at e venly t o t he area around onto puller rod.
each bus hing. Cle an all residual Loc titeä fro m
bushing bore prior to installing new bushing. 7. Install removal tool (Item A, B) into center of sheave
with “A side" toward sheave.

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 CLUTCHING
NOTE: Use Bushing Tool PA-47336. 10. Remove installation tool.

8. Install nut (C) onto end of puller rod and hand tighten. Cover Bushing Removal
Turn pu ller barrel to in crease te nsion on sh eave if
needed. Using a hand held propane torch, apply heat 1. Install main adapter (Item 8) on puller.
around outside of bushing until tiny s moke tailings Removal Tool Nut (C)
appear. (3)

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 Adapter Reducer

(9)
1. Place main adapter (Item 8) on puller. Main Piston Pin
Adapter (8) Puller
Puller Tool (A,B) Nut (C)
Side “A” toward
sheave 2. Install adapter reducer (Item 9).

3. From outside of clutch cover, insert removal tool (Item

3) into cover bushing.

4. With i nside of co ver toward vise , slide cover on to

puller.
6
Bushing 5. Install nut onto puller rod and hand tighten. Turn puller
Piston Pin barrel to increase tension as needed.
Main Adapter Puller
6. Turn clutch cover counterclockwise on puller rod until
(8) bushing is removed and cover comes free.

2. Apply Lo ctiteä 60 9 evenly to b ushing b ore inside 7. Remove nut from puller rod and set aside.
moveable sheave.
8. Remove bushin g and bush ing rem oval tool from
3. Set bushing in place on sheave. puller. Discard bushing.

4. Insert installation puller tool (Item A/B) with “A” side Cover Bushing Installation
down, into center of bushing. 
1. Apply Loctiteä 609 evenly to bushing bore in cover.
NOTE: 800 E FI C lutch - U se Bushing Tool PA-
47336. 2. Working from inside of cover, insert new bushing and
bushing installation tool into center of clutch cover.
5. With towers pointing upward, slide she ave, bushing
and tool onto puller rod. 3. With main adapter on puller, insert cover onto puller
rod, placing outside of cover toward vise.
6. Install nut on puller rod and hand tighten. Turn barrel
to apply additional tension if needed. 4. Install nut on rod and hand tighten. Turn puller barrel
to apply more tension if needed.
7. Turn sheave counterclockwise, making sure bushing
is drawn straight into bore. Continue until bushing is 5. Turn clutch cover counterclockwise on puller rod until
seated. bushing is seated.
8. Remove nut from puller rod and set aside. 6. Remove nut from puller rod. Take installation tool and
clutch cover off rod.
9. Remove sheave from puller.

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 CLUTCHING
Clutch Assembly 3. Compress spider buttons for each tower and install
spider, making sure that “X”, or the marks that were
NOTE: The Teflon bushings are self-lubricating. made earlier, on spider aligns with “X”, or the marks
that were made earlier, in moveable sheave.
CAUTION 4. Torque spider to specification using the holding fixture
and spider tool. Torque with smooth motion to avoid
Do not apply oil or grease to the bushings. damage to the stationary sheave.

Reassemble the drive clutch in the following sequence. Be

sure th e “ X”, or the ma rks that wer e made e arlier are =T
aligned during each phase of assembly.
Spider Torque:
210 ft. lbs. (284 Nm)

5. Install shift weights using new lock nuts on the bolts.

Nut on trailing side Rotation

1. Install th e PTFE washers an d non braking bea ring
over t he c lutch sh aft. There s hould be one fiber
washer on each side of the bearing. 6. Reinstall clutch spring.

2. Install the mo veable sh eave and spa cer on to th e 7. Reinstall cover, aligning “X” mark with other marks.
clutch shaft.
8. Torque cover bolts evenly to specification.
NOTE: To maint ain pr oper clut ch balance and belt-
to-sheave clearance. be sure to reinstall the original
quantity and thickness of washers / spacers beneath
=T
the spider during assembly.
Cover Screw Torque:
100 in. lbs. (12 Nm)
Spacer

PTFE
Washers

Spider

Non-braking
Bearing

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 CLUTCHING
DRIVEN CLUTCH SERVICE
Exploded View

Washer

Bolt
36 ft. lbs. (48.5 Nm)

Compression Spring

Spacer

Outer
Stationary Spring Retainer

6
Secondary Sheave
Inner Retaining
Spring Retainer Ring
Moveable
Secondary Sheave

Clutch Disassembly / Inspection

2. Mark the p osition of the clutch she aves b efore
CAUTION disassembly or use th e X’s o n th e shea ves for
reference. T his a ids in re assembly an d m aintains
clutch balance after reassembly.
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 d riven c lutch from t he tr ansmission in put
shaft.

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 CLUTCHING
3. Place the clutch into the Universal Clutch Compressor 5. Separate the two clutch sheaves.
Tool PN PU- 50518. App ly an d ho ld do wnward
pressure on th e ou ter spr ing r etainer. Car efully
remove the snap rin g. Reme mber the ou ter spring
retainer contains strong spring pressure.

Remove Snap Ring

6. Inspect the helix on the moveable sheave.

Outer Spring Retainer
Inspect for Abnormal Wear

NOTE: Spring is c ompression only a nd h as no

torsional wind.

4. With the snap ring (A) removed and spring pressure

relieved, re move the outer sprin g r etainer ( B),
compression spring (C), spacer (D), and inner spring
retainer (E).

D
B
7. Remove the inne r spr ing retainer from the inn er
A sheave. Inspect for wear and replace as needed.
E
C

C
E

D Inspect for Abnormal Wear

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 CLUTCHING
8. Check the rollers in the stationary sheave for wear. If 10. Inspect the Teflon™ coating on the moveable sheave
rollers are worn, a new driven clutch assembly may be bearings.
needed.
11. Inspect d riven cl utch sh eave fa ces for wear or
damage.

12. Clean and inspect splines on helix and transmission

input shaft.

13. Lube splin es with a lig ht film o f grease. Do not

lubricate the bearings!

Check Rollers for Wear

9. Inspect the bearings inside the moveable sheave.

Inspect Bearings for Wear

Moveable Sheave Bearing Inspection:

Replace the clutch assembly if more brass than
Teflon™ is visible on the bearing.

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 CLUTCHING
Clutch Assembly 5. Install the outer retainer on top of the spring.

1. Install th e in ner spr ing retainer if removed. Do not

apply oil or grease to the bearings.

6. Place the clutch into the Universal Clutch Compressor

Tool PN PU-50518 . Apply a nd hold do wnward
pressure on the outer spring retainer. Carefully install
2. Align th e “ X” ma rks on e ach of the she aves du ring the snap ring.
reassembly.
7. Compress the outer retainer and install the snap ring.

Snap Ring

Assemble Sheaves

3. Install the spring into the inner retainer.

4. Install the spacer over the shaft.

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 CLUTCHING
TROUBLESHOOTING
Situation Probable Cause Remedy
-Wrong or broken drive clutch spring. -Replace with recommended spring.
Engine RPM below  
specified operating -Drive clutch shift weight too heavy. -Install correct shift weight kit to match engine
range, although  application.
engine is properly  
tuned. -Driven clutch spring broken or installed in -Replace spring; refer to proper installation
wrong helix location. 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
-Belt worn unevenly - thin / burnt spots. 
operating RPM
 Replace belt.
during acceleration
-Driven clutch malfunction. 
or load variations.
 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 -Install correct recommended spring.
rate).


-Install correct recommended shift weights. 6
-Drive clutch shift weights incorrect for 
application (too light). 
 -Disassemble and clean clutch, inspecting shift
-Drive clutch binding. weights and rollers. Reassemble without the spring
Engine RPM above
 and move sheaves through entire range to further
specified operating
 determine probable cause.
range.
 
 -Disassemble, clean, and inspect driven clutch,
-Driven clutch binding. noting worn sheave bushing and ramp buttons and
 helix spring location.
 
 -Clean sheaves with denatured alcohol or brake
-Converter sheaves greasy; belt slipage. cleaner, install new belt.
-Drive belt worn too narrow. -Replace belt.
Harsh drive clutch  
engagement. -Excessive belt / sheave clearance with new -Perform belt / sheave clearance adjustment with
belt. shim washers beneath spider.
Drive belt turns -Wrong belt for application. -Replace with correct belt.
over
-Abuse (continued throttle application when -Caution operator to operate machine within
vehicle is stationary, excess load) guidelines.
 
Belt burnt, thin -Dragging brake 
spots -Inspect brake system.
 
-Slow, easy clutch engagement -Fast, effective use of throttle for efficient
engagement.

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 CLUTCHING
Troubleshooting, Continued.....
Situation Probable Cause Remedy
-Plugged air intake or outlet. -Clear obstruction
 
-Belt slippage due to water, oil, grease, etc., -Inspect system. Clean , repair or replace as
rubbing on cover. necessary. 
Seal PVT system ducts.
PVT cover
-Clutches or weight being applied to cover
overheating
while in operation. -Remove weight. Inform operator.
(melting)
 
-High vs. low range. 
-Instruct operator on guidelines for operation in
proper driving range for different terrain as outlined
in Owner’s Safety and Maintenance Manual.
-Cover seals or ducts leaking -Find leak and repair as necessary.
 
Water ingestion -Operator error -Instruct operator on guidelines for operation in wet
terrain as outlined in Owner’s Safety and
Maintenance Manual.
-Belt worn out -Replace belt.
 
Belt slippage -Water ingestion -Inspect and seal PVT system.
 
-Belt contaminated with oil or grease -Inspect and clean.
-Belt worn or separated, thin spots, loose belt -Replace belt.

PVT noise
-Broken or worn clutch components, cover -Inspect and repair as necessary.
hitting clutches
-Thin spots on belt, worn belt -Replace belt. Refer to belt burnt troubleshooting
Engagement and instruct operator.
erratic or stabby
-Drive clutch bushings stick -Inspect and repair clutches.

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 FINAL DRIVE
CHAPTER 7
FINAL DRIVE
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
WHEEL AND HUB TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
FRONT BEARING CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
BEARING CARRIER INSPECTION / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
BEARING CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
DRIVE SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
DRIVE SHAFT / CV JOINT HANDLING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
OUTER CV JOINT / BOOT REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
INNER PLUNGING JOINT / BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
DRIVE SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
PROPSHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
PROPSHAFT U-JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
FRONT GEARCASE / CENTRALIZED HILLIARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
CENTRALIZED HILLIARD EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
ALL WHEEL DRIVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
AWD DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
GEARCASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
GEARCASE DISASSEMBLY / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20

7
GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
GEARCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25
REAR BEARING CARRIER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.26
BEARING CARRIER INSPECTION / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.26
BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27
BEARING CARRIER BUSHING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.28
BEARING CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.29
REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30
DRIVE SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30
OUTER CV JOINT / BOOT REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32
INNER PLUNGING JOINT / BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 7.35
DRIVE SHAFT EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.37
DRIVE SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.38
WHEEL HUBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.40
FRONT HUB EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.40
REAR HUB EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.40

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 FINAL DRIVE
SPECIAL TOOLS FRONT BEARING CARRIER
Bearing Carrier Inspection / Removal
PART NUMBER TOOL DESCRIPTION
1. Elevate front of vehicle and safely support machine
2872608 Roll Pin Removal Tool
under the frame area.
CV Boot Clamp Pliers
8700226
(earless type)
CAUTION
PU-48951 Axle Boot Clamp Tool
Serious injury may result if machine tips or falls.
SPX Tools: 1-800-328-6657 or http://polaris.spx.com/. Be sure machine is secure before beginning this
service procedure. Wear eye protection when
removing bearings and seals.
TORQUE SPECIFICATIONS 2. Check bearings for side play by grasping the top and
bottom of the tire firmly and checking for movement.
Wheel and Hub Torque Table
The tire should rotate smo othly witho ut b inding or
rough spots.
ITEM SPECIFICATION

Steel Wheel Nuts 27 ft. lbs. (37 Nm)

Aluminum Wheel Nuts 30 ft. lbs. (41 Nm)
(INTL) + 90° (1/4 turn)
Front Hub Castle Nut 80 ft. lbs. (108 Nm)
Rear Hub Castle Nut 80 ft. lbs. (108 Nm)

3. Remove the (4) wheel nu ts an d re move the front

wheel.
4. Remove the cotter pin and loosen the front wheel hub
castle nu t. Re move th e nut, and (2 ) cone washers
from the front wheel hub assembly.

Castle Nut

Cone
Washers

Cotter Pin

5. Remove the fastener retaining the steering tie rod end

to the front bearing carrier.

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 FINAL DRIVE
6. Remove th e tw o fr ont b rake caliper m ounting bo lts NOTE: Due to ex tremely clos e t olerances an d
and r emove th e calip er fr om the bra ke disc (see minimal wea r, the be arings mu st be inspected
Chapter 9). visually, an d by f eel. While rot ating bea rings by
CAUTION: Do not hang the caliper by the brake line. hand, in spect for rough spots, disc oloration, o r
Use wire to h ang calipe r to pr event d amage to the corrosion. The be arings should t urn smoo thly an d
brake line. quietly, with no detectable up an d down move ment
and minimal movement sideways between inner and
7. Remove the front wheel hub assembly. outer race.

8. Remove the upper and lower ball joint pinch bolts.

Bearing Replacement
Bearing Removal

1. Remove the outer snap ring.

Snap Ring
Pinch
Bolts

9. Using a soft faced hammer, lightly tap on the bearing

carrier while removing the upper and lower ball joint
ends.

10. Remove the bearing carrier from the front drive shaft.
2. From the back side of the bearing carrier, tap on the
outer bearing race with a drift punch in the reliefs as
7
shown.

11. Rotate be aring by hand and check fo r sm ooth

rotation. Visually inspect bearing for moisture, dirt, or
corrosion.
3. Drive bea ring ou t e venly by ta pping on oute r ra ce
12. Replace bearing if mois ture, dir t, co rrosion, or only. O nce b earing is at bo ttom of ca sting, sup port
roughness is evident. casting on outer edges so bearing can be removed.

4. Inspect the be aring car rier hou sing for scr atches,
wear or dam age. Replace fr ont b earing car rier if
damaged.

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 FINAL DRIVE
Bearing Installation Bearing Carrier Installation
5. Thoroughly clean th e fro nt bea ring car rier ho using 1. Install drive shaft axle through th e b ackside o f the
and the outer race on the new bearing. Be sure that bearing carrier.
all oil residue has been removed from each surface.
2. Install the upper and lower ball joint ends into the front
6. Support the bottom of the bearing carrier housing. bearing carrier.

CAUTION
Use an arbor and press only on the outer race,
otherwise bearing damage may occur.

7. Apply Loctite® 60 3™ retaining comp ound to the

outer circumference of th e ne w bearing r ace and
carefully pr ess the ne w b earing into the b earing
carrier housing.
Apply
Loctite® 603™

Snap Ring 3. Install pinch bolts and torque to specification.

Bearing

NOTE: Use ca re to not allow any of t he L octite® 23 ft. lbs.

compound to get in the bearing. (31 Nm)
8. Wipe the housing clean of any excess compound and
install the snap ring.

=T
Ball Joint Pinch Bolts:
23 ft. lbs. (31 Nm)

4. Apply grease to drive shaft axle splines.

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 FINAL DRIVE
5. Install front wheel hub assembly, cone washers, and 8. Torque the tie r od end fastener to spe cification and
hand tighten th e ca stle nut. Insta ll washers with install a new cotter pin.
domed side out.

Cone Washers =T
Tie Rod End Fastener:
Wheel 42.5 ft. lbs. (58 Nm)
Hub
9. Torque wh eel h ub n ut to spe cification and install a
new cotter p in. Tigh ten n ut slightly if ne cessary to
Out align cotter pin holes.

6. Install b rake caliper mo unting bo lts a nd torque to 80 ft. lbs.

specification. (108 Nm)

=T
Front Caliper Mounting Bolts:
31-34 ft. lbs. (42-46 Nm)

CAUTION
NEW Cotter Pin
New bolts have a pre-applied locking agent
which is destroyed upon removal. Always use
new brake caliper mounting bolts
upon assembly. =T

7. Install the steering tie rod end onto the front bearing
carrier.
Wheel Hub Castle Nut:
80 ft. lbs. (108 Nm) 7
NOTE: Refer t o the photos below to ens ure pr oper 10. Install wheel and (4) wheel nuts. Torque wheel nuts
placement of the tie rod end. to specification.

42.5 ft. lbs.

58 (Nm) =T
Wheel Nuts:
Steel Wheels: 27 ft. lbs. (37 Nm)
Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn)

11. Rotate wheel and check for smooth operation. Bend

both en ds of cotte r pin around end of sp indle in
different directions.

Tie Rod End

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 FINAL DRIVE
FRONT DRIVE SHAFT 6. Remove the upper ball joint pinch bolt.

Drive Shaft Removal Pinch

Bolt
1. Elevate front of veh icle and safely su pport machine
under the 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. Remove th e (4 ) whe el nuts and remove th e fro nt

wheel.
7. Using a soft faced hammer, lightly tap on the bearing
3. Remove the cotter pin and loosen the front wheel hub carrier while removing the upper ball joint end.
castle nut. Rem ove th e n ut, and (2) co ne washers
8. Remove the drive shaft from the front bearing carrier.
from the front wheel hub assembly.

Castle Nut

Cone
Washers

Cotter Pin

9. With a short, sharp jerk, remove drive shaft from the

4. Remove th e tw o fr ont b rake caliper mo unting bo lts
front gearcase.
and r emove th e calip er from the bra ke disc (see
Chapter 9).
CAUTION: Do not hang the caliper by the brake line.
Use wire to h ang calip er to pr event damage to the
brake line.

5. Remove the front wheel hub assembly.

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 FINAL DRIVE
Drive Shaft / CV Joint Handling Tips Outer CV Joint / Boot Replacement
Care should be exercised during drive shaft removal or NOTE: Refer the “Ele ctronic Part s Cata log” for the
when servic ing CV joints. Driv e shaf t components are required parts to service the drive shaft. Some drive
precision parts. shafts have “Boot Replacement Kits” that include a
new boot , c lamps, an d th e re quired amoun t of
Cleanliness and following these inst ructions is very grease.
important to ensure proper sh aft fu nction and a normal
service life. 1. Remove clamps from ru bber bo ot using th e pr oper
boot clamp pliers.
• The comp lete dr ive sha ft a nd jo int sh ould be
handled b y ge tting hold o f the in terconnecting
CV Boot Clamp Pliers:
shaft to avoid disassembly or potential damage to
the drive shaft joints. Earless Type - 8700226

• Over-angling of joints beyond their capacity could

result in boot or joint damage. 2. Remove the lar ge end of the bo ot from the CV joint
and slide the boot back.
• Make su re s urface-ground ar eas a nd sp lines of
3. Use a soft-faced hammer or brass drift to separate the
shaft ar e pr otected d uring h andling to avoid
outer CV joint from the drive shaft.
damage.
NOTE: If using a bra ss drift, b e su re t o t ap on the
• Do not allow boots to come into contact with sharp
inner race of the joint only.
edges or hot engine and exhaust components.
4. Make sure the circlip remains on the shaft and not left
• The drive shaft is not to be used as a lever arm to
in the joint. Discard the circlip as it will be replaced.
position other suspension components.

• Never use a ha mmer or sharp tools to remove or Circlip

to install boot clamps.

7
• Be sur e join ts are thoroughly clean a nd tha t the
proper amount and type of g rease is used to refill
when joint boots are replaced and when joints are
cleaned. Refer to te xt fo r gr ease ca pacity of CV
joints and CV joint boots.

Pull shaft to remove

from CV joint

5. Remove the small cla mp a nd b oot from th e dr ive

shaft.

IMPORTANT: If t he grease in t he joint is o bviously

contaminated with water and/or dirt, the joint should
be replaced.

6. 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.

7. Visually inspect the joint bytilting 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 c age, pitting or galling or chips i n
raceways call for joint replacement.

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 FINAL DRIVE
8. Apply a light coat of grease to the end of the drive shaft 16. While pulling out on the CV shaft, slide a straight O-
and slide the new clamp and boot (small end first) over ring pick or a small slotted screw driver between the
the shaft and position the boot in its groove machined small end of the boot and the shaft. This will allow the
in the shaft. air pressure to equalize in the CV boot in the position
that the joint will spend most of its life. Before you
9. Install a NEW circlip on the end of the shaft. remove your instrument, be sure the small end of the
boot is in its correct location on the shaft.
10. Grease the join t with the special CV joint greas e
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 an d outer face flush wit h
grease. Place an y rem aining g rease into th e bo ot.
Install small boot clamp.

NOTE: It is v ery impo rtant t o us e th e cor rect t ype

and qu antity o f gre ase by using t he grea se
contained in the boot kit. DO NOT use a subs titute
grease and DO NOT overfill or under fill the CV joint.

Boot Replacement Grease Requirement:

Grease Service Kit

1350047 (50g) 17. Install and secure the small clamp on the boot using
the “earless” clamp pliers.
Outer CV Joint Capacity: 80g

CV Boot Clamp Pliers

11. Slide the joint onto the drive shaft splines and align the
circlip with the lead-in chamfer on the inner race. Earless Type: 8700226

12. Use a soft-faced hammer to tap the CV joint into the

splines of the ax le. Pull on the joint to ensure it’s
securely installed.

13. Add the remaining grease through large end of boot.

14. 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.

15. Install and secure the CV boot with the lar ge clamp
using the “earless” clamp pliers.

CV Boot Clamp Pliers

Earless Type: 8700226

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 FINAL DRIVE
Inner Plunging Joint / Boot Replacement 12. Grease the joint with the special joint grease provided
in the boot replacement kit. Fill the cavity behind the
1. Remove th e fr ont dr ive shaft from the vehicle (see balls and the s plined hole in the joint’s inner race.
“FRONT DRIVE SHAFT - Removal”). Pack the ball tracks and outer face flush with grease.
Place any remaining grease into the boot.
2. Remove and discard the boot clamps.

CV Boot Clamp Pliers CAUTION

Earless Type: 8700226
The grease provided in the replacement kit is
specially formulated for wear resistance and
3. Remove the large end of the boot from the plunging durability. DO NOT use substitutes
joint and slide the boot back. or mix with other lubricants.

4. Use a soft-faced hammer or brass drift to separate the NOTE: The amount of grease that’s provided is pre-
plunging joint from the drive shaft. measured, so use all the grease.

NOTE: If u sing a bras s dr ift, be sur e to ta p on t he

inner race of the joint only. Boot Replacement Grease Requirement:

5. Make sure the circlip remains on the shaft and not left Grease Service Kit
in the joint. Discard the circlip. 1350047 (50g)
6. Remove the boot from the drive shaft.
Inner Plunging Joint Capacity: 80g

CAUTION
13. Fully compress the joint and push the drive shaft firmly
into the inner race.
Complete disassembly of the plunging joint is
NOT recommended. The internal components 14. Align the circlip with the lead-in chamfer.
are a precision fit and develop their own
characteristic wear patterns. Intermixing the 15. Use a soft-faced hammer to tap the joint onto the drive
7
internal components could result in looseness, shaft until it locks into place.
binding, and/or premature failure of the joint.
16. Pull on the joint to make sure it is securely locked into
IMPORTANT: If the grease in the joint is obviously place.
contaminated with water and/or dirt, the joint should
be replaced. 17. Remove excess grease from the plun ging joint’s
external surfaces and place the excess grease in the
7. Thoroughly clean the joint with an appropriate solvent boot.
and dry the joint to prevent any residual solvent from
being left in the joint upon reassembly. 18. Pull the boot over the joint and position the boot lips
into the grooves on the joint housing and shaft. Make
8. Visually inspect the joint bytilting the inner race to one sure the boot is not dimpled or collapsed.
side to expose each ball. Severe pitting, galling, play
between the ball and its cage window, any cracking 19. Install and secure the small clamp on the boot using
or damage to the cag e, pitting or galling or chips in the “earless” clamp pliers.
raceways call for joint replacement.
CV Boot Clamp Pliers
9. Clean the splines on the end of the shaft and apply a
light coat of grease prior to reassembly. Earless Type: 8700226

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.

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 FINAL DRIVE
20. Pull ou t on the drive sha ft to cen ter the jo int in the Drive Shaft Installation
housing. Slide a straight O-ring pick or a small slotted
screw driver between the large end of the boot and the 1. Install new spring ring on drive shaft. Apply an anti-
joint housing and lift up to equalize the air pressure in seize compound to splines.
the boot. NEW
Spring Ring
21. Position the boot lip in its groove. Install and secure
the boot with the lar ge cla mp using th e “earless”
clamp pliers.

CV Boot Clamp Pliers

Earless Type: 8700226

Apply
Anti-Seize
FRONT DRIVE SHAFT
2. Align splin es of d rive sha ft with fro nt ge arcase an d
reinstall the drive shaft. Use a rubber mallet to tap on
Plunging the outboard end of the drive shaft if necessary
Joint

Grease Capacity
80 Grams

3. Install drive shaft into the front bearing carrier.

Grease Capacity
80 Grams

CV Joint
4. Install the upp er ball joint end into th e front bearing
carrier.

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 FINAL DRIVE
5. Install the upper pinch bolt and torque to specification. 8. Torque wh eel h ub n ut to spe cification and install a
new cotter p in. Tigh ten n ut slightly if ne cessary to
23 ft. lbs. align cotter pin holes.
(31 Nm)
80 ft. lbs.
(108 Nm)

NEW Cotter Pin

=T
Ball Joint Pinch Bolts: =T
23 ft. lbs. (31 Nm)
Wheel Hub Castle Nut:
6. Apply grease to drive shaft axle splines. 80 ft. lbs. (108 Nm)

7. Install front wheel hub assembly, cone washers, and 9. Install b rake calipe r m ounting b olts and tor que to
hand tighten th e ca stle nut. Insta ll washers with specification.
domed side out.

Cone Washers =T

Wheel
Front Caliper Mounting Bolts:
31-34 ft. lbs. (42-46 Nm)
7
Hub
CAUTION
Out
New bolts have a pre-applied locking agent
which is destroyed upon removal. Always use
new brake caliper mounting bolts
upon assembly.

10. Install wheel and (4) wheel nuts. Torque wheel nuts
to specification.

=T
Wheel Nuts:
Steel Wheels: 27 ft. lbs. (37 Nm)
Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn)

11. Rotate wheel and check for smooth operation. Bend

both en ds of cotte r pin around end of sp indle in
different directions.

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 FINAL DRIVE
PROPSHAFT SERVICE 6. Disconnect the ha rness con nector at the bra ke
switch. Remove the (2) screws securing the brake line
Removal / Installation junction block and move the jun ction block towards
the left-hand frame rail.
1. Remove both seats and the engine service panel as
outlined in Chapter 5.

2. Disconnect the negative (-) battery cable.

3. Raise and support vehicle and remove the left-hand
rear wheel.

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.

4. From th e right-hand front wheel well, locate the 7. Remove the g ear sele ctor ca p a nd remove the
propshaft roll pin. Use the Roll Pin Removal Tool (PN retaining screw and handle.
2872608) to r emove the ro ll pin fro m th e fro nt 8. Remove the Torx screws retaining the center console
gearcase. to access the propshaft.

Cap
Screw
Torx Screws
Handle

Torx Screws

Torx Screws

Roll Pin Removal Tool (PN 2872608)

5. Remove the o uter clutch cover, drive belt and drive

clutch as outlined in Chapter 6.

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 FINAL DRIVE
9. Remove the T-2 7 To rx screws an d the push p ins 14. Maneuver the rear of the propshaft towards the left-
securing the driver’s side floor, left-hand rocker panel hand side of the vehicle under the drivers side floor
and th e rear le ft-hand pa nel div ider a s ou tlined in and rear left-hand panel divider in the battery area.
Chapter 5. Note angle of propshaft below.
10. Gently lift and support floor and panel divider upward
in order to allow the prop shaft to pass beneath them.

15. Remove the propshaft from the left-hand rear wheel

well area.

11. Slide prop shaft back far enough to remove it from the
front gearcase input shaft splines.

12. Pull s harply fo rward to remove th e p ropshaft fr om

transmission shaft.

13. Position prop shaft to the right-hand side of the front

gearcase as shown.

16. Reverse removal steps to reinstall propshaft. Use a

NEW Roll Pin (Spring Pin) upon reassembly. Torque
all fasteners to specification.

=T
Wheel Nuts:
Steel Wheels: 27 ft. lbs. (37 Nm)
Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn)

Drive Clutch Retaining Bolt:

47 ft. lbs (63.5 Nm)

Outer Clutch Cover Screws:

50 in. lbs. (5 Nm)

Brake Line Junction Block Mounting Screws:

36 in. lbs. (4 Nm)

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 FINAL DRIVE
PROPSHAFT U-JOINT SERVICE 3. Support U-joint in vise as shown and drive inner yoke
down to remove remaining bearing caps.
Disassembly
1. Remove internal or e xternal snap ring from bearing
caps.

CAUTION

Always wear eye protection.

4. Force U-jo int cro ss to on e side an d lift o ut of in ner

yoke.

NOTE: If yoke or bearing is removed, cross bearing

must be re placed. Note orient ation of grea se fitting
and mar k inner and o uter yo ke f or c orrect r e-
positioning during installation.

2. Support inn er yoke as sh own an d d rive ou ter yo ke

down (bearing cap out) with a soft face hammer.

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 FINAL DRIVE
Assembly 6. Seat all bearing caps against snap rings by supporting
cross shaft and tapping on each corner as shown.
1. Install new be aring caps in yoke by ha nd. 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.

2. Tighten vise to force bearing caps in.

7. When installation is complete, yokes must pivot freely

in all dir ections without binding. If the joint is stiff or
binding, tap the yoke lightly to center the joint until it
pivots freely.

3. Using a suitable arbor, fully sea t the bearing cap in

one side. Continu ally ch eck for fr ee movement of
bearing cross as bearing caps are assembled.

4. Install snap ring to contain bearing cap just installed.

Repeat procedure for other side.

5. Install ou ter yo ke, a ligning m arks ma de a t

disassembly and repeat Steps 1-3 to install bearing
caps on outer yoke.

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 FINAL DRIVE
FRONT GEARCASE / CENTRALIZED HILLIARD
Centralized Hilliard Exploded View
8-10 ft. lbs.
(11-14 Nm)

8-10 ft. lbs.

(11-14 Nm)

7-11 ft. lbs.

(10-15 Nm)

REF# DESCRIPTION QTY REF# DESCRIPTION QTY

1 O-Ring 1 19 Hub Sub-Assembly (Female) 1
2 O-Ring 1 20 Hub Sub-Assembly (Male) 1
3 Dowel Pin 1 21 Rollers 20
4 Vent Hose Fitting 1 22 Torsion Spring 1
5 Ball Bearing 2 23 Spring, Wireform 2
6 Ball Bearing (Double Row) 1 24 H-Clip Spring 20
7 Bushing 1 26 Nylon Spacer 2
8 Bushing 1 27 Torsion Spring Retainer 1
9 Oil Seal 2 28 Backlash Spacer 1
10 Oil Seal 1 29 Ring Gear Spacer 1
11 Retaining Ring, Internal 1 30 Pinion Gear 1
12 Cover Screws, M6 (T30 Torx) 7 31 Armature Plate 1
13 Cover Plate Assembly 1 32 AWD Coil 1
14 Gearcase Housing 1 35 Fill Plug 1
15 Clutch Housing (Ring Gear) 1 36 Drain Plug, Magnetic 1
16 Roll Cage 1 38 Retaining Ring, External 1
18 Hub / Race Assembly 2

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 FINAL DRIVE
All Wheel Drive Operation AWD Engagement: When the AWD switch is activa ted,
the AWD coil is powered by a 12 Vdc input which creates
The AWD switch may be turned on or off while the vehicle a magnetic field. This magnetic field attracts an armature
is moving, however, AWD will not enable until the engine plate that is keyed to the roll cage. When the ring gear and
RPM dr ops be low 3100. Once the A WD is enabled, it roll cage are spinning (vehicle is moving), the energized
remains enabled until the switch is turned off. coil and armature plate will apply drag to the roll cage that
indexes the rollers inside the ring gear to an engagement
Engage th e A WD switch befor e ge tting into conditions
position. While in the engagement position, the front drive
where the fr ont wheel d rive may b e needed. If the rear
will be in an “over-running” condition (not engaged), until
wheels are spinning, release the throttle before switching
the rear wheels lose traction. Once the rear wheels begin
to AWD.
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 th e torque requirement goes
CAUTION
away (i.e. rear wheels regain traction).
Switching to AWD while the rear wheels are Ring
spinning may cause severe drive shaft and Gear
gearcase damage. Always switch to AWD while
the rear wheels have traction or are at rest.

With the A WD switch of f, the vehicle drives through the

rear wheels only (2 whee l drive). When the A WD is
enabled, th e fr ont dr ive act s as an on -demand A WD
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 Output Hubs
regain traction). Roll Cage
Rollers & H-Springs

CAUTION

If the rear wheels are spinning, release the

AWD Dise ngagement: Once the r ear wh eels re gain
traction, the front wheels will return to the “over-running” 7
throttle before turning the AWD switch on. condition. The vehicle is now back to rear wheel drive until
If AWD is engaged while the wheels are the next loss of rear wheel traction occurs.
spinning, severe drive shaft and front
Torsion Spring Operation: The torsion spring acts as a
gearcase damage could result.
return mechanism to help disengage the coupling of the
output hubs and ring gear by crea ting an “over-running”
condition for the rollers upon disengagement.

Centers Roll Cage and

Rollers in Ring Gear

Output
Hubs

Ring
Gear

Roll Cage Torsion

& Rollers Spring

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 FINAL DRIVE
AWD Diagnosis 4. Inspect the armature plate for a con sistent wear
pattern. There should be two distinct wear bands (one
Symptom: AWD Will Not Engage band inside the oth er). If o nly o ne band of wear is
present (or if there is wear between the two bands),
1. Check the gearcase coil re sistance. To test the coil
inspect the coil ar ea as indicate d in Step 5 . A wear
resistance, me asure between th e Gr ey and Brown/
band with an interrupted wear m ark may in dicate a
White wir es. T he m easurement sh ould b e within
warped pla te, which may ca use inter mittent
specification.
operation. See the following illustrations:

Check for
wear bands

Armature Plate

Front Gearcase Coil Resistance:

21.6 - 26.4 Ohms

5. Check to make sure the coil is seated in the U-shaped
insert that is pressed into the gearcase cover. The top
2. Turn the ignition and AWD switches on and place gear
of the coil should b e se ated below the U-sha ped
selector in H igh or Lo w g ear. Ch eck fo r m inimum
insert. The U-shaped insert controls the pole gap. If
battery voltage at the Gray and Brown/White chassis
the top of the coil is above the surface of the U-shaped
wires that power the coil. A minimum of 11 Vdc should
insert it raises the armature plate, thereby increasing
be present.
pole gap. If the pole gap increases the coil will not be
3. If electrical tests ar e with in spe cification, r emove strong enough to engage the AWD system. If this is
gearcase (s ee “G earcase Re moval”) a nd ins pect found, replace the cover plate assembly.
components.
Gearcase Cover Plate Asm.

Coil

Side cutaway
view of cover U-shaped insert

6. Inspect the rollers for nicks and scratches. The rollers

must slide up, down, in a nd out freely within the r oll
cage sliding surfaces and H-springs.

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 FINAL DRIVE
7. Inspect the roll cage assembly for cracks or excessive 6. Remove the (4) bolts securing the front gearcase to
wear. If damaged, replace the roll cage assembly. frame.

Roll Cage Assembly

Remove
Rollers Vent Line
Disconnect
Harness

Gearcase Removal Remove Gearcase image is

4 Bolts for reference only.
1. Stop engine and place gear selector in Park.
7. Remove the ge arcase from the front LH wheel well
2. Refer to “FRONT DRIVE SHAFT - Driv e Shaft area and slide it between the upper and lower A-arm.
Removal” and remove both front drive shafts from the
front gearcase.

3. Remove the propshaft from the front gearcase. (see

“PROPSHAFT SERVICE”).

4. Disconnect the wire harness above the front gearcase

and remove the harness from the retaining dart.
7
AWD Harness

5. Remove the vent line from the front gearcase.

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 FINAL DRIVE
Gearcase Disassembly / Inspection 3. Remove the LH output hub assembly from the clutch
housing or outer cover plate assembly.
1. Drain an d pr operly dispose of ge arcase fluid.
Remove any me tal particles from th e dr ain plu g
magnet.

2. Remove the (7) cover screws and remove the cover

plate assembly.

LH Output Hub

Non-serviceable
DO NOT Remove

LH Output Hub

NOTE: Nylon spa cer is non- serviceable a nd sh ould

not be removed.

4. Remove an d inspect the ar mature pla te. Refer to

“AWD Diagnosis” for detailed inspection process.

Armature Plate

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 FINAL DRIVE
5. Remove the torsion spring retainer and torsion spring 7. Remove the RH ou tput h ub assembly fr om the
from the top of the ring gear. gearcase housing.

Spring Retainer

8. Remove pinion seal, internal retaining ring and pinion

Torsion Spring gear assemb ly fro m the gea rcase ho using. Inspect
and cle an the ge arcase hou sing a nd r eplace all o il
seals and O-rings.

Pinion
Shaft

External
Snap Ring

Replace
Seal 7
6. Remove the clutch housing / ring gear and roll cage
assembly from the gearcase housing. Bearing

Internal
Remove as Snap Ring
an assembly

9. Inspect the pinion gear for chipped, broken or missing

teeth. Inspect the pinion bearing for signs of wear and
the pinion shaft seal surface for pitting.

Inspect

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 FINAL DRIVE
10. Inspect the AWD coil located in the outer cover plate 14. Inspect the ro ll ca ge a ssembly (B) slid ing surfaces
assembly. Refer to “AWD Diagnosis” for detailed and H-springs. Th e slid ing sur faces must be clea n
inspection process. Replace the cover plate seal and and fre e of n icks, bu rrs or scra tches. If damaged,
O-ring. replace the roll cage assembly.

H-Spring B
Inspect
Coil

Replace
O-Ring & Seal

11. Remove the roll cage assembly and rollers from the 15. Inspect b oth output hub a ssemblies. Inspect the
clutch housing. Use a shop towel to cover the housing bearings and replace if needed.
in order to retain all the rollers.
Thrust
NOTE: Rollers are s pring l oaded. T ake ca re n ot t o Bearing
allow them to fall out or lose them upon removal of Bearing
the roll cage.

12. Thoroughly clean all parts and inspect the rollers (A)
for nicks and scratches. The rollers must slide up and
down and in and ou t free ly within the ro ll cage (B)
sliding surfaces and H-springs.

C
Roller
Spacer Surface

B 16. Clean and insp ect all r emaining fro nt ge arcase

components. Check eac h f or ex cessive wear or
damage.

IMPORTANT: Refer to the “Electronic Parts Catalog”

for individu al part av ailability. Mos t p arts a re t o be
replaced as an assembly or as a complete kit.

13. Inspect clutch housing ring gear (C) for a consistent

wear pattern. Ins pect th e r ing ge ar fo r ch ipped,
broken, or missing teeth.

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 FINAL DRIVE
Gearcase Assembly 5. Carefully install the rollers into the roll cage assembly
while installing the assembly into the clutch housing.
1. As mentioned during gearcase disassembly section,
replace all O-rings, seals and worn components. NOTE: Install t he r oll c age so t hat t he ring gea r
grooves line up with the roll cage slots (see below).
2. Install pinion shaft assembly and install internal snap
ring.

NOTE: If bea ring replac ement was required, pre ss

new bearing onto the pinion s haft and install a new
external snap ring.

3. Install a new pin ion sh aft se al in to th e p inion ge ar

housing. Using a univ ersal seal in staller, press th e Align during
new seal into the housing until the seal is just below installation
the housing chamfer.

Press in oil seal

just past chamfer

6. Install the torsion spring by wrapping each leg of the

spring around the dowel pin on the ring gear.

4. Install the RH output hub into the gearcase housing.

7
RH Output Hub

7. Align the spring retainer dowel pin with the ring gear
dowel pin and install the retainer on top of the torsion
spring.

Align during
installation

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 FINAL DRIVE
8. Check the action of the torsion spring by rotating in 11. Install a new O-ring on the cover plate assembly.
both directions to ensure the spring and retainer are
installed properly. NOTE: Be su re the sq uare O-ring is p laced f lat on
the c over s urface. If th e O- ring i s t wisted f luid
leakage may occur.

12. Carefully install the LH output hub assembly into the

cover plate. Take care not to damage the new cover
plate seal while installing the output hub.

LH Hub

9. Be sure the armature plate tabs are fully engaged into

the ro ll ca ge asse mbly a nd a re re sting on th e cut-
grooves of the ring gear.

13. Install the output cover assembly onto the gearcase

housing. Install the (7) cover plate screws and torque
to specification.
Engage
Tabs
Torque Screws

NOTE: Verify armature plate tabs are in the slots on

the roll cage and are resting in the ring gear grooves.

10. Carefully install the ring gear and roll cage assembly
into the gearcase housing.

=T
Cover Plate Screws:
7-11 ft. lbs. (10-15 Nm)

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 FINAL DRIVE
Gearcase Installation 5. Connect the AWD wire harness.

1. Install the gearcase back into the vehicle through the

left-hand wheel well area, b etween the upper a nd
lower A-arms. AWD Harness

6. Refer to “FR ONT D RIVE SHAFT - Drive Shaft

Installation” and install both front drive shafts into the
gearcase.

2. Install the pr opshaft o nto the fron t gea rcase inpu t 7. Add the proper lubricant to the front gearcase. Refer
shaft. Use a NEW spring pin in the front propshaft. to Chapter 2 for fluid fill and change information.

3. Install the (4) bolts that secure the front gearcase to

Polaris Demand Drive Plus
the frame and torque to 30 ft. lbs. (41 Nm).
(PN 2877922)
4. Install the vent line.
Front Housing Capacity
Install 6.75 fl. oz. (200 ml)
Vent Line
Connect
Harness
7

Gearcase image is
for reference only.

30 ft. lbs.
(41 Nm)

=T
Front Gearcase Mounting Bolts:
30 ft. lbs. (41 Nm)

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 FINAL DRIVE
REAR BEARING CARRIER 5. Remove and discard the two brake caliper mounting
bolts. 
Bearing Carrier Inspection / Removal 
CAUTION: Do not hang the caliper by the brake line.
1. Elevate r ear of ve hicle a nd sa fely s upport m achine Use wire to hang cal iper to p revent da mage to the
under the frame area. brake line.

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. Remove

2. Check bearings for side play by grasping the top and

bottom of the tire firmly and checking for movement.
The tire sho uld r otate smoo thly withou t bin ding or
rough spots.

3. Remove th e ( 4) wh eel n uts an d remove th e r ear

wheel.
6. Remove the rear wheel hub assembly.
4. Remove the cotter pin and loosen the rear wheel hub
castle nut. Rem ove th e n ut, and (2) co ne washers
from the rear wheel hub assembly.

Castle Nut

Cone
Washers Cotter Pin 7. Remove the bolts, nuts and washers that attach the
rear bearing carrier to th e upper and lower A-arms.
Discard nuts and replace with new.

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 FINAL DRIVE
8. Remove the bearing carrier from the rear drive shaft. Bearing Replacement
Bearing Removal

1. Remove outer snap ring.

Snap Ring

9. Rotate be aring by hand and check fo r sm ooth

rotation. Visually inspect bearing for moisture, dirt, or
corrosion.

NOTE: Due to e xtremely close to lerances and 2. From the back side of the bearing carrier, tap on the
minimal wear, t he bea rings mus t be insp ected outer bearing race with a drift punch in the reliefs as
visually, and by feel. W hile r otating be arings by shown.
hand, inspect fo r rough spo ts, disc oloration, or
corrosion. The bea rings sh ould tur n smoothly and
quietly, with no de tectable up and down moveme nt
and minimal movement sideways between inner and
outer race.

7
10. Replace bearing if mois ture, dir t, co rrosion, or
roughness is evident.

3. Drive bea ring ou t e venly by ta pping on oute r ra ce

only. O nce b earing is at bo ttom of ca sting, sup port
casting on outer edges so bearing can be removed.

4. Inspect the be aring car rier hou sing for scr atches,
wear or da mage. Re place rear be aring car rier if
damaged.

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 FINAL DRIVE
Bearing Installation Bearing Carrier Bushing Replacement
1. Thoroughly cle an the rear be aring car rier ho using Check be aring carrier bu shings and piv ot tu bes for
and the outer race on the new bearing. Be sure that excessive wear or d amage. If r eplacement is r equired,
all oil residue has been removed from each surface. slide p ivot tube s out a nd re move bu shings with a d rift
punch. Install new bushings by pr essing th em into th e
2. Support the bottom of the bearing carrier housing. bearing carrier.
Pivot Tube
CAUTION
Use an arbor and press only on the outer race,
otherwise bearing damage may occur.

3. Apply Loctite® 603™ retaining compound to the outer

circumference of the new bearing race and carefully
press th e ne w be aring into the bearing ca rrier
housing. Control Arm
Bearing Bushing
Apply Carrier
Loctite® 603™

Snap Ring

Bearing

NOTE: Use ca re to no t allow any of the L octite®

compound to get in the bearing.

4. Wipe the housing clean of any excess compound and

install the snap ring.

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 FINAL DRIVE
Bearing Carrier Installation 4. Install rear wheel hub assembly, cone washers, and
hand t ighten th e castle n ut. Install w ashers wit h
1. Install d rive sha ft a xle thr ough the ba ckside of the domed side out.
bearing carrier. Be sure bushings and pivot tubes are
installed. Cone Washers

Wheel
Hub

Out

5. Install new brake caliper mounting bolts and torque to

44 ft. lbs. (60 Nm).

2. Install the fasteners that attach the rear bearing carrier

to the upper and lower A-arms. Torque NEW nuts to 44 ft. lbs.
specification. 60 (Nm)

=T
7
Rear Caliper Mounting Bolts:
44 ft. lbs. (60 Nm)

CAUTION

=T New bolts have a pre-applied locking agent

which is destroyed upon removal. Always use
Upper and Lower Rear Bearing Carrier Nuts: new brake caliper mounting bolts
40 ft. lbs. (54 Nm) upon assembly.

3. Apply grease to drive shaft axle splines.

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 FINAL DRIVE
6. Torque whe el hub nut to 80 ft. lbs. (1 08 Nm) an d REAR DRIVE SHAFT
install a NEW cotter pin. Tighten nut slightly if
necessary to align cotter pin holes. Drive Shaft Removal
1. Elevate re ar of ve hicle a nd safely sup port machine
under the frame area.

CAUTION
80 ft. lbs.
(108 Nm) 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.

NEW Cotter Pin 2. Remove th e ( 4) wheel n uts and re move th e r ear

wheel.

3. Remove the cotter pin and loosen the rear wheel hub
=T castle nu t. Re move th e nut, and (2 ) cone washers
from the rear wheel hub assembly.
Wheel Hub Castle Nut:
80 ft. lbs. (108 Nm)

7. Install wheel and (4) wheel nuts. Torque wheel nuts

to specification.

Castle Nut
=T
Wheel Nuts:
Steel Wheels: 27 ft. lbs. (37 Nm)
Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn)
Cone
Washers Cotter Pin
8. Rotate wheel and check for smooth operation. Bend
both end s of co tter pin ar ound en d of spindle in
different directions. 4. Remove and discard the two brake caliper attaching
bolts. 
CAUTION: Do not hang the caliper by the brake line.
Use wire to hang cal iper to p revent da mage to the
brake line.

Remove

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 FINAL DRIVE
5. Remove the rear wheel hub assembly. NOTE: Take c are wh en removing t o prevent
damaging the seal.

6. Remove the bolt that attaches the rear bearing carrier

to the upper A-arm. 9. Inspect the axle spline s a nd CV boo ts for any
damage.

7
7. Slide the rear drive shaft out of the bearing carrier by
pulling the bearin g carrier ass embly outward and
tipping it down to remove the shaft.

8. Grasp the rear drive shaft and pull sharply outward on

the shaft to disengage it from the rear gearcase.

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 FINAL DRIVE
Outer CV Joint / Boot Replacement IMPORTANT: Tap on inner race only!
5. Make sure the circlip is on the shaft and not left in the
1. Using a sid e cutters, cut away and discard the bo ot
joint.
clamps.
Circlip

6. Remove the CV boot from the shaft.

2. Remove the large end of th e boot from the CV jo int
and slide the boot down 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.

3. Clean the grease from the face of the joint.

4. Place the drive shaft in a soft-jawed vise. Using a soft-
faced hammer, or brass drift, strike the inner race of
the joint to drive th e joint off the drive shaft. Be sure
to tap evenly around the joint to avoid binding.

Brass Drift Shown

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.

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 FINAL DRIVE
8. Visually inspect the joint bytilting the inner race to one 13. Slide the joint ontothe drive shaft splines and align the
side to expose each ball. Severe pitting, galling, play circlip with the lead-in chamfer on the inner race of the
between the ball and its cage window, any cracking joint.
or damage to the cag e, pitting or galling or chips in
raceways call for joint replacement.
NOTE: Shiny areas in ball tracks and on t he c age
spheres a re nor mal. Do not rep lace CV jo ints
because parts ha ve polished s urfaces. Rep lace CV
joint on ly if co mponents are cr acked, brok en, 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 th e jo int with the special CV joint grease 14. Use a soft-faced hammer to tap the joint onto the drive
provided in the boot replac ement kit. Fill the cavity shaft until it locks into place.
behind the balls and the splined hole in the joint’sinner
race. Pack the ball tracks an d outer face flush with 15. Pull on the joint to make sure it is securely locked in
grease. Place any remaining grease into the boot. place.

16. Remove excess grease from the CV join t's external

CAUTION surfaces and place the excess grease in the boot.

The grease provided in the replacement kit is 17. Pull the boot over the joint and position the boot lips
specially formulated for wear resistance and into the grooves on the joint housing and shaft. Make
sure the boot is not dimpled or collapsed.
durability. DO NOT use substitutes
or mix with other lubricants. 7
NOTE: The amount of grease that’s provided is pre-
measured, so use all the grease.

Boot Replacement Grease Requirement:

Grease Only Service Kits

1350047 (50g)

Outer CV Joint Capacity:

RZR - 80g

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 FINAL DRIVE
18. Install an d tighte n the la rge cla mp u sing the 20. Install and tighten the small clamp on the boot using
appropriate clamp tool. the appropriate clamp tool.

Axle Boot Clamp Tool: PU-48951 Axle Boot Clamp Tool: PU-48951
or or
CV Boot Clamp Pliers: 8700226 CV Boot Clamp Pliers: 8700226

19. While pulling out on the CV shaft, slide a s traight 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 mos t of its life. Before you
remove your instrument, be sure the small end of the
boot is in its correct location on the shaft.

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 FINAL DRIVE
Inner Plunging Joint / Boot Replacement 4. Using a soft-faced hammer, or brass drift, strike the
inner race of th e joint to dr ive the joint off th e drive
1. Using a sid e cutters, cut away and discard the boot shaft. Be sure to tap evenly around the joint to avoid
clamps. binding.

Brass Drift Shown

2. Remove the large end of the boot from the plunging IMPORTANT: Tap on inner race only!
joint and slide the boot down the shaft. 5. Make sure the circlip is on the shaft and not left in the
joint.

Circlip

3. Clean the grease from the face of the joint and place
the drive shaft in a soft-jawed vise.
6. 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.

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 FINAL DRIVE
IMPORTANT: If the gr ease in the joint is obviousl y NOTE: The amount of grease that’s provided is pre-
contaminated with water and/or dirt, the joint should measured, so use all the grease.
be replaced.
Boot Replacement Grease Requirement:

Grease Only Service Kits

1350047 (50g)

Inner Plunging Joint Capacity:

RZR - 80g

13. Fully compress the joint and push the drive shaft firmly
into the inner race.

14. Align the circlip with the lead-in chamfer.

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 ins pect the join t for damage. Rep lace if
needed.
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 its groove
machined in the shaft.

11. Install a NEW circlip on the end of the shaft.

12. Grease the joint with the special joint grease provided
in the boot replacement kit. Fill the cavity behind the 15. Use a soft-faced hammer to tap the joint onto the drive
balls an d the sp lined ho le in the joint’s inner race. shaft until you reach the end of the splines and the
Pack the ball tracks and outer face flush with grease. joint locks in place.
Place any remaining grease into the boot. 16. Pull on the joint to test that the circlip is seated and
that the joint is securely fastened to the shaft.
CAUTION 17. Remove excess grease fro m th e plun ging join t’s
external surfaces and place the excess grease in the
The grease provided in the replacement kit is boot.
specially formulated for wear resistance and
durability. DO NOT use substitutes 18. Pull the boot over the joint and position the boot lips
or mix with other lubricants. into the grooves on the joint housing and shaft. Make
sure the boot is not dimpled or collapsed.

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 FINAL DRIVE
19. Install and tighten th e sm all clamp using the Drive Shaft Exploded View
appropriate clamp tool.

REAR SHAFT
RZR S / RZR 4 RZR 570

Spring Ring

Plunging
Joint

Spring Ring

Large Clamp

Grease Pack

Axle Boot Clamp Tool: PU-48951 Gear Side

Boot Kit
or
CV Boot Clamp Pliers: 8700226

20. Pull out on the drive sha ft to cente r th e jo int in the

housing. Slide a straight O-ring pick or a small slotted Small Clamp
screw driver between the large end of the boot and the
joint housing and lift up to equalize the air pressure in
the boot.
Wheel Side
21. Position the boot lip in its groove. Install and tighten Boot Kit
the large clamp using the appropriate clamp tool. Grease Pack

Large Clamp
7
Spring Ring

CV Joint

Axle Boot Clamp Tool: PU-48951

or
CV Boot Clamp Pliers: 8700226

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 FINAL DRIVE
Drive Shaft Installation 4. Lift bea ring carrier into place an d install th e bolt
attaching the bea ring carr ier to th e up per A-a rm.
1. Install new spring ring on drive shaft. Apply anti-seize Torque fastener to specification.
compound to splines.
NEW
Spring Ring

Apply
Anti-Seize

2. Align splin es o f drive sha ft with rear g earcase a nd

reinstall the drive shaft. Use a rubber mallet to tap on =T
the outboard end of the drive shaft if necessary.
Upper Rear Bearing Carrier Bolt:
NOTE: Take c are when in stalling the d rive sh aft to 40 ft. lbs. (54 Nm)
prevent damaging the seal.
5. Apply grease to drive shaft axle splines.

6. Install rear wheel hub assembly, cone washers, and

hand tighten the castle nut. Install washers with
domed side out.
Cone Washers

Wheel
Hub

Out

3. Slide the rear drive shaft into the rear bearing carrier.

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 FINAL DRIVE
7. Install NEW brake caliper mounting bolts and torque 8. Torque wheel hu b nut to 80 ft . lbs. (1 08 Nm) and
to 44 ft. lbs. (60 Nm). install a N EW c otter p in. T ighten nut slightly if
necessary to align cotter pin holes.

44 ft. lbs.
60 (Nm) 80 ft. lbs.
(108 Nm)

NEW Cotter Pin

=T =T
Rear Caliper Mounting Bolts: Wheel Hub Castle Nut:
44 ft. lbs. (60 Nm) 80 ft. lbs. (108 Nm)

CAUTION 9. Install wheel and (4) wheel nuts. Torque wheel nuts
to specification.
New bolts have a pre-applied locking agent
which is destroyed upon removal. Always use =T
new brake caliper mounting bolts
upon assembly. Wheel Nuts:
Steel Wheels: 27 ft. lbs. (37 Nm)
7
Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn)

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 FINAL DRIVE
WHEEL HUBS
Front Hub Exploded View
Front Rim Front Rim INTL
(Steel) (Aluminum)

Sealed
Studs Ball Bearing

Wheel Hub
Bearing
Carrier

Cone
Retaining
Washers
Ring

Brake Disc
Bolts
Castle Nut
80 ft. lbs.
Cotter Pin (108 Nm)

Rear Hub Exploded View

Rear Rim INTL
Rear Rim (Aluminum)
(Steel)
Sealed
Ball Bearing

Bolts

Studs Bearing
Carrier

Cone
Washers Retaining
Ring

Brake Disc

Wheel Hub
Cotter Pin Castle Nut
80 ft. lbs.
(108 Nm)

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 TRANSMISSION
CHAPTER 8
TRANSMISSION
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
TRANSMISSION MOUNTING AND TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
SHIFT CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
TRANSMISSION SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
GEAR / SHAFT / BEARING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18
SNORKEL GEAR BACKLASH PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.21
TRANSMISSION SERVICE (INTL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.26
DIFFERENTIAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.26
TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.27
PLANETARY DIFFERENTIAL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.32
PLANETARY DIFFERENTIAL BUSHING REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . 8.32
PLANETARY DIFFERENTIAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.35
GEAR / SHAFT / BEARING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.35
SNORKEL GEAR BACKLASH PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.36
TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.38
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.43

8
TRANSMISSION EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.44
TRANSMISSION EXPLODED VIEW (INTL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.46

SPECIAL TOOLS
SPX Corporation - 1-800-328-6657 or http://polaris.spx.com/.

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 TRANSMISSION
SPECIFICATIONS Special Tools

Torque Specifications PART NUMBER TOOL DESCRIPTION

PA-50231 Snorkel Tool
ITEM TORQUE VALUE
Rear Output
Bearing Retaining 2871698 (Part of 2871702 Kit)
8-10 ft. lbs. (11-14 Nm) Seal Driver
Plate Screws
Rear Driveshaft
Bell Crank Nut 12-18 ft. lbs. (16-24 Nm) 2871699 (Part of 2871702 Kit)
Seal Guide
Fill / Drain Plugs 10-14 ft. lbs. (14-19 Nm)
Bearing Seal Driver
Gear Sector Cover 9-12 ft. lbs. (12-16 Nm) 2871282
(50 mm)
Park Brake Disc
8-10 ft. lbs. (11-14 Nm) Transmission Nut
Mounting Bolt (INT’L) PU-50566
Socket
Park Flange Screws 8-10 ft. lbs. (11-14 Nm)
Rear Transmission Isolator Clutch Center
40 ft. lbs. (54 Nm) PU-50658
Mount Bolt Distance Tool
Refer to “Snorkel Gear
Snorkel Tube Lubrication
Backlash Procedure”
Snorkel Tube
8-10 ft. lbs. (11-14 Nm)
Locking Screw
Support and Shift Cable =
17 ft. lbs. (23 Nm)
Bracket Bolts
Transmission Case Screws 15-20 ft. lbs. (20-27 Nm) Recommended Transmission Lubricant:
Speed Sensor Screw 7 - 9 ft. lbs. (9-12 Nm)
AGL Plus (PN 2878068) (Quart)
Capacity (Standard): 44 oz. (1300 ml)
Capacity (INTL): 41 oz. (1200 ml)

Transmission Mounting and Torque Values

25 ft. lbs. 40 in. lbs.
See Transmission Installation For
(34 Nm) Critical Torque Procedure (4.5 Nm)

Coupler Brackets

Gasket 18 ft. lbs.

(24.5 Nm)

40 ft. lbs. Seal

(54 Nm)

Exhaust System

55 ft. lbs. 40 ft. lbs.

(74.5 Nm) (54 Nm)
See Torque Sequence

40 ft. lbs. Isolator Mount

(54 Nm)

25 ft. lbs.
40 ft. lbs. (34 Nm)
Front Engine Mount
(54 Nm)

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SHIFT LEVER 4. Remove the retaining ring and slide the shift lever off
the mounting bracket and out from the frame.
Removal
1. Remove the shift knob cover, retaining screw and shift
knob from the shift lever.

5. Remove bo th b ushings fr om th e sh ift le ver a nd

2. Remove the scr ews r etaining th e cen ter console service as needed.
using a T27 and T30 Torx driver. Remove the console
from the vehicle.
Installation
3. Remove the clip and washer retaining the shift cable
to the shift lever and disconnect the ca ble end from 1. Perform the removal steps in reverse order to install
the lever. the gear shift lever (lever, cable, console, shift knob).

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SHIFT CABLE 3. If adjustment is required, loosen the lower jam nut and
pull the cable out of the mount to move the upper jam
Inspection nut.

Shift cable adjustment may be nec essary if symptoms

include:

• No gear position or AWD display on instrument

cluster
Lower
• Ratcheting noise on deceleration Jam Nut

• Inability to engage into a gear

• Excessive gear clash (noise)

• Gear selector moving out of desired range Upper

Jam Nut
Inspect shif t cab le, clevis pin s, a nd pivot bu shings a nd
replace if worn or damaged.
4. Adjust the shift cable so there is the same amount of
cable travel when shifting slightly past HIGH gear and
PARK.
Adjustment
1. Locate th e s hift ca ble a ttached to the transmission 5. Thread th e up per or lower jam nu t a s r equired to
case in the right rear wheel well area. obtain proper cable adjustment.

2. Inspect shift cable, clevis pin, pivot bushings, and dust NOTE: This procedure may require a few attempts to
boot. Replace if worn or damaged. obtain the proper adjustment.

6. Once th e pr oper adju stment is obtained, place th e

shift cable and upper jam nut into the mount. Tighten
the lower jam nut against the mount.
Pin and
Bushings Shift Cable 7. Start engine and shift through all gears to ensure the
Mount shift c able is properly adjusted. If trans mission s till
ratchets after cable adjustment, the transmission will
require service.

Dust Boot

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TRANSMISSION SERVICE 6. From th e r ight-hand fro nt wh eel well, locate the
propshaft roll pin. Use the Roll Pin Removal Tool (PN
Transmission Removal 2872608) to remove th e r oll pin from the fro nt
gearcase.

CAUTION

Correct Drive Clutch Puller P/N PA-48595

Roll Pin Removal Tool (PN 2872608)

7. Remove the g ear sele ctor cap an d remove the

1. If internal tra nsmission r epair is re quired, drain the retaining screw and handle.
transmission lubricant (see Chapter 2).
2. Remove th e seats and engine ser vice p anel (see 8. Remove the Torx screws retaining the center console
Chapter 5). to access the propshaft.

3. Disconnect the (- ) n egative batter y cab le fro m the Cap

battery. Screw
Torx Screws
4. Raise and support the vehicle. Handle

CAUTION
8
Serious injury may result if machine tips or falls. Torx Screws
Be sure machine is securebefore beginning this
procedure. Always wear eye protection.
Torx Screws
5. Remove rear wheels from the vehicle.

9. Slide prop shaft back far enough to remove it from the

front gearcase input shaft splines.

10. Pull s harply fo rward to r emove th e p ropshaft fr om

transmission shaft.

11. Remove th e r ear bu mper and cargo b ox as a n

assembly (see Chapter 5).

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12. Loosen the ( 3) clam ps secur ing the intake ba ffle 15. Place a shop to beneath the fuel line quick connector
assembly to th e a ir b ox lid, in ner clutch cover an d to catch any excess fuel. Disconnect the fuel line from
engine crankcase vent. Remove the air intake baffle the fuel rail by pressing in onthe quick connector tabs.
/ intake hoses / en gine cr ankcase ven t tube an Move fue l line to th e left-h and sid e of th e en gine
assembly as shown below. compartment. Make note of line r outing for
installation.

Spring Style
Clamp

13. Remove the o uter clutch cover , dri ve belt, dri ve 16. Disconnect the IAC valve (A), TPS (B), T-MAP sensor
clutch, driven clut ch and inner c lutch c over (see (C), harness leads from the throttle body.
Chapter 6). Make note of hose and wire routings for
reassembly. A C
IMPORTANT: Be sure to use the correct Drive Clutch
Puller ( PN PA-4 8595) to p revent damage to
crankshaft.

14. Loosen the hose clamp that secures the air box to the
throttle body. Cut the t ie strap that secures the wire
harness to the right-hand side of the air box. Remove
the air box assembly.

17. Remove throttle body from the engine and wrap it with
a clean shop towel. Place throttle body on the LH side
frame rail area.
IMPORTANT: Be sure dirt and debris do not enter the
engine, air box or throttle bod y. Use clea n sh op
towels to plug engine and air box intake holes.

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18. Remove the (4 ) fasteners se curing the r ear b olt in 23. Remove and discar d the ( 4) rear br ake ca liper
brace to the vehicle main frame. Maneuver the brace mounting bolts on the RH and LH side as outlined in
forward for transmission removal clearance. Note the Chapter 7 and 9.
routing of the tra nsmission b reather ho se an d wire CAUTION: Do not hang the caliper by the brake line.
harness. Use wir e to hang calip er to p revent da mage to the
brake line.

24. Remove the (4) rear upper and lower A-arm to bearing
carrier bolts, nuts and washers from the RH and LH
side as outlined in chapter 7.
25. With a short, sharp jerk, remove the rear drive shaft /
bearing carrier assemblies from the vehicle as shown.

19. Remove th e clip and washe r (D) secur ing the shift
cable to the bell crank.
20. Remove the (2) fasteners securing the transmission
shift br acket (E) to the transmission case. Swing
assembly cle ar of the main fr ame for tr ansmission
removal.
21. Disconnect the ve hicle spe ed sen sor ( F) and ge ar
26. Remove the (2) bolts securing the starter motor to the
position switch (G) harness connectors. Cut tie strap
engine. Remove starter from the engine. Make note
(H). Note harness routings for reassembly.
of wiring for reassembly.
22. Remove the transmission vent tube (I). 
INTL - Remove the parking break cable and asm.

I
G
8
F

D 27. Place a support in-between the main frame and the

engine crankcase to support the engine in its current
position. Do not pinch brake line.

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28. Remove the ( 8) engine to tr ansmission coup ler Transmission Installation
bracket b olts an d w ashers. Re move th e co upler
brackets from the vehicle. 1. With the help of an assistant lift transmission into the
vehicle frame through the left rear wheel well area as
shown below.

29. Remove the ( 5) faste ners secur ing the re ar

transmission mount to the vehicle frame. Remove the
rear mount as an assembly. 2. Carefully r otate th e to p of the transmission upward
into its proper location.

3. By hand, in stall the ( 5) rear tra nsmission mount

assembly fasteners. Do not torque fasteners at this
time.

30. Rotate the top of the transmission to the left-hand side

of the vehicle. With the help of an assistant, lift the
assembly up and out of the vehicle frame.

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4. By hand, install the (8) engine to transmission coupler 6. Torque the rear tran smission m ount fasteners to
brackets, bolts and washers. Do not torque fasteners specification.
at this time.
40 ft. lbs.
(54 Nm)
25 ft. lbs.
(34 Nm)

20 ft. lbs.
(27 Nm)

7. In se quence, torq ue th e ( 8) e ngine cou pler br acket

5. Install th e Clutch Center Dista nce Too l (PU-50658) fasteners to specification.
onto th e cr ankshaft an d tr ansmission input shaft to
properly position the clu tch ce nter distance. The 55 ft. lbs
pictures below sho w the too l ( PU-50658) p roperly (74.5 Nm)
installed.

=T
8
Drive Clutch Bolt Installed
Rear Engine Coupler Fastener Torque:
(In Sequence)
55 ft. lbs. (74.5 Nm)

8. Remove the clutch center distance tool.

9. Remove th e s pacer o r su pport b etween th e ve hicle

frame and engine.

Tool Fully Seated Inward

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10. Replace starter O-ring if needed and lubricate O-ring 14. Connect the IAC valve (G), TPS (H), T-MAP sensor
with grease. Install the star ter and th e ( 2) b olts (I), harness leads from the throttle body.
securing the star ter motor to the e ngine. Torque
fasteners to specification as outlined in Chapter 10. G C
Be sure wires are routed correctly.

=T
Starter Bolt Torque:
7 ft. lbs. (10 Nm)

11. Install a nd p roperly ro ute the gea r p osition switch

connector (A), speed sensor connector (B), harness I
into tie strap (C), shift bracket, shift bracket bolts (D),
shift cable clevis pin a nd washer ( E) o nto the
transmission and install the vent hose (F). 15. Connect the fuel line to the fuel rail. Be sure routing
INTL - Install the parking break cable and asm. is correct.
16. Install the air box assembly and tighten hose clamp.
F Replace the tie strap and rout wires properly on the
A
right-hand side of the air box.
C 17. Install the (4) fasteners securing the rear bolt in brace
to th e vehicle main frame. Note the ro uting of th e
transmission breather hose and wire harness. Torque
fasteners to specification.
D
B 17 ft. lbs.
(23 Nm)

12. Torque the (2 ) sh ift cable br acket bolts to

specification.

=T
Shift Cable Bracket Bolts:
17 ft. lbs. (23 Nm) 18. Lubricate th e transmission splines with Polaris All
Purpose Gr ease. Install th e pr opshaft on to th e
13. Install the thr ottle b ody in to the en gine in take bo ot. transmission splines.
Tighten hose clamp. Be sure throttle cable is routed 19. Lubricate the fro nt ge arcase splin es with an ti-seize
correctly. and install the propshaft onto the front gearcase (see
Chapter 7). Use a new roll pin at the front gearcase
splines.
20. Install the center console and shift handle.

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21. Install th e in ner clu tch cover, drive clutch, dr iven 25. Install th e r ear dr ive sh aft sp lines into t ransmission
clutch, belt and outer clutch cover (see chapter 6). Be splines. In stall the fa steners th at atta ch th e r ear
sure wir es an d h oses ar e routed co rrectly. To rque bearing carrier to the upper and lower A-arms. Torque
fasteners to specification. new nuts to specification.

=T
Inner Clutch Cover Bolts:
12 ft. lbs. (16.6 Nm)

Driven Clutch Retaining Bolt:

36 ft. lbs. (48.5 Nm)

Drive Clutch Retaining Bolt:

47 ft. lbs. (63.5 Nm)

Outer Clutch Cover Retaining Screws: Image For Reference Only

45-50 in. lbs. (5 Nm)

22. Install th e (3 ) cla mps se curing th e intake ba ffle =T

assembly to the air box lid , inne r clu tch cover a nd
engine crankcase vent. Be sure routings are correct. Upper and Lower Rear Bearing Carrier Nuts:
40 ft. lbs. (54 Nm)
23. Install the rear bumper and cargo box assembly 
(see chapter 5).
26. Install new brake caliper mounting bolts and torque to
24. Install new spring ring on rear drive shafts. Apply an
specification.
anti-seize compound to the splines.

NEW
Spring Ring

8
44 ft. lbs.
60 (Nm)

Apply
Anti-Seize

=T
Rear Caliper Mounting Bolts:
44 ft. lbs. (60 Nm)

CAUTION

New bolts have a pre-applied locking agent

which is destroyed upon removal. Always use
new brake caliper mounting bolts
upon assembly.

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27. Install rear wh eels and wheel nuts. Tor que to Transmission Disassembly
specification.
NOTE: Refer to the exploded view at the end of this
chapter as a reference.
=T
1. Place t he tr ansmission in Hig h g ear be fore
Wheel Nuts: disassembly.
Steel Wheels: 27 ft. lbs. (37 Nm)
Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn) 2. Drain an d p roperly dispose of the tran smission
lubricant (see Chapter 2).
28. Properly lower the vehicle.
29. Verify all wire and hose routings are correct. Connect 3. Remove the bellcrank nut (A) and bellcrank (B).
the (-) negative battery cable.
30. Install the engine service panel and seats. G C F
A E
31. If transmission lubricant was drained, fill the
transmission with th e sp ecified a mount of Polaris
B
AGL Plus (s ee Ch apter 2 “Transmission
Lubrication”).

Recommended Transmission Lubricant:

AGL Plus (PN 2878068) (Quart)

Capacity: 44 oz. (1300 ml) D

4. Remove the E-clip (C) that retains the spring washer

(D), flat washer (D) and gear switch (E). Remove the
switch.

5. Remove the sect or cover bolts ( F) and re move the

sector cover (G).

NOTE: Removal can be aided by using your thumbs

to press in on t he shafts while pulling out the cover
with your fingers.

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6. Remove the compression spring (H).
CAUTION
M
K Do not pry on case sealing surfaces.
L Use only the designated pry points
on the transmission.

12. Lift up on the shift shaf t ra il (Q) and move th e ra il

H assembly rearward to all ow the shift fork pins to be
P removed from the shift drum ( R). Rem ove the shif t
drum (R) from the transmission housing.

Q R

I J N
P

7. Remove the detent star (I). Note how the detent star
fits onto the splined shaft with the raised edge facing
outward for reassembly.

8. Remove the spacer (J).

9. Remove th e sh ift shaft ( K), detent pawl ( L) a nd the

shift sector gears (M and N).

IMPORTANT: Note the timing marks on the shift gears

(M and N) for reassembly purposes. 13. Remove the shift shaft rail (Q) and shift forks from the
transmission housing as an assembly.
10. Remove the O-rings (P) from each shaft and discard.
Use new O-rings upon assembly. Q
11. Remove a ll th e tr ansmission case bolts. Using
suitable pr y b ars, rem ove the cover using the
designated pry points (indicated by the black arrows
in the illustration below).
8

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14. Remove the rear output shaft assembly (S) by lifting 16. Place the gear cluster assembly on a clean surface for
underneath the gear or by tapping the shaft from the inspection. If disassembly is required, refer to “Gear
opposite side. Cluster Disassembly”.

15. Remove the idler gear shaft assembly (T) and gear 17. Using a 5 mm Allen wrench, remove the screws that
cluster assembly (U) from the transmission housing secure the pinion shaft assembly (V). Lift the pinion
by pulling both assemblies straight up. shaft assemb ly str aight up to r emove it fr om the
housing. No te th e lon ger scr ew (W) tha t lo cks th e
T snorkel tube.
U

18. Remove all seals from the gearcase halves and clean
the cases in preparation for assembly.

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Gear Cluster Disassembly 23. If necessary, disassemble the other end of the reverse
shaft. Rem ove th e b earing, engagement do g,
19. Remove the bearing from the reverse shaft using a
retaining ring, washer, gear and needle bearing from
bearing puller. Remove the retaining ring and slide the
the reverse shaft (see Figure 8-2).
washers, 53T gear and needle bearing off the reverse
shaft (see Figure 8-1). Figure 8-2
Figure 8-1

24. To disassemble the shift shaft rail remove the snap

ring (X) from the end of the shift rail on either side.

X X

20. Remove the retaining ring and engagement dog from

the reverse shaft (see Figure 8-1).

21. Remove th e re taining ring, wa sher, n eedle be aring,

and sprocket from the reverse shaft (see Figure 8-1).
8
22. Tilt the two shafts towards each other and remove the
silent chain from the two shafts.

CAUTION
Use caution when disassembling the shift rail.
The compressed springs on the shift rail may
pop off causing eye or face injury.

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Snorkel Shaft Removal / Disassembly 27. Remove the snorkel tube and shaft assembly from the
transmission case.

CAUTION

The pinion shaft must be removed prior to removing

the snorkel shaft assembly. Failure to remove pinion
shaft, will result in damage to the snorkel shaft.

25. Extract the seal from the snorkel shaft to access the
snorkel tube for removal.

28. Remove the sna p rin g (Y) and shim ( Z) fro m th e

snorkel shaft.

Seal Removed

26. Using the Snorkel Tool (PA-50231), fully loosen the

snorkel tube.

Y Z

29. Use an arbor press to remove the snorkel tube from

the snorkel shaft.

30. Remove the snap ring (A) and shim (B) retaining the
bearing in the snorkel tube.
PA-50231

B A

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31. Lightly tap on the bearing from the opposite side to
remove it from the snorkel tube.

32. Remove the re taining ring to r emove the re maining

washer, bearing and gear from the snorkel shaft.

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Gear / Shaft / Bearing Inspection

Inspect all gear sets and shafts for

excessive wear or damage.

IMPORTANT: If gear replacement is

required, be sure to also replace the
corresponding gear or gear shaft.

Inspect all bearings for signs of

wear or damage. If replacement is
required, use a standard bearing
puller or an arbor press.

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Snorkel Gear Backlash Procedure 4. Apply a small amount of white lithium grease or Anti-
Seize on the threads of the snorkel tube.
1. Reassemble the sn orkel tube and snorkel sh aft
assembly by reversing th e dis assembly pr ocedure Grease Threads
(see “Snork el Shaft Remov al / Dis assembly” in
previous section).

Retaining
Ring
Bearing

Snorkel
Shaft
Washer

Bearing
Retaining
13T Ring
5. Install the snorkel shaft into the gearcase. Using the
Gear Snorkel Tool (PA-50231), tighten the snorkel tube until
Retaining
Ring it is lightly seated in the transmission housing.

Snorkel
Tube
Shim
Shim
Seal

2. After the 13T gear and bearing are pressed onto the
snorkel shaft (flush to the shoulder), install the washer
and new retaining ring.

3. Press the gear back towards the retaining ring. Avoid PA-50231

8
excessive force so the retaining ring is not damaged
or pre-stressed significantly.

IMPORTANT: Failure to press the gear back against

the wash er a nd re taining ring will le ad t o a g ear
backlash change after vehicle is placed into service.

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6. Inspect the pinion shaft assembly. Replace bearings 10. Torque the b earing cover re taining scr ews to
if n eeded. Inspect each ge ar for da mage, chip s or specification.
abnormally worn teeth.

=T
Bearing Cover Retaining Screws:
8-10 ft. lbs. (11-14 Nm)

11. Rotate the snorkel tube counterclockwise using the

snorkel too l ( PA-50231) u ntil the snorkel g ear and
pinion gear have ‘zero’ backlash.

IMPORTANT: DO NOT ov ertighten t he s norkel tub e

when backing it out. At the 'zero' backlash position,
you should still be able to turn the snorkel shaft using
your fingers, but it will feel rough and may have some
tight spots.

12. Look down into the transmission housing to see the

snorkel locking screw hole opening to reference your
NOTE: If pinion shaft was disassembled, the bearing starting point.
cover must be installed on the shaft before installing
the 46T gear. NOTE: If you ha ve a hard time seeing into the hole,
insert a small Allen wrench, pu nch or s crewdriver
7. Install the pinion shaft assembly. Be sure to properly into th e hole to feel wh en th e not ch is alig ned wit h
mesh the snorkel shaft bevel gear with the pinion shaft the hole.
bevel gear.
13. Slowly rotate the snorkel tube clockwise while
8. Apply Loctite 242® to the threads of the bearing cover counting the number of notches passing through the
retaining screws. hole op ening a s you ro tate the tube. Rotate the
snorkel tube to the 3rd notch from the ‘zero’ backlash
9. Using a 5 mm Allenwrench, install only the (3) screws position obtained in step 11.
that secur e the pinion shaft asse mbly as shown
below. Leave the longer locking screw (A) out at this Count 3 notches through
point. the locking screw hole

DO NOT Install
Locking Screw

14. Check the pinion shaft gear backlash again by feel. If

the pin ion sh aft g ear la sh app ears to be to o tigh t,
IMPORTANT: DO NOT install the lo nger sc rew (A ). rotate the snorkel shaft clockwise to the next notch
Installing the longer screw will lock the snorkel tube (4th notch).
and not allow for backlash setting adjustment.

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15. Once th e ba cklash is set, a pply Lo ctite 24 2® to the Transmission Assembly
threads an d in stall the locking scr ew to secure the
snorkel tube. IMPORTANT: The snorkel shaft and pinion shaft must
be inst alled pr ior to t ransmission ass embly. The
snorkel shaft cannot be installed after assembling the
transmission.

1. Clean both tra nsmission ca se ha lves thor oughly.

Inspect case half mating surfaces for damage.

2. Assemble the reverse shaft assembly and input shaft

assembly if prev iously disassembled (see
illustrations).

16. Torque the locking screw to specification.

8-10 ft. lbs.

(11-14 Nm)

=T
Snorkel Locking Screw:
8-10 ft. lbs. (11-14 Nm)

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3. Install the id ler ge ar shaf t a ssembly ( A) a nd ge ar 6. Install the shift shaft ra il (D) an d shift fo rks into the
cluster assembly (B) into the transmission housing, all transmission ho using as a n a ssembly. Be sur e the
at the same time. shift forks are engaged into the engagement dogs.

A
B D

Pins should be offset to this side

NOTE: Shift fork p ins s hould b e o ffset t owards th e

4. Install the rear output shaft assembly (C). input shaft as shown above.

7. Inspect the shift drum for any damage or wear. Inspect

the splines of the shift drum.

5. Assemble th e sh ift sh aft rail if pr eviously

disassembled.
8. Install the shift drum (E) into the transmission housing.
Pins should offset to the same side Lift up o n th e shif t sh aft ra il (D) a nd mo ve th e r ail
assembly towards the shift drum to allow the shift fork
ends to be installed into the shift drum (E).

D E

NOTE: Both sh ift forks n eed to be orientated t he

same way, s o that the shift fork pins are both offset
to the same side of the rail.

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9. Apply a continuous b ead o f Crankcase 3 Bo nd 11. Install new seals into the transmission case halves.
Sealant (PN 2871557) to the left hand transmission
• The snorkel shaf t se al ( F), sho uld be pr essed in
mating surface.
until it seats against the housing counter-bore.
10. Install the tra nsmission ca se cover an d r etaining • The input shaft seal (G), should be pressed in until
bolts. Torque bolts to specification. it seats flush with the housing.
• The r ear ou tput sh aft se als (H), ca n be inst alled
using a st andard b ushing inst allation too l. Se als
should b e inst alled j ust p ast the case lea d-in
chamfer (.070 in. or 1.8 mm from the outer face of
the bore).

H
G

=T F

Transmission Case Bolts:

15-20 ft. lbs. (20-27 Nm) 12. Thoroughly clean the shift shaft housing. Be sure the
transmission is in High gear prior to reassembly.

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13. Install the sector gear (16T) onto the shift drum shaft. 16. Install the detent pawl onto the shift shaft and carefully
Install the shift shaft assembly and sector gear (11T) install the compression spring.
into th e bu shing pocket on the left side. Alig n the
timing marks on the gears as shown. Detent Star

Spring

Timing Marks
Detent Pawl

High Gear Shown

17. Install a new O-ring on each shift shaft. Apply a small
amount of white lithium grease on the O-rings, shift
14. Install the spacer onto the shift drum shaft. shafts an d comp onent cont act su rfaces p rior to
installing the sector cover.

Spacer

Dowel
O-Rings

15. Install the detent star onto the shift drum shaft. Be sure
to install the detent star with the raised edge facing 18. Clean the transmission and gear sector cover mating
outward and skip-tooth aligned. surfaces thoroughly.

19. Apply Cr ankcase Sealant (3 -Bond) ( PN 2871557)

onto the cover and transmission case mating surface.

20. Install th e secto r cover an d a lign the tran smission

case dowel with the alignment hole. Install and torque
the bolts to specification.

=T
Sector Cover Bolts:
7-9 ft. lbs. (9-12 Nm)

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21. Install the tra nsmission d rain plu g an d torq ue to
specification.

=T
Fill / Drain Plug:
10-14 ft. lbs. (14-19 Nm)

22. Install the bellcrank onto the shift shaft. Note the key
splined on the bellcrank and shift shaft. Install the nut
and torque to specification.

=T
Bellcrank Nut:
12-18 ft. lbs. (16-24 Nm)

23. Refer to “ Transmission Installa tion” to complete the

repair.

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 TRANSMISSION
TRANSMISSION SERVICE (INTL) When switch position is set
to “Unlock”, the solenoid is
Differential Operation powered and the plunger
extends to disengage the
The INT’L tra nsmission h as two traction operational
side gear and unlock
modes: Differential Lock and Differential Unlock. Locking the differential.
the rear differential is beneficial in low traction and rough
terrain co nditions. Unlo cking the rea r differential makes
maneuvering easier and minimizes damage to terrain.

AWD
When “Dif ferential-Lock” is selected, po wer is re moved
from the electrical solenoid allowing the solenoid plunger
to retract. Spring tensio n moves the shif t fo rk back into
Differential - Lock
place and mates the engagement dog to the side gear that
is part of the planetary differential assembly. This locks the
rear differential as a solid rear axle, increasing traction.
Differential - Unlock
When switch position is set
to “Lock”, power is removed
from the solenoid and spring
tension retracts the plunger
When “Differential-Unlock” is selected, the rear differential
to engage the clutch gear
becomes unlocked for tighter turns. An electrical solenoid and lock the differential.
mounted in the rear portion of the gearcase actuates the
shift fork. The solenoid plunger extends out to move the
fork and slides the engagement dog away from the side
gear that is part of the planetary differential assembly. This
unlocks the rear differential. The rear drive shafts are now
dependent on the differential allowing for tighter turns.

Planetary Differential Components Shift Fork

Torsion Retainer
Spring
Spring
Differential Cover
Assembly Solenoid
Screw
Female Side Gear
Assembly
Planet Gear
Bearing
Assembly
Male Side Gear Engagement Dog
Assembly
Ring Gear
Assembly

Planetary Differential
Assembly

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 TRANSMISSION
Transmission Disassembly 8. Remove the spacer (J).
9. Remove the shif t shaft (K), detent pawl (L) and the
NOTE: Refer to the exploded view at the end of this
shift sector gears (M and N).
chapter as a reference.
IMPORTANT: Note the timing marks on the shift gears
1. Place transmission in High gear before disassembly.
(M and N) for reassembly purposes.
2. Drain a nd pr operly d ispose o f the tr ansmission
lubricant (see Chapter 2). 10. Remove the O-rings (P) from each shaft and discard.
3. Remove the bellcrank nut (A) and bellcrank (B). Use new O-rings upon assembly.
11. Remove the bolt and washer retaining the brake disc
G C F to transmission pinion shaft. Remove disc from shaft.
A E
12. Remove all tra nsmission ca se bolts. Using suitable
pry bars, remove the cover using the designated pry
B points (indicated by black arrows in illustration below).

4. Remove E-clip (C) that retains spring washer (D), flat

washer (D) and gear switch (E). Remove the switch.
5. Remove the se ctor cover bolts (F ) a nd r emove the
sector cover (G).

NOTE: Removal can be aided by using your thumbs

to press in o n the shafts while pulling out the cover

8
with your fingers.

6. Remove the compression spring (H).

CAUTION
M
K Do not pry on case sealing surfaces.
L Use only the designated pry points
on the transmission.

H
P

I J N
P

7. Remove the detent star (I). Note how the detent star
fits onto the splined shaft with the raised edge facing
outward for reassembly.

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 TRANSMISSION
13. Lift up on the shif t sh aft rail ( Q) and mo ve th e ra il 16. Remove the idler gear shaft assembly (T) and gear
assembly rearward to allow the shift fork pins t o be cluster assembly (U) from the transmission housing
removed fr om the shif t d rum ( R). Remo ve the shift by pulling both assemblies straight up.
drum (R) from the transmission housing.
T
R U
Q

17. Place the id ler gear shaft a ssembly ( T) and g ear

cluster assembly (U) on a clean surface for inspection.
14. Remove the shift shaft rail (Q) and shift forks from the If d isassembly is r equired, refer to “Gea r Cluster
transmission housing as an assembly. Disassembly”.
18. Slide engagement dog (X) off of shift fork guides.
Q
19. Remove (2) screws and retaining plates, then lift shift
fork (Y) an d torsio n spr ing o ut of tran smission
housing.

X
15. Remove the rear output shaft assembly (S) by lifting
underneath the gear or by tapping the shaft from the
opposite side. If use of a pr y bar is necessary, take Y
care not to pry on sealing surfaces of case.

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 TRANSMISSION
20. Using a 5 mm Allen wrench, remove the screws that Gear Cluster Disassembly
secure the pin ion shaft assembly (V). Lift the pin ion
22. Remove the b earing from the r everse shaft using a
shaft assembly stra ight up to r emove it fro m the
bearing puller. Remove the retaining ring and slide the
housing. Note the longer screw ( W) th at locks the
washers, 53T gear and needle bearing off the reverse
snorkel tube.
shaft (see Figure 8-1).
V
W Figure 8-1

21. Remove all seals from the gearcase halves and clean
the cases in preparation for assembly.

23. Remove the retaining ring and engagement dog from

the reverse shaft (see Figure 8-1).

24. Remove the retaining ring, washer, needle bearing,

and sprocket from the reverse shaft (see Figure 8-1).
8
25. Tilt the two shafts towards each other and remove the
silent chain from the two shafts.

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 TRANSMISSION
26. If necessary, disassemble the other end of the reverse Snorkel Shaft Removal / Disassembly
shaft. Remo ve the be aring, e ngagement dog,
retaining ring, washer, gear and needle bearing from
the reverse shaft (see Figure 8-2). CAUTION

Figure 8-2 The pinion shaft must be removed prior to removing

the snorkel shaft assembly. Failure to remove pinion
shaft, will result in damage to the snorkel shaft.

28. Extract the seal from the snorkel shaft to access the
snorkel tube for removal.

27. To disassemble t he shift shaft rail remove the snap Seal Removed
ring (X) from the end of the shift rail on either side.

29. Using the Snorkel Tool (PA-50231), fully loosen the

snorkel tube.

X X

PA-50231
CAUTION
Use caution when disassembling the shift rail.
The compressed springs on the shift rail may
pop off causing eye or face injury.

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 TRANSMISSION
30. Remove the snorkel tube and shaft assembly from the 34. Lightly tap on the bearing from the opposite side to
transmission case. remove it from the snorkel tube.

31. Remove th e sn ap ring (Y) an d sh im (Z) fr om the 35. Remove the re taining ring to remove the remaining
snorkel shaft. washer, bearing and gear from the snorkel shaft.

Y Z

32. Use an arbor press to remove the snorkel tube from

the snorkel shaft.
8
33. Remove the snap ring (A) and shim (B) retaining the
bearing in the snorkel tube.

B A

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 TRANSMISSION
Planetary Differential Disassembly 4. Inspect the female side gear (A), male side gear (B),
planet g ears ( C) a nd r ing gear ( D). Replace
NOTE: If the gea rcase is co mpletely as sembled, components or bushings as needed. Bushin g
perform the “Gearcase Disassembly and Inspection” replacement can be per formed on all ne cessary
procedure. differential com ponents. If bu shing re placement is
required, pr oceed to Planetary Dif ferential Bu shing
1. Use a scribe to ma rk the differential cover and ring
Replacement”.
gear prior to disassembly.

A B
Scribe

C
C

2. Remove the (6) screws retaining the differential cover Planetary Differential Bushing Replacement
and remove the cover.
NOTE: If th e diff erential is completely a ssembled,
perform the “Planetary Di fferential Dis assembly”
procedure.

Ring Gear Bushing Replacement

1. Press the old bushing out of the ring gear.

2. Thoroughly clean the bore of the ring gear and check

for any unwanted burs.

3. Press the new bushing into the ring gear housing.

3. Remove th e (6 ) p lanet ge ars a nd ea ch sid e ge ar

assembly from the ring gear.

Planet
Gears

Side Bushing
Gears

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 TRANSMISSION
4. Install the bushing to the specified depth as shown. Differential Cover Bushing Replacement

Install bushing flush to 1. Press the old bushing out of the differential cover.
.039 in. (1 mm) recessed
2. Thoroughly clean the bore of the differential cover and
from end face of hub
check for any unwanted burs.

3. Press the new bushing into the differential cover.

New
Bushing

4. Install the bushing to the specified depth as shown.

Planet Gear Bushing Replacement

1. Press the old bushing out of the planet gear.
2. Thoroughly clea n the bo re of the pla net g ear a nd
check for any unwanted burs.
8
3. Press the new bushing into the planet gear until it is
flush on each en d. Repeat th is procedure for the
remaining planet gears.

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 TRANSMISSION
Female Side Gear Bushing Replacement
1. Locate the bushing split. Using a small chisel or flat
blade scr ewdriver, peel ba ck an d re move the old
bushing fro m the side g ear, be ing careful no t to
damage the side gear.

Bushing Peel Back

Split Here

2. Thoroughly clean the bore of the side gear and check

for any unwanted burs.
3. Press the ne w bushing into the side gea r un til it
bottoms out.

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 TRANSMISSION
Planetary Differential Assembly 5. Install screws hand tight. Place assembly in soft jaw
vise and torque to specification.
1. Thoroughly clean the differential components.
2. Assemble the side gears and place them onto the ring
gear along with the (6) planet gears.

Planet
Gears

Side
Gears =T
3. Align and install the differ ential cover using the Differential Cover Screws:
previously made scribe marks. 18-22 ft. lbs. (24-30 Nm)
4. Apply Loctite® 2760™ to cover screws.

Gear / Shaft / Bearing Inspection

Inspect all gear sets and shafts for

excessive wear or damage.
IMPORTANT: If gear replacement is
required, be sure to also replace the
corresponding gear or gear shaft.

Inspect all bearings for signs of

wear or damage. If replacement is
required, use a standard bearing
puller or an arbor press.

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 TRANSMISSION
Snorkel Gear Backlash Procedure 5. Install the snorkel shaft into the gearcase. Using the
Snorkel Tool (PA-50231), tighten the snorkel tube until
1. Reassemble the snor kel tube and snorkel sh aft it is lightly seated in the transmission housing.
assembly by reversing th e dis assembly procedure
(see “Snorkel Shaft Removal / Disassembly”).

Retaining
Ring
Bearing

Snorkel
Shaft
Washer

Bearing PA-50231
Retaining
13T Ring
Gear
Retaining 6. Inspect the pinion shaft assembly. Replace bearings
Ring if needed. Inspect e ach g ear for d amage, chips or
abnormally worn teeth.
Snorkel
Tube
Shim
Shim
Seal

2. After the 13T gear and bearing are pressed onto the
snorkel shaft (flush to the shoulder), install the washer
and new retaining ring.
3. Press the gear back towards the retaining ring. Avoid
excessive force so the retaining ring is not damaged
or pre-stressed significantly.

IMPORTANT: Failure to press the gear back against

the washer and retai ning ring w ill l ead to a gear
backlash change after vehicle is placed into service.

4. Apply a small amount of white lithium grease or Anti-

Seize on the threads of the snorkel tube. NOTE: If pinion shaft was disassembled, the bearing
cover must be installed on the shaft before installing
Grease Threads the 46T gear.

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 TRANSMISSION
7. Install the pinion shaft assembly. Be sure to properly 12. Look down into the transmission housing to see the
mesh the snorkel shaft bevel gear with the pinion shaft snorkel locking screw hole opening to reference your
bevel gear. starting point.

8. Apply Loctite® 2 42™ to the th reads o f th e be aring NOTE: If you have a hard time seeing into the hole,
cover retaining screws. insert a small A llen wrench, punch or screwdriver
9. Using a 5 mm Allen wrench, install only the (3) screws into th e hole to feel wh en th e not ch is alig ned wit h
that secur e the pinion shaft asse mbly as shown the hole.
below. Leave the longer locking screw (A) out at this
point. 13. Slowly rotate the snorkel tube clockwise while
counting the number of notches passing through the
A hole ope ning as you ro tate the tu be. Rotate the
snorkel tube to the 3rd notch from the ‘zero’ backlash
position obtained in step 11.

Count 3 notches through

the locking screw hole

DO NOT install
locking screw

IMPORTANT: DO NOT install the lo nger sc rew (A ).

Installing the longer screw will lock the snorkel tube
and not allow for backlash setting adjustment.

10. Torque th e be aring cover r etaining scr ews to 14. Check the pinion shaft gear backlash again by feel. If
specification. the pin ion sh aft g ear lash app ears to be to o tight,
rotate the snorkel shaf t clockwise to the next notch
=T (4th notch).
15. Once the backlash is set, apply Loctite® 242™ to the
Bearing Cover Retaining Screws:
8-10 ft. lbs. (11-14 Nm)
threads and inst all the locking screw to secure the
snorkel tube. 8
11. Rotate the snorkel tube counterclockwise using the
snorkel tool ( PA-50231) un til the snorkel ge ar and
pinion gear have ‘zero’ backlash.
IMPORTANT: DO NOT overti ghten the sno rkel t ube
when backing it out. At the 'zero' backlash position,
you should still be able to turn the snorkel shaft using
your fingers, but it will feel rough and may have some
tight spots.

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 TRANSMISSION
16. Torque the locking screw to specification. Transmission Assembly
IMPORTANT: The snorkel shaft and pinion shaft must
8-10 ft. lbs.
be inst alled p rior to tra nsmission as sembly. Th e
(11-14 Nm)
snorkel shaft cannot be installed after assembling the
transmission.

1. Clean both tra nsmission case ha lves thor oughly.

Inspect case half mating surfaces for damage.
2. Install shift for k ( S) and torsion sp ring i nto
transmission housing as an assembly. Load spring as
shown in image below
3. Apply Loctite® 242™ to (2) screws (T) and install with
retaining plates over shift fork. Torque to specification.

=T U

Snorkel Locking Screw:

8-10 ft. lbs. (11-14 Nm)

=T
Shift Fork Screws:
7-10 ft. lbs. (10-14 Nm)

4. Slide engagement dog (U) onto retaining pins of shift

fork.

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 TRANSMISSION
5. Assemble the reverse shaft assembly and input shaft 6. Install the idle r gear shaft assemb ly (A) an d gear
assembly if pr eviously disassembled (see cluster assembly (B) into the transmission housing, all
illustrations). at the same time.

A
B

7. Install th e rear o utput s haft as sembly (C). R otate

output shaft assembly to align slots with engagement
dog. Ensure bearing is fully seated upon assembly.

C
8
8. Assemble shift shaft rail if previously disassembled.

Pins should offset to the same side

NOTE: Both s hift fo rks nee d t o be orien tated the

same way, so that the shift fork pins are both offset
to the same side of the rail.

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 TRANSMISSION
9. Install the shift shaft rail (D) and s hift forks into the 12. Apply a contin uous bead of Cra nkcase 3 Bon d
transmission housing a s an assembly . Be sure the Sealant (PN 2871557) to the left hand transmission
shift forks are engaged into the engagement dogs. mating surface.

D 13. Install the tr ansmission case cove r a nd re taining

bolts. Torque bolts to specification.

Pins should be offset to this side

NOTE: Shift f ork pins should be of fset to wards t he

input shaft as shown above.

10. Inspect the shift drum for any damage or wear. Inspect
the splines of the shift drum.

=T
Transmission Case Bolts:
15-20 ft. lbs. (20-27 Nm)

11. Install the shift drum (E) into the transmission housing.
Lift up o n the s hift sh aft rail (D ) a nd m ove the r ail
assembly towards the shift drum to allow the shift fork
ends to be installed into the shift drum (E).

D E

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 TRANSMISSION
14. Install new seals into the transmission case halves. 16. Thoroughly clean the shift shaft housing. Be sure the
transmission is in High gear prior to reassembly.
• The sn orkel shaft se al ( F), sh ould be pr essed in
until it seats against the housing counter-bore.

• The input shaft seal (G), should be pressed in until

it seats flush with the housing.

• The r ear output shaft sea ls (H) an d p inion sha ft

seal (J) can be installed using a standard bushing
installation tool. Seals should be installed just past
the ca se lead -in ch amfer (.07 0" or 1 .8 mm fr om
outer face of bore).

17. Install the sector gear (16T) onto the shift drum shaft.
H Install the shift shaft assembly and sector gear (11T)
G
into the b ushing po cket on th e left sid e. Align the
timing marks on the gears as shown.

F
15. Install the brake disc onto the pinion shaft. Install the
washer an d app ly Lo ctite® 26 2™ o r 2760™ to the
mounting bo lt thr eads. To rque the b olt to
specification.
Timing Marks

High Gear Shown

8
18. Install the spacer onto the shift drum shaft.

Spacer

=T
Park Brake Disc Mounting Bolt:
18-22 ft. lbs. (24-30 Nm)

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19. Install the detent star onto the shift drum shaft. Be sure 25. Install the tr ansmission dr ain p lug a nd tor que to
to install the detent star with the raised edge facing specification.
outward and skip-tooth aligned.

20. Install the detent pawl onto the shift shaft and carefully =T
install the compression spring.
Fill / Drain Plug:
Detent Star
10-14 ft. lbs. (14-19 Nm)

26. Install the bellcrank onto the shift shaft. Note the key
splined on the bellcrank and shift shaft. Install the nut
and torque to specification.
Spring
=T
Bellcrank Nut:
12-18 ft. lbs. (16-24 Nm)

27. Refer to “T ransmission Installation” to complete the

Detent Pawl
repair.

21. Install a new O-ring on each shift shaft. Apply a small

amount of white lithium grease on the O-rings, shift
shafts and co mponent co ntact sur faces pr ior to
installing the sector cover.

Dowel
O-Rings

22. Clean the transmission and gear sector cover mating

surfaces thoroughly.
23. Apply Cr ankcase Se alant (3-Bond) ( PN 28 71557)
onto the cover and transmission case mating surface.
24. Install the se ctor cover and alig n the tr ansmission
case dowel with the alignment hole. Install and torque
the bolts to specification.

=T
Sector Cover Bolts:
9-12 ft. lbs. (12-16 Nm)

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 TRANSMISSION
TROUBLESHOOTING
Troubleshooting Checklist
Check the following items when shif ting dif ficulty is
encountered.

• Shift cable adjustment/condition

• PVT alignment (clutch center distance)
• Idle speed (throttle cable routing)
• Transmission lubricant type/quality
• Loose fasteners on sector gear cover
• Worn rod ends, clevis pins, or pivot arm bushings
• Shift selector rail travel
• Worn, broken or damaged internal transmission
components

NOTE: To determine if shifting difficulty or problem

is c aused by an int ernal tra nsmission pro blem,
isolate the transmission by disco nnecting the shift
cable end from the transmission bellcrank. Manually
select each gear range at the transmission bellcrank,
and te st rid e ve hicle. If it f unctions pr operly, t he
problem is outside the transmission.

If t ransmission pr oblem rema ins, dis assemble
transmission an d inspect all gear dog s for wear
(rounding) or damage. Inspect all be arings, circlips,
thrust washers and shafts for wear.

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 8.44
TRANSMISSION

10-14 ft. lbs.

(14-19 Nm)

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Refer to “Snorkel Gear
Backlash Procedure”
242 ®
TRANSMISSION EXPLODED VIEW

8-10 ft. lbs.

(11-14 Nm)

12-18 ft. lbs.

(16-24 Nm)

8-10 ft. lbs.

(11-14 Nm)
242 ®
15-20 ft. lbs.

© Copyright 2011 Polaris Sales Inc.

(20-27 Nm)

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10-14 ft. lbs.
(14-19 Nm)

FOR REASSEMBLY
Apply White Lithium
7-9 ft. lbs. Based Grease.
(10-12 Nm)

Apply Polaris
15-20 ft. lbs. Crankcase Sealant.
(20-27 Nm)
Apply Loctite® to
the bolt threads.
 TRANSMISSION
Exploded View, Continued
Ref. Qty. Description Ref. Qty. Description
1. 1 Fill Plug 46. 1 Gear, Sector 16T
2. 1 Drain Plug, Magnetic 47. 1 Gear, Sector 31T
3. 14 Screw, M8 x 1.25 x 30 48. 1 Pawl, Detent
4. 6 Screw, M6 x 1 x 20 49. 1 Star, Detent
5. 3 Screw, M8 x 50 50. 1 Plate, Park, 12-Face
6. 1 Screw, M6 x 1 x 40 51. 1 Shaft, Output 53T
7. 6 Screw, M6 x 1 x 18 52. 1 Shaft, Idler 29T
8. 1 Nut, NyLoc, M8 x 1.25 53. 1 Shaft, Front Output
9. 2 Washer, Cup 54. 1 Shaft, Input, Helical
10. 3 Washer 55. 1 Shaft, Reverse, 27T
11. 1 Washer 56. 1 Bellcrank
12. 1 Washer 57. 1 Collar, Shift
13. 2 Pin, Dowel 58. 1 Rail, Shift Shaft
14. 1 Pin, Spring 59. 1 Tube, Vent, 1/4 in.
15. 1 Retaining Ring, External 60. 1 Shift Dog, Park
16. 1 Snap Ring 61. 1 Gear, 44T
17. 1 Retaining Ring, External 62. 2 Fork, Shift
18. 1 Retaining Ring, External 63. 1 Sprocket, 48T, 6-Face
19. 1 Retaining Ring, Internal 64. 1 Gear, Low 67T
20. 2 Retaining Ring, External 65. 1 Engagement Dog, 6-Face
21. 2 Retaining Ring, External 66. 1 Gear, 53T
22. 3 Retaining Ring, External 67. 1 Shaft, Pinion 11T
23. 1 Retaining Ring, External 68. 1 Gear, 46T
24. 2 Washer, Thrust 69. 1 Gear, Snorkel 13T
25. 1 Washer, Thrust 70. 1 Shaft, Shift
26. 1 Shim 71. 1 Weldment, Rear Mount Bracket
27. 1 Shim 72. 1 Bracket, Rear Mount
28. 2 Bearing, Needle Cage 73. 1 Cover, Bearing, Center Drive
29. 2 Bearing, Ball 74. 1 Spacer
30.
31.
2
2
Bearing, Ball
Bearing, Ball
75.
76.
1
1
Chain, Silent
Switch, Rotary, 2-Pin 8
32. 3 Bearing, Ball 77. 1 O-Ring
33. 1 Bearing, Needle Cage 78. 1 O-Ring
34. 1 Bearing, Ball 79. 1 O-Ring
35. 2 Bearing, Ball 80. 1 Seal, Triple Lip
36. 1 Wire Harness Bracket 81. 1 Seal, Dual Lip
37. 2 Spring, Compression 82. 1 Seal, Triple Lip
38. 2 Spring, Compression 84. 1 Sensor, Speed
39. 1 Spring, Compression, Detent
40. 1 Washer, Spring
41. 1 Tube, Snorkel
42. 1 Cover, Sector Gears
43. 1 Case, LH
44. 1 Case, LH
45. 1 Drum, Shift

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 FOR REASSEMBLY

8.46
Apply White Lithium 18-22 ft. lbs.
Based Grease. (24-30 Nm)
2760 ™

Apply Polaris
Crankcase Sealant.

Apply Loctite® to
TRANSMISSION

the bolt threads.

10-14 ft. lbs.

Downloaded from www.Manualslib.com manuals search engine

(14-19 Nm)
TRANSMISSION EXPLODED VIEW (INTL)

7-10 ft. lbs. Refer to “Snorkel Gear

(10-14 Nm) Backlash Procedure”

242 ™

© Copyright 2011 Polaris Sales Inc.

8-10 ft. lbs.
(11-14 Nm)

9923523 - 2012 RANGER RZR 570 Service Manual

12-18 ft. lbs. 8-10 ft. lbs.
(16-24 Nm) (11-14 Nm)
242 ™
15-20 ft. lbs.
(20-27 Nm)

18-22 ft. lbs.

15-20 ft. lbs.
(24-30 Nm)
(20-27 Nm)
262 ™
9-12 ft. lbs. 10-14 ft. lbs.
(12-16 Nm) (14-19 Nm)
 TRANSMISSION
Exploded View, Continued
Ref. Qty. Description Ref. Qty. Description
1. 1 Fill Plug 53. 1 Pawl, Detent
2. 1 Drain Plug, Magnetic 54. 1 Star, Detent
4. 14 Screw, M8 x 1.25 x 30 55. 1 Plate, Park, 12-Face
5. 6 Screw, M6 x 1 x 20 56. 1 Shaft, Idler 29T
6. 3 Screw, M8 x 50 57. 1 Shaft, Reverse 29T
7. 1 Screw, M6 x 1 x 40 58. 1 Shaft, Front Output
8. 6 Screw, M6 x 1 x 18 59. 1 Shaft, Input Helical
9. 2 Screw, M6 x 1 x 16 60. 1 Shaft, Pinion, 11T
10. 1 Nut, NyLoc, M8 x 1.25 61. 1 Disc, Brake
11. 2 Washer, Cup 62. 1 Bellcrank
12. 1 Washer 63. 1 Collar, Shift
13. 3 Washer 64. 1 Rail, Shift Shaft
14. 1 Washer 65. 1 Tube, Vent, 1/4 in.
15. 1 Washer 66. 1 Fork, Pivot Shaft
16. 2 Pin, Dowel 67. 1 Dog, Engagement
17. 1 Pin, Spring 68. 1 Shift Dog, Park
18. 1 Retaining Ring, External 69. 1 Gear, 44T
19. 1 Snap Ring 70. 2 Fork, Shift
20. 1 Retaining Ring, External 71. 1 Sprocket, 48T, 6-Face
21. 1 Retaining Ring, External 72. 1 Gear, Low 67T
22. 1 Retaining Ring, Internal 73. 1 Engagement Dog, 6-Face
23. 2 Retaining Ring, External 74. 1 Gear, 53T
24. 2 Retaining Ring, External 75. 1 Gear, 46T
25. 3 Retaining Ring, External 76. 1 Gear, Snorkel 13T
26. 1 Retaining Ring, External 77. 1 Shaft, Shift
27. 2 Washer, Thrust 78. 1 Weldment, Rear Mount Bracket
28. 1 Washer, Thrust 80. 2 Retainer, Fork
29. 1 Shim 81. 1 Bracket, Rear Mount
30. 1 Shim 82. 1 Cover, Bearing, Center Drive
31. 2 Bearing, Needle Cage 83. 1 Spacer
32.
33.
2
1
Bearing, Ball
Bearing, Ball
84.
85.
1
1
Chain, Silent
Solenoid 8
34. 2 Bearing, Ball 86. 1 Switch, Rotary, 2-Pin
35. 3 Bearing, Ball 87. 1 O-Ring
36. 1 Bearing, Needle Cage 88. 1 O-Ring
37. 1 Bearing, Ball 89. 1 O-Ring
38. 2 Bearing, Ball 90. 1 Seal, Triple Lip
39. 1 Bearing, Ball 91. 1 Seal, Triple Lip
40. 2 Spring, Compression 92. 1 Seal, Dual Lip
41. 2 Spring, Compression 93. 2 Seal, Triple Lip
42. 1 Spring, Torsion 95. 1 Sensor, Speed
43. 1 Spring, Compression 98. 1 Bracket, Wire Harness
44. 1 Spring, Compression, Detent 99. 2 Plug, Expansion
45. 1 Spring, Washer 100. 1 Side Gear, Male, 39T
46. 1 Tube, Snorkel 101. 3 Bearing, Plain
47. 1 Cover, Sector Gears 102. 1 Side Gear, Female, 39T
48. 1 Case, LH 103. 1 Diff Cover
49. 1 Case, RH 104. 6 Planet Gear
50. 1 Drum, Shift 105. 7 Screw, M8 x 1.25 x 25
51. 1 Gear, Sector 16T 106. 1 Ring Gear, 53T
52. 1 Gear, Sector 31T 108. 6 Bearing, Plain

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 TRANSMISSION

NOTES

8.48
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 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
BRAKE PEDAL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
BRAKE BLEEDING / FLUID CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
PARKING BRAKE (INTL MODEL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
PARKING BRAKE CALIPER SERVICE (INTL MODEL) . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
PARKING BRAKE DISC (INTL MODEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
FRONT BRAKE PADS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
PAD ASSEMBLY / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
FRONT CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
CALIPER EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
CALIPER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
FRONT BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
DISC RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
DISC REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23

9
PAD ASSEMBLY / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
REAR CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
CALIPER EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
CALIPER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
REAR BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
DISC REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.30

9.1
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 BRAKES
GENERAL SPECIFICATIONS
FRONT BRAKE SYSTEM
Item Standard Service Limit
Front Brake Pad Thickness .300 ± .007" (7.62 ± .178 mm) .180" (4.6 mm)
Front Brake Disc Thickness .188" (4.78 mm) .170" (4.32 mm)
Front Brake Disc Runout - .010" (.254 mm)

REAR BRAKE SYSTEM

Item Standard Service Limit
Rear Brake Pad Thickness .298 ± .007" (7.57 ± .178 mm) .180" (4.6 mm)
Rear Brake Disc Thickness .188" (4.78 mm) .170" (4.32 mm)
Rear Brake Disc Runout - .010" (.254 mm)

TORQUE SPECIFICATIONS SPECIAL TOOLS

Torque Torque Part Number Tool Description
Item
ft. lbs. Nm
2870975 Mity Vac™ Pressure Test Tool
Front Caliper Mounting Bolts 31-34 42-46
Rear Caliper Mounting Bolts 18 24 SPX Tools: 
1-800-328-6657 or on-line at http://polaris.spx.com/.
Brake Line Flare 12-15 16-20
Brake Line Banjo Bolts
15 20
(Caliper Attachment)
Brake Line Banjo Bolt
15 20
(Master Cylinder Attachment)
Front Brake Disc to Hub Bolts 18 24
Rear Brake Disc to Hub Bolts 28 38
Brake Switch 12-15 16-20
Master Cylinder to Frame 17 23
Brake Pedal Mounting Bracket
17 23
to Frame
Park Brake Assembly Bolts 37 50
Park Brake Disc Mounting Bolt 18-22 24-30
Park Brake Lever Mount Bolts 16 22
Park Brake Mount Bracket to
37 50
Transmission Bolts

9.2
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 BRAKES
BRAKE SYSTEM SERVICE NOTES
Disc brake sys tems are light weight, low maintenance, and perform well in the conditions this v ehicle will routinely
encounter. There are a few things to remember when replacing disc brake pads or performing brake system service to
ensure proper system function and maximum pad service life.

• Optional pads are available to suit conditions in your area. Select a pad to fit riding style and environment.
• DO NOT over-fill the master cylinder fluid reservoir.
• Make sure the brake pedal returns freely and completely.
• Adjust stop pin on front caliper after pad service.
• Check and adjust master cylinder reservoir fluid level after pad service.
• Make sure atmospheric vent on reservoir is unobstructed.
• Test for brake drag after any brake system service and investigate cause if brake drag is evident.
• Make sure caliper moves freely on guide pins (where applicable).
• Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely.
• Perform a brake burnishing procedure after installing new pads to maximize service life.
• DO NOT lubricate or clean the brake components with aerosol or petroleum products. Use only approved brake
cleaning products.

BRAKE NOISE TROUBLESHOOTING

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

Brake Noise Troubleshooting

Possible Cause Remedy
Spray disc and pads with CRC Brakeleen™ or an
equivalent non-flammable aerosol brake cleaner. Remove
Dirt, dust, or imbedded material on pads or disc
pads and/or disc hubto clean imbedded material from disc
or pads.
Pad(s) dragging on disc (noise or premature pad wear) Adjust pad stop (front calipers) 9
because of improper adjustment 
Master cylinder reservoir overfilled Set to proper level
Master cylinder compensating port restricted Clean compensating port
Master cylinder piston not returning completely Inspect. Repair as necessary
Caliper piston(s) not returning Clean piston(s) seal 
Operator error (riding the brake) Educate operator
Loose wheel hub or bearings Check wheel and hub for abnormal movement.
Brake disc warped or excessively worn Replace disc
Brake disc misaligned or loose Inspect and repair as necessary
If noise does not change when brake is applied check
Noise is from other source (axle, hub, disc or wheel)
other sources. Inspect and repair as necessary
Wrong pad for conditions Change to a softer or harder pad

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 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 levelis critical to propersystem operation. Too little fluid will allow air to enter thesystem 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 temp erature within th e hydr aulic syste m changes, this p ort com pensates fo r fluid exp ansion 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
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 BRAKES
BRAKE SYSTEM EXPLODED VIEW
RZR 570
Caliper Banjo Style Fittings:
Seal 1
15 ft. lbs. (20 Nm).
All Flare Style Fittings:
1 2 12-15 ft. lbs. (16-20 Nm)

All Caliper Bleed Screws:

47 in. lbs. (5.3 Nm)

Rear Calipers
Replace Seal if Fastener is
Loosened or Removed

Lubricate New Seals with

Brake Fluid

LH Rear Line

RH Rear Line
Brake
Switch

MC Rear
Brake Line

2
1 Seal
Cross
Fitting Master Cylinder
1
Seal

Seal LH Front

Master Cylinder View

RH Front
Brake Line
Brake Line
9

Front Calipers

Seal
1

9.5
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 BRAKES
MASTER CYLINDER NOTE: Make no te of fro nt and rea r br ake lin e
locations to master cylinder.
Removal 4. Loosen the brake line banjo bolts (C) and allow fluid
1. Locate the master cylinder above the left front tire in to drain.
the wheel well area. NOTE: Dispose of fluid properly. Do not re-use.
5. Remove the two mounting fasteners (D) that secure
the master cylinder to the frame.

Installation
1. Reverse Ste ps 1-5 fo r master cylin der installation.
Refer to t he to rque specifications in th e
Master Cylinder illustration.
2. After installing the foot brake check pedal freeplay .
Pedal freeplay should not exceed .090” (2.286 mm).

BRAKE PEDAL LEVER

2. Remove th e clip (A) fr om th e cle vis p in (B) tha t
attaches the master cylinder to the brake pedal lever.
Pedal Removal
17 ft. lbs. D 1. Locate the br ake ped al lever (L) an d remove th e
(23 Nm) master cylinder clevis pin (B) and clip (A).
B
2. Remove the E- ring ( E) fro m the pe dal mount an d
remove the brake pedal lever (L) from the vehicle.
L
E
A
B

D
A

C
15 ft. lbs. Pedal Installation
(20 Nm)
1. Reverse “Removal” steps to install brake pedal lever.
3. Place a con tainer to catch brake fluid un der the Brake pedal freeplay should not exceed .090” (2.28
master cylinder brake line banjo bolts (C). mm).

Brake Pedal Freeplay:

CAUTION
.090” (2.28 mm)

Brake fluid will damage finished surfaces.

Do not allow brake fluid to come in contact
with finished surfaces.

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 BRAKES
BRAKE BLEEDING / FLUID CHANGE 5. Have an a ssistant slowly pump fo ot pe dal u ntil
pressure builds and holds.
NOTE: When b leeding t he brakes or replacing t he
fluid always s tart with the f urthest c aliper f rom t he 6. Hold brake pedal on to maintain pedal pressure, and
master cylinder. open bleeder screw. Close bleeder screw and release
foot pedal.

CAUTION NOTE: Do not release foo t peda l before bleeder

screw is t ight or air may b e d rawn in to ma ster
cylinder.
Always wear safety glasses.
7. Repeat procedure until clean fluid appears in bleeder
CAUTION hose and all air ha s be en purged. Add fluid as
necessary to maintain level in reservoir.
Brake fluid will damage finished surfaces. Do not
allow brake fluid to come in contact with finished CAUTION
surfaces. This procedure should be used to
change fluid or bleed brakes during
Maintain at least 1/2"(1.27 cm) of brake fluid in
regular maintenance.
the reservoir to prevent air from
entering the master cylinder.
1. Clean master cylinder reservoir cover thoroughly and
remove the cover.
8. Tighten bleeder screw securely and remove bleeder
hose. Torque bleeder screw to 47 in. lbs. (5.3 Nm).

9. Repeat procedure Ste ps 5 - 8 fo r the r emaining

calipers.

10. Add brake fluid to MAX level inside reservoir.

Master Cylinder Remove Master Cylinder Fluid Level

Cover

Between the MIN and MAX line shown on the

reservoir.

11. Install master cylinder reservoir cover.

2. If changing fluid, remove old fluid from reservoir with
9
12. Field te st ma chine at low spe ed before p utting in to
a Mity Vac™ pump or similar tool.
service. Check fo r pr oper br aking action and pedal
reserve. With p edal fir mly app lied, pe dal r eserve
Mity Vac™ (PN 2870975) should be no less than 1/2"(1.3 cm).

13. Check brake system for fluid leaks.

3. Add brake fluid to the indicated MAX level of reservoir.

Polaris DOT 4 Brake Fluid

(PN 2872189)

4. Begin bleeding pr ocedure wit h th e ca liper th at is

farthest from the ma ster cylin der. Install a b ox end
wrench on caliper bleeder screw. Attach a clean, clear
hose to fitting an d place the othe r end in a cle an
container. Be sure the hose fits tightly on fitting.

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 BRAKES
PARKING BRAKE (INTL MODEL)
Exploded View

37 ft. lbs.
(50 Nm)
Assembly
Bolts

Spacer Parking Brake

Lever

Parking Brake
Caliper

Parking Brake Caliper / Shift Cable

Mount Bracket
Nuts
16 ft. lbs.
(22 Nm)

Mounting Clip
Bolts
37 ft. lbs. Bolts
(50 Nm)

Clevis
Pin
Clevis
Pin Clip

Parking Brake Lever

Mount Bracket

Cable

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 BRAKES
Parking Brake Inspection 1. Pull back on parking brake lever (located in the dash).

1. Inspect parking brake cable and brake pads for wear. 2. After 3 to 4 clicks “BR AKE” should display on the
instrument cluster and the wheels should not rotate
2. Refer to “Parking Br ake Cable Adju stment” if when turning by hand. After 8 full clicks of levertravel,
adjustment is ne cessary. Re fer t o “ Parking Br ake the vehicle should not roll while parked.
Caliper Service” for brake pad replacement.
3. If the vehicle moves, adjustment is necessary.

4. Adjust the parking brake cable where it attaches to the

Inspect Cable caliper mount / shift cable bracket. The mount bracket
is located on the right-hand side of the transmission.

Adjustment Procedure
1. Place the vehicle in neutral on a flat level surface.

2. Locate the p arking b rake ca ble ad justment a rea

where the cable attaches to the caliper mount bracket.

Parking Brake
Cable Adjustment

Outboard Pad

Inboard Pad

Mount Bracket

3. 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
Parking Brake Cable Adjustment Brake Caliper
D C
When the parking brake is fully engaged and “BRAKE” is
displayed on the instrument clu ster, en gine spe ed is 9
limited to 1500 RPM while in gear. If throttle is applied, this
limiting fea ture pr events operation, whi ch pr otects the
parking brake pads from excessive wear.

NOTE: Inspect parking brake cable tension after the

first 25 ho urs of op eration and e very 1 00 hou rs of Mount Bracket
operation afterwards to ensure proper cable tension.
4. Now hold the outer jam nut (D) and turn in the inner
Loss of tension in the p arking brake cable will cause jam nut (C) clockwise, until the jam nut is tight against
illumination of the parking brake indicator and activation of the bracket.
the lim iting fe ature. If this occur s, inspect a nd adjust
parking brake cable tension. If performing this service is 5. Repeat Step 3 and Step 4 until the proper adjustment
difficult due to conditions o r location , tem porarily is obtained for the parking brake.
disconnect the parking brake switch electrical connector.
Reconnect the conn ector as soo n a s practicable a nd NOTE: See Ch apter 10 for more information on the
adjust the parking brake cable to proper tension. parking brake switch.

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 BRAKES
PARKING BRAKE CALIPER SERVICE (INTL MODEL)
Caliper Exploded View

Figure 9.1 Pad & Holder Thrust Washer Lever

Apply Anti-Seize Lubricant

Assembly
Bolt

Sleeve

Nuts
37 ft. lbs.
(50 Nm)

Sleeve

Steel Balls (3)

Assembly Shim Pack (4 Shims)

Bolt Apply Anti-Seize Lubricant Stationary Actuator
Spring

Caliper Removal
NOTE: Do not get oil, grease, or fluid on the parking 2. Remove the two fasten ers (B) retaining the p arking
brake pads. Damage to or contamination of the pads brake caliper mount / shift cable bracket.
may cause the pads to function improperly.

1. Remove the clip pin and pin ( A) fro m th e pa rking

brake cable.

NOTE: Be sure the parking brake is not engaged. Mount

Bracket

A B

3. Lift the parking brake caliper off the brake disc and
remove it from the vehicle.

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 BRAKES
Caliper Disassembly / Inspection New Brake Pad Installation
NOTE: Refer to th e “Electronic Pa rts Catalog” for 1. Install new pads and assemble the caliper with one
parking brake caliper replacement parts information. shim. For shim location, see Figure 9.1 on page 9.11.
2. Measure gap for the brake disc and compare to gap
1. Remove the two caliper assembly bolts (C). specification. Disassemble and add shim(s) between
thrust washer and the inside brake pad as needed to
close the gap to .207-.217 in. (5.25-5.51 mm).

Add shims until gap

measures .207”-.217”
(5.25-5.51 mm)

2. Slide the brake pads and springs from the assembly.

NOTE: Retain t he lever a nd ba ll bearings for
3. Once yo u ha ve de termined th e cor rect a mount of
reassembly.
shims to use, rea ssemble th e calipe r a nd a pply an
3. Inspect brake pads for excessive wear. Replace as Anti-Seize Lubricant to the thrust washer and shims.
needed. 4. Torque the caliper assembly bolts to specification.
4. Check the three steel balls for any signs of cracking.
Replace as needed. =T
5. Check ball seats in lever and stationary actuator. If
excessively worn, replace parts as needed. Parking Brake Caliper - Assembly Bolts:
37 ft. lbs. (50 Nm)
6. Measure thickness of the rear caliper parking brake
pads. Replace assembly or pads as needed. Refer to 5. Ensure the parking brake assembly functions properly
the following image for brake pad specifications. by actuating the lever. Install the mounting sleeves (D)
before installation.

Outboard Inboard

9
Pad Pad

Outboard Pad Thickness Inboard Pad Thickness

New 0.250” (6.35 mm) New 0.300” (7.62 mm)
Limit: 0.190” (4.83 mm) Limit: 0.240” (6.10 mm)

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 BRAKES
Caliper Installation PARKING BRAKE DISC (INTL MODEL)
1. Install the parking brake caliper over the brake disc.
Disc Inspection
Align the cali per mounting sleeves with the h oles in
the mount bracket. 1. Measure the brake d isc with a microm eter. If th e
2. Install and tighten the two caliper mount / shift cable thickness o f th e d isc is l ess than specified, r eplace
bracket fasteners to specification. the brake disc (see “Disc Replacement”).

Mount
Bracket

Service Limit:
.150” (3.81 mm)

=T Disc Replacement
1. Remove the parking brake caliper from the disc (see
Parking Brake Caliper - Mount Bracket Bolts: “Caliper Removal”).
37 ft. lbs. (50 Nm) 2. Using a 1/2” socket an d ra tchet, re move the bra ke
disc retaining bolt and flat washer.
3. Install the cable, pin and clip pin. Test the park brake
for proper function. 3. Remove the disc from the transmission shaft.
4. Install the n ew b rake disc. Install the m ounting b olt
and flat wa sher. Tor que th e mou nting bo lt to
specification.

Disc Bolt Washer

=T
Parking Brake Disc Mounting Bolt:
18-22 ft. lbs. (24-30 Nm)

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 BRAKES
FRONT BRAKE PADS NOTE: Brake fluid will be fo rced t hrough
compensating p ort in to ma ster c ylinder fluid
Pad Removal reservoir whe n pist on is p ushed ba ck into c aliper.
Remove excess fluid from reservoir as required.
1. Elevate and support front of vehicle.
6. Push the mounting bracket inward and the slip outer
brake pad out between the bracket and caliper body.
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 front wheel.

3. Loosen the pad adjuster screw 2-3 turns.

7. Remove the inner pad from the bracket and caliper.

4. Remove and disca rd the upp er and lower calip er

mounting bolts and remove the caliper from the front
hub.
NOTE: When remo ving c aliper, us e c are not to
damage brake line . Supp ort c aliper so t o avo id
kinking or bending brake line.
5. Push caliper pis ton in to caliper bore slowly using a
C-clamp or locking pliers with pads installed.

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 BRAKES
Pad Inspection Pad Assembly / Installation
1. Measure the thickness of the pad material. Replace 1. Lubricate mo unting bracket pin s with a light film of
pads if worn beyond the service limit. silicone grease and install rubber dust boots.

Apply Grease to Each

Bracket Pin

2. Compress mo unting b racket and ma ke sur e dust

boots ar e fu lly se ated. In stall pads with friction
material facing each other.

WARNING

If brake pads are contaminated with grease, oil,

Measure or liquid soaked do not use the pads.
Thickness Use only new, clean pads.

3. Install caliper onto front hub and torque new mounting

Front Brake Pad Thickness: bolts to specification.
.300” ± .007” (7.6 mm ± .178 mm)
Service Limit: .180” (4.6 mm)
=T
Front Caliper Mount Bolt Torque:
31-34 ft. lbs. (42-46 Nm)

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 BRAKES
4. Slowly pump the brake pedal until pressure has been Brake Burnishing Procedure
built up. Maintain at least 1/2, (12.7 mm) of brake fluid
in the reservoir to prevent air from entering the brake It is required tha t a bu rnishing p rocedure b e pe rformed
system. after installation of new brake pads to extend service life
and reduce noise.
5. Install the ad justment se t screw and turn clockw ise Start mach ine an d slowly increase sp eed to 30 mp h.
until st ationary pa d co ntacts disc, then b ack off 1/2
Gradually apply brakes to stop machine. Allow pads and
turn (counterclockwise). disc to cool suf ficiently dur ing the p rocedure. Do n ot
allow pads or disc to become hot or warping may result.
Repeat th is p rocedure 1 0 time s. Do not make more
than 3 stops per 1 mile (1.6 km).

1/2 Turn

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.

=T
Wheel Nuts:
Steel Wheels: 27 ft. lbs. (37 Nm)
Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn)
9

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 BRAKES
FRONT CALIPER SERVICE
Caliper Exploded View
Apply Polaris DOT 4 Brake Fluid 47 in. lbs.
C A
to Component (5.3 Nm)
E B
Apply Silicone Grease F
G
D

A. Socket Set Screw 

I D
B. Bleeder Screw 
C. Caliper Assy. 
D. Boot 
E. Square O-ring
(thick)
F. Square O-ring (thin) 
G. Piston 
H. Caliper Mount 
I. Brake Pads

Caliper Removal 5. Loosen brake pad adjustment set screw 2-3 turns to
allow brake pad removal after the caliper is removed.
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 . Re move br ake line fr om
caliper.

6. Remove and discard the two ca liper mounting bolts

and remove the caliper assembly from the front hub.

Remove
Brake Line

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 BRAKES
Caliper Disassembly 5. Once the pistons are removed, use a pick to carefully
remove the square O-rings from the caliper. O-rings
1. Remove bo th br ake p ads fr om th e ca liper (see should be replaced during caliper service.
“FRONT BRAKE PADS - Pad Removal”).
2. Remove mount bracket assembly and dust boots.

6. Clean the caliper body, piston, and retaining bracket

with brake cleaner or alcohol.
3. Thoroughly clean the caliper before disassembly and
prepare a clean work area for disassembly. Clean
Components
4. Use a commercially available caliper piston pliers to
extract the pistons from the caliper.

NOTE: Be sure to clea n se al grooves in ca liper

body.

9
IMPORTANT: Do not remove the caliper pistons with
a st andard p liers. The piston se aling su rfaces will
become damaged if a standard pliers is used.

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 BRAKES
Caliper Inspection Caliper Assembly
1. Inspect ca liper b ody for n icks, scratches, pitting or 1. Install new O-rings in the caliper body. Be sure the
wear. Measure bor e size and compare to grooves are clean and free of residue or brakes may
specifications. Re place if da maged or wo rn b eyond drag upon assembly.
service limit.

Seal
Grooves

New
O-Rings

2. Coat pistons with clean Polaris DOT 4 Brake Fluid.

= In. / mm. Install pistons with a twisting motion while pushing
inward. Pisto n sh ould slide in and ou t of b ore
smoothly, with light resistance.
Front Caliper Piston Bore I.D.:
Std: 1.004” (25.5 mm) 3. Lubricate the mounting bracket pins w ith silicone
Service Limit: 1.006” (25.55 mm) grease and install the rubber dust seal boots.

2. Inspect pist on fo r nic ks, scratches, pitting or wear . Apply Grease to Each
Measure piston diameter and replace if damaged or Bracket Pin
worn beyond service limit.

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.

= In. / mm.

Front Caliper Piston O.D.:

Std: 1.002” (25.45 mm)
Service Limit: 1.000” (25.4 mm)

3. Inspect the br ake disc and pa ds as o utlined in th is

chapter.

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 BRAKES
Caliper Installation 6. Install wheel and torque wheel nuts to specification.

1. Install the brake line onto the caliper taking care not
to allow any debris to enter the caliper. =T
2. Install the caliper and torque the new mounting bolts Wheel Nuts:
to specification. Steel Wheels: 27 ft. lbs. (37 Nm)
Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn)
=T
7. Field test unit for proper braking action before putting into
service. Inspect for fluid leaks and firm brakes. Make sure
Front Caliper Mount Bolt Torque:
the brake is not dragging when pedal is released. If the brake
31-34 ft. lbs. (42-46 Nm)
drags, re-check assembly and installation.
3. Torque th e ban jo bolt to the pr oper to rque NOTE: If new pad s are inst alled, refer to “FRONT
specification. BRAKE PADS - Brake Burnishing Procedure”.

15 ft. lbs.
(20 Nm)

4. Install the ad justment se t screw and turn clockw ise

until st ationary pa d co ntacts disc, then b ack off 1/2
turn (counterclockwise).

1/2 Turn
9

5. Perform brake bleeding procedure as outlined earlier

in this chapter.

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 BRAKES
FRONT BRAKE DISC Disc Inspection
1. Visually inspect disc fo r s coring, scratches, o r
Disc Runout
gouges. Replace the disc if an y deep scratches are
1. Mount dia l in dicator as sh own to m easure d isc evident.
runout. Slowly rotate the disc and read total runout on
the dial indicator. Replace the disc if runout exceeds 2. Use a 0 -1” micro meter a nd m easure the disc
specification. thickness a t eight different po ints around the pa d
contact surface. Replace disc if worn beyond service
limit.
Measure
Thickness

Front
Disc

Brake Disc Thickness

New .188” (4.78 mm)
Service Limit .170” (4.32 mm)

Brake Disc Runout Brake Disc Thickness Variance

Service Limit: .002” (.051 mm)
Service Limit .010” (.254 mm) difference between measurements

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 BRAKES
Disc Replacement 6. Install wheel hub assembly, washers, and castle nut.
Torque castle nut to 80 ft. lbs. (108 Nm) and install a
1. Remove th e fr ont br ake calip er ( see “FRONT new cotter pin.
CALIPER SERVICE”).
7. Install the front brake caliper (see “FRONT CALIPER
2. Remove wheel hub cotter pin, castle nut and washers. SERVICE”).
3. Remove the wheel hub assembly from the vehicle and 8. Follow blee ding procedure outlin ed ear lier in this
remove the (4) bolts retaining the disc to the hub. chapter.
(4) Bolts
9. Field test unit for proper braking action before putting
into ser vice. In spect for fluid leaks an d fir m b rakes.
Make sure the brake is n ot dragging when pedal is
released. If the brake drags, re-check assembly and
Cotter installation.
Pin

Washers

Nut

4. Clean the wheel hub mating surface and install new

disc on wheel hub.

5. Install new bolts and torque to 18 ft. lbs. (24 Nm).

18 ft. lbs.
(24 Nm)

CAUTION

Always use new brake disc mounting bolts. The

bolts have a pre-applied locking agent which is
destroyed upon removal.

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 BRAKES
REAR BRAKE PADS 5. Push caliper piston into the caliper bore slowly using
a C-clamp or locking pliers with pads installed.
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 rear wheel.

3. Loosen pad adjuster screw 2-3 turns.

NOTE: Brake fluid will be f orced t hrough

compensating p ort in to ma ster c ylinder fluid
reservoir whe n pist on is p ushed ba ck in to c aliper.
Remove excess fluid from reservoir as required.

6. Push caliper mounting bracket inward and slip outer

brake pad past the edge to remove.

4. Remove and discard the two caliper mounting bolts

and lift caliper off the brake disc.

7. Remove the inner brake pad.

NOTE: When re moving ca liper, be careful not to

damage brake line. Support caliper so as not to kink
or bend brake line.

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 BRAKES
Pad Inspection Pad Assembly / Installation
1. Clean the caliper with brake cleaner or alcohol. 1. Lubricate mounting br acket pins with a ligh t film of
silicone grease and install rubber dust boots.
2. Measure the thickness of the pad material. Replace
pads if worn beyond the service limit.

Measure
Thickness

2. Compress mo unting b racket and ma ke sur e dust

Rear Brake Pad Thickness boots ar e fu lly se ated. In stall pa ds with fric tion
New .298” ± .007” (7.57 mm ± .178 mm) material facing each other.
Service Limit .180” (4.6 mm)
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 and torque the new mounting bolts to

specification.

44 ft. lbs.
(60 Nm)

=T
Rear Caliper Mount Bolt Torque:
44 ft. lbs. (60 Nm)

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 BRAKES
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.
5. Install th e a djustment se t screw and turn clockw ise
until the stationary pad contacts the disc, then back
off 1/2 turn.
6. Verify fluid level in rese rvoir is up to t he M AX lin e
inside reservoir and install reservoir cap.

Master Cylinder Fluid

Up to MAX line inside reservoir

7. Install wheel and torque wheel nuts to specification.

=T
Wheel Nuts:
Steel Wheels: 27 ft. lbs. (37 Nm)
Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn)

Brake Burnishing Procedure

It is r equired tha t a bur nishing pr ocedure be per formed
after installation of new brake pads to extend service life
and reduce noise.
Start machin e an d slo wly in crease speed to 30 mp h.
Gradually apply brakes to stop machine. Allow pads and
disc to coo l suf ficiently d uring the pr ocedure. Do n ot
allow pads or disc to become hot or warping may result.
Repeat this pr ocedure 1 0 times. Do not make more
than 3 stops per 1 mile (1.6 km).

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 BRAKES
REAR CALIPER SERVICE
Caliper Exploded View

Apply Polaris DOT 4 Brake Fluid

D to Component
47 in. lbs.
Apply Silicone Grease
(5.3 Nm) G
I

A. Brake Pad
B. Mount Bracket
C. Piston H A
D. Caliper Assy. E
E. Square Ring F
(thick)
F. Square Ring (thin) C
G. Boot, Pin Bushing
H. Boot, Pin Seal
I. Bleeder Screw
K. Set Screw B

Caliper Removal
1. Elevate and safely support the rear of the vehicle. 5. Loosen the brake pad adjustment set screw to allow
brake pad removal after the caliper is removed.
CAUTION 6. Remove and discard the two caliper mounting bolts
and remove the caliper.
Use care when supporting vehicle so that it does not
tip or fall. Severe injury may occur. Remove
2. Remove the (4) wheel nuts and rear wheel. 9
3. Clean caliper area before removal.
4. Place a container below the caliper to catch the brake
fluid when removing the line. Remove brake line from
caliper.

Remove
Brake Line

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 BRAKES
Caliper Disassembly 5. Clean the caliper body, piston, and retaining bracket
with brake cleaner or alcohol.
1. Remove brake pad adjustment set screw (K).
NOTE: Be sure to clea n se al groov es in ca liper
2. Push up per pad r etainer pin in ward an d slip b rake body.
pads past the edge and remove from the caliper.
3. Remove mounting bracket (B) and dust boots (G) and
(H). Clean Components
D
G

K
Pads
H
E F
C

4. Using a h ammer and a small p unch, r emove the

piston (C) from the ca liper bo dy (D) . Rem ove the
square O-rings (E) and (F) from the caliper body (D).

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 BRAKES
Caliper Inspection Caliper Assembly
1. Inspect ca liper b ody fo r n icks, scr atches or wear. 1. Install new caliper seals (A) in the caliper body (B).
Measure bo re size an d comp are to sp ecifications. Be sure groove is clean and free of residue or brakes
Replace if damage is evide nt or if wor n be yond may drag upon assembly.
service limit.
B

2. Coat piston with clean Polaris DOT 4 Brake Fluid (PN

2872189). In stall piston (D) with a twisting motion
= In. / mm. while pushing inward. Piston should slide in and out
of bore smoothly with light resistance.

Rear Caliper Piston Bore I.D. 3. Lubricate the mounting br acket pi ns w ith silicone
Standard: 1.191” (30.25 mm) grease and install the rubber dust seal boots.
Service Limit: 1.192” (30.28 mm)

2. Inspect piston for nicks, scratches, wear or damage.

Measure dia meter an d r eplace if d amaged or wo rn
beyond service limit.

9
4. Compress the mounting bracket and make sure the
dust se als ar e fully seate d. In stall th e br ake p ads.
Clean the disc and pads with brake parts cleaner or
denatured alcohol to remove any dirt, oil or grease.

= In. / mm.

Rear Caliper Piston O.D.

Standard: 1.1875” (30.16 mm)
Service Limit: 1.186” (30.12 mm)

3. Inspect the br ake disc and pa ds as o utlined in th is

chapter.

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 BRAKES
Caliper Installation REAR BRAKE DISC
1. Install the new rear caliper with the mounting bolts.
Disc Inspection
Torque mounting bolts to specification.
44 ft. lbs. 1. Visually inspect disc fo r s coring, scratches, o r
(60 Nm) gouges. Replace the disc if an y deep scratches are
evident.

2. Use a 0 -1” micro meter a nd m easure the disc

thickness a t eight different po ints around the pa d
contact surface. Replace disc if worn beyond service
limit.

Front Side
View View

=T
Rear Caliper Mount Bolt Torque:
44 ft. lbs. (60 Nm) Measure
Thickness
2. Install brake line banjo bolt and torque to specification.

15 ft. lbs. Brake Disc Thickness

(21 Nm) New: .188” (4.78 mm)
Service Limit: .170” (4.32 mm)

Brake Disc Thickness Variance

Service Limit .002” (.051 mm)

difference between measurements

3. Install the pad adju stment scr ew an d tur n un til 3. Mount a d ial in dicator an d m easure disc runout.
stationary pad contacts disc, then back off 1/2 turn. Slowly rotate the disc and read total runout on the dial
indicator. Replace th e disc if runout exceeds
4. Follow b leeding pr ocedure o utlined earlier in this specifications.
chapter.

5. Install wheel and torque wheel nuts to specification. Brake Disc Runout
Service Limit .010” (.254 mm)
=T
Wheel Nuts:
Steel Wheels: 27 ft. lbs. (37 Nm)
Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn)

NOTE: If ne w pa ds a re i nstalled, re fer to “R EAR

BRAKE PADS - Brake Burnishing Procedure”.

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 BRAKES
Disc Replacement 7. Install rear caliper (see “REAR CALIPER SERVICE”).
Follow blee ding procedure outlin ed ear lier in this
1. Remove r ear br ake caliper ( see “ REAR CALIPER chapter.
SERVICE”).
8. Field test unit for proper braking action before putting
2. Remove wheel hub cotter pin, castle nut and washers. into ser vice. In spect for fluid leaks an d fir m b rakes.
3. Remove the hu b a ssembly fr om th e ve hicle an d Make sure the brake is n ot dragging when pedal is
remove the (4) bolts retaining the disc to the hub. released. If the brake drags, re-check assembly and
installation.
(4) Bolts

Cotter
Pin

Washers

Nut

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)

9
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 80 ft. lbs. (108 Nm) and install a
new cotter pin.

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 BRAKES
TROUBLESHOOTING
Brakes Squeal / Poor Brake Performance
• Air in system
• Water in system (brake fluid contaminated)
• Caliper or disc misaligned
• Caliper dirty or damaged
• Brake line damaged or lining ruptured
• Worn disc and/or friction pads
• Incorrectly adjusted stationary pad
• Worn or damaged master cylinder or components
• Damaged break pad noise insulator
• Brake pads dragging
• Brake caliper dragging

Pedal Vibration
• Disc damaged
• Disc worn (runout or thickness variance exceeds
service limit)

Caliper Overheats (Brakes Drag)

• Compensating port plugged
• Pad clearance set incorrectly
• Brake pedal binding or unable to return fully
• Residue build up under caliper seals
• Operator riding brakes

Brakes Lock
• Alignment of caliper to disc
• Caliper pistons sticking
• Improper assembly of brake system components

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 ELECTRICAL
CHAPTER 10
ELECTRICAL
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
UNDER-DASH COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
SWITCHES / CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
IGNITION KEY SWITCH / HEADLAMP SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
IGNITION KEY SWITCH (INTL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
AWD / 2WD SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
AWD / 2WD / TURF SWITCH (INTL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
TRANSMISSION (GEAR POSITION) SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
TURN SIGNAL SWITCH (INTL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
HAZARD SWITCH (INTL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
BRAKE LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
PARKING BRAKE SWITCH (INT’L MODEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
REAR DIFF SOLENOID (INTL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
DIFFERENTIAL SOLENOID OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
DIFFERENTIAL SOLENOID CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9
SPEED SENSOR LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9
SPEED SENSOR TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
RIDER INFORMATION DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
INFORMATION DISPLAY AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
DIAGNOSTIC MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
INSTRUMENT CLUSTER PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
INSTRUMENT CLUSTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
INSTRUMENT CLUSTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
ALL WHEEL DRIVE COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
DIAGNOSING SYSTEM FAILURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
HEAD LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
HEADLIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
HEADLAMP BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
HEADLAMP HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
HEADLAMP HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
TAIL / BRAKE LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19

10
BULB REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
COOLING SYSTEM BREAK-OUT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
FAN CONTROL CIRCUIT OPERATION / TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
FAN CONTROL CIRCUIT BYPASS TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
EFI DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
EFI COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
FUEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22

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 ELECTRICAL
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
CHARGING SYSTEM “BREAK EVEN” TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
CHARGING SYSTEM STATOR (ALTERNATOR) TESTS. . . . . . . . . . . . . . . . . . . . . . 10.24
STATOR (ALTERNATOR) REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
REGULATOR / RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
CHARGING SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
BATTERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27
BATTERY SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27
GENERAL BATTERY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27
BATTERY ACTIVATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
BATTERY REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
BATTERY OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
BATTERY TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
BATTERY CONDUCTANCE ANALYZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
OCV - OPEN CIRCUIT VOLTAGE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
SPECIFIC GRAVITY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
STARTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
STARTER MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
STARTER MOTOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
STARTER SOLENOID BENCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
STARTER SOLENOID OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
STARTING SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34
ELECTRICAL SYSTEM BREAKOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
AWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36
CHARGING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37
CHASSIS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37
LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38

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 ELECTRICAL
GENERAL INFORMATION Electrical Service Notes
Keep th e fo llowing notes in min d whe n d iagnosing an
Special Tools
electrical problem:

Part Number Tool Description • Refer to wir ing dia gram for stator and e lectrical
PV-43568 Fluke™ 77 Digital Multimeter component resistance specifications.

PV-43526 Connector Test Kit • When me asuring re sistance of a component th at

has a resistance value under 10 Ohms, remember
2870630 Timing Light to subtract meter lead resistance from the reading.
PU-50338 Battery Hydrometer Connect the leads tog ether a nd r ecord the
resistance. The r esistance of th e co mponent is
2460761 Hall Effect Sensor Probe Harness equal to tested value minus the lead resistance.
2871745 Static Timing Light Harness
• Become familiar w ith the op eration of your meter.
- Digital Wrench™ (see Chapter 4) Be su re leads are in th e proper jack fo r th e test
being p erformed ( i.e. 1 0A jack fo r cur rent
SPX Corporation: readings). Re fer to th e Owner’s Ma nual included
1-800-328-6657 or http://polaris.spx.com/. with your meter for more information.

• Voltage, am perage, and re sistance valu es

included in this m anual a re ob tained with a
Fluke™ 77 Dig ital Mu ltimeter (PV -43568). This
meter is used when d iagnosing ele ctrical
problems. Re adings o btained with o ther me ters
may differ.

• Pay attention to th e pr efix on th e mu ltimeter

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-Dash Components
The following switches and components can be accessed
underneath the instrument / dash panel:
• Speedometer
• Digital Wrench Diagnostic Connector
• AWD S
witch
• 12 Vdc Accessory Power Point
10
• Ignition Switch / Headlamp Switch
• Fuse / Relay Box

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 ELECTRICAL
SWITCHES / CONTROLS Ignition Key Switch (INTL)
1. Disconnect the key switc h harness by lifting the
Ignition Key Switch / Headlamp Switch
connector lock and pulling on the connector. Do not
1. Disconnect th e ke y switch ha rness by lifting the pull on the wiring.
connector lock and pulling on the c onnector. Do not
pull on the wiring. 2. Test between the 4 sets of outputs (OFF / ONLIGHTS
/ ON / START). If any of the tests fail, replace ignition
2. Test between the 4 sets of outputs (OFF / ON LIGHTS switch assembly.
/ ON / START). If any of the tests fail, replace ignition
switch assembly. • Turn the ignition key to ON LIGHTS. There should
be continuity between swit ch pins A, E and F; C
• Move the switch “ON LIGHTS”. There should be and D.
continuity between pins A and E; C and D.
• Turn the ign ition key to ON. The re should be
continuity between pins C and D; E and F.
• Turn the ignition key to ON. There should be
continuity between switch pins C and D; E and F. • Turn the ignition key to START. Th ere sh ould b e
continuity between pins A a nd B; C and D; E and
• Turn the ignition key to START. There should be F.
continuity between switch pins A and B; C and D;
E and F.

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 ELECTRICAL
AWD / 2WD Switch AWD / 2WD / TURF Switch (INTL)
1. Disconnect the AWD / 2W D sw itch harness by 1. Disconnect the AWD / 2WD / TURF switch harness
depressing the c onnector locks and pulling on the by depressing the connector locks and pulling on the
connector. Do not pull on the wiring. connector. Do not pull on the wiring.

2. Test between the 2 se ts of outputs (AWD / 2WD). If 2. Test betwee n th e 3 se ts of ou tputs (A WD / 2WD /
any of the tests fail, replace the switch assembly. TURF). If any of the test s fail, r eplace the switch
assembly.
• Move the switch to AWD (ON). There should be
continuity between switch pins 2 and 3. • Move the switch to A WD. T here sho uld be
continuity between switch pins 2 and 3; 5 and 6.
• Move the switch to 2WD (NONE / OFF). There
should be no continuity between any pins. • Move the switch to 2WD. There should b e no
continuity between any pins.
• Move the switch to TURF . Th ere shou ld be
continuity between switch pins 1 and 2; 4 and 5.

10

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 ELECTRICAL
Transmission (Gear Position) Switch Turn Signal Switch (INTL)
1. The transmission (gear position) switch is located on 1. Disconnect the Tu rn Signal switch ha rness by
the RH side of the transmission and can be accessed depressing the connector locks and pulling on the
through the RH wheel well area. connector. Do not pull on the wiring.

2. Disconnect the transmission switch harness by lifting 2. Test between the 5 set s of output s (H I BEAM / LO
the connector loc k and pulling on the c onnector. Do BEAM / L-TURN / R-TURN/ HORN). If any ofthe tests
not pull on the wiring. fail, replace the switch assembly.

3. Test the transmission swit ch continuity readings for

each gear position and compare to th e specification
table below. Orientation
Tab

1 2 3 4 6 7 8 9
HI BEAM O O
LO BEAM O O
L - TURN O O
R - TURN O O
HORN O O

Hazard Switch (INTL)

1. Disconnect wires or harness from the Hazard switch.

2. Test between the outputs (ON / NONE / OFF). If any

of the tests fail, replace the switch assembly.

• Move switch to ON. The re sh ould be continuity

between switch pins 2 and 3.
• Move switch to NONE / OF F. There should be no
continuity between switch pins.

Resistance Value
Gear Position when measured at switch terminals
A and B

HIGH 24 Ohms

LOW 75 Ohms

NEU 160 Ohms

REV 300 Ohms

PARK 620 Ohms

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 ELECTRICAL
Brake Light Switch Parking Brake Switch (INTL Model)
1. The br ake switch ca n be acce ssed thr ough the L H The p arking brak e s witch is located within the p arking
rear wheel well area. The switch is located near the brake lever. Remove the rubber boot covering the parking
outer PVT cover along th e lower fr ame. The b rake brake lever to locate the internally mounted switch.
pressure switch is installed into the cross fitting block.

PVT Cover

Brake Switch

2. Disconnect wire harness from switch and connect an

ohmmeter acr oss switch co ntacts. The reading
should be infinite (OL).

3. Apply the brake and check for continuity. If there is no

continuity or if re sistance is gr eater tha n 0 .5 oh ms,
clean the switch terminals. Re-test and replace switch
if necessary.

The switch remains in the “open” position when the park

brake lever is not applied.

When the parking brake lever is applied, the switchmakes

contact and sends volt age to the ECU to illuminate
“BRAKE” in th e in strument clu ster r ider in formation
display area (see “Park Brake Indicator”).

NOTE: If the pa rking bra ke is applied th e ECU will

rev limit th e engine at 1500 RPM until the park ing
brake is relea sed. This f eature has be en ad ded t o
prevent drive-away with the parking brake applied.
10

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 ELECTRICAL
Testing The Parking Brake Switch REAR DIFF SOLENOID (INTL)
1. Disconnect the harness co nnector a t the parking
brake switch (Orange/Red and Red/Blue wires). Differential Solenoid Overview
The differential solenoid is located on the rear portion of
2. Place the ohmmeter leads onto the switch terminals. the transmission case. The solenoid actuates a shift fork
The reading should be infinite (OL).
with an engagement dog, which locks and unlocks the rear
differential. Refer to Chapter 8 for more information.

3. Apply the parking brake. Continuity should now exist

between the switch terminals. If n o continuity exists
when the pa rking br ake is ap plied, try to clea n the Differential Solenoid
switch terminals and re-tes t. Replace switch if
necessary.
Differential Solenoid Circuit Operation
Park Brake Indicator The R ear Diff S olenoid Relay is att ached to the lower
This warning is used to notify the operator that the p ark airbox bracket and can be accessed through the right rear
brake lever is engaged. wheel well.
When the switch is pushed to activate “TURF”, a ground
When the p arking brake is fully engaged, “BRAKE” signal is provided to the ECU from the AWD / 2WD / TURF
appears in the rider information display. Engine speed is Switch.
limited to 1500 RPM in all gears, except neutral. If throttle
is applied, this limiting feature prevents operation, which Depending on engine speed and gear position criteria, the
protects the park brake pads from excessive wear. ECU energizes the Rear Diff Solenoid Relay allowing it to
enable the differential solenoid.
If the rear diff fails to switch from operational modes:
• Check the solenoid and relay connectors. Look for
loose wires or bad connections.
• Check for po wer fr om th e relay conn ector, to
ensure the solenoid has power to be activated.
• Check the A WD / 2WD / TURF Sw itch w ires for
loose connections.
• Remove solenoid from rear differential and ensure
the solenoid plunger is actuating.

CAUTION

Do not power the solenoidwith 12 Volts for more

than 1 second, or damage may occur to solenoid.

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 ELECTRICAL
VEHICLE SPEED SENSOR
Speed Sensor Location
The speed se nsor is loc ated on th e RH side of th e
transmission and can be accessed through the rear RH
wheel well area.

Speed Sensor

Transmission Switch

Speed Sensor Testing

Special Tools Required:
Static Timing Light Harness (PN 2871745)
Hall Sensor Probe Harness (PN 2460761)
1. Disconnect the 3 wire harness from the speed sensor
and remove the sensor from the transmission.
2. Connect th e wi res fr om the Static Timing Lig ht
Harness to the sensor 3 pin connector using the Hall
Sensor Probe Harness (PN 2460761).
3. Pass a scr ewdriver back an d forth in front of the
sensor tip.
4. Be sur e con nections are go od and 9V battery is in
good condition. If the light flashes, the sensor is good.

10

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 ELECTRICAL
INSTRUMENT CLUSTER
Overview
The instrument cluster displays critical vehicle information to the user. Reference the following page for display functions
and descriptions.

NOTE: Some features are not applicable to all models.

IMPORTANT: The use of a high pressure washer may damage the instrument cluster. Wash the vehicle by hand
or with a garden hose using mild soap. Certain products, including insect repellents and chemicals, will damage
the instrument cluster lens. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to
contact the lens.

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 ELECTRICAL
Rider Information Display 12. Neutral Gear Indicator - LED icon illuminates when
gear selector is in the neutral (N) position.
The rider information display is located in the instrument
cluster. All segments will light up for 1 second at start-up. 13. Gear Posit ion In dicator - Displays gear selec tor
position.
NOTE: If the instrument cluster fails to i lluminate, a
battery ov er-voltage may ha ve occurred a nd t he H = High
instrument c luster may ha ve shut off to pr otect the L = Low
electronic speedometer.
N = Neutral
1. Vehicle Sp eed Display - Ana log display o f vehicle R = Reverse
speed in MPH or km/h.
P = Park
2. Information Display Area - Odometer / Trip Meter -- = Gear Signal Error (shifter stuck between gears)
/ Tac hometer / Engine Temperature / Engine
Hours / Service Info / Cl ock - LCD displa y of the 14. Power Steering System MIL - LED icon illuminates
service hour interval, total vehicle miles or km., total when a fault ha s occu rred with the powe r steering
engine hours, a trip meter, engine RPM a nd engine system. This indicator illuminates when the key is
temperature. turned to the ON po sition and goe s o ff when the
engine is started.
3. MPH / KM/H Display - MP H is dis played when the
instrument cluster is in the Standard mode. KM/H is 15. Turn Signal / Hazar d La mp Indica tor - LED icon
displayed when the instrument cluster is in the Metric illuminates whenever the LH, RH or hazard lamps are
mode. activated (INTL Models Only).

4. High Beam Indicator LED icon illuminates whenever 16. Helmet / Seat Belt Indicator - LED icon illuminates
the Headlamp switch is in the high beam position. for several seconds when the key is turned to the ON
position. T he la mp is a r eminder to the op erator to
5. Fuel L evel Indicator - LCD b ar g raph indicating ensure all riders are wearing helmets and seat belts
current fuel level. All segments will flash when the last before operating the vehicle.
segment is cleared indicating a low fuel warning.

6. Clock - Displays current time in either 12-hour or 24- Information Display Area
hour formats.
The LC D p ortion of the in strument c luster is the
7. Engine T emperature Indicator - L ED icon information display a rea. In formation dis played in this
illuminates when the ECM de termines the engine is area includes: odometer, trip meter, engine RPM, engine
overheating. The indicators will initially flash to hours, service interval, clock, engine Diagnostic Trouble
indicate the engine is overheating. The indicators will Codes (DTCs) and power steering DTCs.
stay lit and not flash if a severe overheating condition
exists. Odometer

8. Service Interval Indicator - Preset at the factory and

adjustable by the user , a flashing wre nch sym bol
alerts the operator that the preset service interval has 10
been reached and maintenance should be performed.
The wrench icon will flash for 10 seconds upon start-
up once it reaches 0.

9. Check Engine MIL - Illuminated when the ECM has

detected a Diagnostic Trouble Co de in th e eng ine
management system.

10. AWD Indicator - Illuminated when the AWD / TURF

switch is in the AWD position.
The o dometer reco rds an d disp lays the to tal dist ance
11. TURF Indicator - Illuminated when the AWD / TURF traveled by the vehicle. The odometer can not be reset.
switch is in the TURF position (INTL Models Only).

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 ELECTRICAL
Trip Meter Engine Temperature

The trip meter records the miles traveled by the vehicle on Engine temperature can be displayed in Fah renheit or
each trip. To reset the trip meter: Celsius. Refer to “Units of M easurement” to change the
format.
1. Toggle the MODE button to TRIP 1.

2. To reset to 0, push and hold the MODE button un til Engine Hours
the distance display changes to 0.

Tachometer (RPM)

Engine hours are logged anytime the e ngine is ru nning.

Total hours can not be reset.

Engine RPM can be displayed digitally.

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 ELECTRICAL
Programmed Service Interval Clock

The initial factory service interval setting is 50 hours. Each The clock displays the time in a 12-hour or 24-hour format.
time the engine is started, the engine hours are subtracted Refer to “Units of Measurement” to change the format
from the service interval hours. When the service interval (Standard 12 -hour / Metr ic-24 hour). To set th e clo ck,
reaches 0, the LCD wren ch icon will flas h for follow these steps:
approximately 10 seconds each time theengine is started.
1. Toggle the MODE bu tton un til the od ometer is
To cha nge th e ho ur setting or r eset th e fun ction, follo w displayed.
these steps:
2. Press an d ho ld the MO DE bu tton until the hour
1. Toggle th e MODE bu tton until th e wr ench ico n is segment flashes. Release the button.
displayed in the information area.
3. With the segment flashing, tap the MODE button to
2. Press and hold the MODE button until the information advance to the desired setting.
display area begins to flash.
4. Press an d hold the MODE button un til the next
3. Toggle th e MODE bu tton to incre ase the ser vice segment flashes. Release the button.
interval hours in 5 hour increments to a maximum of
100 hours. 5. Repeat steps 3- 4 twice to set the 1 0 m inute an d 1
minute se gments. After co mpleting the 1- minute
4. To tu rn off th e ser vice in terval fu nction, togg le the segment, step 4 will save the new settingsand exit the
MODE button until “OFF” is displayed. clock mode.

10

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 ELECTRICAL
Units of Measurement Under / Over Voltage
This warning usually indicates that the vehicle is operating
Standard Display Metric Display at an RPM too low to keep the battery charged. It may also
occur when the engine is at idle and a high electrical load
Distance Miles (MPH) Kilometers (KM/H)
is applied (lights, cooling fan or other accessories).
Time 12-Hour Clock 24-Hour Clock
If battery voltage drops below 11 volts, a warning screen
Temperature Fahrenheit Celsius will display “Lo” and provide the present battery voltage. If
voltage drops below 8.5 volts, LCD backlighting and icons
To cha nge between S tandard an d Metr ic u nits of will turn off.
measurement, follow these steps:

1. Turn the key to the OFF position.

2. Press and hold the MODE button while turning the key
to the ON position.

3. When the display flashes the distance setting, tap the

MODE button to advance to the desired setting.

If battery voltage rises above 16 volts, a warning screen

will display “OV” and provide the present battery voltage.
If volt age r ises abo ve 16 .5 volt s, L CD b acklighting an d
icons will turn off.

4. Press and hold the MODE button to save the setting

and advance to the next display option.

5. Repeat th e pr ocedure to change re maining displ ay

settings.

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 ELECTRICAL
Park Brake Indicator (INTL Model Only) 3. A set of three numbers will appear in the information
area.
This warning is used to notify the operator that the park
brake lever is engaged. • The first number (located far left) can range from 0
to 9. Th is n umber re presents th e total nu mber o f
When the park brake is fully engaged, “BRAKE” appears trouble code present (example: 2 means there are
in the rider information display. Engine speed is limited to 3 codes present).
1500 RPM in all gears, except neutral. If throttle is applied,
• The second number (located top right) can be 2 to
this limiting feature prevents operation, which protects the
6 digit s in length. This num ber equates to the
park brake pads from excessive wear. suspected area of fault (SPN).
• The third number (located bottom right) can be 1 to
2 digits in length. This number equates to the fault
mode (FMI).

Diagnostic Mode
The diagnostic mode is a ccessible only when the check
engine MIL has been activated.

Use the following procedure to display diagnostic trouble

codes that wer e a ctivated dur ing curr ent ignition cycle
causing the MIL toilluminate. Diagnostic trouble codes will 4. Use the tro uble co de r eference table in the EFI
remain stored in the gauge (even if MIL turns off) until the Chapter for a description of each code.
key is turned off. 5. If more than one code exists, press the MODE button
to advance to the next trouble code.
1. If th e tr ouble cod e(s) ar e not d isplayed, u se the
MODE button to togg le u ntil “ CK ENG” d isplays on 6. To exit the dia gnostic mode, pr ess and ho ld the
the information display area. MODE button or turn the ignition key OFF once the
codes are recorded.

NOTE: If the re is a diag nostic pro blem with the

power s teering system, t he power steering MIL will
illuminate and blink in place of the check engine MIL.
10

2. Press an d ho ld th e MODE button to en ter the

diagnostics code menu.

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 ELECTRICAL
Instrument Cluster Pinouts Instrument Cluster Removal
NOTE: Do no t allo w alcoh ol or petroleum produ cts
to come in contact with the instrument cluster lens.

1. Disconnect the wire harness connector from the back

side of the instrument cluster.

2. Push the instrument cluster out from the back side of

the dash while securely holding the dash and rubber
mount.

FUNCTION PIN
Push Instrument Dash Panel
CAN High 1 Cluster Outward
CAN Low 2
Switched Power (Vdc) 3
Constant Power (Vdc) 4
Ground 5
High Beam Input 8
Fuel Level Sensor 11

Rubber Mount

Instrument Cluster
Bezel

NOTE: Do no t re move t he ru bber mount f rom th e

dash p anel. Only remove the ru bber moun t if
necessary. The bezel is a snap-on assembly and is a
serviceable part.

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 ELECTRICAL
Instrument Cluster Installation ALL WHEEL DRIVE COIL
1. Spray a soap an d water mixtur e o nto th e o uter
Operation Overview
surface area of the instrument cluster. This will help
the instrument cluster slid e into the r ubber mount • When the AWD switch is “ON”, 12 VDC power is
more easily. present at the hub coil.

• If the criteria is met, the Engine Controller provides

a ground path (brown/white wire). When this
occurs the AWD icon should display in the
instrument cluster.

• The AWD system must be grounded to operate.

Diagnosing System Failures

• Verify the AWD switch is functional and that a
minimum of 11 volts is present at the hub coil.

• Verify the AWD hub coil is functional. Test the

AWD hub coil using an ohm meter. See
2. Be sur e the r ubber mou nt inside the dash is fu lly specifications below:
installed a nd that the ind exing key on the ru bber
mount is lined up with the keyway in the dash.

3. Hold the das h securely and inse rt the in strument

cluster into the dash. Twist the instru ment cluster
gently in a c lockwise moti on to p roperly seat the
Test Resistance
instrument cluste r into the r ubber mo unt. App ly Readings should be:
pressure on th e b ezel wh ile pr essing do wn on th e GY to BN/WH: ~ 24 Ohms
instrument cluster. GY to Ground: No Connection

AWD Hub Coil Resistance:

24 Ohms ± 5%

• Verify the wiring harness, wiring, connectors,

connector pins and grounds are undamaged,
clean and connect properly.

• Verify continuity of wire connections with a known

10
good volt/ohm meter.

IMPORTANT: Verify all wires and wiring connections

have be en tested properly wit h a k nown go od v olt/
ohm mete r bef ore suspecting a co mponent f ailure.
80% of all electrical issues are caused by bad/failed
connections and grounds.

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 ELECTRICAL
HEAD LIGHTS
Headlight Adjustment
WARNING
The headlight beam is adjustable.
Due to the nature of light utility vehicles and
1. Place the vehicle on a level surface with the headlight
where they are operated, headlight lenses
approximately 25 ft. (7.6 m) from a wall.
become dirty. Frequent washing is necessary to
maintain lighting quality. Riding with poor
lighting can result in severe injury or death.

Headlamp Bulb Replacement

1. Disconnect the wire harness from the headlamp bulb.
Be sure to pull on the connector, not on the wiring.
Image for Reference Only

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 Park, start the engine and turn the
headlight switch to on.

4. The most intense part of the headlight beam should

be aimed 8 in. (20 cm) below the mark placed on the
wall in Step 2.

NOTE: Rider weight mu st be in cluded in the s eat 2. Turn the bulb counterclockwise to remove it.
while performing this procedure.
Image for Reference Only
5. Adjust the beam to the desired position by loosening
the adjustment screw (A) and moving the lamp to the
appropriate height.

A
3. Insert new bulb. Reinsta ll the wire harness onto the
headlamp assembly.

NOTE: Make s ure the t abs on t he bulb loc ate

properly in the housing.
6. Adjust th e b eam to de sired po sition. Repe at the
procedure to adjust the other headlight.

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 ELECTRICAL
Headlamp Housing Removal TAIL / BRAKE LIGHTS
1. Disconnect the wire harness from the headlamp bulb.
Bulb Replacement
Be sure to pull on the connector, not on the wiring.
Before replacing the bulb(s), use a dig ital multi-meter to
2. Remove the O-rings (A) from the headlamp brackets test the harness to ensure the lamp is receiving 12 volts
on both sides of the headlamp. and that a ground path is present.
3. Remove the adjustment screw (B) from the bracket. If a tail light, brake light or turn signal (INTL Only) does not
Image for Reference Only work the bulb may need to be replaced.

1. Disconnect the wire harness.

2. Remove bulb by turning the rubber base 1/4 turn and
pulling the bulb out. Repl ace it with recommended
bulb. Apply Dielectric Grease (PN 2871329).
B
A Tail / Brake
Light
A

4. Carefully remove the he adlamp from the front

bumper.
Image for Reference Only

INTL Tail / Brake

Models Light

Turn Signal
Light

Headlamp Housing Installation 10

1. Install th e hea dlamp ho using ba ck into th e fron t 3. Test the tail lig ht, br ake lig ht an d tur n sign al ( INTL
bumper. Only) to verify it is working properly.

2. Secure the headlamp housing with the rubber O-rings

(A) on both side s o f the hea dlamp an d install the
adjustment screw (B).

3. Reconnect wire harness or re-insert bulb if previously

removed.

4. Adjust h eadlights using the “ Headlight Adj ustment”

procedure in this section.

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 ELECTRICAL
COOLING SYSTEM
Cooling System Break-Out Diagram

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 ELECTRICAL
Fan Control Circuit Operation / Testing Coolant Temperature Sensor
Power is supplied to th e fan via the Ora nge/Black wire The coolant temperature sensor can be tested u sing an
when the relay is ON. The ground path for the fan motor ohmmeter or voltmeter.
is thr ough the Bro wn ha rness wi re. Refer to “ RELAYS”
later in this chapter for more information on fan functions. 1. With the engine an d temp erature se nsor at room
temperature (68°F = 20°C), disconnect the harness.

CAUTION 2. With the m eter in th e o hms m ode, p lace th e meter

leads onto the sensor contacts.
Keep hands away from fan blades during 3. Use the ta ble T emperature / Resistance t able t o
operation. Serious personal injury could result. determine if the sensor needs to be replaced.

NOTE: The fan may not function or operation may

TEMPERATURE F (C) RESISTANCE
be delayed if coolant level is low or if air is trapped in
the coo ling system. Be su re coo ling system is full 68F (20 C) 2.5 k  6%
and purged of air. Refer to Chapter 2 “Maintenance”
for cooling system information. 212F (100 C) 186  2%

Fan Control Circuit Bypass Test NOTE: If the coo lant t emperature sen sor o r circu it
malfunctions the radiator fan will default to 'ON'.
1. Disconnect harness from coolant temperature sensor
on th e en gine cylin der h ead (see Ch apter 4 fo r
location).
2. With the transmission in Park, start the engine. After
a few seconds, the fan should start running and the
“Check Engin e” ind icator should d isplay on the
instrument cluster. This indic ates al l other
components are working properly.
3. If the fan does not run or runs slowly, check the fan
motor wiring, ground, motor condition and mechanical
relay fo r pr oper op eration. Re pair or replace as
necessary. If the fan runs with the se nsor ha rness
disconnected, but will not turn on when the engine is
hot, ch eck th e coolant te mperature sensor and
connector terminals.

10

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 ELECTRICAL
EFI DIAGNOSTICS 5. If the readings are out of specification, or if the reading
is erratic or LCD display “sticks”, check the following
EFI Component Testing before replacing the fuel pump assembly:

All EFI component info rmation an d dia gnostic testing • Loose float
procedures are located in Chapter 4.
• Float contact with tank
Refer to Chapter 4 “Electronic Fuel Injection System (EFI)” • Bent float rod
when diagnosing an EFI system or component.
If none of the conditions exist, the fuel sender assembly is
FUEL SENDER faulty. Replace the fuel pump assembly (see Chapter 4).

Testing
1. Drain the fu el tan k a nd r emove it fr om th e vehicle
(see Chapter 4).
2. Set th e f uel ta nk on a fla t su rface. U sing a n O hm
meter, measure the resistance of the fuel sen der as
shown below.

3. Allow the sender float to sit in the empty position and

compare to specification.

Fuel Sender - Empty: 90 ± 4.5 

4. Slowly tilt the tank so that gravity moves the sender

float to the full position and compare to specification.

Fuel Sender - Full: 6 ± 1 

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 ELECTRICAL
CHARGING SYSTEM Charging System “Break Even” Test

Current Draw - Key Off

CAUTION

CAUTION Do not allow the battery cables to become

disconnected with the engine running. Follow the
Do not connect or disconnect the battery cable steps below as outlined to reduce the chance of
or ammeter with the engine running. Damage will damage to electrical components.
occur to electrical components.
The “break even” point of the charging system is the point
Connect an ammeter in se ries with the negative battery at which the alternator overcomes all system loads (lights,
cable. Check for current draw with the key off. If the draw etc.) and be gins to cha rge the batter y. De pending on
is excess ive, loads should b e disconn ected fr om the battery condition and system load, t he break even point
system one b y on e un til the d raw is eliminated. Ch eck may vary slightly. Th e batter y shou ld be fully ch arged
component wir ing as well as th e comp onent fo r p artial before performing this test.
shorts to ground to eliminate the draw.

Current Draw Inspection WARNING

Key Off
Never start the engine with an ammeter
connected in series. Damage to the meter or
meter fuse will result.
Do not run test for extended period of time.
Do not run test with high amperage accessories.
1. Using an inductive amperage metering device, (set to
DC amps) connect to the negative battery cable.
2. With engine off, k ey switch and lights in the on
position, the am meter sh ould re ad ne gative a mps
(battery discharge).

Current Draw - Key Off: 3. Shift transmission into park and start the engine. With
the engine running at idle, observe meter readings.
Maximum of .01 DCA (10 mA)
4. Increase engine RPM while observing ammeter and
tachometer. Note the RPM at which the battery starts
to charge (ammeter indication is positive).
5. With lights and other electrical loads off, the “b reak
even” point should occur at approximately 1500 RPM
or lower.
6. With the eng ine run ning, tu rn th e ligh ts on and
depress the brake pedal to keep brake lights on.
7. Repeat te st, ob serving a mmeter and tachometer.
10
With lights on, charging should occur at or below 2000
RPM.

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 ELECTRICAL
Charging System Stator (Alternator) Tests TEST 3: Mea sure AC Voltage Out put of Each S tator
Leg at Charging RPM
Three test s can be pe rformed u sing a mu lti-meter to
determine the condition of the stator (alternator). 1. Set the selector dial to measure AC Voltage.

2. Start the engine and let it idle.

3. While hold ing the eng ine at a specified RPM,

separately measure the voltage across each ‘leg’ of
the stator by connecting the meter leads to the wires
Y1 leading from the alternator (Y1 to Y2, Y1 to Y3, Y2 to
Y2 Y3).
Y3
4. Refer to the fo llowing table for approximate AC
Voltage readings according to RPM. Test each leg at
the specified RPM in the table.

Example: The alt ernator cu rrent ou tput reading
should b e approximately 21 VAC at 1300 RPM
between each ‘leg’.
TEST 1: Resistance Value of Each Stator Leg NOTE: If one or more of the st ator leg output AC
1. Measure the r esistance valu e of e ach o f the thr ee voltage varies significantly from the specified value,
stator legs: Y1 to Y2, Y1 to Y3, and Y2 to Y3. Each the stator may need to be replaced.
test should measure: 0.2 Ohms ± 15%
RPM Reading AC Voltage (VAC) Reading
Connect Meter 1300 22 VAC ± 25%
Test Ohms Reading
Leads To: 3000 51 VAC ± 25%
Battery Charge Coil Y1 to Y2 0.2 ± 15% 5000 85 VAC ± 25%
Battery Charge Coil Y1 to Y3 0.2 ± 15%
Battery Charge Coil Y2 to Y3 0.2 ± 15% Stator (Alternator) Replacement
Refer to Chapter 3 (Engine / Cooling System) to service
NOTE: If there are any significant variations in oh m
the stator.
readings b etween t he three legs it is a n indic ation
that one of the stator legs may be weak or failed. NOTE: The stator co ver ca n be remo ved with th e
engine installed in the chassis.
TEST 2: Re sistance Value of Eac h S tator Leg to
Ground IMPORTANT: Be sure to thoroughly drain the engine
1. Measure the r esistance valu e of each of the stator coolant and clea n the are a around the st ator cover
legs to gr ound: Y1 to Ground, Y2 to Ground, Y3 to prior to removal. See chapter 3.
Ground.
Each test should measure: Open Line (OL)

Connect Meter
Test Ohms Reading
Leads To:
Battery Charge Y1, Y2, or Y3 Open Line
Coil to Ground (Infinity)

NOTE: Any meas urement ot her than Inf inity ( open)

will indicate a failed or shorted stator leg.

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 ELECTRICAL
Regulator / Rectifier
The Regulator / Rectifier is located in the left rear wheel
well area in front of theleft rear wheel. It is mounted under
the LH panel divider, below the ECU.

Regulator / Rectifier

NOTE: If t he reg ulator / re ctifier ove rheats, t he unit

will turn itself off to cool down. The unit w ill turn on
again af ter it has co oled down. If it t urns off, ve rify
the cooling fins are clean, free from debris and that
adequate airflow is present.
Image for Reference Only

Regulator Heat Sink

75 in. lbs.
(7 Nm)
10

Keep Regulator Cooling Fins Clean

To Stator
To Battery Terminals

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 ELECTRICAL
Charging System Testing Flow Chart
Whenever charging system problems are suspected, proceed with the following system check after verifying that all wires
are in good condition, connected and not exposed or pinched.

Using a multitester set on D.C. volts, mea- Remove the battery and properly ser-
sure the battery open circuit voltage (see No vice. Reinstall the fully charged battery
Battery Service). It should be 12.4 volts or or a fully charged shop battery.
more. Is it?
Yes

Meter Setting: DC Volts

With the transmission in Park, start the
engine and increase RPM to between 3000
and 4000. Read battery voltage with the Yes Check Key off Current Draw.
multimeter. Readings should increase to
between 13.0 and 14.6 V D.C. Do they?
NOTE: Disconnect all accessories.
No
Check for owner modification, and
discuss operating habits. The battery
Meter Setting: DC Amps will continually discharge if operated
Perform system “Break Even Amperage” Yes below the “Break Even” RPM. Con-
test outlined in this chapter. tinued problems would call for battery
Does charging occur as specified? inspection.
No

Ohm stator wires, if bad replace stator, if good, Inspect the wiring harness between
continue with alternator output test.
the regulator and the stator for
Meter Setting: AC Volts
damage. If no damage is found,
Disconnect the Yellow wires from the regulator /
rectifier. Using a multimeter, perform an Alternator No remove the stator cover.
Output test. See test procedure on Page 10.22. Inspect the flywheel magnets, stator
coils and stator wires for damage.
Does output meet specification? Repair or replace any damaged
components.
Yes

Meter Setting: DC Volts

Reconnect the alternator wires. Measure
between the Red and Black terminals with the
harness disconnected. Battery voltage must be Check battery and battery connections.
present on harness side of voltage regulator. No Also check wire connections and wire
condition. Repair or replace faulty wiring
Is voltage present? or components.
Yes

If all of the previous tests indicate a good

condition, but the charging voltage does not
rise above battery voltage at the connector
or wire harness, replace the voltage regulator.

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 ELECTRICAL
BATTERY SERVICE 1. Check battery voltage with a volt/ohm meter. A fully
charged battery should be 12.8 V or higher.
Battery Specifications
2. If the voltage is below 12.6 V, the battery will need to
be recharged (see “Charging Procedure”).
RZR 570
Battery PN 4012622
Type Polaris / YB14-B2
Voltage 12 Vdc
Nominal Capacity @
14 AH
10 HR Rate
Nominal Open
12.8 Vdc or more.
Circuit Voltage
Recommended 10 - 17 hours at
Charging Rate 1 to 1.5 AMPS

General Battery Information

WARNING

CALIFORNIA PROPOSITION 65 WARNING:

Batteries, battery posts, terminals and related
accessories contain lead and lead compounds, and
other chemicals known to the State of California to
cause cancer and birth defects or other reproductive
harm. WASH HANDS AFTER HANDLING.

WARNING

Battery electrolyte is poisonous. It contains acid!

Serious burns can result from contact with the 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. 10
Call a 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 closed space. Always shield eyes when
working near batteries.

Keep out of reach of children.

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 ELECTRICAL
Battery Activation To activate a new battery:
1. Remove all the filling plugs.
WARNING 2. Remove the sealing tube (red cap) from vent fitting.

Battery electrolyte is poisonous. It contains 3. Place battery on a level surface. Fill battery with
sulfuric acid. Serious burns can result from electrolyte to upper level marks on the battery case.
contact with skin, eyes or clothing. Antidote:
NOTE: Never act ivate a ba ttery o n th e v ehicle.
External: Flush with water. Electrolyte spills can cause damage.

Internal: Drink large quantities of water or milk. 4. Set ba ttery aside to al low for acid a bsorption an d
Follow with milk of magnesia, beaten egg, or stabilization for 30 minutes.
vegetable oil. Call physician immediately.
5. Add e lectrolyte to br ing the level b ack to the up per
Eyes: Flush with water for 15 minutes and get level mark on the battery case.
prompt medical attention.
6. Charge battery for 10 - 17 hours at 1 to 1.5 AMPS.
Batteries produce explosive gases. Keep
sparks, flame, cigarettes etc. away. Ventilate 7. Check during initial charging to see if electrolyte level
when charging or using in an enclosed space. has fallen, and if s o, fill wit h acid to the upper level.
Always shield eyes when working After adding, charge for another hour at the same rate.
near batteries.
KEEP OUT OF REACH OF CHILDREN. NOTE: This is t he la st time t hat e lectrolyte sh ould
be a dded. I f t he level b ecomes lo w af ter t his point,
add only distilled water.
WARNING
8. When charging is complete , install the filling plugs
The gases given off by a battery are explosive. firmly.
Any spark or open flame near a battery can
cause an explosion which will spray battery acid IMPORTANT: Do not a pply e xcessive pre ssure.
on anyone close to it. Should there be contact Finger tighten only. Do not over-tighten.
with battery acid, wash the affected area with
large quantities of cool water and seek 9. Wash off s pilled acid wit h water and bak ing soda
immediate medical attention. solution, paying particular attention that any acid is
washed off the terminals. Dry the battery case.
To ensure maximum service life and performance from a
new battery, perform the following steps. NOTE: Do n ot
service the battery unless it will be put into regular service Battery Removal / Installation
within 30 days. After initial service, add only distilled water
See Ch apter 2 “Ma intenance” for battery re moval an d
to the ba ttery. Nev er ad d e lectrolyte a fter a b attery ha s
installation procedures.
been in service.

NOTE: New Battery: Battery must be fully charged

before use or b attery life will b e significantly
reduced 10-30% of the battery’s full potential.

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 ELECTRICAL
Battery Off Season Storage Battery Conductance Analyzer
Whenever the ve hicle is n ot used fo r a pe riod of thr ee Conductance describes the ability of a battery to conduct
months or mor e, r emove th e b attery fro m th e veh icle, current. A conductance tester functions by sending a low
ensure that it's fully charged, and store it out of the sun in frequency AC signal through the battery and a portion of
a cool, d ry p lace. Che ck battery voltage e ach m onth the cu rrent response is cap tured, fr om this ou tput a
during storage and recharge as needed to maintain a full conductance me asurement is ca lculated. Con ductance
charge. testing is more accurate than voltage, specific gravity, or
load testing.
NOTE: Battery charge can be maintained by using a
Polaris battery tender charger or by charging once a Authorized Polaris dealers/distributors are required to use
month to make up for normal self-discharge. Battery the cond uctance ana lyzer whe n testing 1 2V Pola ris
tenders can b e lef t co nnected d uring the s torage batteries.
period, a nd w ill au tomatically c harge th e b attery if
the voltage drops below a pre-determined point.

Battery Testing
Whenever a ser vice comp laint is related to e ither the
starting or ch arging syste ms, the battery sh ould be
checked first.

Polaris MDX-610P
SPX PN: PU-50296

10

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 ELECTRICAL
OCV - Open Circuit Voltage Test Specific Gravity Test
Battery volt age sho uld be checked with a digital A tool such as a Battery Hydrometer (PN 2870836) can be
multitester. Readings of 12.6 volts or less require further used to measure electrolyte strength or sp ecific gravity.
battery testing and charging. See the following chart and As the battery goes through the charge/discharge cycle,
“Load Test”. the electrolyte goes from a heavy (more acidic) state at full
charge to a light (more water) state when discharged. The
NOTE: Use a volt/ohm meter to test battery voltage. hydrometer can measure state of charge and differences
between cells in a multi-cell battery. Readings of 1.270 or
Battery PN 4012622 greater s hould b e observed in a f ully ch arged ba ttery.
Differences o f mo re th an .0 25 b etween th e lowest an d
OPEN CIRCUIT VOLTAGE highest ce ll r eadings indicate a n eed to r eplace the
battery.
State of Charge Maintenance Free
100% 12.7 V and up
75% Charged 12.5 V
50% Charged 12.2 V
25% Charged 12.0 V
0% Charged 11.9 V or less

Load Test
Battery Hydrometer
(PN 2870836)
CAUTION

To prevent shock or component damage, remove spark SPECIFIC GRAVITY

plug high tension leads and connect securely to
engine ground before proceeding. State of Charge* YuMicron™ Type
100% Charged 1.275
A battery may indicate a full charge condition in the OCV
test, but still may not have the storage capacity necessary 75% Charged 1.225
to pr operly function in the e lectrical s ystem. F or t his
50% Charged 1.175
reason, a ba ttery cap acity or lo ad test sho uld be
conducted whenever po or batter y pe rformance is 25% Charged 1.135
encountered.
0% Charged 1.115 or less
To perform this test, use a load testing device that has an * At 80° F. NOTE: Subtract .01 from the specific
adjustable load. Apply a load of three times the ampere- gravity reading at 40° F.
hour rating. At 14 seconds in to the te st, che ck battery
voltage. A good 12V battery will have at least 10.5 volts. NOTE: Lead-acid batteries should be kept at or near
If the reading is low, charge the battery and retest. a full charge as possible. Electrolyte level should be
kept between the low and full marks. If the battery is
stored or us ed in a pa rtially c harged c ondition, or
with low electrolyte levels, hard crystal sulfation will
form on the plat es, re ducing t he ef ficiency a nd
service life of the battery.

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 ELECTRICAL
Charging Procedure STARTING SYSTEM
1. Remove the battery to prevent damage from leaking
Troubleshooting
or spilled acid during charging.
Starter Motor Does Not Run
2. Charge the battery with a ch arging output no la rger
than 1/ 10 of the ba ttery’s am p/hr ra ting. Ch arge as • Battery discharged
needed to raise the specific gravity to 1.270 or greater. • Loose or faulty battery cables or corroded
connections (see Voltage Drop Tests)
3. Install battery in vehicle. Coat threads of battery bolt
with a corrosion resistant dielectric grease. • Related wiring loose, disconnected, or corroded
• Poor ground connections at battery cable, starter
Dielectric Grease
motor or starter solenoid (see Voltage Drop Tests)
(PN 2871329)
• Faulty key switch

4. Connect battery cables. • Faulty starter solenoid or starter motor

• Engine problem - seized or binding (can engine be
rotated easily)
WARNING
Starter Motor Turns Over Slowly
To avoid the possibility of explosion, connect
positive (+) cable first and negative (-) cable last. • Battery discharged
• Excessive circuit resistance - poor connections
5. After connecting the battery cables, install the cover (see Voltage Drop Test)
on the battery and attach the hold down strap.
• Engine problem - seized or binding (can engine be
6. Install clear battery vent tube from vehicle to battery rotated easily)
vent. WARNING: Vent tube must be free from
obstructions and kinks a nd securely installed. If n ot, • Faulty or worn brushes in starter motor
battery gases co uld accumu late an d ca use an Starter Motor Turns - Engine Does Not Rotate
explosion. Ve nt sho uld be routed away fro m fr ame
and bod y to prevent contact with e lectrolyte. Avoid • Faulty starter drive
skin co ntact with e lectrolyte, a s sever e burns could • Faulty starter drive gears or starter motor gear
result. If e lectrolyte contacts the veh icle frame,
corrosion will occur. • Faulty flywheel gear or loose flywheel

7. Route ca bles so th ey ar e tu cked awa y in fro nt an d

behind battery. Voltage Drop Test
The Voltage Drop Test is used to test for bad connections.
When performing the test, you are testing the amount of

10
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 0.1 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 th e volt age dr op te sts o n the starter system in this
chapter.

Voltage should not exceed

.1 DC volts per connection

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 ELECTRICAL
Starter Motor Removal Starter Motor Installation
1. Remove th e dr iver’s side seat an d disconn ect the 1. Inspect and replace starter motor O-ring if needed.
battery.
2. Lubricate the starter motor O-ring with fre sh engine
2. Raise and support rear of vehicle. Remove the right- oil.
hand rear wheel if necessary.
3. Place the lower starter motor fastener (C) through the
3. Remove the (+) positive wire (A) from the starter motor lower mounting boss in the starter motor.
terminal.
4. Install the starter motor onto the engine case.
4. From the righ t-hand side wh eel well, re move the
5. Install the (- ) n egative batter y cab le in th e up per
upper starter motor fastener (B) securing the starter
starter bo lt an d hand tighten th e upp er starter
motor a nd ( -) neg ative batter y cab le to th e en gine.
mounting bolt (B).
Completely loosen the lowe r starter motor fas tener
(C). 6. Install a nd tor que th e lower mounting bo lt (C) to
specification.
IMPORTANT: Tighten th e lowe r sta rter bolt first, a s
the bottom hole acts as a pilot hole to properly align
the starter drive (bendix) with the flywheel. This helps
A prevent binding and starter damage.
7. Torque th e up per star ter mounting bo lt ( B) to
specification.

=T

C B Starter Mounting Bolts and Nut:

7 ft. lbs. (10 Nm)

8. If r emoved, ins tall th e r ight-hand rear wh eel a nd

NOTE: The (- ) ne gative bat tery ca ble is mounted to torque wheel nuts to specification (see chapter 2).
the engine using the upper starter mounting bolt. 9. Lower vehicle.
5. Remove the starter from the engine. 10. Connect the (-) negative battery cable and install the
driver’s side seat.

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 ELECTRICAL
Starter Solenoid Bench Test
Test the st art so lenoid by powering th e so lenoid using
battery vo ltage fo r a maximum of 5 seconds . Wit h the
solenoid energized, resistance should read about 0 - 0.5
Ohms b etween ter minals (A) an d (B). If r esistance
measurement is ou t of specif ication, re place the starter
solenoid.

Energize
Here

A 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 wire.
• The key switch must be turned to the “start”
position to provide 12V power via the Green /
White wire.
• Once the pull-in coil is energized, the solenoid
provides a current path for 12V power to reach the
starter motor.

10

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 ELECTRICAL

STARTING SYSTEM TESTING FLOW CHART

Condition: Starter fails to turn over the engine. 

With the tester on the VDC position, place the

tester's black lead on the battery negative and the Remove battery and properly service. Install
red lead on the battery positive. Reading should No
fully charged shop battery to continue test.
be 12.4 V D. C. or greater.

Yes

Disconnect 2-wire connector at the solenoid. Check for voltage at the chassis 20 Amp fuse
Using a multi-meter, connect the black meter lead and then check for voltage entering the
to the Orange/Green harness wire and the red No ignition switch. Battery voltage should be
meter lead to the White/Red harness wire. Apply present. If battery voltage is present at the
the brake and turn ignition switch to the “start” ignition switch, but not the solenoid, replace
position. Meter should read battery voltage. the switch. NOTE: The brake MUST be
applied when performing these tests.
Test the start solenoid by powering the solenoid via the 2-wire connection.
Yes With the solenoid energized, resistance should read about 0.5 ± 10%
between the two terminals. If resistance measurement is out of specification,
Voltage Drop replace the starter solenoid (see “Starter Solenoid Bench Test”)
Testing
Reconnect the solenoid. Connect the tester black lead No Clean the battery-to-solenoid cable ends
to the battery positive and the red lead to the solenoid or replace the cable.
end of the battery-to-solenoid wire. Turn the ignition
key to the “start” position. Reading should be less
than .1 V D.C.

Yes

Connect the black tester lead to solenoid end of

battery-to-solenoid cable. Connect red tester lead No
to solenoid end of solenoid-to-starter cable. Turn Replace the starter solenoid.
the ignition key to the “start” position. Reading
should be less than .1 V D.C.

Yes

Connect the black tester lead to the solenoid end of

the solenoid-to-starter cable. Connect the red Clean the solenoid-to-starter cable ends or
tester lead to the starter end of the same cable. Turn No
replace the cable.
the ignition key to the “start” position. The reading
should be less than .1 V D.C.

Yes

If all of these indicate a good condition, yet the starter still fails to
turn, the starter must be removed for static testing and inspection.

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 ELECTRICAL
ELECTRICAL SYSTEM BREAKOUTS
AWD

Vehicle Speed Sensor

10

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 ELECTRICAL
Cooling Fan

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 ELECTRICAL
Charging System

Chassis Power

10

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 ELECTRICAL
Lights

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 A C
Air Box / Air Filter Exploded View . . . . . . . . . . . . . . . 2.15
Air Filter Service . . . . . . . . . . . . . . . . . . . . . . . . . 2.13, 2.14
Cab Frame, Assembly / Removal . . . . . . . . . . . . . . . . . 5.3
Caliper, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
IX
All Wheel Drive (AWD) Coil . . . . . . . . . . . . . . . . . . . 10.17 Caliper, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
Assembly, Connecting Rod and Piston . . . . . . . . . . 3.54 Cam Chain and Guide Service . . . . . . . . . . . . . . . . . . 3.41
Authorization Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.46 Cam Shaft Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37
Authorization, Reflash . . . . . . . . . . . . . . . . . . . . . . . . . 4.43 Camshaft Installation / Timing . . . . . . . . . . . . . . . . . . 3.63
AWD, Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18 Camshaft Sprocket Inspection . . . . . . . . . . . . . . . . . . 3.39
AWD, Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17 Camshaft Timing - Quick Reference . . . . . . . . . . . . . 3.66
B Cargo Box Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
Balance Shaft Installation . . . . . . . . . . . . . . . . . . . . . . 3.84 Centralized Hilliard, Exploded View . . . . . . . . . . . . . . 7.16
Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
Balance Shaft Removal / Inspection . . . . . . . . . . . . . 3.77
Charging System Testing Flow Chart . . . . . . . . . . . 10.26
Balance Shaft Timing . . . . . . . . . . . . . . . . . . . . . . . . . 3.84
Charging System, Alternator Tests . . . . . . . . . . . . . 10.24
Ball Joint Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
Chassis (RZR / RZR S) . . . . . . . . . . . . . . . . . . . . . . . . 5.11
Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
Clutch Center Distance . . . . . . . . . . . . . . . . . . . . . . . . 6.10
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
Clutch, Starter One Way . . . . . . . . . . . . . . . . . . . . . . . 3.70
Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
Combustion Chamber . . . . . . . . . . . . . . . . . . . . . . . . . 3.45
Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27
Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29 Communication Problems, Digital Wrench . . . . . . . . 4.39
Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
Body Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
Connecting Rod Assembly . . . . . . . . . . . . . . . . . . . . . 3.54
Boring, Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.52
Console and Floor Panel Removal . . . . . . . . . . . . . . 5.15
Brake Burnishing . . . . . . . . . . . . . . . . . . . . . . . . 9.15, 9.24
Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
Brake Caliper Assembly, Front . . . . . . . . . . . . 9.16, 9.18
Coolant Drain / Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
Brake Caliper Assembly, Rear . . . . . . . . . . . . . . . . . . 9.25
Coolant Drain / Radiator Removal . . . . . . . . . . . . . . . 3.17
Brake Caliper Inspection, Front . . . . . . . . . . . . . . . . . 9.18
Coolant Level Inspection . . . . . . . . . . . . . . . . . . . . . . . 2.26
Brake Caliper Installation, Front . . . . . . . . . . . . . . . . 9.19
Coolant Strength and Type . . . . . . . . . . . . . . . . . . . . . 2.27
Brake Caliper Removal, Front . . . . . . . . . . . . . . . . . . 9.16
Cooling System Bleeding Procedure . . . . . . . . . . . . . 3.18
Brake Disc, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
Cooling System Exploded View . . . . . . . . . . . . . . . . . 2.25
Brake Disc, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
Cooling System Hoses . . . . . . . . . . . . . . . . . . . . . . . . 2.27
Brake Hose and Fitting Inspection . . . . . . . . . . . . . . 2.37
Cooling System Overview . . . . . . . . . . . . . . . . . . . . . . 2.26
Brake Pad Assembly, Front . . . . . . . . . . . . . . . . . . . . 9.14
Cooling System Pressure Cap Test . . . . . . . . . . . . . 3.16
Brake Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 2.37
Cooling System Specifications . . . . . . . . . . . . . . . . . . 3.15
Brake Pad Thickness, Front . . . . . . . . . . . . . . . . . . . . 9.14
Cooling System, Pressure Test . . . . . . . . . . . . . . . . . 3.15
Brake Pads, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
Crankcase Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.79
Brake Pads, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
Crankcase Breather Service . . . . . . . . . . . . . . . . . . . . 3.76
Brake Pads, Removal, Front . . . . . . . . . . . . . . . . . . . 9.13
Crankcase, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 3.82
Brake Pedal, Installation . . . . . . . . . . . . . . . . . . . . . . . . 9.6
Crankcase, Disassembly . . . . . . . . . . . . . . . . . . . . . . . 3.68
Brake Pedal, Removal . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
Crankcase, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 3.81
Brake System Inspection . . . . . . . . . . . . . . . . . . . . . . 2.37
Crankcase, Separation . . . . . . . . . . . . . . . . . . . . . . . . 3.76
Brake System, Bleeding . . . . . . . . . . . . . . . . . . . . . . . . 9.7
Crankshaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 3.78
Brake System, Exploded View . . . . . . . . . . . . . . . . . . . 9.5
Crankshaft Position Sensor (CPS) . . . . . . . . . . . . . . 4.14
Brake System, Operation . . . . . . . . . . . . . . . . . . . . . . . 9.4
Crankshaft, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 3.78
Brake, Front Pad Assembly . . . . . . . . . . . . . . . . . . . . 9.14
Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . 3.56
Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
Cylinder Head Disassembly . . . . . . . . . . . . . . . . . . . . 3.42
Break-In, PVT System (Belt) . . . . . . . . . . . . . . . . . . . . 6.3
Cylinder Head Inspection . . . . . . . . . . . . . . . . . . . . . . 3.44
Breather Hose Inspection . . . . . . . . . . . . . . . . . . . . . . 2.18
Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . 3.58
Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . 3.42
Cylinder Head Warp . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
Cylinder Honing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.52
Cylinder, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48
Cylinder, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.55
Cylinder, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48

IX.1

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 D Engine Exploded Views . . . . . .3.9, 3.10, 3.11, 3.12, 3.13
Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
Dash Instruments / Controls / Glove box . . . . . . . . . .5.5
Engine Lubrication . . . . . . . . . . . . . . . . . . . 3.3, 3.34, 3.35
Decal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . .5.28
Engine Mounting Exploded View . . . . . . . . . . . . . . . 3.35
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . . . . . .1.10
Engine Oil and Filter Change . . . . . . . . . . . . . . . . . . 2.16
Decompression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.41
Engine Oil Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Diagnostic Code Table . . . . . . . . . . . . . . . . . . . . . . . .4.34
Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
Diagnostic Codes, Instrument Cluster . . . . . . . . . . .10.15
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
Digital Wrench Communication Errors . . . . . . . . . . .4.39
Engine Serial Number Location . . . . . . . . . . . . . . . . . 1.2
Digital Wrench Diagnostic Software . . . . . . . . . . . . .4.38
Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
Digital Wrench Versions . . . . . . . . . . . . . . . . . . . . . . .4.38
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
Digital Wrench, Controller Reprogramming . . . . . . .4.43
Engine Temperature Sensor Replacement . . . . . . . 4.32
Digital Wrench, Updates . . . . . . . . . . . . . . . . . . . . . . .4.40
Engine Temperature Sensor Test . . . . . . . . . . . . . . 4.31
Digital Wrench, Version and Update ID . . . . . . . . . .4.40
Engine, Accessible Components . . . . . . . . . . . . . . . 3.26
Disassembly, Engine Lower End . . . . . . . . . . . . . . . .3.68
Engine, Cam Shaft Removal . . . . . . . . . . . . . . . . . . . 3.37
Drive Belt, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .6.8
Engine, Camshaft Installation / Timing . . . . . . . . . . 3.63
Drive Belt, Installation . . . . . . . . . . . . . . . . . . . . . . . . . .6.9
Engine, Camshaft Sprocket Inspection . . . . . . . . . . 3.39
Drive Belt, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.8
Engine, Camshaft Timing - Quick Reference . . . . . 3.66
Drive Clutch, Assembly . . . . . . . . . . . . . . . . . . . . . . . .6.20
Engine, Cooling System Troubleshooting . . . . . . . . 3.87
Drive Clutch, Exploded View . . . . . . . . . . . . . . . . . . .6.12
Engine, Cylinder Head Assembly . . . . . . . . . . . . . . . 3.56
Drive Clutch, Operation . . . . . . . . . . . . . . . . . . . . . . . . .6.3
Engine, Cylinder Head Inspection . . . . . . . . . . . . . . 3.44
Drive Clutch, Service . . . . . . . . . . . . . . . . . . . . . . . . . .6.12
Engine, Cylinder Head Installation . . . . . . . . . . . . . . 3.58
Drive Clutch, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . .6.14
Engine, Cylinder Head Removal . . . . . . . . . . . . . . . . 3.42
Drive Shaft Boot Inspection . . . . . . . . . . . . . . . . . . . .2.30
Engine, Cylinder Head Warp . . . . . . . . . . . . . . . . . . . 3.44
Driven Clutch, Assembly . . . . . . . . . . . . . . . . . . . . . . .6.24
Engine, Piston / Connecting Rod Assembly . . . . . . 3.54
Driven Clutch, Disassembly . . . . . . . . . . . . . . . . . . . .6.21
Engine, Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Driven Clutch, Exploded View . . . . . . . . . . . . . . . . . .6.21
Engine, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 3.86
Driven Clutch, Operation . . . . . . . . . . . . . . . . . . . . . . . .6.3
Engine, Valve Cover Installation . . . . . . . . . . . . . . . . 3.67
Driven Clutch, Service . . . . . . . . . . . . . . . . . . . . . . . . .6.21
Engine, Valve Cover Removal . . . . . . . . . . . . . . . . . 3.37
Driveshaft / CV Joint, Handling Tips . . . . . . . . . . . . . .7.7
Engine, Valve Inspection . . . . . . . . . . . . . . . . . . . . . . 3.44
E Engine, Valve Sealing Test . . . . . . . . . . . . . . . . . . . . 3.57
ECU Replacement . . . . . . . . . . . . . . . . . . . . . . . 4.12, 4.38 Engine, Valve Seat Reconditioning . . . . . . . . . . . . . 3.46
EFI Operation Overview . . . . . . . . . . . . . . . . . . . . . . .4.10 Exhaust Camshaft Decompression Mechanism . . 3.41
EFI Priming / Starting Procedure . . . . . . . . . . . . . . . .4.10 Exhaust Valve Lash - Shim Selection Matrix . . . . . 3.62
EFI System, Component Locations . . . . . . . . . . . . . . .4.6 Exhaust, Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . 2.20
EFI System, Exploded View . . . . . . . . . . . . . . . . . . . . .4.5 F
EFI, Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . .4.34
Fan Control Circuit Bypass Test . . . . . . . . . . . . . . . 10.21
EFI, Service Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4
Fan Control Circuit Operation . . . . . . . . . . . . . . . . . 10.21
EFI, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .4.37
Floor (RZR / RZR S) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
Electrical, AWD Breakout Diagram . . . . . . . . . . . . .10.35
Flywheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 3.71
Electrical, Chassis Power Breakout Diagram . . . .10.37
Flywheel, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.68
Electrical, Cooling Fan Breakout Diagram . . . . . . .10.36
Front A-arm, Replacement . . . . . . . . . . . . . . . . . . . . 5.18
Electrical, Cooling System Breakout Diagram . . . .10.20
Front Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
Electrical, Lights Breakout Diagram . . . . . . . . . . . .10.38
Front Body / Dash Removal . . . . . . . . . . . . . . . . . . . 5.13
Electrical, System Breakouts . . . . . . . . . . . . . . . . . .10.35
Front Body Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
Electrical, Vehicle Speed Sensor Breakout Diagram . .
10.35 Front Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.7, 5.12
Front Caliper, Piston Bore I.D. . . . . . . . . . . . . . . . . . 9.18
Electronic Control Unit (ECU) . . . . . . . . . . . . . . . . . . .4.11
Front Driveshaft, CV Joint / Boot Replacement . . . . 7.7
Engine Assembly - Top End . . . . . . . . . . . . . . . . . . . .3.53
Front Driveshaft, Installation . . . . . . . . . . . . . . . . . . . 7.10
Engine Assembly, Lower End . . . . . . . . . . . . . . . . . . .3.82
Front Driveshaft, Removal . . . . . . . . . . . . . . . . . . . . . . 7.6
Engine Break-In Period . . . . . . . . . . . . . . . . . . . . . . . .3.34
Front Fender Flair Removal . . . . . . . . . . . . . . . . . . . . 5.14
Engine Coolant Temperature Sensor (ECT) . . . . . .4.31
Front Gearcase Lubrication . . . . . . . . . . . . . . . . . . . . 2.23
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . .3.14
Front Gearcase, Assembly . . . . . . . . . . . . . . . . . . . . 7.23
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . .3.15
Front Gearcase, Centralized Hilliard . . . . . . . . . . . . 7.16
Engine Designation Number . . . . . . . . . . . . . . . . . . . . .1.2
Front Gearcase, Disassembly / Inspection . . . . . . . 7.20
Engine Disassembly / Inspection - Top End . . . . . .3.37
IX.2

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 Front Gearcase, Installation . . . . . . . . . . . . . . . . . . . . 7.25 M
Front Gearcase, Removal . . . . . . . . . . . . . . . . . . . . . 7.19
Front Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
MAG Side Crankcase Bearing Service . . . . . . . . . . . 3.80
Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
IX
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
Maintenance Quick Reference Chart . . . . . . . . . 2.6, 2.7
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
Maintenance, Brake System . . . . . . . . . . . . . . . . . . . . 2.37
Fuel Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
Maintenance, Cooling System . . . . . . . . . . . . . . . . . . 2.25
Fuel Lines, Quick Connect . . . . . . . . . . . . . . . . . . . . . . 4.9
Maintenance, Electrical and Ignition . . . . . . . . . . . . . 2.30
Fuel Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
Maintenance, Engine . . . . . . . . . . . . . . . . . . . . . . . . . .2.16
Fuel Pump Replacement . . . . . . . . . . . . . . . . . . . . . . 4.21
Maintenance, Final Drive . . . . . . . . . . . . . . . . . . . . . . . 2.28
Fuel Pump Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
Maintenance, Fuel System . . . . . . . . . . . . . . . . . . . . . 2.11
Fuel Sender Test . . . . . . . . . . . . . . . . . . . . . . . 4.19, 10.22
Maintenance, General Vehicle Inspection . . . . . . . . 2.10
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
Maintenance, Service Products and Lubricants . . . . 2.9
Fuel System Diagnostics . . . . . . . . . . . . . . . . . . . . . . 4.38
Maintenance, Steering . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
Fuel Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . 4.24
Maintenance, Transmission and Gearcases . . . . . . 2.21
Fuel Tank, Exploded View . . . . . . . . . . . . . . . . . . . . . . 4.8
Master Cylinder, Installation . . . . . . . . . . . . . . . . . . . . . 9.6
G Master Cylinder, Removal . . . . . . . . . . . . . . . . . . . . . . . 9.6
General Specifications, Brakes . . . . . . . . . . . . . . . . . . 9.2 Metric Bolt Torque Specification . . . . . . . . . . . . . . . . . 1.9
Ground, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33 Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Guided Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.38 N
H Nets, Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
Head Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18 O
Head, Cylinder, Disassembly . . . . . . . . . . . . . . . . . . . 3.42 Oil Pickup Assembly Inspection . . . . . . . . . . . . . . . . . 3.81
Honing, Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.52
Oil Pressure Regulator (Bypass) Valve Inspection . 3.81
Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
Oil Pressure Specifications . . . . . . . . . . . . . . . . . . . . . . 3.4
Hood Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
Oil Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
I Oil Pump, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.75
Idle Air Control (IAC) . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27 Oil Pump, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.73
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.32
Ignition Coil Replacement . . . . . . . . . . . . . . . . . . . . . . 4.33
Ignition Coil Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.33
Installation, Piston Ring . . . . . . . . . . . . . . . . . . . . . . . 3.53
Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
Instrument Cluster, Installation . . . . . . . . . . . . . . . . 10.17
Instrument Cluster, Removal . . . . . . . . . . . . . . . . . . 10.16
Intake Valve Lash - Shim Selection Matrix . . . . . . . 3.61
K
Key, Reprogramming Authorization . . . . . . . . . . . . . 4.46
Keys, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
L
Leakdown Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
Lubrication Grease Points . . . . . . . . . . . . . . . . . . . . . . 2.8
Lubrication Specifications . . . . . . . . . . . . . . . . . . 3.3, 3.35
Lubrication Transmission . . . . . . . . . . . . . . . . . . . . . . . 8.2

IX.3

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 P R
Parking Brake Caliper, Disassembly (INT’L) . . . . . .9.11 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
Parking Brake Caliper, Exploded View (INT’L) . . . .9.10 Rear A-arm, Replacement . . . . . . . . . . . . . . . . . . . . . 5.24
Parking Brake Caliper, Installation (INT’L) . . . . . . . .9.12 Rear Bearing Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . 7.26
Parking Brake Caliper, Pad Installation (INT’L) . . . .9.11 Rear Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.7, 5.12
Parking Brake Caliper, Removal (INT’L) . . . . . . . . . .9.10 Rear Cargo Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
Parking Brake Disc (INT’L) . . . . . . . . . . . . . . . . . . . . .9.12 Rear Drive Shaft, CV Joint / Boot Replacement . . 7.32
Parking Brake Pad Inspection (INT’L) . . . . . . . . . . . .2.38 Rear Drive Shaft, Plunging Joint / Boot Replacement .
Parking Brake, Adjustment (INT’L) . . . . . . . . . . 2.38, 9.9 7.35
Parking Brake, Exploded View (INT’L) . . . . . . . . . . . .9.8 Rear Driveshaft, Installation . . . . . . . . . . . . . . . . . . . 7.38
Parking Brake, Inspection (INT’L) . . . . . . . . . . . . . . . .9.9 Rear Driveshaft, Removal . . . . . . . . . . . . . . . . . . . . . 7.30
Periodic Maintenance Chart . . . . . . . . . . . . . . . . . . . . .2.3 Rear Fender, Flair, and Tie Down Removal . . . . . . 5.14
Piston Ring Installation . . . . . . . . . . . . . . . . . . . . . . . .3.53 Rear Fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
Piston, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.50 Rear Service Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
Piston, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.49 Rear Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26
Piston, Ring Installed Gap . . . . . . . . . . . . . . . . . . . . . .3.51 Reflash Authorization . . . . . . . . . . . . . . . . . . . . . . . . . 4.43
Piston-to-Cylinder Clearance . . . . . . . . . . . . . . . . . . .3.50 Regulator / Rectifier Location . . . . . . . . . . . . . . . . . 10.25
Pre-Ride / Daily Inspection . . . . . . . . . . . . . . . . . . . . .2.10 Reprogramming Authorization . . . . . . . . . . . . . . . . . 4.43
Pressure Cap Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16 Ring, Piston, Installed Gap Measurement . . . . . . . . 3.51
Pressure Test, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4 Rocker Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . 5.15
Propshaft Removal / Installation . . . . . . . . . . . . . . . .7.12 Rocker Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
Propshaft, U-Joint Service . . . . . . . . . . . . . . . . . . . . .7.14 S
Publication Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3 Safety Nets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
PVT System, Assembly . . . . . . . . . . . . . . . . . . . . . . . . .6.7
Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
PVT System, Disassembly . . . . . . . . . . . . . . . . . . . . . .6.5
Seat Belts / Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
PVT System, Maintenance . . . . . . . . . . . . . . . . . . . . . .6.3
Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
PVT System, Overheating Diagnostics . . . . . . . . . . . .6.4
Sequence, Engine Cover Torque . . . . . . . . . . . . . . . . 3.8
PVT System, Overview . . . . . . . . . . . . . . . . . . . . . . . . .6.2
SETTING TDC (TOP-DEAD-CENTER) . . . . . . . . . . 3.36
PVT System, Service . . . . . . . . . . . . . . . . . . . . . . . . . . .6.5
Shift Cable Inspection and Adjustment . . . . . . .2.10, 8.4
PVT Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .6.26
Shift Cable, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
PVT, Button to Tower Clearance . . . . . . . . . . . . . . . .6.16
Shift Lever, Installation . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
PVT, Drive Clutch Bushing Service . . . . . . . . . . . . . .6.18
Shift Lever, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
PVT, Drive Clutch Cover Bushing . . . . . . . . . . . . . . .6.19
Shocks and Springs . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
PVT, Drive Clutch Disassembly . . . . . . . . . . . . . . . . .6.13
Software Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.38
PVT, Drive Clutch Spider Removal . . . . . . . . . . . . . .6.15
Solenoid, Rear Differential (INT’L) . . . . . . . . . . . . . . 10.8
Spark Plug Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
Special Tools . . . . . . . . . . . . . . . . . . . . . . 1.3, 2.2, 5.2, 8.1
Special Tools, Body/Steering/Suspension . . . . . . . . 5.2
Special Tools, Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
Special Tools, Clutching . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Special Tools, EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Special Tools, Electrical . . . . . . . . . . . . . . . . . . . . . . . 10.3
Special Tools, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Special Tools, Final Drive . . . . . . . . . . . . . . . . . . . . . . 7.2
Special Tools, Transmission . . . . . . . . . . . . . . . . . . . . 8.2
Specification Chart, Maintenance . . . . . . . . . . . . . . . 2.21
Specification, Coolant Sensor Resistance . . . . . . 10.21
Specification, Cylinder Head Warp . . . . . . . . . . . . . . 3.44
Specification, Valve Seat Contact Width . . . . . . . . . 3.47
Specification, Valve Spring Free Length . . . . . . . . . 3.43
Specification, Valve Stem Diameter . . . . . . . . . . . . . 3.45
Specification, Valve Stem Guide I.D. . . . . . . . . . . . . 3.45
Specification, Wheel Toe-Out . . . . . . . . . . . . . . . . . . 2.35
Specifications, Camshaft . . . . . . . . . . . . . . . . . . . . . . 3.40
Specifications, Cooling System . . . . . . . . . . . . . . . . . 3.15
IX.4

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 Specifications, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 Transmission Disassembly . . . . . . . . . . . . . . . . . . . . . 8.12
Specifications, Engine Lubrication . . . . . .3.3, 3.34, 3.35
Specifications, Engine Oil Pressure . . . . . . . . . . . . . . 3.4
Transmission Disassembly (INT’L) . . . . . . . . . . . . . . 8.27
Transmission Gear Cluster Disassembly . . . . . . . . . 8.15 IX
Specifications, General . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 Transmission Gear Cluster Disassembly (INT’L) . . 8.29
Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 Transmission Installation . . . . . . . . . . . . . . . . . . . . . . . . 8.8
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 Transmission Lubrication . . . . . . . . . . . . . . . . . . 2.21, 8.2
Standard Bolt Torque Specification . . . . . . . . . . . . . . 1.9 Transmission Mounting and Torque Value . . . . . . . . . 8.2
Starter Assembly, Exploded View . . . . . . . . . . . . . . 10.34 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
Starter Drive, Removal . . . . . . . . . . . . . . . . . . . . . . . . 3.69 Transmission Snorkel Shaft Removal / Disassembly 8.16
Starter Motor, Installation . . . . . . . . . . . . . . . . . . . . . 10.32 Transmission Snorkel Shaft Disassembly (INT’L) . .8.30
Starter Motor, Removal . . . . . . . . . . . . . . . . . . . . . . . 10.32 Transmission, Assembly . . . . . . . . . . . . . . . . . . . . . . . 8.21
Starter Solenoid, Operation . . . . . . . . . . . . . . . . . . . 10.33 Transmission, Assembly (INT’L) . . . . . . . . . . . . . . . . 8.38
Starter Solenoid, Test . . . . . . . . . . . . . . . . . . . . . . . . 10.33 Transmission, Exploded View . . . . . . . . . . . . . . . . . . 8.44
Starter System Flow Chart . . . . . . . . . . . . . . . . . . . . 10.34 Transmission, Exploded View (INT’L) . . . . . . . . . . . . 8.46
Starter System, Troubleshooting . . . . . . . . . . . . . . . 10.31 Transmission, Output Shaft Backlash Procedure . .8.19
Stator Housing Removal . . . . . . . . . . . . . . . . . . . . . . . 3.68 Transmission, Output Shaft Backlash(INT’L) . . . . . . 8.36
Stator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.73 Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.34
Stator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.72 Troubleshooting, Brake Noise . . . . . . . . . . . . . . . . . . . 9.3
Steering Shaft, Bearing Replacement . . . . . . . . . . . 5.17 Troubleshooting, Brake System . . . . . . . . . . . . . . . . . 9.30
Steering Wheel Freeplay . . . . . . . . . . . . . . . . . . . . . . 2.34 Troubleshooting, Clutching . . . . . . . . . . . . . . . . . . . . . 6.25
Steering Wheel Removal (Non-EPS) . . . . . . . . . . . . 5.17 Troubleshooting, Transmission . . . . . . . . . . . . . . . . . 8.43
Steering, Exploded View (Non-EPS) . . . . . . . . . . . . 5.16 V
Steering, Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
Valve Clearance Check / Adjustment . . . . . . . . . . . . 3.59
Suspension, Spring Preload Adjustment (Standard) 2.36
Valve Clearance Inspection . . . . . . . . . . . . . . . . . . . . 2.18
Sway Bar Linkage Removal . . . . . . . . . . . . . . . . . . . . 5.21
Valve Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . 3.67
Switch, AWD/2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
Valve Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . 3.37
Switch, AWD/2WD/TURF (INT’L) . . . . . . . . . . . . . . . 10.5
Valve Sealing Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.57
Switch, Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
Valve Seat Reconditioning . . . . . . . . . . . . . . . . . . . . . 3.46
Switch, Gear Position . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
Valve Spring Free Length . . . . . . . . . . . . . . . . . . . . . . 3.43
Switch, Hazard (INT’L) . . . . . . . . . . . . . . . . . . . . . . . . 10.6
Valve Spring Removal . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
Switch, Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
Vent Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
Switch, Ignition (INT’L) . . . . . . . . . . . . . . . . . . . . . . . . 10.4
Version, Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.38
Switch, Parking Brake (INT’L) . . . . . . . . . . . . . . . . . . 10.7
VIN Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Switch, Turn Signal (INT’L) . . . . . . . . . . . . . . . . . . . . 10.6
VIN Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
T Voltage Drop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
Tail Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19 W
Tap/Drill Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 Water Pump Installation . . . . . . . . . . . . . . . . . . . . . . . 3.20
TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
Water Pump Mechanical Seal / Oil Seal . . . . . . . . . . 3.21
Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . 3.18
Water Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
Throttle Freeplay Adjustment . . . . . . . . . . . . . . . . . . . 2.13
Water Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
Throttle Pedal Inspection . . . . . . . . . . . . . . . . . . . . . . 2.12
Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35
Throttle Position Sensor (TPS) . . . . . . . . . . . . . . . . . 4.28
Wheel Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.40
Tie Rod End and Steering Inspection . . . . . . . . . . . . 2.34
Wheel, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
Timing, Balance Shaft . . . . . . . . . . . . . . . . . . . . . . . . . 3.84
Wheel, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
Tire Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
T-MAP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
Toe Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35
Torque Patterns, Engine Components . . . . . . . . . . . . 3.8
Torque Specifications, Body/Steering/Suspension . 5.2
Torque Specifications, Brakes . . . . . . . . . . . . . . . . . . . 9.2
Torque Specifications, Clutching . . . . . . . . . . . . . . . . . 6.2
Torque Specifications, Final Drive . . . . . . . . . . . . . . . 7.2
Torque Specifications, Transmission . . . . . . . . . . . . . 8.2
Torque Specifications, Wheel and Hub . . . . . . . . . . 2.28

IX.5

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