Polaris 2009 Ranger RZR 800 EFI Manual
  1. Manuals
  2. Brands
  3. Polaris Manuals
  4. Utility Vehicle
  5. 2009 Ranger RZR 800 EFI
  6. Manual

Polaris 2009 Ranger RZR 800 EFI Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
UNIT SERIAL NUMBER (VIN) LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
GENERAL: 2009 RANGER RZR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
GENERAL: 2009 RANGER RZR "S" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
DETAILED: 2009 RANGER RZR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
DETAILED: 2009 RANGER RZR "S" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
GENERAL INFORMATION
GENERAL INFORMATION
CHAPTER 1
1
1.1

Advertisement

Table of Contents
loading

Related Manuals for Polaris 2009 Ranger RZR 800 EFI

Summary of Contents for Polaris 2009 Ranger RZR 800 EFI

  • Page 1: Table Of Contents

    GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION MODEL INFORMATION ..........1.2 MODEL IDENTIFICATION .

  • Page 2: Model Information

    GENERAL INFORMATION MODEL INFORMATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification R 0 9 V H 7 6 A D Emissions & Model Year Model Option Designation Basic Chassis Engine Designation Designation...

  • Page 3: Unit Serial Number (Vin) Location

    GENERAL INFORMATION Unit Serial Number (VIN) Location The machine model number and serial number (VIN) are important for vehicle identification. The VIN number (A) is stamped on a portion of the front left frame rail close to the left front wheel. The VIN and model number are also located on a decal (B) attached to the frame support accessible through the front right wheel well.

  • Page 4: Vehicle Information

    Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product.

  • Page 5: General Specifications

    GENERAL INFORMATION GENERAL SPECIFICATIONS MODEL: 2009 RANGER RZR MODEL NUMBER: R09VH76AD, AG, AH, AO ENGINE MODEL: EH076OLE022 Category Dimension / Capacity Length 102 in. / 259 cm Width 50 in. / 127 cm Height 68.5 in. / 174 cm Wheel Base 77 in.
  • Page 6 Polaris Automatic PVT MODEL NUMBER: R09VH76AD, AG, AH, AO Gear Ratio: Front / Rear ENGINE MODEL: EH076OLE022 High 3.14:1 Engine 8.71:1 Polaris Domestic Twin Cylinder, 5.94:1 Platform Liquid Cooled, 4-Stroke Drive Ratio - Front 3.82:1 Engine Model Number EH076OLE022 Drive Ratio - Final 3.70:1...
  • Page 7 Polaris Automatic PVT MODEL NUMBER: R09VH76AX Gear Ratio: Front / Rear ENGINE MODEL: EH076OLE072 High 3.14:1 Engine 8.71:1 Polaris Domestic Twin Cylinder, 5.94:1 Platform Liquid Cooled, 4-Stroke Drive Ratio - Front 3.82:1 Engine Model Number EH076OLE072 Drive Ratio - Final 3.70:1...

  • Page 8: Misc. Specifications And Charts

    GENERAL INFORMATION MISC. SPECIFICATIONS AND CHARTS Conversion Table °C to °F: (°C + 32) = °F °F to °C: (°F - 32) = °C...

  • Page 9: Standard Torque Specifications

    GENERAL INFORMATION Standard Torque Specifications The following torque specifications are to be used only as a general guideline. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque.

  • Page 10: Sae Tap / Drill Sizes

    GENERAL INFORMATION SAE Tap / Drill Sizes Decimal Equivalents Metric Tap / Drill Sizes 1.10...

  • Page 11: Glossary Of Terms

    CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches.
  • Page 12 GENERAL INFORMATION NOTES 1.12...
  • Page 13 MAINTENANCE CHAPTER 2 MAINTENANCE PERIODIC MAINTENANCE CHART ......... 2.3 PERIODIC MAINTENANCE OVERVIEW .
  • Page 14 MAINTENANCE ELECTRICAL AND IGNITION SYSTEM ........2.27 BATTERY MAINTENANCE .

  • Page 15: Periodic Maintenance Chart

    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.

  • Page 16: Pre-Ride - 25 Hour Maintenance Interval

    Engine Oil Change 25 H 250 (400) Perform a break-in oil change at one month (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.

  • Page 17: 50 - 300 Hour Maintenance Interval

    Clean out 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.

  • Page 18: Component Inspection / Service Locations

    MAINTENANCE COMPONENT INSPECTION / SERVICE LOCATIONS Front and Rear View Standard RZR Shown Standard RZR Shown...

  • Page 19: Rh And Lh Side Views

    MAINTENANCE RH and LH Side Views Standard RZR Shown Standard RZR Shown *Standard RZR Only...

  • Page 20: Lubricants / Service Products

    MAINTENANCE LUBRICANTS / SERVICE PRODUCTS NOTE: Each item can be purchased separately at your local Polaris dealer. Polaris Lubricants, Maintenance and Service Part No. Description Products Additives / Sealants / Thread Locking Agents / Misc. Part No. Description 2870585 Loctite™ Primer N, Aerosol, 25 g Engine Lubricant Loctite™...

  • Page 21: Maintenance References

    Semi-annually** Lube (PN 2871551) grease gun. Locate grease fittings on the upper and lower A-arms of Control Arm Pivot Polaris Premium All Season the front and rear suspension Page 2.6 Semi-annually** Bushings, FT / RR Grease (PN 2871423) and grease with grease gun.

  • Page 22: General Vehicle Inspection And Maintenance

    MAINTENANCE GENERAL VEHICLE INSPECTION Shift Cable Inspection / Adjustment AND MAINTENANCE Shift cable adjustment may be necessary if symptoms include: • No AWD or gear position display on instrument cluster Pre-Ride / Daily Inspection • Ratcheting noise on deceleration Perform the following pre-ride inspection daily, and when •...

  • Page 23: Fuel System And Air Intake

    MAINTENANCE Once the proper adjustment is obtained, place the shift Be sure fuel line is routed properly. cable and upper jam nut into the mount. Tighten the lower IMPORTANT: Make sure line is not kinked or pinched. jam nut against the mount. Replace fuel line every two years.

  • Page 24: Throttle Pedal Inspection

    MAINTENANCE Throttle Pedal Inspection Slide back the cable adjuster boot. Using a 10 mm open-end wrench, loosen the adjustment If the throttle pedal has excessive play due to cable stretch or jam nut. cable misadjustment, it will cause a delay in throttle speed. Also, the throttle may not open fully.
  • Page 25 MAINTENANCE 11. Lift up on the floor and remove the panduit strap retaining 20. Route the cable through the retainer at the bottom of the the throttle cable and brake line to the frame. frame in the floor console opening. 12.

  • Page 26: Air Filter Service

    MAINTENANCE 24. Route the cable around the circumference of the PVT cover 33. Install the throttle body cover and PVT inlet duct. up and over to the throttle body. 34. Verify the vehicle is still in PARK. 25. Apply pipe sealant or PTFE Teflon® tape to the threads at 35.
  • Page 27 MAINTENANCE Inspect the main air filter element and replace if necessary. Installation Do not clean the main filter, the filter should be replaced. Clean the air box thoroughly. NOTE: If the filter has been soaked with fuel or oil it Install a new or clean pre-filter over the main air filter must be replaced.

  • Page 28: Engine

    MAINTENANCE ENGINE Lever Lock Engine Oil Level The twin cylinder engine is a wet-sump engine, meaning the oil is contained in the bottom of the crankcase. To check the oil level follow the procedure listed below. Dipstick SAFE ADD 8 OZ Dipstick Reinstall the dipstick completely, but do not lock it.

  • Page 29: Engine Oil And Filter Service

    MAINTENANCE Engine Oil and Filter Service NOTE: The sealing surface on the drain plug should be clean and free of burrs, nicks or scratches. Always change engine oil and filter at the intervals outlined in Reinstall drain plug and torque to 16 ft. lbs. (22 Nm). the Periodic Maintenance Chart.

  • Page 30: Engine Breather Hose Inspection

    MAINTENANCE Engine Breather Hose Inspection A smooth idle generally indicates good compression. Low engine compression is rarely a factor in running condition The engine is equipped with a breather hose. Inspect the problems above idle speed. breather hose for possible kinks or wear. The hose is form fit- A cylinder leakdown test is the best indication of engine ted for a proper fit.

  • Page 31: Transmission And Gearcases

    MAINTENANCE TRANSMISSION AND GEARCASES Transmission / Gearcase Specification Chart RAIN EVEL HECK EARCASE UBRICANT APACITY ORQUE ORQUE Transmission AGL - Synthetic ATV 24 oz. (710 ml) 40-50 ft. lbs. (54-68 Nm) 30-45 in. lbs. (3-5 Nm) (Main Gearcase) Gearcase Lubricant Transmission AGL - Synthetic ATV 14 oz.
  • Page 32 MAINTENANCE Main Gearcase - Lubricant Level Check: The fill plug is located on the side of the gearcase just below the shift lever bell crank. Maintain the fluid level even with the bottom of the fill plug hole. Position vehicle on a level surface. Remove the fill plug.

  • Page 33: Front Gearcase Lubrication

    MAINTENANCE Front Gearcase Lubrication Position vehicle on a level surface. The front gearcase lubricant level should be checked and Remove the fill plug and check the fluid level. changed in accordance with the maintenance schedule. Add the recommended fluid as needed. •...

  • Page 34: Rear Gearcase Lubrication

    MAINTENANCE Rear Gearcase Lubrication Lubricant Change: The drain plug is located on the bottom right side of the rear Rear Gearcase Specifications gearcase. Specified Lubricant: ATV Angle Drive Fluid (PN 2871653) Capacity: 26 oz. (769 ml) Fill Plug Fill Plug Torque: 40-50 ft. lbs. (54-68 Nm) Drain Plug Torque: 30-45 in.

  • Page 35: Cooling System

    Remove recovery bottle cap and add coolant using a funnel. Polaris Premium 60/40 is already premixed and ready to use. Do Fill recovery bottle to MAX level with Polaris 60/40 not dilute with water.

  • Page 36: Cooling System Pressure Test

    MAINTENANCE Cooling System Pressure Test Carefully straighten any bent radiator fins. Refer to Chapter 3 for cooling system pressure test procedure. Remove any obstructions with compressed air or low pressure water. Cooling System Hoses CAUTION Inspect all hoses for cracks, deterioration, abrasion or leaks.

  • Page 37: Final Drive / Wheel And Tire

    MAINTENANCE FINAL DRIVE / WHEEL AND TIRE Radiator Removal Remove the front bumper (see Chapter 5). Wheel, Hub, and Spindle Torque Table Remove the upper engine outlet hose and recovery hose from the top of the radiator. Item Nut Type Specification Remove the (2) upper radiator retaining bolts and the (4) Aluminum Wheels...

  • Page 38: Tire Inspection

    MAINTENANCE Carefully lower the vehicle to the ground. WARNING Torque the wheel nuts and/or hub nut to the proper torque specification listed in the torque table at the beginning of this section. Operating a RANGER with worn tires will increase the possibility of the vehicle skidding If hub nut was removed, install a new cotter pin after the easily with possible loss of control.

  • Page 39: Electrical And Ignition System

    MAINTENANCE ELECTRICAL AND IGNITION SYSTEM Battery Removal Remove the driver’s seat to access the battery. Battery Maintenance Keep battery terminals and connections free of corrosion. If Battery cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water.

  • Page 40: Battery Off Season Storage

    NOTE: Battery charge can be maintained by using a A hot exhaust system and engine can cause serious Polaris battery tender charger or by charging about burns. Allow engine to cool or wear protective once a month to make up for normal self-discharge.

  • Page 41: Engine To Frame Ground

    12. Install spark plug and torque to specification. Due to the critical nature of the procedures outlined in Recommended Spark Plug: this chapter, Polaris recommends steering component Champion RC7YC3 repair and adjustment be performed by an authorized Polaris MSD certified technician when replacing Spark Plug Torque: worn or damaged steering parts.

  • Page 42: Steering Inspection / Tie Rod Ends And Hubs

    MAINTENANCE Steering Inspection / Tie Rod Ends and Hubs Toe Alignment Inspection • To check for play in the tie rod end, grasp the steering Place machine on a smooth level surface. tie rod and pull in all directions feeling for movement. Set steering wheel in a straight ahead position and secure the steering wheel in this position.

  • Page 43: Toe Adjustment

    MAINTENANCE Toe Adjustment SUSPENSION (RZR) If toe alignment is incorrect, measure the distance between Spring Preload Adjustment vehicle center and each wheel. This will tell you which tie rod needs adjusting. The front and rear shock absorber springs are adjustable by rotating the adjustment cam to change spring tension preload.

  • Page 44: Suspension (Rzr "S")

    MAINTENANCE SUSPENSION (RZR “S”) Once you have obtained the correct preload, holding the lower adjustment ring while tightening the upper adjustment ring to lock them in place. Spring Preload Adjustment The front and rear shocks have a preload adjustment. Shock Compression Adjustment Suspension spring preload may be adjusted to suit different riding conditions or vehicle payloads.

  • Page 45: Brake System

    MAINTENANCE BRAKE SYSTEM Brake Pad / Disc Inspection Check the brake pads for wear, damage, or looseness. Brake Fluid Inspection Inspect the brake pad wear surface for excessive wear. Always check the brake pedal travel and inspect the brake fluid reservoir level before each operation.

  • Page 46: Maintenance Log

    MAINTENANCE MAINTENANCE LOG Service Date Hours / Miles (km) Service Performed / Comments Dealer / Technician 2.34...
  • Page 47 ENGINE CHAPTER 3 ENGINE ENGINE SPECIFICATIONS ..........3.2 CRANKCASE EXPLODED VIEWS .

  • Page 48: Engine Specifications

    ENGINE ENGINE SPECIFICATIONS Crankcase Exploded Views...
  • Page 49 ENGINE Oil Pump / Water Pump / Engine Cover Exploded View...
  • Page 50 ENGINE Stator Cover / Starter / Water Pump Oil Filter / Pressure Relief / Exploded View...
  • Page 51 ENGINE Cylinder / Cylinder Head / Piston Exploded View...
  • Page 52 ENGINE Engine EFI Sensors / Valve Cover General Component Exploded View NOTE: See Chapter 4 for more information on the EFI System...

  • Page 53: Engine Fastener Torque Patterns

    ENGINE Engine Fastener Torque Patterns Crankcase Bolt Tighten Sequence 22 ± 2 ft. lbs. (30 ± 3 Nm) Cylinder Head Bolt Tighten Sequence Lubricate threads and between washer and underside of bolt with engine oil. Torque in sequence to spec provided, allow the gasket to set for 1 minute, then °...

  • Page 54: Torque Specifications

    ENGINE Torque Specifications Engine Torque Specifications Fastener Size in. lbs. (Nm) ft. lbs. (Nm) Camshaft Gear 8 mm 22 ± 2 (30 ± 3) Camshaft Thrust Plate 6 mm 115 ± 12 (13 ± 1.35) 9.5 ± 1 (13 ± 1.35) Throttle Body Adaptor Bolts 8 mm 216 ±...

  • Page 55: 800 Efi Engine Service Specifications

    ENGINE 800 EFI Engine Service Specifications Cylinder Head - Engine Specifications Main Component: Cylinder Head EH076OLE022 / EH076OLE072 Cam Lobe Height - Intake 1.333” (33.867 mm) / 1.357” (34.477 mm) Cam Lobe Height - Exhaust 1.333” (33.867 mm) / 1.342” (34.096 mm) 1.654"...
  • Page 56 ENGINE Cylinder / Piston - Engine Specifications Main Components: Cylinder / Piston / Connecting Rod EH076OLE022 / EH076OLE072 Cylinder - Surface warp limit 0.004" (0.10 mm) (mating with cylinder head) Cylinder Bore - Standard 3.1495" (80 mm) Cylinder Cylinder Taper Limit 0.00031"...

  • Page 57: Special Tools

    ENGINE Special Tools Part Number Tool Description PV-43527 OIL FILTER WRENCH PU-45257 VALVE SPRING COMPRESSOR PU-45652 VALVE PRESSURE HOSE 2871043 FLYWHEEL PULLER 2870390 PISTON SUPPORT BLOCK PU-45497-1 CAM GEAR SPRING INSTALLATION KIT PU-45497-2 CAM GEAR TOOTH ALIGNMENT TOOL PU-45498 CAM SPANNER WRENCH PU-45838 GEAR HOLDER PA-44995...

  • Page 58: Engine Cooling System

    CAUTION: Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Polaris Premium 60/40 Antifreeze/Coolant is recommended for use in all cooling systems and comes pre-mixed, ready to use.

  • Page 59: Cooling System Exploded View

    ENGINE Cooling System Exploded View Engine Outlet Hose (Thermostat Housing) Radiator Inlet Hose Engine Inlet Hose (Water Pump Cover) Fan Motor Pressure Cap Shroud Filler Neck To Bottle Recovery Bottle Radiator Outlet Hose Radiator To Filler Neck Coolant Flow Diagram Filler Neck Engine Water Pump...

  • Page 60: Cooling System Bleeding Procedure

    ENGINE Cooling System Bleeding Procedure Remove pressure cap and top off coolant. Remove recovery bottle cap and fill bottle to the full line. WARNING Recovery Bottle Always wear safety glasses and proper shop clothing when performing the procedures in this Pressure Cap manual.

  • Page 61: General Engine Service

    ENGINE GENERAL ENGINE SERVICE 10. Add Polaris Premium Antifreeze to the radiator filler neck if the level goes down. If no bubbles are seen at the filler neck, the system should be purged of air Engine Lubrication Specifications WARNING Be sure to install the pressure cap before shutting off the engine.

  • Page 62: Oil Flow Chart

    ENGINE Oil Flow Chart This chart describes the flow of oil through the 800 EFI engine. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through the oil filter. If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element.

  • Page 63: Engine Removal

    Engine Removal Remove the (2) push rivets from the rear of the center console. Because of its design configuration, Polaris recommends removing the engine, transmission, and rear gearcase as one assembly. Use the following procedure when engine removal is required.
  • Page 64 ENGINE 12. Elevate the rear of the vehicle off the ground using a 18. Remove the (6) fasteners retaining the upper bolt-in frame suitable ATV lift and remove both rear wheels. brace and remove it from the vehicle with the ignition coil and PVT duct attached.
  • Page 65 ENGINE 22. Loosen the hose clamp between the throttle body and intake 25. Remove the airbox and throttle body from the vehicle as an adaptor. assembly. Take care in not allowing the throttle cable to bend excessively or kink. Carefully place the assembly on the floor next to the vehicle.
  • Page 66 ENGINE 29. Mark the upper jam nut and loosen the lower jam nut. Pull 32. Disconnect the stator / alternator harness. the shift cable out of the mount. Stator Mark Upper Connector Jam Nut Lower Jam Nut 33. Disconnect the transmission speed sensor harness. NOTE: If the upper jam nut is moved, shift cable adjustment will...
  • Page 67 ENGINE 35. Remove the through-bolt that attaches the upper A-arm to 38. Disconnect the engine coolant temperature (ECT) sensor the rear hub on both sides of the vehicle. harness. Connector 36. Pivot the A-arms upward and rear hub carriers downward 39.
  • Page 68 ENGINE 44. Remove RH engine mount fastener. 47. Using an engine hoist, hook a chain between the engine / transmission mounting plate and the transmission / rear gearcase mounting plate. 45. Remove the (2) lower bolts that retain the LH transmission mount to the frame.

  • Page 69: Engine / Transmission Separation

    ENGINE 49. Remove propshaft from the transmission output shaft. Remove only the (4) outer fasteners retaining the engine to the transmission bracket. 50. Then move assembly towards the front of the vehicle while lifting it out to allow the rear gearcase to clear the rear portion of the frame.

  • Page 70: Engine Disassembly And Inspection

    ENGINE ENGINE DISASSEMBLY AND INSPECTION Cylinder Head Assembly Exploded View Rocker Arms Retainer Locks (keepers) Push Rods Spring Retainers Springs Valve Seals Valve Spring Seats Cylinder Head Hydraulic Lifters Valves 3.24...

  • Page 71: Rocker Arms / Push Rods

    ENGINE Rocker Arms If the push rod (A) is visibly bent, it should be replaced. Remove the valve cover. Mark or tag rocker arms in order of disassembly to keep them in order for reassembly. Cylinder Head Removal NOTE: The cargo box assembly and the upper frame bolt-in brace must be removed to allow enough clearance to remove all the cylinder head bolts.

  • Page 72: Cylinder Head Inspection / Warp

    ENGINE Cylinder Head Inspection Valve Seal / Spring Service (On Engine) NOTE: The following procedure is only for servicing Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon. the top end of the valve train when replacing valve springs or replacing valve seals.

  • Page 73: Cylinder Head Disassembly

    ENGINE Cylinder Head Disassembly Remove valve guide seals. Carefully remove the cylinder components. IMPORTANT: It is recommended to replace seals whenever the cylinder head is disassembled. Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup. Mark the valves with a white pen.

  • Page 74: Valve Inspection

    ENGINE Valve Inspection Remove all carbon from valves with a soft wire wheel or = In. / mm. brush. Check valve face for runout, pitting, and burnt spots. To check for bent valve stems, mount valve in a drill or use “V” Valve Stem Diameter: blocks and a dial indicator.

  • Page 75: Combustion Chamber / Valve Seat Reconditioning

    Combustion Area Install pilot into valve guide. Valve Seat Reconditioning Apply cutting oil to valve seat and cutter. NOTE: Polaris recommends that the work be done ° by a local machine shop that specializes in this area. Place 46 cutter on the pilot and make a light cut.
  • Page 76 ENGINE NOTE: When using an interference angle, the seat Inspect the cut area of the seat: contact point on the valve will be very narrow, and is * If the contact area is less than 75% of the circumference of the a normal condition.

  • Page 77: Cylinder Head Reassembly

    ENGINE Cylinder Head Reassembly Clean all filings from the area with hot soapy water. Rinse and dry with compressed air. NOTE: Assemble the valves one at a time to maintain proper order. Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the Apply engine oil to valve guides and seats.

  • Page 78: Valve Sealing Test

    ENGINE Valve Sealing Test Valve Lifter Removal / Inspection Clean and dry the combustion chamber area (A). Remove the valve lifters by reaching into the crankcase and pushing the lifter up through the lifter bore by hand. Thoroughly clean the lifters in cleaning solvent and wipe them with a clean, lint-free cloth.

  • Page 79: Piston Removal

    ENGINE Piston Removal The oil control ring is a three piece design consisting of a top and bottom steel rail and a center expander section. The top rail has Remove circlip (A). Mark the piston with a white pen to a locating tab on the end which fits into a notch (B) in the upper ensure proper orientation (if reused) during assembly.

  • Page 80: Cylinder Inspection

    ENGINE Cylinder Inspection Inspect cylinder for wear, scratches, or damage. Remove all gasket material from the cylinder sealing surfaces. Inspect the top of the cylinder (B) for warp using a straight edge (A) and feeler gauge (C). Refer to Ill. 1 and Ill. 2. Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge.

  • Page 81: Cylinder Hone Selection And Honing Procedure

    IMPORTANT: Clean the cylinder after honing for honing is not advised for nicasil cylinders. Polaris recommends using a rigid hone or arbor If cylinder wear or damage is excessive, it will be necessary to honing machine. Cylinders may be wet or dry replace the cylinder.

  • Page 82: Piston-To-Cylinder Clearance

    ENGINE Piston-to-Cylinder Clearance Measure piston pin O.D. Replace piston and/or piston pin if out of tolerance. Measure piston outside diameter at a point 5 mm up from the bottom of the piston at a right angle to the direction of the piston pin.

  • Page 83: Piston Ring Installed Gap

    ENGINE Measure piston ring to groove clearance by placing the ring If the bottom installed gap measurement exceeds the in the ring land and measuring with a thickness gauge. service limit, replace the rings. If ring gap is smaller than Replace piston and rings if ring-to-groove clearance the specified limit, file ring ends until gap is within exceeds service limits.

  • Page 84: Flywheel / Stator Removal / Inspection

    ENGINE Inspect gear teeth on starter drive (A). Replace starter drive if gear teeth are cracked, worn, or broken. Inspect the bendix bushing (C) in the mag cover for wear. Replace as needed. 2871043 Use caution when removing the wire holddown (B) and the stator assembly (D).
  • Page 85 ENGINE Remove the nylok nut (C), washer (D), and water pump Remove the starter bendix (G), wire holddown plate (H), impeller (E). Remove part of the water pump seal behind and the woodruff key (I) from the crankshaft. The stator the impeller.
  • Page 86 ENGINE Use a white pen to accent the timing marks on the following gears: camshaft gear (K), crankshaft gear (M), or CAUTION counterbalance gear (N) This will ensure proper gear alignment and timing during reassembly of the gears. Wear safety glasses at all times. Use caution when working with the top gear.
  • Page 87 ENGINE 14. Inspect the gear teeth and the three tabs on the gears for To Assemble: wear. • Hold the spring with one finger. • Start the pointed end of the tapered pin into the cam Inspect Teeth & Tabs gear hole.
  • Page 88 ENGINE 19. Once the gears are pressed together, firmly hold the gears 21. To remove the balance shaft gear, the flat side of the together with one hand. Carefully remove the Tapered Pins camshaft (P) must face the balance shaft gear. To rotate the (PU-45497-1) by pulling them out one at a time with the camshaft, use the Cam Spanner Wrench (PU-45498) to other hand.
  • Page 89 ENGINE 23. Inspect the crankshaft gear (Q) for broken or worn teeth. If 26. Rotate the water/oil pump gear (S), so that all four bolts are the crankshaft gear does not need to be replaced, it does not visible though the gear. Remove the four bolts with a hex need to be removed.
  • Page 90 ENGINE 29. Remove the oil pressure relief. The oil pressure relief 31. Carefully press the gear off the assembly while supporting consists of a bolt, washer, spring, and valve (dowel). the housing assembly. Inspect the valve (dowel) for signs of possible obstructions. Use compressed air to blow out any debris.
  • Page 91 ENGINE 34. Press shaft into the new bearing.. 37. Remove thrust plate (U). Press On Bearing 35. Press the bearing/shaft assembly using the bearing's outer race. Do not use the shaft to press the assembly into the 38. Remove PTO end engine mount. Remove crankcase bolts. housing, as bearing damage may result.

  • Page 92: Camshaft Inspection

    ENGINE Camshaft Inspection 39. Remove and clean oil pick up (V) and oil baffle weldment (W). Thoroughly clean the cam shaft. Visually inspect each cam lobe for wear, chafing or damage. Measure height of each cam lobe using a micrometer. Compare to specification.

  • Page 93: Engine Reassembly

    ENGINE ENGINE REASSEMBLY Measure camshaft journal outside diameters (O.D.). Crankcase Reassembly CAUTION After any reassembly or rebuild, the engine must be primed using the Oil Priming Adapter (PU-45778) and a 3/4-full oil filter before initial start-up (see “Oil Pump Priming”). NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2874275) to remove any debris.
  • Page 94 ENGINE NOTE: Always install new balance shaft bearings. Assemble the crankcase halves. Apply LocTite™ 242 (PN 2871949) to the threads and pipe sealant to the bolt flanges. Apply assembly lube to cam journals and balance shaft Torque bolts to specification following torque pattern at bearing surfaces of the MAG case halve.
  • Page 95 ENGINE 10. Lubricate connecting rods with 2W-50 synthetic engine oil. 13. Install piston assemblies into cylinder aligning the piston pin holes, to ensure proper alignment of the pistons to the connecting rods upon assembly. Partially install the piston pins into the pistons. 11.
  • Page 96 ENGINE NOTE: While installing in piston circlips, cover all 17. Assemble rotors as marked when disassembled. Use a engine passages. The clip could fall into the engine cleaner to remove the marks previously made on the rotors. during installation. Line Up Marks 18.
  • Page 97 ENGINE 20. Install oil pump housing bolts (H). The new bolts contain 22. Before installing the crankshaft gear (I), heat the crankshaft ° ° ™ patch lock, so Loctite is not needed on the new bolts. gear to 250 F (121 C) on a hot plate (J).
  • Page 98 ENGINE NOTE: Cam Spanner Wrench (PU-45498) is only 25. Install counter balance shaft gear (J) with new key, aligning needed to rotate the camshaft when the entire valve timing marks with crankshaft gear (I). Install washer and bolt. Use the Gear Holder (PU-45838). Torque to train is assembled.
  • Page 99 ENGINE 28. Before installing the gear / stator housing, replace the seals NOTE: Install the crankshaft seal (P) with the seal lip facing out (towards the crankcase). in the cover. Install a new water pump seal (N) into the gear / stator housing.
  • Page 100 ENGINE 32. Before installing the gear/stator housing cover, install the Water Pump Seal Saver (PA-45401) onto the water pump shaft. PA-45401 35. Install the gear/stator housing gasket onto he crankcase. Gear / Stator Housing Gasket 33. Install a NEW gasket to the gear/stator housing cover and crankcase.
  • Page 101 ENGINE NOTE: Before assembly, clean the bolts and bolt 39. Install water pump cover (R) with new O-ring seal. Torque holes with Primer N (PN 2874275) to remove any bolts to specification in proper sequence (see Page 3.4). debris. This will ensure proper sealing when installing bolts.

  • Page 102: Flywheel / Stator Installation

    ENGINE Flywheel / Stator Installation NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2874275) to remove any debris. This will ensure proper sealing when Flywheel Nut Torque installing bolts. 65 ± 7 ft.lbs. (88 ± 9.50 Nm) Install stator assembly (S) and bolts.
  • Page 103 ENGINE Lubricate threads and top of washers underside of bolt head Lubricate rockers (E) with engine oil. with engine oil. Install head bolts (C) and torque to specification. Verify pushrods are engaged in lifters. Install rockers. Be sure that tab of fulcrum (F) is seated in head stand-off.

  • Page 104: Oil Pump Priming

    ENGINE Install breather reed (G) into rocker cover (H). Lightly 11. Install thermostat (J), new O-ring, and thermostat housing. apply black RTV sealant to the outer edges of the breather Torque to specification. reed. The reed has a tab and will assemble one-way only. Torque the breather bolts to specification.

  • Page 105: Engine Installation

    Polaris PS-4 PLUS 2W-50 Synthetic Oil (PN 2876244). Engine Assembly and Installation Fill the oil filter three-quarters full with Polaris PS-4 PLUS Use the following procedure to reinstall the engine assembly. 2W-50 Synthetic Oil (PN 2876244). Let the oil soak into the filter for 8-10 minutes.

  • Page 106: Engine Break-In Period

    RH side of Capacity - Approximately 2 U.S. Quarts (1.9 l) the vehicle. Oil Type - Polaris PS-4 PLUS 2W-50 Synthetic Filter Wrench - PV-43527 or equivalent • Replace exhaust gaskets. Seal connections with high - Oil Pressure Specification - temp silicone sealant.

  • Page 107: Troubleshooting

    ENGINE TROUBLESHOOTING Engine Idles But Will Not Accelerate • Spark plug fouled/weak spark Engine • Broken throttle cable Spark Plug Fouling • Obstruction in air intake • Spark plug cap loose or faulty • Air box removed (reinstall all intake components) •...

  • Page 108: Cooling System

    ENGINE Cooling System Excessive Smoke and Carbon Buildup • 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 •...
  • Page 109 ELECTRONIC FUEL INJECTION CHAPTER 4 ELECTRONIC FUEL INJECTION GENERAL INFORMATION ..........4.2 SPECIAL TOOLS .

  • Page 110: General Information

    TPS adjustment procedure. NOTE: Voltage Regulator (4010264) is required if using TPS Tester Adapter Harness (PU-47082). If your dealership sells Polaris snowmobiles, you may already have this regulator from TPS Tester Kit (2201519). If you do not have this regulator, you...
  • Page 111 PU-47468, Vehicle Interface Cable PU-47469 and PC Interface Cable PU-47470. This module kit is used on all 8 pin Relief Valve 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...

  • Page 112: Service Notes

    • 80% of all EFI problems are caused by wiring harness connections. • For the purpose of troubleshooting difficult running issues, a known-good ECU from another Polaris RANGER RZR EFI of the same model may be used without damaging system or engine components.

  • Page 113: Efi System Exploded View

    ELECTRONIC FUEL INJECTION EFI System Exploded View 1. Electronic Control Unit (ECU) 2. Intake Air Temperature / Barometric Air Pressure Sensor (T-BAP) 3. Crankshaft Position Sensor (CPS) 4. Fuel Injectors 5. Fuel Filter 6. Fuel Pump / Regulator / Gauge Sender Asm. (Located in tank as an assembly) 7.

  • Page 114: Efi System Component Locations

    ELECTRONIC FUEL INJECTION EFI System Component Locations Fuel Injectors / Fuel Rail - Attached to the fuel rail located in the intake track of the Electronic Control Unit (ECU) cylinder head. - Located behind the driver’s seat next to the seat belt assembly.
  • Page 115 ELECTRONIC FUEL INJECTION Throttle Body Ignition Coil - Located between the rubber air box boot and the rubber - Located behind the driver’s seat and rear service panel just cylinder head adaptor. above the PVT cover. Ignition Coil Throttle Body Throttle Position Sensor (TPS) - Located on the right-hand side of the throttle body.

  • Page 116: Fuel Tank

    ELECTRONIC FUEL INJECTION FUEL TANK Exploded View Screw Screw Rear Front Tank Bracket Tank Bracket Hi-Temp Flex Conduit Quick Connect Fuel Line Fuel Pump Asm Gasket Fuel Tank Fuel Flow Fuel Injectors Fuel Rail Fuel Tank Pressure Regulator Fuel Pump Assembly Fuel Filters Quick Connect Fuel Line...

  • Page 117: Fuel Lines - Quick Connect

    ELECTRONIC FUEL INJECTION Fuel Lines - Quick Connect ELECTRONIC FUEL INJECTION RANGER EFI models use quick connect fuel lines. Refer to the Principal Components steps below for fuel line removal. The Electronic Fuel Injection (EFI) system is a complete engine Place a shop towel around the fuel line to catch any fuel and ignition management design.

  • Page 118: Initial Priming / Starting Procedure

    ELECTRONIC FUEL INJECTION ELECTRONIC CONTROL UNIT (ECU) The ECU controls the amount of fuel being injected and the ignition timing by monitoring the primary sensor signals for air temperature, barometric air pressure, engine temperature, speed Operation Overview (RPM), and throttle position (load). These primary signals are The ECU is the brain or central processing computer of the compared to the programming in the ECU computer chip, and entire EFI fuel/ignition management system.

  • Page 119: Ecu Service / Replacement

    Software (dealer only). Refer to the EFI Diagnostic For the purpose of troubleshooting, a known-good ECU from Software Manual for more information. another Polaris RANGER RZR EFI of the same model may be T-BAP Replacement used without system or engine component damage.

  • Page 120: Crankshaft Position Sensor (Cps)

    ELECTRONIC FUEL INJECTION Install new sensor using a light coating of oil on the o-ring The two-tooth gap creates an “interrupt” input signal, to aid installation. corresponding to specific crankshaft position for PTO cylinder. This signal serves as a reference for the control of ignition Bolt timing by the ECU.

  • Page 121: Cps Replacement

    ELECTRONIC FUEL INJECTION If the resistance is correct. Remove the (3) bolts retaining the front portion of the - Test the main harness circuit between the sensor mounting bracket to the transmission. Retain the bolts, connector terminals and the corresponding pin terminals at washers, and spacers for installation.
  • Page 122 ELECTRONIC FUEL INJECTION Installation Lift the mounting bracket straight up and out from the vehicle. IMPORTANT: When reinstalling the transmission to rear gearcase mount bracket, it is extremely important Remove to torque all (7) fasteners to specification. Refer to the Bracket following procedure.
  • Page 123 ELECTRONIC FUEL INJECTION Using special tool (PA-48873), torque the (3) bolts that Remove the special tool and attach an extension to the retain the front portion of the mounting bracket to the torque wrench. Torque the bottom bolt that attaches the transmission.
  • Page 124 ELECTRONIC FUEL INJECTION Upper Rear Gearcase Bolt Torque the remaining bolt that attaches the bracket to the front side of the rear gearcase. Front Rear Gearcase Bolt NOTE: A multi-directional torque wrench is required in this application because of the limited access to this bolt.

  • Page 125: Fuel Injectors

    ELECTRONIC FUEL INJECTION FUEL INJECTORS Fuel Injector Service Injector problems typically fall into three general categories- Operation Overview electrical, dirty / clogged, or leakage. An electrical problem usually causes one or both of the injectors to stop functioning. NOTE: All EFI units utilize quick connect fuel lines. Several methods may be used to check if the injectors are The fuel injectors mount into the cylinder head, and the fuel rail operating.

  • Page 126: Fuel Injector Test / Replacement

    ELECTRONIC FUEL INJECTION Fuel Injector Test Fuel Injector Replacement NOTE: The Bosch harness connector and locking Be sure the engine has cooled enough to work on. spring is bonded to the fuel injectors with an epoxy Place a suitable container below the quick connect plug at mix.
  • Page 127 ELECTRONIC FUEL INJECTION Disconnect the harness for the fuel injector(s) located next Using a 6mm hex wrench, loosen the fuel rail mounting to the ignition coil. Cut the plastic tie strap and push the screw from the cylinder head. Carefully pull the rail away harness for the fuel injector(s) up over the air box to allow from the injectors and remove the injector(s) from the fuel injector removal.

  • Page 128: Fuel Pump

    ELECTRONIC FUEL INJECTION FUEL PUMP • If the engine is stopped with the key switch "on" (as in the case of an accident). Operation Overview In these situations, the “check engine” light will go on, but will turn off after 4 cranking revolutions if system function is OK. NOTE: All EFI units utilize quick connect lines.
  • Page 129 ELECTRONIC FUEL INJECTION Connect the hose from the Fuel Pressure Gauge Kit (PU- If the reading is between 7 and 14 volts, turn key switch off 43506-A) to the test valve on the Fuel Pressure Gauge and connect an ohmmeter between the terminals “A” and Adaptor (PV-48656).

  • Page 130: Fuel Tank / Fuel Pump Replacement

    ELECTRONIC FUEL INJECTION Fuel Tank / Fuel Pump Replacement Remove the fuel tank vent hose. IMPORTANT: Syphon as much fuel from the tank as possible before attempting to remove it from the vehicle. WARNING Always wear safety goggles when working with high pressure or flammable fluids.
  • Page 131 ELECTRONIC FUEL INJECTION Remove the (11) push rivets and (4) Torx screws retaining IMPORTANT: Take care not to place any excessive force on the filler neck the RH rocker panel and remove panel from the vehicle. 11. Remove the (2) tank bracket fasteners that retain the fuel tank in the chassis.

  • Page 132: Throttle Position Sensor (Tps)

    Tester Regulator (4010264). 4010264 TPS Tester Regulator Yellow (Output) TPS Connector NOTE: If your dealership sells Polaris snowmobiles, Black Blue you may already have this regulator from TPS Tester (Ground) (Input) Kit (2201519). If you do not have this regulator, you must order one from SPX at 1-800-328-6657.

  • Page 133: Checking Tps Reading

    ELECTRONIC FUEL INJECTION Checking TPS Reading Verify TPS Tester Reference Voltage A 5 volt reference voltage from the TPS Tester harness is Remove the driver and passenger seats along with the rear required for the TPS test to be accurate. Refer to the instructions service panel.

  • Page 134: Tps Adjustment / Replacement

    ELECTRONIC FUEL INJECTION TPS Replacement 10. Allow the throttle foot pedal to rest in the idle position. The voltmeter should read .730 ± .010 volts. NOTE: The correct position of the TPS angle on the throttle body is established and set at the factory. If PU-47082 Tester the TPS is replaced, repositioned or loosened it must be recalibrated.

  • Page 135: Engine Coolant Temperature Sensor (Ect)

    Negative Temperature Coefficient (NTC) type sensor, as the temperature increases the resistance decreases. ECT Sensor Refer to Chapter 10 for ECT testing. Polaris dealers can also test the sensor by using the Digital Wrench™ Diagnostic Software (dealer only). Refer to the Digital Wrench™ User Guide for more information.

  • Page 136: Ignition Coil

    ELECTRONIC FUEL INJECTION IGNITION COIL Primary Test Operation Overview Measure Between The ignition coil is used to provide high voltage to fire the spark Connector Pins plugs. When the ignition key is on, DC voltage is present in 0.4 Ω primary side of the ignition coil windings.

  • Page 137: General Troubleshooting

    ELECTRONIC FUEL INJECTION GENERAL TROUBLESHOOTING Any “blink codes” stored in the ECU will display a numerical “blink code”, one at a time, in numerical order, on the instrument cluster display. Diagnostic “Blink Codes” NOTE: The EFI diagnostic mode is intended to The word “End”...

  • Page 138: Efi Troubleshooting

    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 intake / exhaust, hesitation, detonation, low power, •...

  • Page 139: Efi System Breakout Diagrams

    ELECTRONIC FUEL INJECTION EFI SYSTEM BREAKOUT DIAGRAMS Diagnostic Connector Circuit Malfunction Indicator Lamp (MIL) Circuit 4.31...

  • Page 140: Fuel Injector (Pto) Circuit

    ELECTRONIC FUEL INJECTION Fuel Injector (PTO) Circuit Fuel Injector (MAG) Circuit 4.32...

  • Page 141: Engine Coolant Temperature Sensor (Ect) Circuit

    ELECTRONIC FUEL INJECTION Engine Coolant Temperature Sensor (ECT) Circuit Engine Overheat Lamp Driver Circuit 4.33...

  • Page 142: Crankshaft Position Sensor (Cps) Circuit

    ELECTRONIC FUEL INJECTION Crankshaft Position Sensor (CPS) Circuit Air Temperature and Barometric Air Pressure Sensor (T-BAP) Circuit 4.34...

  • Page 143: Throttle Position Sensor (Tps) Circuit

    ELECTRONIC FUEL INJECTION Throttle Position Sensor (TPS) Circuit Fuel Pump Circuit 4.35...
  • Page 144 ELECTRONIC FUEL INJECTION NOTES 4.36...
  • Page 145 BODY / STEERING / SUSPENSION CHAPTER 5 BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS..........5.2 SPECIAL TOOLS .

  • Page 146: Torque Specifications

    BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS SPECIAL TOOLS ITEM TORQUE VALUE TOOL DESCRIPTION PART NUMBER ft.lbs. (Nm) Shock Spanner Wrench 2870872 Front LH / RH Upper 33 ft. lbs. (45 Nm) Shock Spring Compressor Tool 2870623 A-Arm Bolt Multi-Function Pliers 2876389 Front LH / RH Lower 33 ft.

  • Page 147: Cab Frame (Rzr)

    BODY / STEERING / SUSPENSION CAB FRAME (RZR) Assembly / Removal NOTE: Finger tighten all components until cab frame is completely assembled on vehicle, then tighten to specifications listed. Assemble the rear cab frame and the front cab frame at the coupler joints and secure with four (3/8-16 x 1 1/4) screws and (3/8-16 Nyloc) nuts.

  • Page 148: Cab Frame (Rzr "S")

    BODY / STEERING / SUSPENSION CAB FRAME (RZR “S”) Assembly / Removal NOTE: Finger tighten all components until cab frame is completely assembled on vehicle, then tighten to specifications listed. Assemble the rear cab frame and the front cab frame at the coupler joints and secure with four (3/8-16 x 1 1/4) screws and (3/8-16 Nyloc) nuts.

  • Page 149: Body Exploded Views

    BODY / STEERING / SUSPENSION BODY EXPLODED VIEWS Dash Instruments / Controls A. Instrument Cluster (Speedo) B. Headlight Switch C. 2WD/AWD Switch D. 12 Volt Accessory Receptacle E. Speedometer “Mode” Button F. Key Switch...
  • Page 150 BODY / STEERING / SUSPENSION Front Bumper Front Bumper Support Screws Washers Front Bumper Torx Screws Radiator Screen O-Ring Bulb Screw Screw Screw Headlight Winch Pocket Cover Bumper Retaining Bracket Screws Rear Bumper LH Tail Light RH Tail Light Screw Speed Screws Nuts...

  • Page 151: Hood / Front Body Work

    BODY / STEERING / SUSPENSION Hood / Front Body Work 1/4 Turn Latch Center Hood Panel Washer Grommet T27 Screws T25 Screws Hood Pad Push Rivets Hood / Dash Push Rivet Front LH Front RH Fender Flair Fender Flair T27 Screws Push Rivets Reflector Front Bumper...
  • Page 152 BODY / STEERING / SUSPENSION Seat Assembly Seat Back Seat Hoop Tube 48 in. lbs. (5.4 Nm) Seat Bottom Latch Body Nuts Lever Seat Base Asm. Spring Plate 41-57 in. lbs. 41-57 in. lbs. Grommets (4.6-6.4 Nm) (4.6-6.4 Nm) Seat Belts / Mounting Driver 3 Point Seat...

  • Page 153: Floor / Rocker Panels

    BODY / STEERING / SUSPENSION Floor / Rocker Panels Self-Tapping Screw LH Rocker Rear Support Bracket Push Rivets Self-Tapping Screws Console Cover Screws Front Support Bracket Rear Support Bracket Self-Tapping Screws Screw Screw Screws Push Rivets U-Type Upper Floor Nuts Torx Screws Plastic Dart...

  • Page 154: Rear Cargo Box / Fenders

    BODY / STEERING / SUSPENSION Rear Cargo Box / Fenders Rear LH Fender Flair Tie Down Screws Bracket Push Tie Down Rear LH Rivets Bracket Fender Torx Screw & Nut Rear Cargo Box Tie Down Torx Screw Ring & Nut Screws Rear LH Screws...

  • Page 155: Chassis / Main Frame

    BODY / STEERING / SUSPENSION Chassis / Main Frame 15 ft. lbs. Bolt-In Brace (20 Nm) Rear Bumper Support Main Frame 15 ft. lbs. 17 ft. lbs. (20 Nm) (23 Nm) Skid Plate 6-8 ft. lbs. (8-11 Nm) 5.11...

  • Page 156: Body Component Removal

    BODY / STEERING / SUSPENSION BODY COMPONENT REMOVAL Front Bumper Remove the (4) push rivets from the sides of the front Seats bumper. To remove the driver or passenger seat, lift upward on the latch lever located behind the seat bottom. Latch Lever Torx...

  • Page 157: Hood And Front Body Work

    BODY / STEERING / SUSPENSION Hood and Front Body Work Remove the (8) push rivets that attach the dash assembly to the rocker panels on each side. Hood Removal To remove the hood, turn both latches to disengage the rear portion of the hood. Remove the (2) Torx screws and (2) push rivets that retain the front and rear portions of the dash assembly and remove the dash assembly from the vehicle.

  • Page 158: Rocker Panels, Console And Floor

    BODY / STEERING / SUSPENSION Rocker Panels, Console and Floor Rear Fender, Flair and Tie Down Removal Rocker Panel Removal Remove the rear bumper (see “BODY COMPONENT REMOVAL - Rear Bumper”). Remove the (11) push rivets and (4) screws from the RH Remove the (8) push rivets that retain the rear portion of rocker panel and remove panel from the vehicle.

  • Page 159: Steering Assembly

    BODY / STEERING / SUSPENSION STEERING ASSEMBLY Exploded View Spacer Thick Steering Wheel Washers Thin 25-31 ft. lbs. Washer (34-42 Nm) Thin Washer Thick Washer Thin Washer Steering Shaft Pivot Tube Spacer Bearing 7 ft. lbs. Bushing 42.5 ft. lbs. (10 Nm) (58 Nm) 23 ft.
  • Page 160 BODY / STEERING / SUSPENSION Steering Wheel Removal Steering Shaft Bearing Replacement Remove the steering wheel cap. Perform the “Steering Shaft Removal” procedure. Loosen the nut and back it half way off the steering shaft. Remove the steering wheel cap and retaining nut. With a glove on your hand, place it under the steering Press steering shaft out of the steering wheel and pivot tube.

  • Page 161: Wheel Hubs

    BODY / STEERING / SUSPENSION WHEEL HUBS Front Hub Exploded View Sealed Ball Bearing Bolts Wheel Hub Front Rim Cone (Aluminum) Bearing Front Tire Cotter Pin Washers Carrier Retaining Wheel Nuts Ring 90 ft. lbs. (122 Nm) Brake Disc Studs Castle Nut 80 ft.

  • Page 162: Front A-Arms

    BODY / STEERING / SUSPENSION FRONT A-ARMS 15. Using a soft face hammer, tap on bearing carrier to loosen the lower A-arm ball joint end while pushing downward on the lower A-arm. Completely remove the ball joint end Removal / Replacement from the bearing carrier.

  • Page 163: Exploded Views

    BODY / STEERING / SUSPENSION Exploded View (RZR) Exploded View (RZR “S”) 33 ft. lbs. (45 Nm) 33 ft. lbs. (45 Nm) Bushings Pivot Pivot Tube Tube Upper Upper A-arm Grease A-arm Zerk Ball Joint 33 ft. lbs. Grease Zerk Ball Joint (45 Nm) Bushings...

  • Page 164: Ball Joint Service

    BODY / STEERING / SUSPENSION BALL JOINT SERVICE Use a press and correct size driver to remove the ball joint from the A-arm. Removal Correct Driver Placement IMPORTANT: Do not reuse a ball joint if it has been removed for any reason. If removed, it must be replaced.

  • Page 165: Installation

    BODY / STEERING / SUSPENSION Installation FRONT STABILIZER BAR (RZR) Place the A-arm in the correct position for ball joint Sway Bar Linkage Removal installation. Face the A-arm end flat on top of the driver. Carefully drive the ball joint into place until the ball joint Elevate and safely support the front of the vehicle off the is properly seated.

  • Page 166: Exploded View

    BODY / STEERING / SUSPENSION Remove the (2) upper radiator retaining bolts. Main Frame Mount Bracket Lift up on the stabilizer bar and remove it from the vehicle. Remove the (4) bolts retaining the lower radiator mount bracket and remove the bracket from the frame. 10.

  • Page 167: Rear A-Arms

    BODY / STEERING / SUSPENSION REAR A-ARMS WARNING Removal The locking agent on the existing bolts was The following procedure details upper and lower A-arm destroyed during removal. DO NOT reuse old removal and replacement on one side of the vehicle. Repeat the hardware.

  • Page 168: Installation

    BODY / STEERING / SUSPENSION Remove the (2) fasteners (E) attaching the lower A-arm to Remove the fastener (H) attaching the lower A-arm to the the frame and remove the lower A-arm from the vehicle bearing carrier (see previous illustration). (see previous illustration).

  • Page 169: Exploded Views

    BODY / STEERING / SUSPENSION Exploded View (RZR) Exploded View (RZR “S”) 33 ft. lbs. (45 Nm) 33 ft. lbs. Pivot Tube (45 Nm) Pivot Tube Upper Upper A-arm A-arm 33 ft. lbs. (45 Nm) Grease Bushings Zerk Bushings Bushings 33 ft.

  • Page 170: Rear Stabilizer Bar (Rzr)

    BODY / STEERING / SUSPENSION REAR STABILIZER BAR (RZR) Remove the stabilizer bar and bracket from the frame as an assembly. Removal / Installation Remove the exhaust pipe and exhaust silencer from the vehicle. Remove Fasteners Inspect the stabilizer bar for straightness. Inspect the bushings and replace if needed.

  • Page 171: Rear Stabilizer Bar (Rzr "S")

    BODY / STEERING / SUSPENSION REAR STABILIZER BAR (RZR “S”) Remove the stabilizer bar from the bracket (bracket can remain attached to the frame). Removal / Installation Leave bracket Remove the exhaust pipe and exhaust silencer from the attached to frame. vehicle.

  • Page 172: Decal Replacement

    BODY / STEERING / SUSPENSION DECAL REPLACEMENT SHOCKS / SPRINGS (RZR) Exploded View WARNING Spring 27-33 ft. lbs. (37-45 Nm) The following procedure involves the use of an open flame. Perform this procedure in a well Spring ventilated area, away from gasoline or other Retainer flammable materials.

  • Page 173: Fox™ Shock Exploded View (Rzr "S")

    BODY / STEERING / SUSPENSION FOX™ SHOCK EXPLODED VIEW (RZR “S”) FOX™ PODIUM X ‘Piggyback’ Shock Preload Ring 10 ft. lbs. (14 Nm) Ref. Description Ref. Description Shaft Preload Ring Body Preload Ring Body Cap Asm. Lock Nut Reservoir Bearing, External Shock Oil (2870995) Bearing, External Decal...

  • Page 174: Fox™ Shock Service (Rzr "S")

    BODY / STEERING / SUSPENSION FOX™ SHOCK SERVICE (RZR “S”) Rear Shock Service Information General Service Information Recommended Service Intervals FOX™ Racing Shocks will perform the best if serviced at regular intervals: • Every ride - Wash and dry the vehicle and suspension. •...

  • Page 175: Fox™ Podium X Shock Rebuild Information

    BODY / STEERING / SUSPENSION FOX™ PODIUM X Shock Rebuild Information Special Tools Required: When performing maintenance on FOX™ shocks, use the Gas Body Holding Tool (PN 2871071) Shock Recharging Kit (PN 2200421), as it contains the Charging Needle (PN 7052069-A) necessary valves, pressure gauge, and fittings to deflate and Gas Shock Recharging Kit (PN 2200421) pressurize shocks.

  • Page 176: Fox™ Podium X Shock Disassembly

    BODY / STEERING / SUSPENSION FOX™ Podium X Shock Disassembly Figure 2 NOTE: Read through all of these instructions first to familiarize yourself with the rebuild procedure. Make sure you have a clean work area, and all of the necessary tools are available. Always use proper safety equipment when...
  • Page 177 BODY / STEERING / SUSPENSION 12. Clamp the body cap of the shock securely in vise with shaft 17. Align the slot of the IFP Depth Setting Tool with the end side up. of the IFP (Internal Floating Piston). Engage the IFP by rotating the tool 90 degrees (Fig.

  • Page 178: Fox™ Podium X Shock Rebuild

    BODY / STEERING / SUSPENSION Figure 9 Figure 7 Thoroughly clean the bearing housing, and piston assembly 24. Slide bearing assembly off of shaft. Use extreme caution with solvent. Dry with compressed air in a well ventilated not to scratch inside of the bearing assembly when passing area.

  • Page 179: Fox™ Podium X Shock Reassembly

    Shock oil will come up through the IFP bleed hole. FOX™ Podium X Shock Reassembly Polaris Gas Shock Oil - 5 wt. Clamp shaft eyelet securely in vise, and place seal bullet PN 2870995 - qt. tool on end of shaft.
  • Page 180 BODY / STEERING / SUSPENSION 12. Fill shock body to the bottom of the bearing threads with 20. Add oil to the body tube until the surface of the oil is to the oil. top of the threads inside the body tube. 13.
  • Page 181 BODY / STEERING / SUSPENSION 34. Continue charging with gas as you pull the reservoir away Figure 17 from the FOX™ Nitrogen Safety Needle using a smooth, straight motion. Keep the reservoir as straight as possible to prevent the safety needle from bending. As the safety needle is pulled free from the FOX™...
  • Page 182 BODY / STEERING / SUSPENSION NOTES 5.38...
  • Page 183 CLUTCHING CHAPTER 6 CLUTCHING SPECIAL TOOLS AND SUPPLIES ......... . 6.2 TORQUE SPECIFICATIONS.

  • Page 184: Special Tools And Supplies

    The internal components of the drive clutch and driven clutch control engagement (initial vehicle movement), clutch upshift TORQUE SPECIFICATIONS and backshift. During the development of the Polaris vehicle, the PVT system is matched first to the engine power curve; then PVT System Fastener Torques to average riding conditions and the vehicle’s intended usage.

  • Page 185: Driven Clutch Operation

    CLUTCHING Driven Clutch Operation Maintenance / Inspection Under normal use the PVT system will provide years of trouble Driven clutches primarily sense torque, opening and closing free operation. Periodic inspection and maintenance is required according to the forces applied to it from the drive belt and the to keep the system operating at peak performance.

  • Page 186: Overheating / Diagnosis

    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.

  • Page 187: Pvt System Service

    CLUTCHING PVT SYSTEM SERVICE PVT Sealing and Ducting Components Clutch Clutch Inlet Duct Outlet Duct Push Rivets Inner Clutch Cover Boot Clamps Boot Clamps Bolt/Washer Cover Screws Retainer Screws Outer Outer Cover Seal Clutch Cover Disassembly Mark the drive belt direction of rotation and remove drive belt (see “DRIVE BELT - Belt Removal”).

  • Page 188: Assembly

    CLUTCHING Assembly Remove driven clutch offset spacers from the transmission input shaft. Inspect inner clutch cover-to-engine seal. Replace if cracked or damaged. Keep Spacers In Order (Note Thickness) Place a new foam seal on transmission input shaft. Apply RTV silicone sealant to outside edge of inner clutch cover-to-engine seal, to ensure a water tight fit between the seal and the cover.

  • Page 189: Drive Belt

    CLUTCHING DRIVE BELT Clean splines inside driven clutch and on the transmission input shaft. Belt Removal Apply a light film of grease to the splines on the shaft. Remove outer clutch cover as described in PVT 10. Install the driven clutch, washer, lock washer, and retaining Disassembly.

  • Page 190: Belt Inspection

    CLUTCHING Belt Inspection PVT Break-In (Drive Belt / Clutches) Inspect belt for hour glassing (extreme circular wear in at A proper break-in of the clutches and drive belt will ensure a least one spot and on both sides of the belt). Hour glassing longer life and better performance.

  • Page 191: Drive Clutch Service

    CLUTCHING DRIVE CLUTCH SERVICE Spring Specifications The drive clutch spring has two primary functions: To control clutch engagement RPM. The springs which have a higher rate when the clutch is in neutral will increase clutch engagement RPM. To control the rate at which the drive belt moves Red/White 7043349 upward in the drive clutch sheaves.

  • Page 192: Shift Weights

    CLUTCHING Shift Weights Shown below are the shift weights which have been designed for the PVT system. These shift weights have many factors designed into them for controlling engagement RPM and shifting patterns. Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to sheave clearance, clutch balance and shifting pattern.

  • Page 193: Non-Braking Exploded View (Rzr)

    CLUTCHING Non-Braking Exploded View (RZR) Lock Bushing Washer Spring Cover Limiter Bearing Bolt Spider Bearing Flat Non-Braking Spacer Washer Bearing Cover Button Screws Roller Washers Button Bolt Shift Washers Weight EBS Exploded View (RZR “S”) Lock Bushing Washer Spring Cover Bearing Bolt Spider...

  • Page 194: Clutch Disassembly

    CLUTCHING Clutch Disassembly Inspect area on shaft where bushing rides for wear, galling, nicks, or scratches. Replace clutch assembly if worn or Using a permanent marker, mark the cover, spider, and damaged. moveable and stationary sheaves for reference, as the cast in X's may not have been in alignment before disassembly.

  • Page 195: Roller, Pin, And Thrust Washer Inspection

    CLUTCHING Roller, Pin, and Thrust Washer Inspection NOTE: It is important that the same number and thickness of washers are reinstalled beneath the Inspect all rollers, bushings and roller pins by pulling a flat spider during assembly. Be sure to note the number metal rod across the roller.

  • Page 196: Button To Tower Clearance Inspection

    CLUTCHING Button To Tower Clearance Inspection Remove shift weight bolts and weights. Inspect the contact surface of the weight. The surface should be smooth and Inspect for any clearance between spider button to tower. free of dents or gall marks. Inspect the weight pivot bore If clearance exists, replace all buttons and inspect surface and pivot bolts for wear or galling.

  • Page 197: Clutch Inspection

    CLUTCHING Clutch Inspection Inspect surface of shaft for pitting, grooves, or damage. Measure outside diameter compare NOTE: Remove cover, spring, and spider following specifications. Replace the drive clutch assembly if shaft instructions for drive clutch removal, then proceed is worn or damaged. as follows: Remove the moveable sheave spacer sleeve (1) and the thrust washer (2).

  • Page 198: Moveable Sheave Bushing Inspection

    CLUTCHING Moveable Sheave Bushing Inspection Bushing Service IMPORTANT: Special Tools Required Inspect the Teflon™ coating (arrow) on the moveable sheave bushing. Inspect both sheaves for signs of wear, grooving or EBS Clutch Bushing Tool Kit - 2201379 cracking. De-glaze sheave surfaces with a 3M™ Scotch-Brite Pad if needed.
  • Page 199 CLUTCHING NOTE: Use Bushing Tool PA-47336. CAUTION Install nut (C) onto end of puller rod and hand tighten. Turn puller barrel to increase tension on sheave if needed. Using Clutch components will be hot! In order to avoid a hand held propane torch, apply heat around outside of serious burns, wear insulated gloves during the bushing until tiny smoke tailings appear.

  • Page 200: Clutch Assembly

    CLUTCHING Cover Bushing Removal Clutch Assembly Install main adapter (Item 8) on puller. NOTE: It is important that the same number and thickness of washers are reinstalled beneath the Removal Tool Nut (C) spider during assembly. The Teflon bushings are self-lubricating.

  • Page 201: Driven Clutch Service

    CLUTCHING DRIVEN CLUTCH SERVICE Torque spider to specification using the holding fixture and spider tool. Torque with smooth motion to avoid damage to the stationary sheave. Clutch Disassembly Remove driven clutch from the transmission input shaft. Do not attempt disassembly of the driven clutch from the outside snap ring.
  • Page 202 CLUTCHING Place the clutch into the Clutch Compression Tool PN Remove the inside spider plate (D) and spider dampener 8700220. Using Compression Extensions PN PS-45909, (E). Inspect the spider dampener (E) for wear and replace press down on top of the spider assembly, compressing the if needed.
  • Page 203 CLUTCHING Press out the spring pins (K) in the inner sheave. 12. Inspect the bearing for wear. Spin the bearing, if the bearing does not spin smoothly, replace it. To remove the bearing, press the bearing off the shaft. 10. Pull out the clutch roller pins (L) and rollers (M). Inspect Sheave Surface 13.

  • Page 204: Bushing Service

    CLUTCHING Bushing Service Clutch Bushing Removal IMPORTANT: Special Tools Required Install main puller adapter (Item 8) onto puller. EBS Clutch Bushing Tool Kit - 2201379 Install adapter reducer (Item 9). Item Qty. Part Description Part # Using a hand held propane torch, apply heat around outside of bushing until tiny smoke tailings appear.

  • Page 205: Clutch Assembly

    CLUTCHING Clutch Bushing Installation Clutch Assembly Install puller adapter (Item 10) onto puller. Install a new bearing onto the output shaft using a press. Install adapter (Item 9) onto puller. Install the shaft/bearing into the outer sheave. Apply Loctite™ 609 evenly to bushing bore inside moveable sheave.
  • Page 206 CLUTCHING Line up the “X” on the moveable sheave with the “X” on Install the roller pin into the sheave assembly on both sides. the stationary sheave or use the marks previously used. Put The flat side of the roller pin faces downward when the the sheaves together.
  • Page 207 CLUTCHING 10. Install the spider dampener (G) inside the outer spider and 12. Place the clutch into Clutch Compression Tool PN install the inside spider plate (H). 8700220. Using Compression Extensions PN PS-45909, press down on the top of the spider assembly, pushing the Outer Spider spider onto the shaft.
  • Page 208 CLUTCHING 14. Install the cam (helix) assembly over the shaft. Line up the “X” on the cam, “X” on spider, and “X” on the stationary sheave or use the marks previously made before disassembly. NOTE: If the cam assembly (helix) is difficult to install, be sure the sheaves are aligned.

  • Page 209: Exploded View

    CLUTCHING Exploded View Screws E-Clips Thrust Spider Washer Dampener Roller Compression Spring (Helix) Retaining Ring Moveable Sheave Outer Roller Spider Spider Insert Clutch Shaft Slotted Spring Pin Retaining Ring Stationary Ball Sheave Bearing 6.27...

  • Page 210: Driven Clutch Service (Late Build Rzr)

    CLUTCHING DRIVEN CLUTCH SERVICE (LATE BUILD RZR) Exploded View Compression Spring Spacer Outer Stationary Spring Retainer Secondary Sheave Inner Retaining Spring Retainer Ring Moveable Secondary Sheave Clutch Disassembly / Inspection Place the clutch into the Clutch Compression Tool PN 8700220. Using Compression Extensions PN PS-45909, apply and hold downward pressure on the outer spring CAUTION retainer.
  • Page 211 CLUTCHING With the snap ring (A) removed and spring pressure Remove the inner spring retainer from the inner sheave. relieved, remove the outer spring retainer (B), compression Inspect for wear and replace as needed. spring (C), spacer (D), and inner spring retainer (E). Inspect for Abnormal Wear Check the rollers in the stationary sheave for wear.

  • Page 212: Clutch Assembly

    CLUTCHING 10. Inspect the Teflon™ coating on the moveable sheave bearings. 11. Inspect driven clutch sheave faces for wear or damage. 12. Clean and inspect splines on helix and transmission input shaft. 13. Lube splines with a light film of grease. Do not lubricate the bearings! Clutch Assembly Assemble Sheaves...

  • Page 213: Troubleshooting

    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.
  • Page 214 CLUTCHING Troubleshooting, Continued..Situation Probable Cause Remedy -Plugged air intake or outlet. -Clear obstruction -Belt slippage due to water, oil, grease, etc., rubbing -Inspect system. Clean , repair or replace as necessary. on cover. Seal PVT system ducts. PVT cover -Clutches or weight being applied to cover while in -Remove weight.
  • Page 215 FINAL DRIVE CHAPTER 7 FINAL DRIVE SPECIAL TOOLS ............7.2 TORQUE SPECIFICATIONS.

  • Page 216: Special Tools

    FINAL DRIVE SPECIAL TOOLS Check bearings for side play by grasping the top and bottom of the tire firmly and checking for movement. The tire should rotate smoothly without binding or rough spots. PART NUMBER TOOL DESCRIPTION 2872608 Roller Pin Removal Tool CV Boot Clamp Pliers 8700226 (earless type)

  • Page 217: Bearing Replacement

    FINAL DRIVE Remove the two brake caliper mounting bolts. NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected CAUTION: Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. visually, and by feel.

  • Page 218: Bearing Carrier Installation

    FINAL DRIVE Bearing Installation Install pinch bolts and torque to 17 ft. lbs. (23 Nm). Thoroughly clean the front bearing carrier housing and the outer race on the new bearing. Be sure that all oil residue has been removed from each surface. Support the bottom of the bearing carrier housing.
  • Page 219 FINAL DRIVE Torque wheel hub nut to 80 ft. lbs. (108 Nm) and install a NEW cotter pin. Tighten nut slightly if necessary to align cotter pin holes. Front Caliper Mounting Bolts: 80 ft. lbs. 30 ft. lbs. (40 Nm) (108 Nm) CAUTION New bolts have a pre-applied locking agent...

  • Page 220: Front Drive Shaft

    FINAL DRIVE FRONT DRIVE SHAFT Remove the upper ball joint pinch bolt. Drive Shaft Removal Pinch Bolt Elevate front of vehicle and safely support 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.

  • Page 221: Drive Shaft / Cv Joint Handling Tips

    FINAL DRIVE Drive Shaft / CV Joint Handling Tips Make sure the circlip remains on the shaft and not left in the joint. Discard the circlip as it will be replaced. Care should be exercised during drive shaft removal or when Circlip servicing CV joints.

  • Page 222: Inner Plunging Joint / Boot Replacement

    FINAL DRIVE Inner Plunging Joint / Boot Replacement 11. Slide the joint onto the drive shaft splines and align the circlip with the lead-in chamfer on the inner race. Remove the front drive shaft from the vehicle (see “FRONT DRIVE SHAFT - Removal”). 12.
  • Page 223 FINAL DRIVE 12. Grease the joint with the special CV joint grease provided 21. Position the boot lip in its groove. Install and secure the in the boot replacement kit. Fill the cavity behind the balls boot with the large clamp using the “earless” clamp pliers. and the splined hole in the joint’s inner race.

  • Page 224: Drive Shaft Installation

    FINAL DRIVE Drive Shaft Installation Install the upper pinch bolt and torque to 17 ft. lbs. (23 Nm). Install new spring ring on drive shaft. Apply an anti-seize 17 ft. lbs. compound to splines. (23 Nm) Spring Ring Apply Anti-Seize Align splines of drive shaft with front gearcase and reinstall the drive shaft.

  • Page 225: Propshaft Service

    FINAL DRIVE PROPSHAFT SERVICE Removal / Installation Locate the propshaft roll pin and use the Roll Pin Removal Wheel Hub Castle Nut: Tool (PN 2872608), to remove the roll pin. 80 ft. lbs. (108 Nm) NOTE: Front wheel can be removed to gain better Install brake caliper mounting bolts and torque to 30 ft.

  • Page 226: Propshaft U-Joint Service

    FINAL DRIVE Remove the fasteners retaining the plastic skid plate and Support inner yoke as shown and drive outer yoke down remove the skid plate from the vehicle. (bearing cap out) with a soft face hammer. Cupped Washers Screws Support U-joint in vise as shown and drive inner yoke down to remove remaining bearing caps.
  • Page 227 FINAL DRIVE Tighten vise to force bearing caps in. Using a suitable arbor, fully seat the bearing cap in one side. Continually check for free movement of bearing cross as bearing caps are assembled. Install snap ring to contain bearing cap just installed. Repeat procedure for other side.
  • Page 228 FINAL DRIVE FRONT GEARCASE / CENTRALIZED HILLIARD Centralized Hilliard Exploded View 7-11 ft. lbs. (10-15 Nm) ESCRIPTION ESCRIPTION Cover Screws Roll Cage Assembly with H-Springs Cover Plate Assembly Rollers Thrust Plate Clutch Housing / Ring Gear Armature Plate Gearcase Housing Output Hub Assembly Wire Harness Retainer 7.14...
  • Page 229 FINAL DRIVE All Wheel Drive Operation AWD Engagement: When the AWD switch is activated, the AWD coil is powered by a 12 Vdc input which creates a The AWD switch may be turned on or off while the vehicle is magnetic field.

  • Page 230: Awd Diagnosis

    FINAL DRIVE AWD Diagnosis Check to make sure the coil is seated in the U-shaped insert that is pressed into the gearcase cover. The top of the coil Symptom: AWD Will Not Engage should be seated below the U-shaped insert. The U-shaped insert controls the pole gap.

  • Page 231: Gearcase Removal

    FINAL DRIVE Gearcase Removal Remove the gearcase from the front LH wheel well area and slide it between the upper and lower A-arm. Stop engine and place gear selector in Park. Refer to “FRONT DRIVE SHAFT - Drive Shaft Removal” and remove both front drive shafts from the front gearcase.
  • Page 232 FINAL DRIVE NOTE: The backlash for the centralized hilliard is set Remove the (4) screws retaining the pinion shaft assembly at the factory. No adjustment is required unless the and remove the assembly from the gearcase housing. cover plate assembly is replaced, or the backlash Inspect and clean the gearcase housing and replace the seal.

  • Page 233: Gearcase Assembly / Inspection

    FINAL DRIVE 12. Remove the roll cage assembly and rollers from the clutch 16. Inspect both output hub assemblies. Inspect the bearings housing. Use a shop towel to cover the housing in order to and replace if needed. retain all the rollers. Thrust Bearing NOTE: Rollers are spring loaded.
  • Page 234 FINAL DRIVE Carefully install the rollers into the roll cage assembly Install the RH output hub into the clutch housing assembly. while installing the assembly into the clutch housing. RH Hub Clutch Housing 10. While holding the hub in the clutch housing, flip the clutch housing over and install the armature plate.

  • Page 235: Backlash Thrust Plate Adjustment

    FINAL DRIVE Backlash Thrust Plate Adjustment 12. Line up the gearcase housing with the cover plate assembly. Set the gearcase housing on top of the assembled cover NOTE: Ring gear backlash is set from the factory. plate. Take care not to damage the new seal when installing No adjustment is required unless the cover plate, the gearcase housing.

  • Page 236: Gearcase Installation

    FINAL DRIVE Set the gearcase upright. Install the vent line. Install Back the adjustment screw out while rotating the pinion Vent Line shaft. The pinion shaft should rotate freely during four Connect complete rotations. The four pinion shaft rotations ensures Harness that the ring gear completes one full rotation.

  • Page 237: Rear Bearing Carrier

    FINAL DRIVE REAR BEARING CARRIER Remove the rear wheel hub assembly. Bearing Carrier Inspection / Removal Elevate rear of vehicle and safely support 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.

  • Page 238: Bearing Replacement

    FINAL DRIVE NOTE: Due to extremely close tolerances and Bearing Installation minimal wear, the bearings must be inspected Thoroughly clean the rear bearing carrier housing and the visually, and by feel. While rotating bearings by outer race on the new bearing. Be sure that all oil residue hand, inspect for rough spots, discoloration, or has been removed from each surface.

  • Page 239: Bearing Carrier Installation

    FINAL DRIVE Bearing Carrier Installation Install brake caliper mounting bolts and torque to 18 ft. lbs. (24 Nm). Install drive shaft axle through the backside of the bearing carrier. Be sure bushings and pivot tubes are installed. 18 ft. lbs. 24 (Nm) Install the fasteners that attach the rear bearing carrier to the Rear Caliper Mounting Bolts:...

  • Page 240: Rear Drive Shaft

    FINAL DRIVE Install wheel and (4) wheel nuts. Torque wheel nuts to Remove the two brake caliper attaching bolts. specification. CAUTION: Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. Wheel Nuts: Steel Wheels: 27 ft.

  • Page 241: Outer Cv Joint / Boot Replacement

    FINAL DRIVE Outer CV Joint / Boot Replacement Slide the rear drive shaft out of the bearing carrier by pulling the bearing carrier assembly outward and tipping it Using a side cutters, cut away and discard the boot clamps. down to remove the shaft. Grasp the rear drive shaft and pull sharply outward on the Remove the large end of the boot from the CV joint and shaft to disengage it from the rear gearcase.
  • Page 242 FINAL DRIVE NOTE: Shiny areas in ball tracks and on the cage Make sure the circlip is on the shaft and not left in the joint. spheres are normal. Do not replace CV joints because parts have polished surfaces. Replace CV Circlip joint only if components are cracked, broken, worn or otherwise unserviceable.
  • Page 243 FINAL DRIVE 14. Slide the joint onto the drive shaft splines and align the 20. While pulling out on the CV shaft, fully extend the CV joint circlip with the lead-in chamfer on the inner race of the and slide a straight O-ring pick or a small slotted screw joint.

  • Page 244: Inner Plunging Joint / Boot Replacement

    FINAL DRIVE Inner Plunging Joint / Boot Replacement Make sure the circlip is still on the shaft and not left in the joint. Using a side cutters, cut away and discard the boot clamps. Circlip Remove the boot from the shaft. Remove the large end of the boot from the plunging joint CAUTION and slide the boot down the shaft.
  • Page 245 FINAL DRIVE 12. Install a NEW circlip on the end of the shaft. 18. Remove excess grease from the plunging joint’s external surfaces and place the excess grease in the boot. 13. Grease the joint with the special CV joint grease provided in the boot replacement kit.

  • Page 246: Drive Shaft Exploded View

    FINAL DRIVE Drive Shaft Exploded View Installation Install new spring ring on drive shaft. Apply anti-seize REAR SHAFT compound to splines. RZR “S” SHAFT RZR SHAFT Spring Ring Spring Ring Plunging Joint Spring Ring Apply Large Clamp Anti-Seize Grease Pack Gear Side Align splines of drive shaft with rear gearcase and reinstall Boot Kit...
  • Page 247 FINAL DRIVE Lift bearing carrier into place and install the bolt attaching the bearing carrier to the upper A-arm. Torque fastener to specification. Rear Caliper Mounting Bolts: 18 ft. lbs. (24 Nm) 33 ft. lbs. 45 (Nm) CAUTION New bolts have a pre-applied locking agent which is destroyed upon removal.

  • Page 248: Rear Gearcase

    FINAL DRIVE REAR GEARCASE Remove the fasteners and bracket that secure the rear gearcase to the transmission. Gearcase Removal Drain the fluid from the rear gearcase and remove the rear drive shafts from each side of the rear gearcase. See “REAR DRIVE SHAFT” on page 7.26 Remove the exhaust pipe and exhaust silencer to allow for gearcase removal.

  • Page 249: Gearcase Disassembly

    FINAL DRIVE Gearcase Disassembly IMPORTANT: Due to the manufacturing process, the pinion and ring gear assembly are NOT intended to be disassembled and replaced. Pinion and ring gear shimming information is NOT provided. The components are matched at the factory which requires special OEM tooling in order to properly assemble and shim the gears.
  • Page 250 FINAL DRIVE Inspect the ring gear teeth for chipped, worn, or broken Remove the input shaft seal using a seal puller or other teeth. If damaged, replace the ring gear and pinion gear as suitable method. a set. Inspect Inspect the input shaft by rotating the assembly in the NOTE: In the event damage to the gears or housing gearcase housing while checking for any looseness or requires replacement, the entire assembly must be...

  • Page 251: Gearcase Assembly

    FINAL DRIVE Gearcase Assembly If removed, install each axle spool bearing race using standard bearing installation tools and a shop press. Install a new input shaft seal using a standard seal installer or other suitable method. Install new seals on each side of the gearcase housing using a standard seal installer or other suitable method.

  • Page 252: Gearcase Installation

    Install the gearcase cover. Verify the o-ring is in position. Install the cover screws onto the rear gearcase. Torque to specification. Add Polaris ATV Angle Drive Fluid to rear gearcase. Refer to maintenance information in Chapter 2 for more details. Torque drain and fill plugs to specification.

  • Page 253: Gearcase Exploded View

    FINAL DRIVE Gearcase Exploded View 23-27 ft. lbs. (31-37 Nm) 70-80 ft. lbs. (95-108 Nm) 23-27 ft. lbs. (31-37 Nm) 23-27 ft. lbs. 40 ft. lbs. (31-37 Nm) (54 Nm) 30-45 in. lbs. (3-5 Nm) ESCRIPTION ESCRIPTION Screw Axle, Spool Screw O-Ring Bracket, Rear Mount, RH...

  • Page 254: Wheel Hubs

    FINAL DRIVE WHEEL HUBS Front Hub Exploded View Sealed Ball Bearing Bolts Wheel Hub Front Rim Cone (Aluminum) Bearing Washers Front Tire Cotter Pin Carrier Retaining Wheel Nuts Ring 90 ft. lbs. (122 Nm) Brake Disc Studs Castle Nut 80 ft. lbs. Wheel Nuts (108 Nm) 27 ft.
  • Page 255 TRANSMISSION CHAPTER 8 TRANSMISSION TORQUES / SPECIFICATIONS ..........8.2 SHIFT LEVER .

  • Page 256: Torques / Specifications

    TRANSMISSION TORQUES / SPECIFICATIONS SHIFT LEVER Removal Maintain and check/change these items in accordance with the maintenance schedule in Chapter 2 or during service repairs. Pry the shift lever cover using a suitable tool and remove the screw. Pull knob off the shifter. ITEM TORQUE VALUE Transmission Fill Plugs...

  • Page 257: Shift Cable Inspection / Adjustment

    TRANSMISSION Shift Cable Inspection / Adjustment Adjust the shift cable so there is the same amount of cable travel when shifting slightly past the detents of HIGH (H) Shift cable adjustment may be necessary if symptoms include: gear and PARK (P). •...

  • Page 258: Transmission Service

    TRANSMISSION TRANSMISSION SERVICE Remove the (7) bolts retaining the transmission support bracket. Transmission Removal / Service Notes The engine, transmission and rear differential are bolted together as a unit. Removal of the transmission is not possible without removing the engine and differential. The shift housing cannot be removed without first disassembling the transfer case.
  • Page 259 TRANSMISSION After removing the cover, remove the intermediate shaft 10. Remove the intermediate pinion shaft assembly from the bearing cup and shims from the cover. Bearing cup is a housing. Check bearings and gear teeth for wear or damage slip-fit. Note and record the number and thickness of shims and replace as needed.
  • Page 260 TRANSMISSION 13. Remove the front output pinion shaft assembly. The shaft 15. Remove the lower snap ring from under the gear. can be disassembled as shown using a press and standard bearing removal tools. 16. Remove the intermediate shaft seal using a seal puller or other suitable method.

  • Page 261: Transfer Case Reassembly

    TRANSMISSION Transfer Case Reassembly Install the shims, bearing cup and alignment dowels into the retaining bracket. Install the intermediate shaft seal (circled) flush or slightly below the case. Install circlips and gear onto the input intermediate shaft as shown. Install a new output shaft seal flush with the case. Install the output pinion shaft assembly and bearing cup/bracket assembly as shown.
  • Page 262 TRANSMISSION Reinstall the intermediate pinion shaft assembly and Install the transfer case cover. Align the dowels (#1 & #7) bearing cup. and insert the cover screws (note position of the longest screw #4). Torque the screws evenly to specification in sequence as shown.

  • Page 263: Transmission Shift Housing Disassembly

    TRANSMISSION Transmission Shift Housing Disassembly Place the transmission shift housing onto a flat surface as shown. Lift the transmission case half straight up and IMPORTANT: Shift housing repairs are not possible remove. without performing transfer case disassembly. Read and understand all instructions before beginning disassembly.
  • Page 264 TRANSMISSION Remove the (5) screws retaining the park flange. Inspect the Remove the input shaft seal and clutch intermediate shaft park flange dogs for wear or damage. Replace as required. seal using a seal puller or punch. Inspect the shaft bearing. Use a standard bearing puller to Remove the (2) screws that attach the shift switch to the remove the shaft bearing if required.
  • Page 265 TRANSMISSION Remove the plate, pins, springs, drum gear and thrust 11. Remove the park flange sleeve from the clutch shaft. washer from the shift housing. Replace any worn or damaged components. 12. Pull back fully on gear selector arm to bring shift collar up and disengage the shift collar from the clutch yoke.
  • Page 266 TRANSMISSION 14. Remove the sliding shoes from the clutch yoke. 17. From the back side of the high gear assembly, separate the high and low gear assemblies by tapping the gear retaining plate from the roll pins using a brass punch. Note the order of disassembly on the entire gear assembly (plate, thrust washer, bearing, thrust washer).
  • Page 267 TRANSMISSION 20. Remove the clutch yoke from the gear selector shaft and 22. Remove the screw from the end of the gear selector shaft spring. assembly and remove the assembly from the housing. Note the clips, spring and plate orientation. 23.

  • Page 268: Transmission Shift Housing Reassembly

    TRANSMISSION Transmission Shift Housing Reassembly Install the input shaft assembly. Install a new shift lever seal flush with the case. Apply lubricant to the seal lip. Press new bearings (if required) into the housing. Install clutch yoke into the gear selector shaft and spring. Align the pivot pin holes and install clutch yoke pivot pin.
  • Page 269 TRANSMISSION Assemble the high and low gear assemblies as shown. Install the clutch shaft into the housing. Note that the Complete the assembly by aligning the roll pin holes and forward gear assembly is loose in the housing and that tapping the roll pins through the retaining plate and into the alignment of the shaft, gear assembly, thrust washer and high gear using a brass punch.
  • Page 270 TRANSMISSION 11. Install the outer sleeve screws and inner shift detent screws, With the transmission in neutral, lubricate and install the thrust washer, drum gear, plate, springs, pins and the shift position springs, and balls from each side of the shift housing. Use sensor/o-ring assembly into the shift housing.
  • Page 271 TRANSMISSION 13. Install the reverse idler lower washer, needle bearing, gear, 16. Install the reverse clutch/gear assembly onto the park upper washer and snap ring onto the idler shaft of the flange. Note the orientation of the (2) thrust washers (top / transmission case half.
  • Page 272 TRANSMISSION 18. Place the transmission shift housing onto a flat surface as 20. Install the (2) shift housing case screws to the backside as shown. Apply a bead of crankcase sealant onto the mating shown. Torque to specification. surfaces. Align the dowels and install the transmission case NOTE: Shift cable bracket installation is required.

  • Page 273: Troubleshooting

    TRANSMISSION TROUBLESHOOTING Troubleshooting Checklist Check the following items when shifting difficulty is encountered: • Idle speed adjustment • PVT alignment • Transmission oil type/quality • Transmission torque stop adjustment (where applicable) • Engine torque stop adjustment (where applicable) • Drive belt deflection •...

  • Page 274: Transmission Exploded Views

    TRANSMISSION TRANSMISSION EXPLODED VIEWS Shift Housing / Transfer Case Exploded View Shift Housing Transfer Case 8.20...
  • Page 275 BRAKES CHAPTER 9 BRAKES GENERAL SPECIFICATIONS..........9.2 TORQUE SPECIFICATIONS.

  • Page 276: General Specifications

    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" (.254mm) REAR BRAKE SYSTEM Item Standard...

  • Page 277: Brake System Service Notes

    BRAKES BRAKE SYSTEM SERVICE NOTES Disc brake systems are light weight, low maintenance, and perform well in the conditions this vehicle will routinely encounter. There are a few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function and maximum pad service life.

  • Page 278: Hydraulic Brake System Operation

    MAX LEVEL line! resulting friction reduces brake disc and vehicle speed. When servicing Polaris brake systems use only Polaris DOT 4 The friction applied to the brake pads will cause the pads to Brake Fluid (PN 2872189). WARNING: Once a bottle is wear.

  • Page 279: Master Cylinder

    BRAKES MASTER CYLINDER CAUTION Removal Brake fluid will damage finished surfaces. Locate the master cylinder above the LH front tire in the Do not allow brake fluid to come in contact wheel well area. with finished surfaces. Master Cylinder NOTE: Make note of front and rear brake line locations to master cylinder.

  • Page 280: Brake Bleeding / Fluid Change

    Mity Vac™ pump or similar tool. 1/2"(1.3 cm). Mity Vac™ (PN 2870975) 13. Check brake system for fluid leaks. Add brake fluid to the indicated MAX level of reservoir. Polaris DOT 4 Brake Fluid (P/N 2872189)

  • Page 281: Front Brake Pads

    BRAKES FRONT BRAKE PADS Push mounting bracket inward and slip outer brake pad past edge. Then remove inner pad. Pad Removal Elevate and support front of vehicle. CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls.

  • Page 282: Pad Assembly / Installation

    1/2 turn Lubricate mounting bracket pins with a light film of (counterclockwise). Polaris Premium All Season Grease (PN 2871423), and install rubber dust boots. 1/2 Turn Verify fluid level in reservoir is up to MAX line inside Compress mounting bracket and make sure dust boots are reservoir and install reservoir cap.

  • Page 283: Front Caliper Service

    BRAKES FRONT CALIPER SERVICE Caliper Exploded View Apply Polaris DOT 4 Brake Fluid 47 in. lbs. to Component (5.3 Nm) Apply Polaris All Purpose Grease A. Socket Set Screw B. Bleeder Screw C. Caliper Assy. D. Boot E. Square O-ring (thick) F.

  • Page 284: Caliper Disassembly

    BRAKES Remove the two caliper mounting bolts and remove the Remove mounting bracket, pin assembly and dust boot. caliper assembly from the front hub. Remove Thoroughly clean the brake caliper before disassembly and prepare a clean work area to disassemble the caliper. Caliper Disassembly Use low pressure compressed air to remove the pistons Push brake pad retainer pin inward and slip brake pads past...

  • Page 285: Caliper Inspection

    Caliper Piston Bore I.D.: Std: 1.004” (25.5 mm) Service Limit: 1.006” (25.55 mm) Coat pistons with clean Polaris DOT 4 Brake Fluid. Install pistons with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance.

  • Page 286: Caliper Installation

    BRAKES Lubricate the mounting bracket pins with Polaris Premium Install brake line and tighten securely with a line wrench. All Season Grease (PN 2871423), and install the rubber Torque the banjo bolt brake line(s) to the proper torque dust seal boots.

  • Page 287: Front Brake Disc

    BRAKES FRONT BRAKE DISC Remove the hub assembly from the vehicle and remove the (4) bolts retaining the disc to the hub. Disc Inspection (4) Bolts Visually inspect disc for scoring, scratches, or gouges. Replace the disc if any deep scratches are evident. Use a 0-1”...

  • Page 288: Rear Brake Pad

    BRAKES REAR BRAKE PAD Push caliper piston into the caliper bore slowly using a C- clamp or locking pliers with pads installed. Pad Removal 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.

  • Page 289: Pad Inspection

    Lubricate mounting bracket pins with a light film of Install the adjustment set screw and turn clockwise until the Polaris Premium All Season Grease (PN 2871423), and stationary pad contacts the disc, then back off 1/2 turn install rubber dust boots.

  • Page 290: Rear Caliper Service

    BRAKES REAR CALIPER SERVICE Caliper Exploded View Apply Polaris DOT 4 Brake Fluid to Component 47 in. lbs. Apply Polaris All Purpose (5.3 Nm) Grease A. Brake Pad B. Mount Bracket C. Piston D. Caliper Assy. E. Square Ring (thick) F.

  • Page 291: Caliper Disassembly

    BRAKES Caliper Disassembly Caliper Inspection Remove brake pad adjustment set screw (K). Inspect caliper body for nicks, scratches or wear. Measure bore size and compare to specifications. Replace if damage Push upper pad retainer pin inward and slip brake pads past is evident or if worn beyond service limit.

  • Page 292: Caliper Assembly

    18 ft. lbs. (24 Nm) Coat piston with clean Polaris DOT 4 Brake Fluid (PN 2872189). Install piston (D) with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly with light resistance.

  • Page 293: Rear Brake Disc

    BRAKES REAR BRAKE DISC Remove the hub assembly from the vehicle and remove the (4) bolts retaining the disc to the hub. Disc Inspection (4) Bolts Visually inspect disc for scoring, scratches, or gouges. Replace the disc if any deep scratches are evident. Cotter Use a 0-1”...

  • Page 294: Troubleshooting

    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 •...
  • Page 295 ELECTRICAL CHAPTER 10 ELECTRICAL GENERAL INFORMATION ..........10.3 SPECIAL TOOLS .
  • Page 296 ELECTRICAL BATTERY SERVICE ........... 10.24 GENERAL BATTERY INFORMATION.

  • Page 297: General Information

    ELECTRICAL GENERAL INFORMATION Under-Dash Components The following switches and components can be accessed Special Tools underneath the instrument / dash panel: Part Number Tool Description • Speedometer PV-43568 Fluke™ 77 Digital Multimeter • Speedometer Mode Switch 2870630 Timing Light • Digital Wrench Diagnostic Connector 2870836 Battery Hydrometer •...

  • Page 298: Switches / Controls

    ELECTRICAL SWITCHES / CONTROLS AWD SWITCH Headlamp Switch Disconnect the headlamp switch harness (Brown, Green, and Red/Yellow), by depressing the connector lock and pulling on the connector. Do not pull on the wiring. Test the switch connections and check for continuity at the following pins as shown in the illustration.

  • Page 299: Instrument Cluster

    ELECTRICAL INSTRUMENT CLUSTER Rider Information Display The rider information display is located in the instrument Overview cluster. All segments will light up for 2.5 seconds at start-up. The instrument cluster senses vehicle speed from the speed NOTE: If the instrument cluster fails to illuminate, a sensor located in the transmission.

  • Page 300: Standard Display Modes

    ELECTRICAL Standard Display Modes Clock Screen Use the mode button (location shown in the illustration on page 10.5) to toggle through the mode options. Odometer Mode The odometer records the miles or kilometers traveled by the vehicle. Trip Meter Mode The trip meter records the miles or kilometers traveled by the vehicle on each trip if it's reset before each trip.
  • Page 301 ELECTRICAL AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the AWD coil. Gear Circuit Diagnostic Screen This screen displays the resistance value (in ohms) being read at the gear switch input of the gauge. NOTE: A 10 - 20% variance from these readings is within normal parameters.

  • Page 302: Viewing Diagnostic Codes

    ELECTRICAL NOTE: If you scroll past the intended number, press Programmable Service Interval and hold the button until the hours cycle back to When the hours of engine operation equal the programmed zero. service interval setting, the wrench icon will flash for 5 seconds each time the engine is started.

  • Page 303: Instrument Cluster Removal

    ELECTRICAL Turn the key switch off and on three times in less than five Push the instrument cluster out from the back side of the seconds, then leave the switch on. The word “Wait” will dash while securely holding the dash and rubber mount. appear on the screen along with a flashing “Check Engine”...

  • Page 304: Instrument Cluster Troubleshooting Tests

    ELECTRICAL INSTRUMENT CLUSTER TROUBLESHOOTING TESTS TEST 1 - No All Wheel Drive 10.10...

  • Page 305: Test 2 - No Display

    ELECTRICAL TEST 2 - No Display TEST 3 - Vehicle Speed Sensor 10.11...

  • Page 306: Test 4 - No Awd Hub Safety Limiter

    ELECTRICAL TEST 4 - No AWD Hub Safety Limiter 10.12...

  • Page 307: Test 5 - Fuel Gauge Display Not Working

    ELECTRICAL TEST 5 - Fuel Gauge Display Not Working TEST 6 - Gear Indicator Not Working (Transmission Switch) 10.13...

  • Page 308: All Wheel Drive Coil

    ELECTRICAL ALL WHEEL DRIVE COIL GEAR POSITION INDICATOR SWITCH Operation Overview Switch Resistance Value Table • When the AWD switch is “ON”, 12 VDC power is Resistance Value present at the hub coil. Gear Position when measured at terminals A and B •...

  • Page 309: Head Lights

    ELECTRICAL HEAD LIGHTS Adjust the beam to desired position. Repeat the procedure to adjust the other headlight. Headlight Adjustment WARNING The headlight beam is adjustable. Due to the nature of light utility vehicles and Place the vehicle on a level surface with the headlight where they are operated, headlight lenses approximately 25 ft.

  • Page 310: Headlamp Housing Removal

    ELECTRICAL Headlamp Housing Removal TAIL / BRAKE LIGHTS Disconnect the headlamp from the wiring harness. Be sure Bulb Replacement to pull on the connector, not on the wiring. Before replacing the bulb, use a digital multi-meter to test the Remove the O-rings (A) from the headlamp brackets on harness to ensure the lamp is receiving 12 volts and that a ground both sides of the headlamp.

  • Page 311: Cooling System Schematic

    ELECTRICAL COOLING SYSTEM SCHEMATIC Cooling System Break-Out Diagram 10.17...

  • Page 312: Fan Control Circuit Operation / Testing

    ELECTRICAL Fan Control Circuit Operation / Testing EFI DIAGNOSTICS Power is supplied to the fan via the Orange/Black wire when the EFI Component Testing relay is ON. The ground path for the fan motor is through the Brown harness wire. Refer to “RELAYS” later in this chapter All EFI component information and diagnostic testing for more information on fan functions.

  • Page 313: Relays

    ELECTRICAL RELAYS FAN RELAY Operation OLOR UNCTION Key-On battery power supply, switched on Located in the fuse box under the dash, the relays assist with Red / White by key switch, enables power to relay. component operation like the fan, fuel pump, and EFI system. Fused 20-Amp power, switched by relay, The fan relay, controlled by the ECU and Temp Sensor, operates Orange / Black...

  • Page 314: Fuses / Circuit Breaker

    ELECTRICAL FUSES / CIRCUIT BREAKER Operation Located in the fuse box under the dash, the fuse panel provides current protection for components such as the Instrument Cluster, ECU, EFI system, Chassis Power and Accessories. A separate 20-amp circuit breaker protects the fan motor circuit (see wire diagram for details). 10.20...

  • Page 315: Charging System

    ELECTRICAL CHARGING SYSTEM Charging System “Break Even” Test Alternator Output CAUTION AMPS VOLTS Do not allow the battery cables to become 2500 13.2 Vdc disconnected with the engine running. Follow the steps below as outlined to reduce the chance of Current Draw - Key Off damage to electrical components.

  • Page 316: Charging System Alternator Tests

    ELECTRICAL Charging System Alternator Tests TEST 3: Measure AC Voltage Output of Each Stator Leg at Charging RPM Three tests can be performed using a multi-meter to determine the condition of the stator (alternator). Set the selector dial to measure AC Voltage. Start the engine and let it idle.

  • Page 317: Charging System Testing Flow Chart

    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.: Remove the battery and properly ser- Using a multitester set on D.C. volts, mea- vice.

  • Page 318: Battery Service

    ELECTRICAL BATTERY SERVICE OCV - Open Circuit Voltage Test Battery voltage should be checked with a digital multimeter. General Battery Information Readings of 12.8 volts or less require further battery testing and charging. See the following chart and “Load Test”. The single most important thing to maintaining a sealed “Maintenance Free”...

  • Page 319: Starting System

    ELECTRICAL STARTING SYSTEM Voltage Drop Test The Voltage Drop Test is used to test for bad connections. When Troubleshooting performing the test, you are testing the amount of voltage drop through the connection. A poor or corroded connection will Starter Motor Does Not Run appear as a high voltage reading.

  • Page 320: Brush Inspection / Replacement

    ELECTRICAL NOTE: Note the alignment marks on both ends of Measure resistance between insulated brush and starter the starter motor casing. These marks must align housing. Reading should be infinite (OL). Inspect during reassembly. insulation on brush wires for damage and repair or replace as necessary.

  • Page 321: Armature Testing

    ELECTRICAL Brush Replacement Measure the resistance between each commutator segment and the armature shaft. The reading should be infinite (no Remove terminal nut with lock washer, flat washer, large continuity). phenolic washer, the small phenolic spacers, and sealing O-ring. Inspect O-ring and replace if damaged. Slide positive brush springs to the side, pull brushes out of their guides and remove brush plate.

  • Page 322: Starter Drive

    ELECTRICAL NOTE: It is important to tighten the bottom starter Install O-ring, two small phenolic spacers, large phenolic bolt first (circle), as the bottom hole acts as a pilot washer, flat washer, lock washer, and terminal nut. hole to properly align the starter drive (bendix) with While holding brush springs away from brushes, push the flywheel.

  • Page 323: Starter Solenoid Bench Test

    ELECTRICAL Remove the retaining ring, thrust washer, spring retainers and clutch return spring. Screw the overrun clutch off the end of the pinion shaft. Remove the old spring and install a new one. Lightly grease the pinion shaft and reinstall the clutch, spring, retainers, end washer and lock ring in the reverse order.

  • Page 324: Starter Exploded View

    ELECTRICAL Starter Exploded View Indicates Do not reuse. 10. Gear Assembly 1. Rubber Ring* Replace with new parts. 11. Through Bolt 2. Brush Spring 12. Cover 3. Thrust Washer 13. Stopper 4. Gear Assembly 14. Snap Ring 5. O-Ring* 15. Washer 6.

  • Page 325: Starting System Testing Flow Chart

    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 fully charged shop battery to continue test.

  • Page 326: Electrical Breakout Diagrams

    ELECTRICAL ELECTRICAL BREAKOUT DIAGRAMS 12V Key-On Power Circuit Starting System Circuit 10.32...

  • Page 327: Instrument Cluster Circuit

    ELECTRICAL Instrument Cluster Circuit Transmission Switch Circuit 10.33...

  • Page 328: Wheel Speed Sensor Circuit

    ELECTRICAL Wheel Speed Sensor Circuit AWD Circuit 10.34...

  • Page 329: Fuel Gauge Display Circuit

    ELECTRICAL Fuel Gauge Display Circuit Cooling Fan Circuit 10.35...

  • Page 330: Charging System Circuit

    ELECTRICAL Charging System Circuit 10.36...
  • Page 331 WIRE DIAGRAM 2009 RANGER RZR / RZR “S” (PAGE 1 OF 2) WD.1...
  • Page 332 WIRE DIAGRAM 2009 RANGER RZR / RZR “S” (PAGE 2 OF 2) WD.2...

Table of Contents