POLARIS RANGER XP 700 4X4 RANGER 6X6 SERVICE MANUAL
GENERAL INFORMATION
1
MAINTENANCE
2
ENGINE
3
FUEL INJECTION
4
BODY / STEERING / SUSPENSION
5
CLUTCHING
6
FINAL DRIVE
7
TRANSMISSION
8
BRAKES
9
ELECTRICAL
10
POLARIS RANGER XP 700 4X4 RANGER 6X6 SERVICE MANUAL
GENERAL INFORMATION
CHAPTER 1 GENERAL INFORMATION
1
MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 UNIT SERIAL NUMBER (VIN) LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 TRANSMISSION I.D. NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
VEHICLE DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 VEHICLE DIMENSIONS RANGER 4X4, 6X6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 MODEL: RANGER XP 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 MODEL: RANGER XP 6X6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 MODEL: RANGER XP 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 MODEL: RANGER XP 6X6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
1.1
GENERAL INFORMATION MODEL INFORMATION Model Identification The machine model number must be used with any correspondence regarding warranty or service.
Model Year Designation
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Machine Model Number Identification R 07 RH 68 AG Emissions & Model Option
Basic Chassis Designation
Engine Designation
Engine Designation Number EH068OLE043PLE ..............................Twin, Liquid Cooled, OHV 4 Stroke, Electric Start
VIN Identification World Mfg. ID
Vehicle Identifier
Vehicle Description
Body Style
}
}
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A R H 6 8 A * 7 P 0 0 0 0 0 0 Model Year
Engine Emissions
Powertrain
Plant No.
Check Digit
Individual Serial No. * This could be either a number or a letter
Engine Serial Number Location Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This information can be found on the sticker applied to the cylinder head on the side of engine. Engine Serial Number
1.2
A
GENERAL INFORMATION Unit Serial Number (VIN) Location
Transmission I.D. Number Location
The machine model number and serial number are important for vehicle identification. The machine serial number (A) is stamped on the lower LH frame rail close to the front drive wheel. The model and serial number are also located on a sticker under the hood (B).
1
The transmission I.D. number is located on the right side when installed in the machine.
A
A
A
B
1.3
GENERAL INFORMATION VEHICLE DIMENSIONS RANGER 4X4, 6X6
75 in. 190.50 cm
RANGER 4x4
10 in. 25.4 cm
58 in. 147 cm
1.4
GENERAL INFORMATION Vehicle Dimensions RANGER 4X4, 6X6
1
120 in. 305 cm
58 in. 147 cm
27 in. 69 cm 90 in. 229 cm 113 in. 287 cm
58 in. 147 cm
76 in. 193 cm
1.5
GENERAL INFORMATION GENERAL SPECIFICATIONS MODEL: RANGER XP 4X4 MODEL NUMBER: R07RH68AD,AG,AH,AK,AL,AW ENGINE MODEL: EH068OLE Category Dimension / Capacity Length 113 in. / 287 cm Width 60 in. / 152.4 cm Height 75 in. / 190.5 cm Wheel Base 76 in. / 193 cm Ground Clearance 11.5 in. / (29 cm) Turning Radius 132 in. / 335 cm Dry Weight 1185 lbs. / 537 kg Gross Vehicle Weight 2750 lbs. / 1247 kg Cargo Box Capacity 1000 lbs. / 454 kg 58 x 42 x 10 in. Cargo Box Dimensions (147 x 106.7 x 25.4 cm) 1500 lbs. / 681 kg Vehicle Payload (Includes driver and two passengers - 500 lbs. / 227kg) Hitch Towing Capacity 1500 lbs. / 681 kg Hitch Tongue Capacity 150 lbs. / 68 kg
MODEL: RANGER XP 6X6 MODEL NUMBER: R07RF68AF ENGINE MODEL: EH068OLE Category Dimension / Capacity Length 120 in. / 305 cm Width 60 in. / 152.4 cm Height 75 in. / 190.5 cm Wheel Base 90 in. / 229 cm Ground Clearance 7.2 in. / (18.25 cm) Turning Radius 180 in. / 457 cm Dry Weight 1410 lbs. / 640 kg Gross Vehicle Weight 2900 lbs. / 1315 kg Cargo Box Capacity 1250 lbs. / 567 kg 58 x 48 x 10 in. Cargo Box Dimensions (147 x 122 x 25.4 cm) 1750 lbs. / 794 kg Vehicle Payload (Includes driver and two passengers - 500 lbs. / 227kg) Hitch Towing Capacity 1750 lbs. / 794 kg Hitch Tongue Capacity 150 lbs. / 68 kg
1.6
GENERAL INFORMATION MODEL: RANGER XP 4X4 MODEL NUMBER: R07RH68AD,AG,AH,AK,AL,AW ENGINE MODEL: EH068OLE Engine Polaris Domestic Twin Cylinder, Platform Liquid Cooled, 4-Stroke Engine Model Number EH068OLE044 Engine Displacement 683cc Number of Cylinders 2 Bore & Stroke (mm) 80 x 68 mm Compression Ratio 9.40:1 Compression Pressure 150-170 psi Engine Idle Speed 1150 ± 100 RPM Lubrication Pressurized Wet Sump Oil Requirements 0W-40 Oil Capacity 2 qts. / 1.9 L Coolant Capacity 3.25 qts. / 3.1 L Overheat Warning Instrument Cluster Indicator Exhaust System 2 to 1 Canister Style Fuel System Fuel System Type Bosch Electronic Fuel Injection Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 39 psi Fuel Filters See Chapter 4 9 gal. (34 l) Fuel Capacity / Requirement 87 Octane (minimum) Electrical Alternator Max Output 500 watts @ 3000 RPM Lights: Main Headlights 2 - Dual Beam 35 watts / quartz Tail 5 watts x 2 Brake 5 watts x 2 Indicator Panel Lights 1 watt (ea.) Starting System Electric Start Ignition System Bosch EFI (ECU Controlled) Ignition Timing 7° BTDC @ 1200 RPM Champion RC7YC3 / Spark plug / Gap .035 in. (0.9 mm) Yuasa YB30L-B / Battery / Model / Amp Hr 30 Amp Hr. / 12 Volt Instrument Type Multifunction Speedometer DC Outlet Standard Fan: 20 Amp Dash Harness: 20 Amp Circuit Breakers Accessory Terminal: 20 Amp Power Relay: 15 Amp ECU Battery Supply: 6 Amp
Drivetrain Transmission Type Polaris Automatic PVT Gear Ratio: Front / Rear High 3.34:1 / 2.89:1 Low 8.67:1 / 7.49:1 Rev 5.92:1 / 5.11:1 Drive Ratio - Front 3.818:1 Drive Ratio - Final 3.70:1 Shift Type In Line Shift - H / L / N / R Trans. Oil Requirements Polaris AGL Gearcase Lube Belt 3211106 Drive Belt Deflection 1.125” / 28.57 mm Center Distance 10” / 254.5 mm Clutch Offset 0.365” / 9.27 mm Steering / Suspension Front Suspension MacPherson Strut Front Travel 8 in. / 20 cm Rear Suspension Independent Rear Suspension Rear Travel 9 in. / 23 cm Ground Clearance 11.5 in. / 29 cm Shock Preload Adjustment Cam Adjustment Front / Rear 2-2” Twin Tubes Turning Radius 132 in. / 335 cm Toe Out 1/8-1/4 in. / 3-6.35 mm Wheels / Brakes 12 x 6 / 10 gauge Front Wheel Size L.E. Model AW - 14 x 7 12 x 8 / 10 gauge Rear Wheel Size L.E. Model AW - 14 x 8 Carlisle / PXT / 26 x 8 R12 Front Tire L.E. Model AW - Kenda / Radial Make / Model / Size Bounty Hunter / 26 x 10 R14 Carlisle / PXT / 26 x 11 R12 Rear Tire L.E. Model AW - Kenda / Radial Make / Model / Size Bounty Hunter / 26 x 12 R14 F/R Tire Air Pressure 8-12 psi Front / 8-12 psi Rear Foot Actuated - 4 Wheel Brake - Front / Rear Hydraulic Disc Parking Brake Foot Actuated (Mechanical) Brake Fluid DOT 3 or DOT 4
CLUTCH CHART Altitude
Meters (Feet)
Shift Weight Drive Spring
Driven Spring
0-1500 (0-5000)
20-60 (5631698)
Blu/Gray (7042202)
Blk/Almd (7043167)
1500-3700 (5000 - 12000)
20-56 (5631215)
Blu/Gray (7042202)
Blk/Almd (7043167)
1.7
1
GENERAL INFORMATION MODEL: RANGER XP 6X6 MODEL NUMBER: R07RF68AF ENGINE MODEL: EH068OLE Engine Polaris Domestic Twin Cylinder, Platform Liquid Cooled, 4-Stroke Engine Model Number EH068OLE044 Engine Displacement 683cc Number of Cylinders 2 Bore & Stroke (mm) 80 x 68 mm Compression Ratio 9.40:1 Compression Pressure 150-170 psi Engine Idle Speed 1150 ± 100 RPM Lubrication Pressurized Wet Sump Oil Requirements 0W-40 Oil Capacity 2 qts. / 1.9 L Coolant Capacity 3.25 qts. / 3.1 L Overheat Warning Instrument Cluster Indicator Exhaust System 2 to 1 Canister Style Fuel System Fuel System Type Bosch Electronic Fuel Injection Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 39 psi Fuel Filters See Chapter 4 9 gal. (34 l) Fuel Capacity / Requirement 87 Octane (minimum) Electrical Alternator Max Output 500 watts @ 3000 RPM Lights: Main Headlights 2 - Dual Beam 35 watts / quartz Tail 5 watts x 2 Brake 5 watts x 2 Indicator Panel Lights 1 watt (ea.) Starting System Electric Start Ignition System Bosch EFI (ECU Controlled) Ignition Timing 7° BTDC @ 1200 RPM Champion RC7YC3 / Spark plug / Gap .035 in. (0.9 mm) Yuasa YB30L-B / Battery / Model / Amp Hr 30 Amp Hr. / 12 Volt Instrument Panel Type Multifunction Speedometer DC Outlet Standard Fan: 20 Amp Dash Harness: 20 Amp Circuit Breakers Accessory Terminal: 20 Amp Power Relay: 15 Amp ECU Battery Supply: 6 Amp
1.8
Drivetrain Transmission Type Polaris Automatic PVT Gear Ratio: Front / Rear High 3.89:1 / 3.36:1 Low 10.08:1 / 8.71:1 Rev 6.87:1 / 5.94:1 Drive Ratio - Front 3.818:1 Drive Ratio - Mid 3.70:1 Drive Ratio - Final 3.70:1 Shift Type In Line Shift - H / L / N / R Trans. Oil Requirements Polaris AGL Gearcase Lube Belt 3211106 Drive Belt Deflection 1.125” / 28.57 mm Center Distance 10” / 254.5 mm Clutch Offset 0.365” / 9.27 mm Steering / Suspension Front Suspension MacPherson Strut Front Travel 8 in. / 20 cm Center Suspension Progressive Rate / Independent Center Travel 5.25 in. / 13 cm Rear Suspension Swing Arm w/Dual Shocks Rear Travel 6.25 in. / 16 cm Ground Clearance 7.2 in. / 18.25 cm Shock Preload Adjustment Cam Adjustment Front / Rear 2-2” Twin Tubes Turning Radius 180 in. / 457 cm Toe Out 1/8-1/4 in. / 3-6.35 mm Wheels / Brakes Front Wheel Size 12 x 6 / 10 gauge Middle / Rear Wheel Size 12 x 8 / 10 gauge Front Tire Titan / AT489 / 25 x 10 R12 Make / Model / Size Middle / Rear Tire Titan / AT489 / 25 x 11 R12 Make / Model / Size F/M/R Tire Air Pressure 8-12 psi Front / 8-12 psi Rear Foot Actuated - 4 Wheel Brake - Front / Rear Hydraulic Disc Parking Brake Foot Actuated (Mechanical) Brake Fluid DOT 3 or DOT 4
CLUTCH CHART Altitude
Meters (Feet)
Shift Weight Drive Spring
Driven Spring
0-1500 (0-5000)
20-60 (5631698)
Blu/Gray (7042202)
Blk/Almd (7043167)
1500-3700 (5000 - 12000)
20-56 (5631215)
Blu/Gray (7042202)
Blk/Almd (7043167)
GENERAL INFORMATION V
1
P M 20 20 NOTE: NOTE: www.purepolaris.com.
Paint Codes Painted Part
Color Description
Polaris Number
Frame / Cab
Medium Gloss Black
P-067
RANGER XP 4x4 - Plastic - Hood / Dash
Black Metallic
P-177
RANGER XP 6x6 - Plastic - Hood / Dash
Dark Green
P-195
RANGER XP 4x4 - Plastic - Hood / Dash
Turbo Silver
P-402
RANGER XP 4x4 - Plastic - Hood / Dash
Mossy Oak™
P-455
RANGER XP 4x4 - Plastic - Hood / Dash
Delta Green
P-492
RANGER XP 4x4 - Plastic - Hood / Dash
Sunset Red Metallic
P-520
Replacement Keys Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number.
KEY COVER P/N 5533534
Key Series Number
Series# 20 21 22 23 27 28 31 32 67 68
Part Number 4010278 4010278 4010321 4010321 4010321 4010321 4110141 4110148 4010278 4010278
SPECIAL TOOLS Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, 1-800-328-6657.
1.9
GENERAL INFORMATION MISC. SPECIFICATIONS AND CHARTS Conversion Table
°C to °F: 9 (°C + 40) ÷ 5 - 40 = °F
1.10
°F to °C: (°F + 40) ÷ 9 - 40 = °C
GENERAL INFORMATION Standard Torque Specifications The following torque specifications are to be used only as a general guideline. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque.
1.11
1
GENERAL INFORMATION SAE Tap / Drill Sizes
Metric Tap / Drill Sizes
1.12
Decimal Equivalents
GENERAL INFORMATION Glossary of Terms ABDC: After bottom dead center. ACV: Alternating current voltage. Alternator: Electrical generator producing voltage alternating current. ATDC: After top dead center. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8' or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches. Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch. Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face. Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close and grip the drive belt. Crankshaft Run-Out: Run-out or 'bend' of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase. Measure at various points especially at PTO. DCV: Direct current voltage CVT: Centrifugal Variable Transmission (Drive Clutch System) DCV: Direct current voltage. Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the cylinder bore. Electrical Open: Open circuit. An electrical circuit which isn't complete. Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire touching the chassis). End Seals: Rubber seals at each end of the crankshaft. Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt. ft.: Foot/feet. Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction. g: Gram. Unit of weight in the metric system. gal.: Gallon. ID: Inside diameter. in.: Inch/inches. Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb. kg/cm²: Kilograms per square centimeter. kg-m: Kilogram meters. Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction. l or ltr: Liter. lbs/in²: Pounds per square inch. Left or Right Side: Always referred to based on normal operating position of the driver. m: Meter/meters. Mag: Magneto. Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings. Mechanical energy is converted to electrical energy in the stator. mi.: Mile/miles. mm: Millimeter. Unit of length in the metric system. 1 mm = approximately .040'. Nm: Newton meters. OD: Outside diameter. Ohm: The unit of electrical resistance opposing current flow. oz.: Ounce/ounces. Piston Clearance: Total distance between piston and cylinder wall. psi.: Pounds per square inch. PTO: Power take off. PVT: Polaris Variable Transmission (Drive Clutch system) qt.: Quart/quarts. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases. Reservoir Tank: The fill tank in the liquid cooling system. Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat. RPM: Revolutions per minute. Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings. Stator Plate: The plate mounted under the flywheel supporting the battery charging coils. TDC: Top dead center. Piston's most outward travel from crankshaft. Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit. Watt: Unit of electrical power. Watts = amperes x volts. WOT: Wide open throttle.
1.13
1
GENERAL INFORMATION
CHAPTER 2 GENERAL INFORMATION PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 PERIODIC MAINTENANCE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 PRE-RIDE - 25 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 50 - 100 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 100 - 300 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2
GENERAL COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 RH SIDE AND DASH VIEW (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 LH SIDE AND REAR VIEW (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 LH SIDE AND RH SIDE VIEWS (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
SERVICE PRODUCTS AND LUBES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS . . . . . . . . . . . 2.10
MAINTENANCE REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 MAINTENANCE REFERENCES, CONTINUED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 2.13 PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 SHIFT LINKAGE INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14 FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14 FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14 VENT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14 THROTTLE PEDAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14 THROTTLE FREEPLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15 AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15 AIR INTAKE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17 COMPRESSION AND LEAKDOWN TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17 BREATHER HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17 ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17 ENGINE OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18 EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
TRANSMISSION AND GEARCASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20 TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20 FRONT GEARCASE LUBRICATION (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 MIDDLE GEARCASE LUBRICATION (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22 REAR GEARCASE LUBRICATION (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23 REAR GEARCASE LUBRICATION (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 LIQUID COOLING SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 RADIATOR COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26 COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26 COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26 COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27 COOLANT DRAIN / RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
2.1
GENERAL INFORMATION FINAL DRIVE / WHEEL AND TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27 WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27 CV SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28 WHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28 WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28 TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28 TIRE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29 BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29 BATTERY FLUID LEVEL (CONVENTIONAL BATTERY) . . . . . . . . . . . . . . . . . . . . . . . 2.29 BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29 BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30 BATTERY STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30 BATTERY CHARGING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30 SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30 ENGINE TO FRAME GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
STEERING AND SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31 TIE ROD END / STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31 CAMBER AND CASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31 WHEEL TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32 TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32 FRONT SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33 REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33 REAR SUSPENSION ADJUSTMENT (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33 REAR SPRING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34 BRAKE SYSTEM INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34 BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34 PARKING BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35 BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35
2.2
GENERAL INFORMATION PERIODIC MAINTENANCE CHART Periodic Maintenance Overview Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations. Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently. Severe Use Definition • Frequent immersion in mud, water or sand • Racing or race-style high RPM use • Prolonged low speed, heavy load operation • Extended idle • Short trip cold weather operation Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.
Maintenance Chart Key The following symbols denote potential items to be aware of during maintenance:
001f= CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an authorized Polaris dealer. 0017= SEVERE USE ITEM --If vehicle is subjected to severe use, decrease interval by 50% (Severe Use is defined as frequent vehicle immersion in mud, water or sand, racing or race-style high rpm use, prolonged low speed - heavy load operation or extended idle. More preventative maintenance is required under these conditions. Fluid changes, cable, chain and chassis lubrication are required more frequently. For engine oil, short trip cold weather riding also constitutes severe use. Pay special attention to oil level. A rising oil level in cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately and monitor level. If oil level begins to rise, discontinue use and determine cause.) 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 with a001f could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.
2.3
2
GENERAL INFORMATION Pre-Ride - 25 Hour Maintenance Interval
Item 001f Steering
0017 Front Suspension 0017 Rear Suspension Tires
Maintenance Interval (whichever comes first) Miles Hours Calendar (KM) Pre-Ride -
Pre-Ride
-
-
Pre-Ride
-
-
Pre-Ride
-
Remarks
0017 Brake Fluid Level 0017 Brake Pedal Travel
-
Pre-Ride
-
-
Pre-Ride
-
Brake Systems Wheels / Fasteners Frame Fasteners
-
Pre-Ride Pre-Ride Pre-Ride
-
0017 Engine Oil Level
-
Pre-Ride
-
0017 Air Filter / Pre-Filter
-
Daily
-
Inspect;clean often
0017 Air Box Sediment Tube
-
Daily
-
Drain deposits when visible
Coolant Level
-
Daily
-
Head Lamp / Tail Lamp
-
Daily
-
-
Weekly
-
Inspect; replace as needed
10 H
Monthly
-
Inspect periodically
20 H
Monthly
-
Check terminals; clean; test
25 H
Monthly
-
Inspect level; change yearly
25 H
Monthly
-
Inspect level; change yearly
25 H
Monthly
-
Inspect level; change yearly
25 H
Monthly
-
Inspect level; change yearly
25 H
Monthly
-
Inspect; replace if necessary
25 H
1M
-
Perform a break-in oil change at one month
E
E
E
0017 Air Filter, E
Main Element
0017 Brake Pad Wear / Inspect 001f Parking Brake Pads Battery Front Gearcase Oil 0017 (if equipped)
0017 Middle Gearcase Oil (if equipped) Rear Gearcase Oil
0017 (if equipped) 0017 Transmission Oil 0017 Engine Breather
E Filter (if equipped)
0017 Engine Oil Change E
(Break-In Period)
Make adjustments as needed. See Pre-Ride Checklist on Page 2.13.
Check level daily, change coolant every 2 years Check operation; apply dielectric grease if replacing
0017Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) 001f Have an authorized Polaris dealer perform these services.
2.4
GENERAL INFORMATION 50 - 100 Hour Maintenance Interval
Item
Maintenance Interval (whichever comes first) Miles Hours Calendar (KM)
Remarks
50 H
6M
-
Lubricate all grease fittings, pivots, cables, etc. Inspect, lubricate, adjust
001f Steering
50 H
6M
-
Lubricate
0017 Front Suspension 0017 Rear Suspension
50 H
6M
-
Lubricate
50 H
6M
-
50 H
6M
-
Lubricate Inspect; adjust; lubricate; replace if necessary
50 H
6M
-
Inspect ducts for proper sealing/air leaks
50 H
6M
-
Cooling System
50 H
6M
-
0017 Engine Oil Change
100 H
6M
-
Inspect; adjust; replace as needed Inspect coolant strength seasonally; pressure test system yearly Perform a break-in oil change at 25 hours/ one month
0017 Oil Filter Change
100 H
6M
-
0017 General Lubrication Shift Linkage
001f Throttle Cable / Throttle E Pedal Throttle Body Air Intake E Ducts / Flange Drive Belt
E E
50 H
3M
-
Replace with oil change
0017 Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) 001f Have an authorized Polaris dealer perform these services.
2.5
2
GENERAL INFORMATION 100 - 300 Hour Maintenance Interval
Item
Maintenance Interval (whichever comes first) Miles Hours Calendar (Km)
Remarks
001f Fuel System E
100 H
12M
-
Check for leaks at tank cap, fuel lines, fuel pump, and fuel rail. Replace lines every two years.
001f Fuel Filter E
100 H
12M
-
Replace yearly
0017 Radiator 0017 Cooling Hoses 0017 Engine Mounts
100 H
12M
-
Inspect; clean external surfaces
100 H
12M
-
Inspect for leaks
100 H
12M
-
Inspect
100 H
12M
-
Inspect
100 H
12M
-
Inspect; replace as needed
100 H
12M
-
001f Clutches (Drive and Driven) 100 H 001f Front Wheel Bearings 100 H
12M 12M
-
24M 36M
-
Exhaust Muffler / Pipe 001f Spark Plug E
0017 Wiring
001f Toe Adjustment
100 H
001f Brake Fluid Spark Arrestor
200 H 300 H
0017 Auxiliary Brake 001f
Headlight Aim
Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc. Inspect;clean; replace worn parts Inspect; replace as needed Inspect periodically; adjust when parts are replaced Change every two years (DOT 3 or DOT 4) Clean out
-
Inspect daily; adjust as needed
-
Adjust as needed
0017Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) 001f Have an authorized Polaris dealer perform these services.
2.6
GENERAL INFORMATION GENERAL COMPONENT LOCATIONS RH Side (4X4) and Dash View
2
Rear Gearcase
Gas Tank Front Gearcase (Behind Radiator)
Engine (under seat)
Dash Components Instrument Cluster
Cup Holder
Light Switch
AWD / Differential Switch (if equipped) Cup Holder
Storage Box
Ignition Switch Storage Tray
12V Accessory Outlet Mode Button
Storage Compartment (with lid)
2.7
GENERAL INFORMATION LH Side and Rear View (4X4) Battery
Storage Compartment
Rear Prop Shaft
Front Prop Shaft
Transmission
Tail Gate Latch
Air Cleaner
Muffler 2' Hitch
2.8
Drive Shafts
GENERAL INFORMATION LH Side and RH Side Views (6X6)
2
Front Gearcase (behind radiator)
Engine (under seat)
Rear Gearcase
Transmission Mid Gearcase
Battery
Drive Shafts
Front Prop Shaft Rear Prop Shaft
2.9
GENERAL INFORMATION SERVICE PRODUCTS AND LUBES Polaris Lubricants, Maintenance and Service Products Part No.
Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) Premium 2 Cycle Engine Oil (Quart) (12 2871098 Count) Engine Oil (Quart) Premium 4 Synthetic 2871281 0W-40 (4-Cycle) (12 Count) Engine Oil (Gallon) Premium 4 Synthetic 2871844 0W-40 (4-Cycle) (4 Count) Engine Oil (16 Gallon) Premium 4 2871567 Synthetic 0W-40 (4-Cycle) Gearcase / Transmission Lubricants Premium Synthetic AGL Gearcase Lube 2873602 (12 oz. bottle) (12 Count) Premium Synthetic AGL Gearcase Lube 2873603 (1 Gal.) (4 Count) Premium ATV Angle Drive Fluid 2871653 (8 oz.) (12 Count) Premium ATV Angle Drive Fluid 2872276 (2.5 Gal) (2 Count) 2870465 Oil Pump for 1 Gallon Jug Premium Demand Drive Hub Fluid 2871654 (8 oz.) (12 Count) Premium Demand Drive Hub Fluid 2872277 (2.5 gal.) (2 Count) Grease / Specialized Lubricants Premium All Season Grease 2871322 (3 oz. cartridge) (24 Count) Premium All Season Grease 2871423 (14 oz. cartridge) (10 Count) 2871460 Starter Drive Grease (12 Count) 2871515 Premium U-Joint Lube (3 oz.) (24 Count) 2871551 Premium U-Joint Lube (14 oz.) (10 Count) 2871312 Grease Gun Kit 2871329 Dielectric Grease (Nyogel™) Coolant 2871323 60/40 Coolant (Gallon) (6 Count) 2871534 60/40 Coolant (Quart) (12 Count)
2.10
NOTE: Each item can be purchased separately at your local Polaris dealer. Part No. Description Additives / Sealants / Thread Locking Agents / Misc. 2870585 Loctite™ Primer N, Aerosol, 25 g Loctite™ Thread Sealant 565 2871956 (50 ml.) (6 Count) Loctite™ Threadlock 242 2871949 (50 ml.) (10 Count) Loctite™ Threadlock 242 2871950 (6 ml.) (12 Count) Loctite™ Threadlock 262 2871951 (50 ml.) (10 Count) Loctite™ Threadlock 262 2871952 (6 ml.) (12 Count) Loctite™ Threadlock 271 2871953 (6 ml.) (12 Count) Loctite™ Threadlock 271 2871954 (36 ml.) (6 Count) Loctite™ 680-Retaining Compound 2870584 (10 ml.) Loctite™ 518 Gasket Eliminator / Flange 2870587 Sealant (50 ml.) (10 Count) Premium Carbon Clean 2871326 (12 oz.) (12 Count) 2870652 Fuel Stabilizer (16 oz.) (12 Count) Black RTV Silicone Sealer 2871957 (3 oz. tube) (12 Count) Black RTV Silicone Sealer 2871958 (11 oz. cartridge) (12 Count) 2870990 DOT 3 Brake Fluid (12 Count) 2871557 Crankcase Sealant, 3-Bond 1215 (5oz.) 2872893 Engine Degreaser (12oz.) (12 Count) NOTE: The number count indicated by each part number in the table above indicates the number of units that are shipped with each order.
GENERAL INFORMATION MAINTENANCE REFERENCES Item
Lube Rec.
1. Engine Oil
Polaris 0W-40 Synthetic (PN 2871281)
2. Brake Fluid
DOT 3 (PN 2870990) or Dot 4
3. Transmission 4. Front Gearcase 5. Middle Gearcase
Polaris AGL Gearcase Lubricant (PN 2873602) Polaris Demand Drive Hub Fluid (PN 2871654) ATV Angle Drive Fluid (PN 2871653)
Method
Frequency* Change after 1st month (25 hrs), 6 months or 100 hours thereafter; Change more often in extremely dirty conditions, or short trip cold weather operation.
Add oil to proper level. Fill reservoir between MAX and Min lines. Add lube to bottom of fill plug threads. Drain completely. Add lube to specified quantity. Drain completely. Add lube to specified quantity.
As required. Change fluid every 2 years. Change annually. Change more often if used in severe conditions. Change annually*** Semi-annually**
* More often under severe use, such as operated in water or under severe loads. **Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information) ***Annually or 100 hours of operation (refer to Maintenance Schedule for additional information) 2. Brake Master Cylinder
1. Engine Dipstick / Fill Tube
3. Transmission
4. Front Gearcase 5. Middle Gearcase (6x6)
Fill Plug
Drain Plug
Fill Plug Drain Plug
2.11
2
GENERAL INFORMATION Maintenance References, Continued... Item
Lube Rec.
6. Hubstrut Assembly (Both Sides) 7. Swing Arm Pivot 8. Rear Prop Shaft Yoke 9. Front Prop Shaft Yoke 10. Rear Gearcase
Polaris All Season Grease (PN 2871423) Polaris All Season Grease (PN 2871423) Polaris Premium U-Joint Lube (PN 2871551) Polaris Premium U-Joint Lube (PN 2871551) ATV Angle Drive Fluid (PN 2871653)
Method Locate grease fitting on the underside of the hubstrut assembly and grease with grease gun. Locate grease fitting on inside of the swing arm pivot. Locate fittings and grease with grease gun. Locate fittings and grease with grease gun. Drain completely. Add lube to specified quantity.
Frequency* Semi-annually**
Semi-annually** Semi-annually** Semi-annually** Change annually***
* More often under severe use, such as operated in water or under severe loads. **Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information) ***Annually or 100 hours of operation (refer to Maintenance Schedule for additional information) Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or Mobilegrease Special
Yoke
6. Hubstrut Assembly 9. Front Prop Shaft
Yoke 7. Swing Arm (6x6)
8. Rear Prop Shaft (6x6)
Swing Arm Pivot
10. Rear Gearcase (6x6)
2.12
Fill Plug
10. Rear Gearcase (4x4)
GENERAL INFORMATION GENERAL VEHICLE INSPECTION AND MAINTENANCE
Shift Linkage Inspection / Adjustment Linkage rod adjustment is necessary when symptoms include:
Pre-Ride / Daily Inspection
• No All Wheel Drive light
Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.
• Noise on deceleration
2
• Inability to engage a gear
• Tires - check condition and pressures
• Excessive gear clash (noise)
• Fuel and oil tanks - fill both tanks to their proper level; Do not overfill oil tank
• Shift selectors moving out of desired range
• All brakes - check operation and adjustment (includes auxiliary brake)
NOTE: Remove necessary components to gain access to shift linkage cable ends (i.e. exhaust heat shield, exhaust pipe, etc.)
• Throttle - check for free operation and closing • Headlight/Taillight/Brakelight - check operation of all indicator lights and switches • Engine stop switch - check for proper function • Wheels - check for tightness of wheel nuts and axle nuts; check to be sure axle nuts are secured by cotter pins • Air cleaner element - check for dirt; clean or replace • Steering - check for free operation noting any unusual looseness in any area
1.
• Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners
2. 3.
• Engine coolant - check for proper level at the recovery bottle
4.
• Check all rear suspension components for wear or damage.
Inspect shift linkage cable, clevis pins, and pivot bushings and replace if worn or damaged. Be sure idle speed is adjusted properly. Place gear selector in neutral. Make sure the transmission bell crank is engaged in the neutral position detents. With two wrenches loosen the outside jam nut counterclockwise. Turn the outside jam nut 1 1/2 turns. Perform this procedure on the shift lever end, also. Inside Jam Nut
Outside Jam Nut
Frame, Nuts, Bolts, and Fasteners Periodically inspect the torque of all fasteners in accordance with the maintenance schedule. Check that all cotter pins are in place. Refer to specific fastener torques listed in each chapter.
Shift Cable Adjustment 5.
6.
After turning the outside jam nut 1 1/2 turns. Hold the outside jam nut with a wrench and tighten the inside jam nut clockwise, until it is tight against the bracket. Repeat Step 4 and Step 5 until the proper adjustment is made for the transmission cable.
2.13
GENERAL INFORMATION 7.
Use this procedure to loosen or tighten the shift linkage cable as needed. Clockwise
Counterclockwise
Inside Jam Nut
Fuel Filter The RANGER XP 4x4 and 6x6 EFI engines use a nonserviceable, high-volume, high-pressure, 60-micron internal fuel pump filter and an internal 10-micron filter located before the pump regulator. Neither filter is servicable.
Outside Jam Nut Fuel filter in tank is not serviceable
FUEL SYSTEM AND AIR INTAKE Fuel System
NOTE: For all other information related to the EFI fuel system refer to Chapter 4.
WARNING Gasoline is extremely flammable and explosive under certain conditions. Always stop the engine and refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. Do not overfill the tank. Do not fill the tank neck. If you get gasoline in your eyes or if you swallow gasoline, seek medical attention immediately. If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing. Never start the engine or let it run in an enclosed area. Engine exhaust fumes are poisonous and can result loss of consciousness or death in a short time. Never drain the fuel when the engine is hot. Severe burns may result.
Vent Lines 1.
2.
Check fuel tank and transmission vent lines for signs of wear, deterioration, damage or leakage. Replace every two years. Be sure vent lines are routed properly and secured with cable ties. CAUTION: Make sure lines are not kinked or pinched
Throttle Pedal Inspection
Throttle Pedal
Fuel Lines 1. 2.
3.
Check fuel lines for signs of wear, deterioration, damage or leakage. Replace if necessary. Be sure fuel lines are routed properly and secured with cable ties. CAUTION: Make sure lines are not kinked or pinched. Replace all fuel lines every two years.
2.14
If the throttle pedal has excessive play due to cable stretch or cable misadjustment, it will cause a delay in throttle speed. Also, the throttle may not open fully. If the throttle pedal has no play, the throttle may be hard to control, and the idle speed may be erratic. Check the throttle pedal play periodically in accordance with the Periodic Maintenance Chart and adjust the play if necessary.
GENERAL INFORMATION Throttle Freeplay Adjustment
Air Filter Service
Inspection
It is recommended that the air filter be replaced annually. When riding in extremely dusty conditions replacement will be required more often.
1. 2. 3. 4.
Apply the parking brake. Put the gear shift lever in the N (Neutral) position. Start the engine, and warm it up thoroughly. Measure the distance the throttle pedal moves before the engine begins to pick up speed. Free play should be 1/16” - 1/8” (1.5 - 3 mm).
The filter should be inspected periodically before each ride, using the following procedure. 1.
Lift the box to access the filter box cover.
Adjustment 1. 2. 3.
Air Box Location
Remove the seat. Locate the throttle cable adjuster. Squeeze the end of the rubber boot and slide it far enough to expose the end of the inline cable adjuster.
Boot 2.
3. Lock Nut 4. 5.
Adjuster
4.
Loosen the adjuster lock nut. Rotate the boot to turn the adjuster until 1/16' to 1/8' (1.5 - 3 mm) of freeplay is achieved at the throttle pedal.
Breather Filter Cover Seal
NOTE: While adjusting, lightly flip the throttle pedal up and down. 6. 7.
Remove clips (2) from air box cover and remove cover. Inspect the gasket. It should adhere tightly to the cover and seal all the way around. Remove air filter assembly. Do not clean the main filter, the filter should be replaced. Inspect main element and replace if necessary. If the filter has been soaked with fuel or oil it must be replaced.
Tighten the lock nut. Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position.
Filter Cover Installation 1.
Reinstall the filter into the air box container. Be sure the filter fits tightly in the air box.
NOTE: Apply a small amount of general purpose grease to the sealing edges of the filter before installing.
2.15
2
GENERAL INFORMATION 2.
Check air box. If oil or water deposits are found, drain them into a suitable container.
NOTE: Service more frequently if vehicle is operated in wet conditions or at high throttle openings for extended periods. 3.
Air Intake Inspection 1.
Lift the hood.
2.
Inspect the foam inserts in the air baffle boxes. If the foam inserts are dirty, clean the foam with a high flash point solvent, followed by hot soapy water.
3.
Rinse and dry the foam thoroughly.
4.
Inspect the foam for tears or damage. Replace if necessary.
5.
Reinstall the foam inserts into the air baffle boxes.
Install air box cover and secure with clips.
Air Baffing Box
Foam Air Box
Engine Intake Duct
PVT Intake Duct
2.16
GENERAL INFORMATION ENGINE
Engine Oil Level
Compression and Leakdown Test
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.
NOTE: This engine does NOT have decompression components. Compression readings will vary in proportion to cranking speed during the test. Average compression (measured) is about 150-200 psi during a compression test.
2
A smooth idle generally indicates good compression. Low engine compression is rarely a factor in running condition problems above idle speed. Abnormally high compression can be caused by carbon deposits in the combustion chamber or worn, damaged exhaust cam lobes. Inspect camshaft and combustion chamber if compression is abnormally high. A cylinder leakdown test is the best indication of engine condition. Follow manufacturer's instructions to perform a cylinder leakage test. (Never use high pressure leakage testers, as crankshaft seals may dislodge and leak). Cylinder Compression Standard: 150-200 PSI Cylinder Leakdown Service Limit 15%
Dipstick
1. 2.
Set machine on a level surface and set the parking brake. Be sure the machine has sat for awhile before removing the dipstick. IMPORTANT: Do not run the machine and then check the dipstick. 3. Stop engine and unlock the lever lock. Remove dipstick and wipe dry with a clean cloth.
(Inspect for cause if test exceeds 15%)
Breather Hose Inspection The engine is equipped with a breather hose (A). Inspect the breather hose for possible kinks or wear. The hose is form fitted for a proper fit. Follow the breather hose from the side of the airbox to the engine valve cover.
Lever Lock
Dipstick
NOTE: Make sure lines are not kinked or pinched.
2.17
GENERAL INFORMATION 4.
Reinstall dipstick and push it into place. Do not lock the dipstick. NOTE: Make certain the dipstick is inserted all the way into the filler tube to keep the angle and depth of dipstick consistent. When reinstalling the dipstick, make certain to seat the lever lock.
Engine Oil and Filter Change WARNING Personal injury can occur when handling used oil. Hot oil can cause burns or skin damage.
5.
Remove dipstick and check to see that the oil level is in the normal range. Add oil as indicated by the level on the dipstick. Do not overfill. (See NOTE below!) NOTE: Due to the dipstick entry angle into the crankcase, the oil level will read higher on the bottom side of the dipstick. Proper level indication is determined on the upper surface of the dipstick as it is being removed, regardless of the level marks being on top or on bottom. (See the next illustration)
Recommended Engine Oil: Polaris Premium Synthetic OW-40 (PN 2871281) (Quart) Ambient Temperature Range -40° F to 120° F
Dipstick 1. 2. Always read top side of dipstick to properly check oil level in crankcase
3. 4.
Place vehicle on a level surface. To ease access to the oil filter, try to access the oil filter from the front engine cover or remove the storage container located under the driver side seat (refer to Chapter 5 for front engine cover and storage removal). Run engine two to three minutes until warm. Stop engine. Clean area around drain plug at bottom of oil engine. Drain plug is accessible through the skid plate.
CAUTION NOTE: A rising oil level between checks weather driving can indicate contaminants gas or moisture collecting in the crankcase. level is over the full mark, change immediately.
in cool such as If the oil the oil
Oil may be hot. Do not allow hot oil to come into contact with skin, as serious burns may result. 5.
Place a drain pan beneath crankcase and remove drain plug. Drain Plug
6. Allow oil to drain completely. 7. Replace the sealing washer on drain plug. NOTE: The sealing surface on the drain plug should be clean and free of burrs, nicks or scratches. 8.
2.18
Reinstall drain plug and torque to 192 ± 24 in. lbs. (21.7 ± 2.7 Nm).
GENERAL INFORMATION 9.
Place shop towels beneath oil filter. Using Oil Filter Wrench (PV-43527), turn filter counterclockwise to remove.
Exhaust Pipe WARNING
Oil Filter
10. Using a clean dry cloth, clean filter sealing surface on crankcase. 11. Lubricate O-ring on new filter with a film of fresh engine oil. Check to make sure the O-ring is in good condition. 12. Install new filter and turn by hand until filter gasket contacts the sealing surface, then turn an additional 1/2 turn. 13. Remove dipstick and fill sump with 2 quarts (1.9 l) of Polaris Premium 4 Synthetic Oil (PN2871281)
Do not perform clean out immediately after the engine has been run, as the exhaust system becomes very hot. Serious burns could result from contact with exhaust components. To reduce fire hazard, make sure that there are no combustible materials in the area when purging the spark arrestor. Wear eye protection. Do not stand behind or in front of the vehicle while purging the carbon from the spark arrestor. Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas. Do not go under the machine while it is inclined. Set the hand brake and block the wheels to prevent roll back. Failure to heed these warnings could result in serious personal injury or death. The exhaust pipe must be periodically purged of accumulated carbon as follows: 1.
Crankcase Drain Plug Torque: 192 ± 24 in. lbs. (21.7 ± 2.7 Nm) Oil Filter Torque: Turn by hand until filter gasket contacts sealing surface, then turn an additional 1/2 turn Oil Filter Wrench: (PV-43527)
Clean Out Plug 2.
3. 14. Place gear selector in neutral and set parking brake. 15. Start the engine and let it idle for one to two minutes. Stop the engine and inspect for leaks. 16. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick. 17. Dispose of used oil and oil filter properly.
Remove the clean out plugs located on the bottom of the muffler as shown below.
Place the transmission in Park and start the engine. Purge accumulated carbon from the system by momentarily revving the engine several times. If some carbon is expelled, cover the exhaust outlet and lightly tap on the pipe around the clean out plugs with a rubber mallet while revving the engine several more times.
2.19
2
GENERAL INFORMATION 4.
5.
If particles are still suspected to be in the muffler, back the machine onto an incline so the rear of the machine is one foot higher than the front. Set the hand brake and block the wheels. Make sure the machine is in Park and repeat Steps 2 and 3. SEE WARNING If particles are still suspected to be in the muffler, drive the machine onto the incline so the front of the machine is one foot higher than the rear. Set the hand brake and block the wheels. Make sure the machine is in Park and repeat Steps 2 and 3. SEE WARNING
The transmission lubricant level should be checked and changed in accordance with the maintenance schedule. • Be sure vehicle is level with the parking brake on before proceeding. • Check vent hose to be sure it is routed properly and unobstructed. To check the level: 1.
Remove the fill plug on the backside of the transmission.
Fill Plug
1 ft. 6. 7. 8.
Repeat steps 2 through 5 until no more particles are expelled when the engine is revved. Stop the engine and allow the arrestor to cool. Reinstall the clean out plugs.
2.
The fluid should be at the bottom of the fill plug hole threads. Figure 7-26
TRANSMISSION AND GEARCASES Transmission Lubrication NOTE: It is very important to follow a regular transmission fluid check/change schedule. The service manual of the RANGER recommends the level be checked every twenty-five (25) hours of operation, and changed once (1) a year.
TRANSMISSION SPECIFICATIONS Specified Lubricant: AGL Synthetic Gearcase Lubricant (PN 2873602) (32 oz.) Approximate Capacity at Change: 15.2 oz. (450 ml.) Drain Plug / Fill Plug Torque: 14 ft. lbs. (19 Nm)
2.20
Fill Plug Threads Proper Fluid Level
GENERAL INFORMATION To change lubricant: 1.
Remove skid plate (if necessary).
2.
Place a drain pan beneath the transmission oil drain plug area.
3.
Remove the drain plug and wipe the magnetic end clean to remove accumulated metallic filings. TRANSMISSION
• The correct front gearcase lubricant to use is Polaris Premium Demand Hub Fluid.
Front Gearcase Specifications
2
Specified Lubricant: Premium Demand Drive Hub Fluid (PN 2871654) Capacity: 5.0 oz. (150 ml.) Fill Plug Torque: 8-30 ft. lbs. (11-41 Nm) Drain Plug Torque: 10 ft. lbs. (14 Nm)
FRONT GEARCASE Drain Plug 14 ft. lbs. (19 Nm) 4.
Make sure vent is unobstructed
After the oil has drained completely, install the drain plug. Torque to 14 ft. lbs. (19 Nm).
5.
Add the proper lubricant through the fill plug hole until the oil level is at the bottom of the fill plug threads (see figure 7-26). Do not overfill.
6.
Torque fill plug to 14 ft. lbs. (19 Nm)
7.
Check for leaks.
Fill Plug 8-30 ft. lbs. (11-41 Nm)
Drain Plug: 10 ft. lbs. (14 Nm)
Front Gearcase Lubrication To check the lubricant level: The gearcase lubricant level should be checked and changed in accordance with the maintenance schedule. • Be sure vehicle is level with parking brake on before proceeding.
The front gearcase lubricant level cannot be checked with a dipstick. The gearcase must be drained and re-filled with the proper amount of lubricant or be filled to the bottom of the fill plug hole threads. Refer to procedures.
• Check vent hose to be sure it is routed properly and unobstructed.
2.21
GENERAL INFORMATION To change gearcase lubricant:
4.
Remove fill plug (8 mm hex) and check the O-ring.
Fill Plug
A B 10 ft. lbs (14 Nm)
1.
2. 3.
Remove gearcase drain plug (B) (11 mm) located on the bottom of the gearcase and drain oil. (The drain plug is accessible through the skid plate.) Catch and discard used oil properly. Clean and reinstall drain plug (B) using a new sealing washer (A). Toque to 10 ft. lbs. (14 Nm). The fill plug can be accessed through the top hood area by removing the storage box or by removing the left side panel in the left wheel well.
5.
Fill with the recommended fluid amount (5 oz.) or to the bottom of the fill plug hole threads. Front Gearcase Plug Threads Fill with 5 oz.
Top View of Hood Area
6.
Install fill plug and check for leaks.
Middle Gearcase Lubrication (6x6) Middle Gearcase Specifications LH Side Panel
Specified Lubricant: ATV Angle Drive Fluid (PN 2871653) Capacity: 6.75 oz. (200 ml.) Drain Plug / Fill Plug Torque: 14 ft. lbs. (19.4 Nm) The gearcase lubricant level should be checked and changed in accordance with the maintenance schedule. • Be sure vehicle is level with parking brake on before proceeding. • Check vent hose to be sure it is routed properly and unobstructed. • The correct middle gearcase lubricant to use is ATV Angle Drive Fluid
2.22
GENERAL INFORMATION Rear Gearcase Lubrication (4x4)
To check the lubricant level: The gearcase must be drained and re-filled with the proper amount of lubricant. Refer to the procedure below.
REAR GEARCASE SPECIFICATIONS
To change middle gearcase lubricant: 1.
2. 3.
4. 5. 6. 7.
With the RANGER on a level surface, remove the fill plug and check the lubricant level. Lubricant should be kept at the specified level, according to the proper gearcase specifications listed. Support the vehicle securely with a jack stand and remove the front tire on the driver’s side. Remove gearcase drain plug located on the bottom of the gearcase and drain oil. (The drain plug is accessible through the skid plate.) Catch and discard used oil properly. Clean and reinstall drain plug using a new sealing washer. Remove fill plug. Fill with the recommended fluid amount or fill to the bottom of the threads of the fill plug hole. Install fill plug. Check for leaks.
Specified Lubricant: ATV Angle Drive Fluid (PN 2871653) Capacity: 18 oz. (532 ml) Fill Plug Torque: 40 ft. lbs. (54 Nm) Drain Plug Torque: 30-45 in. lbs. (3-5 Nm) To check the level: 1. 2.
MIDDLE GEARCASE (6X6) Make sure vent is unobstructed
With machine on level ground and with the parking brake on, remove fill plug from rear gearcase. The fluid level should be 0.75 in. (1.9 cm) from the bottom of the fill plug hole threads. Use a light colored and nonabsorbent measuring instrument (white zip tie) to measure the depth of the fluid in the rear gearcase. If level is low, add ATV Angle Drive Fluid (PN 2871653).
Side View 0.75 in. (1.9 cm)
Measuring Instrument 0.75 in. (1.9 cm) Fill to bottom of fill plug hole threads: 6.75 oz.
Fluid Level Fill Plug 14 ft. lbs. (19 Nm) Bottom View
3. 4.
Reinstall fill plug. Tighten to 40 ft. lbs. (54 Nm). Check for leaks.
Drain Plug 14 ft. lbs. (19 Nm)
2.23
2
GENERAL INFORMATION Rear Gearcase Lubrication (6x6)
To change the lubricant: 1.
Remove gearcase drain plug located on the bottom and drain the oil. Catch and discard used oil properly.
Rear Gearcase Specifications
Under Side View
Specified Lubricant: ATV Angle Drive Fluid (PN 2871653) Capacity: 10 Oz. (300 ml.) Drain Plug / Fill Plug Torque: 14 ft. lbs. (19.4 Nm)
Drain Plug 30-45 in. lbs. (3-5 Nm) 2. 3.
The gearcase lubricant level should be checked and changed in accordance with the maintenance schedule. • Be sure vehicle is level before proceeding with parking brake on.
Clean and reinstall the drain plug with a new sealing washer and tighten to 30-45 in. lbs. (3-5 Nm). Remove fill plug.
• Check vent hose to be sure it is routed properly and unobstructed. • The correct rear gearcase lubricant to use is Polaris ATV Angle Drive Fluid To check the lubricant level: The gearcase must be drained and re-filled with the proper amount of lubricant. Refer to the procedure below. To change rear gearcase lubricant:
Fill Plug 40 ft. lbs. (54 Nm) 4. 5.
1.
Add 18 oz. (532 ml.) of ATV Angle Drive Fluid (PN 2871653). Reinstall fill plug. Tighten to 40 ft. lbs (54 Nm).
2. 3.
4.
With the vehicle on a level surface, remove the fill plug and check the lubricant level. Lubricant should be kept at the specified level, according to the proper gearcase specifications listed. Support the vehicle securely with a jack stand and remove the front tire on the driver’s side. Remove gearcase drain plug located on the bottom of the gearcase and drain oil. (The drain plug is accessible through the skid plate.) Catch and discard used oil properly. Clean and reinstall drain plug using a new sealing washer. REAR GEARCASE - 6X6 Make sure vent is unobstructed
40 ft. lbs (54 Nm) Fill Plug
6.
Check for leaks. Drain Plug
2.24
GENERAL INFORMATION 5.
Coolant Level Inspection
Remove fill plug (A).
The recovery bottle, located on the left side of the machine, must be maintained between the minimum and maximum levels indicated on the recovery bottle.
A
6. 7.
Surge Tank Cap
2
Fill with 10 oz. (300 ml.) or fill to the bottom of the threads of the fill plug hole. Install fill plug and torque to 14 ft. lbs (19 Nm). Check for leaks.
COOLING SYSTEM
With the engine at operating temperature, the coolant level should be between the upper and lower marks on the coolant reservoir. If not:
Liquid Cooling System Overview
1.
The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose.
2.
As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle. As engine coolant temperature decreases the contracting (cooled) coolant is drawn back up from the tank past the pressure cap and into the radiator.
3.
Remove reservoir cap. Inner splash cap vent hole must be clear and open. Fill reservoir to upper mark with Polaris Premium 60/40 Anti Freeze / Coolant or 50/50 or 60/40 mixture of antifreeze and distilled water as required for freeze protection in your area. Reinstall cap.
NOTE: Some coolant level drop on new machines is normal as the system is purging itself of trapped air. Observe coolant levels often during the break-in period. Overheating of engine could occur if air is not fully purged from system. Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water.
Surge Tank
NOTE: If overheating is evident, allow system to cool completely and check coolant level in the radiator and inspect for signs of trapped air in system.
2.25
GENERAL INFORMATION Radiator Coolant Level Inspection
• Straight water or antifreeze may cause the system to freeze, corrode, or overheat.
NOTE: This procedure is only required if the cooling system has been drained for maintenance and/or repair. However, if the recovery bottle has run dry, or if overheating is evident, the level in the radiator should be inspected and coolant added if necessary. Radiator Cap
Polaris 60/40 Anti-Freeze / Coolant (PN 2871323) Cooling System Pressure Test Refer to Chapter 3 for cooling system pressure test procedure.
Cooling System Hoses 1.
Inspect all hoses for cracks, deterioration, abrasion or leaks. Replace if necessary. Coolant Lines
WARNING Never remove the pressure cap when the engine is warm or hot. Escaping steam can cause severe burns. The engine must be cool before removing the pressure cap. NOTE: Use of a non-standard pressure cap will not allow the recovery system to function properly. To access the radiator pressure cap raise the front hood. The radiator cap is located on the drivers side.
Coolant Strength / Type Test the strength of the coolant using an antifreeze hydrometer.
Antifreeze Hydrometer • A 50/50 or 60/40 mixture of antifreeze and distilled water will provide the optimum cooling, corrosion protection, and antifreeze protection. • Do not use tap water, straight antifreeze, or straight water in the system. Tap water contains minerals and impurities which build up in the system.
2.26
Radiator
2.
Check tightness of all hose clamps.
CAUTION Do not over-tighten hose clamps at radiator, or radiator fitting may distort, causing a restriction to coolant flow. Radiator hose clamp torque is 36 in. lbs. (4 Nm).
GENERAL INFORMATION Radiator 1.
4.
Check radiator (A) air passages for restrictions or damage.
A
5.
Remove the outlet radiator hose, inlet radiator hose, surge tank hose, and overflow hose from the radiator. Remove the radiator. Inlet Radiator Hose
2
Outlet Radiator Hose
2. 3.
Carefully straighten any bent radiator fins. Remove any obstructions with compressed air or low pressure water.
Surge Tank Hose Plug
Coolant Drain / Radiator Removal 1.
Remove the front bumper. Remove three bolts that secure the bumper to the bottom of the frame. Remove six screws (both sides) that secure the wheel well panel to the frame. Remove two bolts that secure the top bumper to the frame. Remove the darts that attach the plastic to the bumper.
Bolts
Wheel Well
FINAL DRIVE / WHEEL AND TIRE Wheel, Hub, and Spindle Torque Table Item
Nut Type
Specification
Aluminum Wheels (Cast)
Lug Nut (1)
Steel Wheels (Black / Camo)
Flange Nut (2) 35 ft. lbs. (47 Nm)
90 ft. lbs. (122 Nm)
Front Spindle Nut
-
70 Ft. Lbs. (95 Nm)
Rear & Center Hub Retaining Nut
-
110 Ft. Lbs. (150 Nm)
Bolts 2.
Remove two mounting screws that secure the top of the radiator to the frame. Remove the radiator cap. Pull the radiator out of the frame at an angle. NOTE: If you have trouble reaching the top radiator bolts, remove four screws from the top front of the hood liner. Prop the front of the hood up 1.5 inches (38.10 mm) to help remove the top bolts that secure the radiator to the frame. 3.
#2
#1
Aluminum Wheel
Steel Wheel
(LE Models) 90 ft. lbs. (122 Nm)
(Standard Models) 35 ft. lbs. (47 Nm)
Remove the drain plug and drain the coolant from the radiator. Drain the coolant into a suitable container and properly dispose of the coolant.
2.27
GENERAL INFORMATION CV Shaft Boot Inspection Inspect the CV shaft boots in the front and rear of the RANGER for damage, tears, wear, or leaking grease. If the rubber boot exhibits any of these symptoms, replace the boot. Refer to Chapter 7 for CV boot replacement, or have you Polaris dealer replace the boot.
4.
Securely tighten the wheel nuts to the proper torque listed in the torque table at the beginning of this section.
CAUTION If wheels are improperly installed it could affect vehicle handling and tire wear. On vehicles with tapered rear wheel nuts, make sure tapered end of nut goes into taper on wheel.
Tire Inspection • Improper tire inflation may affect vehicle maneuverability. • When replacing a tire always use original equipment size and type. Inspect Boots
Wheel Removal Front & Rear Wheel Nuts (4)
• The use of non-standard size or type tires may affect vehicle handling. Tire Tread Depth Always replace tires when tread depth is worn to 1/8' (3 mm) or less. Tread Depth 1/8' (3 mm)
Front Hub Nut 70 ft. lbs. (95 Nm)
Rear Hub Nut 110 ft. lbs. (150 Nm) 1. 2. 3. 4.
Stop the engine, place the transmission in gear and lock the parking brake. Loosen the wheel nuts slightly. Elevate the side of the vehicle by placing a suitable stand under the footrest frame. Remove the wheel nuts and washers and remove the wheel.
Wheel Installation 1.
2. 3.
With the transmission in gear and the parking brake locked, place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation. Attach the washers (if applicable) and wheel nuts and finger tighten them. Lower the vehicle to the ground.
2.28
WARNING Operating a RANGER with worn tires will increase the possibility of the vehicle skidding easily with possible loss of control. Worn tires can cause an accident. Always replace tires when the tread depth measures 1/8', (.3 cm) or less.
GENERAL INFORMATION Tire Pressure CAUTION Maintain proper tire pressure. Refer to the warning tire pressure decal applied to the vehicle.
NOTE: Batteries must be fully charged before use or battery life will be reduced by 10-30% of full potential. Charge battery for 3-5 hours at a current equivalent of 1/10 of the battery’s rated amp/hour capacity. Do not use the alternator to charge a new battery. (Refer to Battery Activation and Maintenance video PN 9917987)
Battery Fluid Level (Conventional Battery) Tire Pressure Inspection (PSI - Cold) Front
Rear
8-12
8-12
A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. Maintain the fluid level between the upper and lower level marks. Upper Level
ELECTRICAL AND IGNITION SYSTEM Battery Maintenance Keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly. Be careful not to allow cleaning solution or tap water into the battery
WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote:
Lower Level Add only distilled water. Tap water contains minerals that are harmful to a battery.
Battery Removal 1.
Open the Hood.
2. 3. 4.
Remove the battery vent tube from the battery. Disconnect the black (negative) battery cable. Disconnect the red (positive) battery cable.
External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.
2.29
2
GENERAL INFORMATION 5.
Lift the battery out of the vehicle, being careful not to tip it sideways and spill any electrolyte.
Spark Plug Service 1.
CAUTION
Remove both spark plug high tension leads (A). Clean plug area so no dirt and debris can fall into engine when plug is removed.
To reduce the chance of sparks: Whenever removing the battery, disconnect the negative (black) cable first. When reinstalling the battery, install the negative cable last.
A
Battery Installation Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging procedure before installing the battery. 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. Install the battery vent tube. NOTE: The vent tube must be free of obstructions and securely installed. Route the tube away from the frame and vehicle body to prevent contact with electrolyte. 4. 5. 6. 7.
B
2.
Remove spark plugs (B).
3.
Inspect electrodes for wear and carbon buildup. Look for a sharp outer edge with no rounding or erosion of the electrodes. Inspect electrode for wear and buildup
Coat the terminals with dielectric grease or petroleum jelly. Connect and tighten the red (positive) cable first. Connect and tighten the black (negative) cable last. Verify that cables are properly routed.
Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge. NOTE: Battery charge can be maintained by using a Polaris battery tender charger or by charging about once a month to make up for normal self-discharge. Battery tenders can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point.
4.
Clean with electrical contact cleaner or a glass bead spark plug cleaner only. CAUTION: A wire brush or coated abrasive should not be used.
5.
Measure gap with a wire gauge. Refer to specifications in picture below for proper spark plug type and gap. Adjust gap if necessary by bending the side electrode carefully. Spark Plug Gap
Battery Charging 1. 2.
3.
Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater. Reinstall the battery.
2.30
Gap - .035' (0.90 mm) 6.
If necessary, replace spark plug with proper type. CAUTION: Severe engine damage may occur if the incorrect spark plug is used.
7.
Apply a small amount of anti-seize compound to the spark plug threads.
GENERAL INFORMATION 8.
Install spark plug and torque to specification
Recommended Spark Plug: Champion RC7YC3 Spark Plug Torque: 18 Ft. Lbs. (24 Nm)
WARNING Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized Polaris MSDcertified technician when replacing worn or damaged steering parts. Use only genuine Polaris replacement parts.
Engine To Frame Ground Inspect engine ground cable connection. Be sure it is clean and tight. The ground cable runs from the engine to the terminal block located under the front hood next to the battery.
One of two methods can be used to measure toe alignment. The string method and the chalk method. If adjustment is required, refer to following pages for procedure.
Tie Rod End / Steering Inspection Black Ground
• To check for play in the tie rod end, grasp the steering tie rod, pull in all directions feeling for movement. • Repeat inspection for inner tie rod end (on steering post). Terminal Block (under hood)
• Replace any worn steering components. Steering should move freely through entire range of travel without binding.
STEERING AND SUSPENSION Steering The steering components should be checked periodically for loose fasteners, worn tie rod ends, and damage. Also check to make sure all cotter pins are in place. If cotter pins are removed, they must not be re-used. Always use new cotter pins. Replace any worn or damaged steering components. Steering should move freely through entire range of travel without binding. Check routing of all cables, hoses, and wiring to be sure the steering mechanism is not restricted or limited. NOTE: Whenever steering components are replaced, check front end alignment. Use only genuine Polaris parts.
• Elevate front end of machine so front wheels are off the ground. Check for any looseness in front hub / wheel assembly by grasping the tire firmly at top and bottom first, and then at front and rear. Try to move the wheel and hub by pushing inward and pulling outward. • If abnormal movement is detected, inspect the hub and wheel assembly to determine the cause (loose wheel nuts or loose front hub nut). • Refer to the Body/Steering or Final Drive chapter for more information.
Camber and Caster The camber and caster are non-adjustable.
2.31
2
GENERAL INFORMATION Wheel Toe Alignment Inspection
Toe Adjustment
1. 2.
If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell you which tie rod needs adjusting.
3.
Place machine on a smooth level surface. Set steering wheel in a straight ahead position and secure the steering wheel in this position. Place a chalk mark on the center line of the front tires approximately 10” (25.4 cm) from the floor or as close to the hub/axle center line as possible.
NOTE: Be sure steering wheel is straight ahead before determining which tie rod(s) need adjustment.
CAUTION During tie rod adjustment, it is very important that the following precautions be taken when tightening tie rod end jam nuts. If the rod end is positioned incorrectly it will not pivot, and may break. To adjust toe alignment: • Hold tie rod end to keep it from rotating. • Loosen jam nuts at both end of the tie rod. Chalk Mark Measurement “A”
Measurement “B”
NOTE: It is important that the height of both marks be equally positioned in order to get an accurate measurement. 4. 5.
6.
Measure the distance between the marks and record the measurement. Call this measurement “A”. Rotate the tires 180° by moving vehicle forward or backward. Position chalk marks facing rearward, even with the hub/axle centerline. Again measure the distance between the marks and record. Call this measurement “B”. Subtract measurement “B” from measurement “A”. The difference between measurements “A” and “B” is the vehicle toe alignment. The recommended vehicle toe tolerance is 1/8”, to 1/4”, (.3 to .6 cm) toe out. This means the measurement at the front of the tire (A) is 1/8”, to 1/4”, (.3 to .6 cm) wider than the measurement at the rear (B).
= In. / mm. Wheel Toe-Out: (A) - (B) = 1/8 - 1/4' (.3 to .6 cm)
• Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified in “Wheel Toe Alignment”. • IMPORTANT: When tightening the tie rod end jam nuts, the rod ends must be held parallel to prevent rod end damage and premature wear. Damage may not be immediately apparent if done incorrectly. Hold Rod End
Correctly Tightened Jam Nut
Incorrectly Tightened Jam Nut
• After alignment is complete, torque jam nuts to 12-14 ft. lbs. (16-19 Nm).
=T Tie Rod Jam Nut Torque: 12-14 ft. lbs. (16-19 Nm)
2.32
GENERAL INFORMATION Front Suspension
Rear Suspension
• Compress and release front suspension. Damping should be smooth throughout the range of travel. • Check all front suspension components and fasteners for wear or damage.
2
• Inspect front strut cartridges for leakage.
Bolt Torque 15 ft. lbs. (20 Nm)
RANGER 4X4 Independent Rear Suspension
Inspect for leaks
RANGER 6X6 Rear Swingarm Suspension • Compress and release rear suspension. Damping should be smooth throughout the range of travel. • Check all rear suspension components for wear or damage. • Inspect shock for leakage.
2.33
GENERAL INFORMATION Rear Suspension Adjustment (4x4)
BRAKE SYSTEM
The rear suspension may be adjusted to provide a stiffer suspension if necessary.
Brake System Inspection
1. 2. 3.
Remove the top shock mounting bolts from the inside mounting holes. Reposition the shocks to the outside mounting holes. Reinstall the shock mounting bolts. Torque to 30 ft. lbs. (40 Nm).
The following checks are recommended to keep the brake system in good operating condition. Service life of brake system components depends on operating conditions. Inspect brakes in accordance with the maintenance schedule and before each ride.
Outside Mounting Holes
• Keep fluid level in the master cylinder reservoir to the indicated level inside reservoir. Inside Mounting Holes • Use Polaris DOT 3 or DOT 4 Brake Fluid. • Check brake system for fluid leaks.
Rear Spring Adjustment The rear shock absorber springs are adjusted by rotating the adjustment cam either clockwise or counterclockwise to increase or decrease spring tension. To adjust the suspension, use the adjustment cam located near the bottom of the rear shock. This will allow you to increase or decrease the amount of spring preload.
• Check brake for excessive travel or spongy feel. • Check friction pads for wear, damage or looseness. • Check surface condition of the disc.
Brake Pad Inspection Pads should be changed when the friction material is worn to .180' (4.6 mm). When the pad are new the thickness is .298 ± .007' (7.56 ± .178 mm).
Rear Spring Adjustment Cam Brake Pad Measure Thickness Service Limit - .180' (4.6 mm)
Shock Spanner Wrench (PN 2870872)
2.34
GENERAL INFORMATION Parking Brake Pad Inspection Measure the thickness of the rear caliper parking brake pads. Replace assembly as needed. See illustration below for proper readings. Inboard Pad Thickness New .304” (7.72 mm) Limit: 0.24” (6.1 mm) Inboard Pad
2
Outboard Pad
Outboard Pad Thickness New 0.360” (9.14 mm) Limit: 0.31” (7.87 mm) Installed Disc to Park Brake 0.375” (0.953 cm)
New Rotor Disc Thickness 0.150” - 0.164” (3.81 - 4.16 mm)
Brake Hose and Fitting Inspection Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose fittings and replace any worn or damaged parts.
2.35
ENGINE
CHAPTER 3 ENGINE ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 CRANKCASE EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 ENGINE FASTENER TORQUE PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10 700 EFI ENGINE SERVICE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
GENERAL ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13 ACCESSIBLE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13 PISTON IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13 COOLING SYSTEM SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13 COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14 COOLING SYSTEM EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15 COOLING SYSTEM BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15 VALVE COVER REMOVAL - 6X6 MODELS (ENGINE INSTALLED) . . . . . . . . . . . . . . 3.17 ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18 ENGINE INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19 CYLINDER HONE SELECTION AND HONING PROCEDURE . . . . . . . . . . . . . . . . . . . 3.20 HONING TO DEGLAZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20 CLEANING THE CYLINDER AFTER HONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21 ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21 OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21 OIL FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
3
ENGINE DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23 CYLINDER HEAD ASSEMBLY EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23 ROCKER ARMS / PUSH RODS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24 CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24 CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25 CYLINDER HEAD WARP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25 VALVE SEAL / SPRING SERVICE (ON ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25 CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26 VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27 COMBUSTION CHAMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28 VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28 CYLINDER HEAD REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30 VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31 CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31 VALVE LIFTER REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31 PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32 CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33 PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34 PISTON / ROD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34 PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35 STARTER DRIVE BENDIX REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 3.35 FLYWHEEL / STATOR REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36 ENGINE CRANKCASE DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 3.36 CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
ENGINE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45 CRANKCASE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45 FLYWHEEL / STATOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.54 CYLINDER HEAD REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.54 OIL PUMP PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.57
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.58 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.58 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59
3.1
ENGINE ENGINE SPECIFICATIONS Crankcase Exploded Views A. B. C. D. E. F. G. H. I. J. K. L. M. N. O.
Journal Bearings Camshaft Thrust Plate Balance Shaft Woodruff Key Flange Seal Crankshaft Oil Pickup Journal Bearings Baffle Oil Plug Washer O-ring Crankcase Crankcase Bolts
B C A
115 ± 12 in. lbs. (13 ± 1.35 Nm)
D F
E
60 ± 6 in. lbs. (6.8 ± .68 Nm)
G
I
H
I
60 ± 6 in. lbs. (6.8 ± .68 Nm)
J NOTE: If needed, heat the oil baffle bolts with a heat gun to remove.
M 192 ± 24 in. lbs
K (21.7 ± 2.7 Nm) L N
Apply Loctite™ 242 to bolt threads.
O Apply White Lithium Grease 22 ± 2 ft. lbs. (30 ± 3 Nm)
3.2
Apply Moly Lube Grease.
ENGINE Oil Pump / Water Pump / Engine Cover Exploded View
A B
C D
J
E
F
K
22 ± 2 ft. lbs. (30 ± 3 Nm)
A. Split Gear B. Washer C. Bolt D. Oil Rotor E. Oil Pump F. Mag Gasket Cover G. Impeller H. Washer I. Nut J. Counterbalance Gear K. Washer L. Bolt M. Oil Pump Bolts N. Engine Cover O. Wire Hold down P. Stator Housing Bolts
L G
M
H I
84 ± 8 in. lbs. (9.5 ± .90 Nm)
No Grease on this Portion of the Gasket!
N
Apply corrosion resistant grease to stator grommet area.
108 ± 12 in.lbs. (6.8 ± .68 Nm)
O P
96 ± 3 in.lbs. (10.85 ± 0.35 Nm)
Oil Pump Bolt Tighten Sequence
Mag Cover Bolt Tighten Sequence Apply Polaris OW-40 oil to component Apply White Lithium Grease
3.3
3
ENGINE Stator Cover / Starter / Water Pump Exploded View Apply Polaris Starter Grease Apply Polaris 0W-40 oil to seal
Water Pump Cover Bolt Tighten Sequence
5
3
2
7 1
4
Loctite™ Pipe Sealant
6
(PN 2871956)
J No Grease or Oil
A
84 ± 8 ft.lbs. (9.5 ± 0.9 Nm)
K L
B
Tighten Top Bolt First
96 ± 12 in. lbs. (10.85 ± 1.35 Nm)
1st
2nd
C D
E
O
108 ± 12 ft.lbs. (12 ± 1.35 Nm)
F
N
M
65 ± 7 ft. lbs. (88 ± 9.5 Nm)
G
I A. Bolts B. Starter C. Washer D. Nut E. Positive Cable F. Negative Cable G. Gasket H. Clamp I. Bolts J. Gasket K. Water Pump Cover L. Bolts M. Crank Nut / Washer N. Flywheel
3.4
H
96 ± 12 in. lbs. (10.85 ± 1.35 Nm)
Stator Cover Bolt Tighten Sequence
ENGINE Oil Filter / Pressure Relief / Dipstick Assembly Exploded View A. Clamp B. Oil Fill Tube C. Dipstick D. O-ring E. Hex Plug F. Oil Filter Nipple G. Oil Filter H. Dowel I. Galley Plug Asm. J. Screw K. Relief Spring
C
3
B
50 ± 5 in. lbs.
22 ± 2 ft. lbs. (30 ± 3 Nm)
J (5.65 ± 0.56 Nm) I
K
A
H
D
18 ± 2 ft. lbs.
E (24.4 ± 2.71 Nm)
35 ± 4 ft. lbs. F (47.5 ± 5.4 Nm)
50 ± 5 in. lbs. (5.65 ± 0.56 Nm)
G
3.5
ENGINE Cylinder / Cylinder Head / Piston Exploded View
Lubricate threads & between washers and underside of bolt heads with engine oil. Torque in sequence provided.
Initial: 35 ± 4 ft. lbs (47.5 ± 5.5 Nm) in sequence. Finalize sequence by tightening an additional 90° (1/4 turn)
1 (Apply each Bolt Threads)
Apply Moly Lube grease to valve tips.
A
22 ± 2 ft. lbs. Gasket free of oil. Verify tabs are (30 ± 3 Nm) visible.
B
2C
Apply thin film of 0W- 40 to 25-55 mm of cylinder bore.
Head Bolt Tighten Sequence
Apply 0W-40 to piston pin or pin bore.
D3
Apply 0W- 40 to lifters.
F
Do Not install expansion plug more than 1.5 mm inward. 1.5 mm
E
G
4
4
Side View
A. B. C. D. E. F. G. H. I. J. K. L.
Head Bolts Rocker Arms Head Assembly Gasket Pushrods Bushing Expansion Plug Cylinder Piston Assembly Circlip Gasket Hydraulic Lifter
Apply Polaris 0W-40 Oil
Apply Moly Lube Grease
3.6
H I
5 3
UP J Circlip for Install
K L
6
ENGINE Engine Sensors / Valve Cover / General Component Exploded View
84 ± 8 in. lbs. (9.5 ± 0.9 Nm)
A. B. C. D. E. F. G. H. I. J. K. L. M. N. O. P. Q. R. S.
A B C
Screws 20 ± 5 in. lbs. Rocker Cover (2.5 ± 0.55 Nm) E Breather O-ring Seal 18 ± 2 ft. lbs. F Breather Bolts (24.5 ± 2.7 Nm) Spark Plugs (Apply Dielectric Grease Intake Boot to threads of Spark Plug) Bolts Boot Clamp G 18 ± 2 ft. lbs. Throttle Body (24.5 ± 2.7 Nm) Crank Position Sensor H Thermistor O-ring 20 ± 5 in. lbs. Thermostat (2.5 ± 0.55 Nm) I Bolts Gasket Exhaust Manifold Bolts J Thermostat Housing
3
D
K
Apply Corrosion Resistant Grease
84 ± 4 in. lbs. (9.5 ± 0.9 Nm)
17 ± 2 ft. lbs.
L (23 ± 3 Nm)
P
S
Q
M O R
18 ± 2 ft. lbs. (24.5 ± 2.7 Nm)
N
84 ± 8 in. lbs. (9.5 ± 0.9 Nm)
3.7
ENGINE EFI Harness / Fuel Injection Exploded View
A. Fuel Injector B. Fuel Rail C. EFI Harness
B
A
18 ± 2 ft. lbs. (24.5 ± 2.7 Nm)
C
NOTE: See Chapter 4 for more information on the EFI system.
3.8
ENGINE Engine Fastener Torque Patterns Crankcase Bolt Tighten Sequence
3
22 ± 2 ft. lbs. (30 ± 3 Nm)
Cylinder Head Bolt Tighten Sequence Lubricate threads and between washer and underside of bolt with engine oil. Torque in sequence to spec provided, allow the gasket to set for 1 minute, then tighten in sequence 90° (1/4 turn). 35 ± 4 ft. lbs. (47.5 ± 5.5 Nm) + 90° (1/4 turn)
3.9
ENGINE Torque Specifications Engine Torque Specifications Fastener
Size
in. lbs. (Nm)
ft. lbs. (Nm)
Camshaft Gear
8 mm
22 ± 2 (30 ± 3)
Camshaft Thrust Plate
6 mm
115 ± 12 (13 ± 1.35)
9.5 ± 1 (13 ± 1.35)
Throttle Body Adaptor Bolts
8 mm
216 ± 24 (24.5-± 2.7)
18 ± 2 (24.5 ± 2.7)
Counterbalance Gear
8 mm
22 ± 2 (30 ± 3)
Crankcase Bolts
8 mm
* 22 ± 2 (30 ± 3)
Crankcase Breather
5 mm
Cylinder Head Bolts
11 mm
Exhaust Manifold
8 mm
Flywheel
14 mm
Injector Rail
8 mm
216 ± 24 (24.5 ± 2.70)
18 ± 2 (24.5 ± 2.7)
Magneto Cover
6 mm
* 96 ± 3 (10.85 ± 0.35)
-
Oil Baffle Weldment
5 mm
60 ± 6 (6.8 ± 0.68)
-
Oil Drain Bolt (Crankcase)
12 mm
192 ± 24 (21.7 ± 2.7)
16 ± (21.7)
Oil Fill Tube Bolt
5 mm
50 ± 5 (5.64 ± 0.56)
-
Oil Filter Pipe Fitting
20 mm
Oil Pick Up
5 mm
60 ± 6 (6.8 ± 0.68)
-
Oil Pressure Relief Plug
10 mm
22 ± 2 (30 ± 3)
-
Oil Pump Housing Screw
6 mm
* 84 ± 8 (9.50 ± 0.90)
-
Rocker Arm
8 mm
Rocker Cover
6 mm
* 84 ± 8 (9.5 ± 0.9)
-
Spark Plug
14 mm
216 ± 24 (24.5 ± 2.7)
18 ± 2 (24.5 ± 2.7)
Starter Motor
6 mm
* 84 ± 8 (9.5 ± 0.9)
-
Stator Assembly
6 mm
96 ± 3 (10.85 ± 0.35)
-
Stator Housing
6 mm
* 96 ± 3 (10.85 ± 0.35)
-
20 ± 5 (2.5 ± 0.55)
* 35 ± 4 (47.5 ± 5.5)
216 ± 24 (24.5 ± 2.70)
18 ± 2 (24.5 ± 2.7) 65 ± 7 (88 ± 9.50)
35 ± 4 (47.5 ± 5.4)
* 22 ± 2 (30 ± 3)
Temperature Switch
3/8 NPT
17 ± 2 (23 ± 3)
Thermostat Housing
6 mm
Timing Plug
3/4-16
Trigger Coil/Stator Wire Holddown
5 mm
* 96 ± 3 (10.85 ± 0.35)
-
Water Pump Housing Cover
6 mm
* 96 ± 3 (10.85 ± 0.35)
-
Water Pump Impeller Nut
8 mm
108 ± 3 (12 ± 0.35)
-
84 ± 8 (9.5 ± 0.9)
7 - 9 (10 - 12)
NOTE: * See exploded views for notes or torque sequences.
3.10
-
ENGINE 700 EFI Engine Service Specifications Cylinder Head - Engine Specifications Main Component: Cylinder Head
Camshaft
Counter Balance
EH068OLE
Cam Lobe Height - Intake / Exhaust
1.3334' (33.8674 mm)
Camshaft Journal Outer Diameter - Mag
1.654' ± 0.00039' (42 ± 0.010 mm)
Camshaft Journal Outer Diameter - Center
1.634'± 0.00039' (41.50 ± 0.010 mm)
Camshaft Journal Outer Diameter - PTO
1.614' ± 0.00039' (41 ± 0.010 mm)
Camshaft Journal Bore Inner Diameter - Mag
1.656' ± 0.00039' (42.07 ± 0.010 mm)
Camshaft Journal Bore Inner Diameter - Center
1.637' ± 0.00039' (41.58 ± 0.010 mm)
Camshaft Journal Bore Inner Diameter - PTO
1.617' ± 0.00039' (41.07 ± 0.010 mm)
Camshaft Oil Clearance
0.00276' ± 0.00079' (0.07 ± 0.02 mm)
Camshaft End Play
0.0167' ± 0.0098' (0.425 ± 0.25 mm)
Counter Balance End Play
0.005' (0.127 mm)
Cylinder Head - Surface warp limit
0.00394' (0.1 mm)
Cylinder Head - Standard height
3.478' (88.35 mm)
Valve Seat - Contacting Width - Intake
0.0472' ± 0.00787' - 0.0039' (1.20 ± 0.20 - 0.10mm)
Valve Seat - Contacting Width - Exhaust
0.0591' ± 0.00787' - 0.0039' (1.50 ± 0.20 - 0.10 mm)
Valve Seat Angle
45.5° ± 0.255°
Valve Guide Inner diameter
0.2367' ± 0.00029' (6.012 ± 0.007 mm)
Valve Guide Protrusion Above Head
0.807' ± 0.0039' (20.50 ± 0.01 mm)
Valve Margin Thickness - Intake
Standard: 0.79' (20.06 mm) Max- 0.98' (24.89 mm) Min.- 0.59' (14.98 mm)
Valve Margin Thickness - Exhaust
Standard: 0.80' (20.32 mm) Max- 1.0' (25.4 mm) Min.- 0.60' (15.24 mm)
Valve Stem Diameter - Intake
0.2356' ± 0.00039' (5.985 ± 0.01 mm)
Valve Stem Diameter - Exhaust
0.2351' ± 0.00039' (5.972 ± 0.01 mm)
Valve Stem Oil Clearance - Intake
0.00228' ± 0.00098' (0.058 ± 0.025 mm)
Valve Stem Oil Clearance - Exhaust
0.00275' ± 0.00098' (0.0870 ± 0.025mm)
Valve Stem Overall Length - Intake
4.51' ± 0.01476' (114.5550 ± 0.375 mm)
Valve Stem Overall Length - Exhaust
4.5453' ± .01496' (115.45 ± 0.38 mm)
Valve Spring Overall Length - Free Length
1.735' (46.069 mm)
Valve Spring Overall Length - Installed Height
Intake - 1.4638' (37.18 mm) Exhaust - 1.4736' (37.43 mm)
3
Cylinder Head
Valve Seat
Valve Guide
Valve
Valve Spring
3.11
ENGINE Cylinder / Piston - Engine Specifications Main Components: Cylinder / Piston / Connecting Rod
Cylinder
Lifter
Piston
Piston Pin
EH068OLE
Cylinder - Surface warp limit (mating with cylinder head)
0.004' (0.10 mm)
Cylinder Bore - Standard
3.1495' (80 mm)
Cylinder Taper Limit
0.00031' (0.008 mm)
Cylinder Out of Round Limit
0.00030' (0.0075 mm)
Cylinder to Piston Clearance
.0015' ± .00059' (.040 ± .015mm)
Lifter Outer Diameter Standard
0.84245' ± 0.00025' (21.39 8 ± 0.00635 mm)
Lifter Block Bore
0.8438' ± 0.00062' (21.4322 ± 0.0157 mm)
Piston - Standard
3.1477' ± .000121' (79.954 ± .003mm)
Piston Standard Inner Diameter of Piston Pin Bore
0.78789' ± .00009' (20.0125 ± 0.003 mm)
Piston Pin Outer Diameter
0.7874' - 0.7872' (20 - 19.995 mm)
Piston Pin - Standard Clearance - Piston Pin to Pin Bore
0.00059' ± 0.0002' (0.015 ± 0.005 mm)
Piston Pin - Degree of Fit
Piston pin must be a push fit (by hand) at 68° F (20° C)
Piston / Connecting Rod / Crankshaft - Engine Specifications Main Components: Piston / Connecting Rod
Installed Gap Piston Ring
Ring to Groove Clearance
Top Ring - Standard
0.0059± 0.138' (0.15 ± 0.35mm)
Top Ring - Limit
> 15% Leakdown
Second Ring - Standard
0.0098 ± 0.197' (0.25 ± 0.50mm)
Second Ring - Limit
> 15% Leakdown
Oil Ring - Standard
0.0196± 0.00984' (0.50 ± 0.25mm)
Oil Ring - Limit
> 15% Leakdown
Top Ring - Standard
0.0024' ± 0.0008' (0.060 ± 0.020 mm)
Top Ring - Limit
> 15% Leakdown
Second Ring - Standard
0.0028' ± 0.0008' (0.070 ± 0.020 mm)
Second Ring - Limit
> 15% Leakdown
Connecting Rod Small End I.D.
Connecting Rod
Crankshaft
3.12
EH068OLE
Connecting Rod Small End Radial Clearance Connecting Rod Big End Side Clearance Connecting Rod Big End Radial Clearance Crankshaft Runout Limit
0.789'− 0.78841' (20.030 − 20.015 mm) 0.0098'± 0.00039' (0.025 ± 0.010mm) 0.01181'± 0.00591' (0.030 ± 0.015mm) 0.0015'± 0.00006' (0.0038 ± 0.0015mm) 0.00236' (0.060mm)
ENGINE Special Tools Part Number
Tool Description
PV-43527
OIL FILTER WRENCH
2200634
VALVE SEAT RECONDITIONING KIT
PU-45257
VALVE SPRING COMPRESSOR
PU-45652
VALVE PRESSURE HOSE
2871043
FLYWHEEL PULLER
2870390
PISTON SUPPORT BLOCK
PU-45497-1
CAM GEAR SPRING INSTALLATION KIT
PU-45497-2
CAM GEAR TOOTH ALIGNMENT TOOL
PU-45498
CAM SPANNER WRENCH
PU-45838
GEAR HOLDER
3
PA-44995
WATER PUMP MECHANICAL SEAL INSTALLER
PU-45543
UNIVERSAL DRIVER HANDLE
PA-45483
MAIN SEAL INSTALLER
PU-45658
CRANKSHAFT MAIN SEAL SAVER
PA-45401
WATER PUMP SEAL SAVER
2870975
MITY VAC™ PRESSURE TEST TOOL
PU-45778
OIL SYSTEM PRIMING TOOL
GENERAL ENGINE SERVICE
Piston Identification
Accessible Components
Four stroke engine rings have a rectangular profile. See “PISTON RING INSTALLED GAP” for ring installation. Use the information below to identify pistons and rings.
Following Components can be serviced or removed with the engine installed: (See Page 3.17 for 6x6 Valve Cover R & R) • Flywheel • Alternator (Stator) • Starter Motor/Drive
Engine Model
Piston Diameter
EH068OLE
80 mm
Cooling System Specifications
• Cylinder Head (6x6: See Page 3.17) • Cylinder (6x6: See Page 3.17)
Condition
• Piston / Rings (6x6: See Page 3.17)
Thermostat Open
• Camshaft (6x6: See Page 3.17)
Thermostat Full Open Lift
• Rocker Arms (6x6: See Page 3.17)
Thermostat Closed
• Oil pump / Water Pump / Oil Pump Drive Gear
System Capacity
• Gear Train Components
Radiator Cap Pressure Relief
Specification 180° F (82° C) 6 mm at 203° F (95° C) 171° F (77° C) 3.25 Quarts (2.13L) 13 PSI
Following Components Require Engine Removal for service: • Counterbalance Shaft or Bearings • Connecting Rod • Crankshaft
Polaris Premium Antifreeze 2871534 - Quart 2871323 - Gallon
• Crankshaft Main Bearings • Crankcase
3.13
ENGINE Recommended Coolant
Radiator Cap Pressure Test
Use only high quality antifreeze/coolant mixed with distilled water in a 50/50 or 60/40 ratio, depending on freeze protection required in your area. CAUTION: Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Polaris Premium 60/40 Antifreeze/Coolant is recommended for use in all cooling systems and comes pre-mixed, ready to use.
Radiator
Thermostat
Water Pump
Cylinder Head
Cylinder
WARNING Never remove radiator cap when engine is warm or hot. The cooling system is under pressure and serious burns may result. Allow the engine and cooling system to cool before servicing. 1.
Remove radiator cap and test cap using a commercially available cap tester.
2.
The radiator cap relief pressure is 13 psi. Replace cap if it does not meet this specification. Radiator Cap
Cooling System Pressure Test 1.
Open front hood.
2.
Remove surge tank hose from coolant filler neck.
3.
Connect a Mity Vac™ (PN 2870975) to the filler neck nipple and pressurize system to 10 psi. The system must retain 10 psi for five minutes or longer. If pressure loss is evident within five minutes, check the radiator, hoses, clamps and water pump seals for leakage. Coolant Flow Diagram
Surge Tank
From Thermostat Housing
To Water Pump
3.14
Radiator
ENGINE Cooling System Exploded View Radiator Inlet Hose
Engine Outlet Hose Engine Inlet Hose
Radiator Outlet Hose
3 Surge Tank
Radiator Cap
Fan
Radiator
Shroud Drain Plug
Cooling System Bleeding Procedure
PROCEDURE 1: 1.
WARNING
CAUTION
Always wear safety glasses and proper shop clothing when performing the procedures in this manual. Failing to do so may lead to possible injury or death.
CAUTION Use caution when performing these procedures. Coolant may be hot and may cause severe injury or burns. NOTE: If the coolant level is LOW in the radiator, or if there are leaks in the system, the coolant system will not draw coolant from the reservoir tank.
Park machine on a flat surface. Place the vehicle in Neutral and set the parking brake.
Be sure the engine has cooled and there is no pressure built up in the cooling system before removing the radiator cap. The coolant may be hot and could cause severe injury or burns. 2. 3.
Remove radiator cap (A) and top off coolant. Remove surge tank fill cap (B) and fill the surge tank to the full line.
B
A
NOTE: Use this procedure when a unit overheats and no apparent leaks in the cooling system are found.
3.15
ENGINE 4.
5.
Leave the cap off of the radiator to allow any possible air to escape. Start the engine and let it idle for 5-10 minutes or until the thermostat opens and allows coolant to flow through the system. Slightly loosen the bleed screw (C) on the thermostat cover to let air escape. If no air is present, a steady stream of coolant will stream out. If air is present, the screw will bubble and sputter as the air escapes.
Top LH Side of Engine
6. 7. 8.
WARNING Be sure to install the radiator cap before shutting off the engine. Coolant may spit out of the radiator. Stop the engine and let cool, top off the radiator filler neck with coolant. If you hear or see a “glug” at the filler neck or there is a dropping of the coolant level, indicating that coolant has been pulled into the system. Fill the surge tank only after you have completely filled the cooling system at the radiator filler neck. 10. Repeat this procedure, if overheating still occurs. If overheating occurs after repeating this procedure, proceed to Procedure 2.
3.16
1.
Drive the machine onto a slight incline or use properly weight rated ramps. Place the machine in Neutral and set the parking brake. Block the rear wheels. The radiator neck should be above the level of the top of the engine.
C
Squeeze the coolant lines by hand to help purge the system of air. Add Polaris Premium Antifreeze to the radiator if the level goes down. Tighten the bleed screw to 70 ± 10 in.lbs. (8 ± 1.13 Nm) on the thermostat housing and properly install the radiator cap.
9.
PROCEDURE 2:
CAUTION Be sure the engine has cooled and there is no pressure built up in the cooling system before removing the radiator cap. The coolant maybe hot and could cause severe injury or burns. 2.
Remove radiator cap and top off coolant. Fill the surge tank to the full line. 3. Leave the cap off of the radiator to allow any possible air to escape. Start the engine and let it idle for 5-10 minutes or until the thermostat opens and allows coolant to flow through the system. NOTE: If there is air in the system you will see air bubbles forming through the radiator fill neck. 4. 5.
Add coolant as needed. If no bubbles are seen at the filler neck, the system should be purged of air. Install the radiator cap and turn off the machine.
WARNING Be sure to install the radiator cap before shutting off the engine. Coolant may spit out of the radiator.
ENGINE Valve Cover Removal - 6x6 Models (Engine Installed)
5.
Remove the heat shield shown below and loosen the exhaust mounts.
The RANGER 6x6 models have a different engine mounting system that makes it more difficult to access and remove the engine valve cover. Use the procedure provided in this section of the chapter to remove the valve cover and allow for engine top-end component service. 1.
Remove the seat base.
2.
Remove the clamp from the valve cover breather hose and remove the hose and valve cover vent. Screws (7)
Remove
3
Valve Cover
Breather Hose Vent
3.
Remove the 7 screws that retain the valve cover.
4.
Remove the front dog house cover located in the floor panel of the RANGER. The valve cover will have to be removed through the dog house. Floor Panel
Loosen
6.
Remove the upper engine mount.
7.
Loosen the lower engine mount bolts, but DO NOT completely remove them.
8.
Remove the front engine mount bolts from the engine case.
NOTE: You may need to support the engine during this step by using a jack or by using wooden blocks between the engine and frame. Upper Mount
Remove
Dog House Cover
Remove Lower Mount Loosen 9.
Front Mount
Move the engine to allow the valve cover to be removed through the dog house cover hole.
10. To reinstall, reverse steps 1-9. Torque all bolts to specification as listed earlier in this chapter. NOTE: It may be necessary to use a pry bar to get the bolts back in during reassembly.
3.17
ENGINE Engine Removal
12. Disconnect the air intake hose (D) from the air box and remove the air intake hose.
WARNING
C
B
Always wear safety glasses and proper shop clothing when performing the procedures in this manual. Failing to do so may lead to possible injury or death. 1. 2. 3. 4.
Clean work area. Thoroughly clean the engine and chassis. Disconnect battery (-) negative cable. Remove the following parts as required: • Seat • Storage unit under driver seat (Refer to chapter 5)
5.
A
Remove middle dog house cover and remove exhaust pipe bolts.
D 13. Disconnect the Throttle Position Sensor at the electrical connector (E). Remove the clamps that secure the throttle body (F) to the air intake boot and engine intake boot. Remove the throttle body (F). Insert a shop towel into the engine intake to prevent dirt from entering the intake port.
E
F 6.
Remove springs from exhaust pipe and remove pipe.
7.
Refer to PVT System in Chapter 6 to remove outer clutch cover, drive belt, drive clutch, driven clutch, and inner cover.
8.
Drain coolant and engine oil.
9.
Remove the air breather line (A).
14. Relieve the fuel pressure in the fuel rail (refer to Chapter 4, “FUEL INJECTION”) for proper procedure. Carefully remove the fuel rail (G) and injectors. 15. Remove the spark plug high tension leads (H).
G
10. Remove PVT exhaust duct (B). 11. Remove the exhaust shield (C).
H
3.18
ENGINE 16. Remove the crank position sensor (I) located on the mag cover.
NOTE: Use caution when lifting the engine out of frame. Use an engine lift or other means if the engine is too heavy to be lifted manually.
I
3 17. Disconnect the coolant temperature sensor (J) from the left side of the cylinder.
J
22. For engine installation, reverse procedures.
Engine Installation Notes After the engine is installed in the frame, review this checklist and perform all steps that apply: General Items 1.
18. Disconnect the coolant hoses. Properly dispose of any antifreeze from the engine or hoses. 19. When removing starter cables, note and mark ground cable and positive (+) cable mounting angle and locations. Remove the cables.
Install previously removed components using new gaskets, seals, and fasteners where applicable.
NOTE: Properly route all electrical harnesses and re-attach any fasteners or protective tubing. Check for any possible rubbing points of electrical wires. 2.
20. Remove all engine mount nuts and / or engine mount plates.
Perform regular checks on fluid levels, controls, and all important areas on the vehicle as outlined in the daily preride inspection checklist (refer to Chapter 2 or the Owner's Manual).
PVT System 21. With all hoses and wires disconnected, the engine can be pulled straight out of the chassis. NOTE: Rotating the engine to the left 90 degrees (valve cover facing left), may ease engine removal.
1. 2. 3.
Adjust center distance of drive and driven clutch. (Chapter 6) Adjust clutch offset, alignment, and belt deflection. (Chapter 6) Clean clutch sheaves thoroughly and inspect inlet and outlet ducts for proper routing and sealing. (Chapter 6)
Transmission 1.
Inspect transmission operation and adjust linkage if necessary. Refer to Chapter 2 and Chapter 8.
3.19
ENGINE Exhaust 1.
2.
Replace exhaust gaskets. Seal connections with high temp silicone sealant. Check to be sure all springs are in good condition.
Cylinder Hone Selection And Honing Procedure Cylinders may be wet or dry honed depending upon the hone manufacturer’s recommendations. Wet honing removes more material faster and leaves a more distinct pattern in the bore.
Bleed Cooling System NOTE: Follow coolant bleeding procedure outlined earlier in this chapter Engine Break-In Period The break-in period for a Polaris RANGER engine is defined as the first ten hours of operation, or the time it takes to use two full tanks of gasoline. No single action on your part is as important as a proper break-in period. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.
CAUTION
CAUTION A hone which will straighten as well as remove material from the cylinder is very important. Using a common spring loaded glaze breaker for honing is not advised for nicasil cylinders. Polaris recommends using a rigid hone or arbor honing machine. Cylinders may be wet or dry honed depending upon the hone manufacturer's recommendations. Wet honing removes more material faster and leaves a more distinct pattern in the bore.
Honing To Deglaze Use only Polaris Premium 0-40W All Season synthetic oil or equivalent. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result. Do not operate at full throttle or high speeds for extended periods during the first three hours of use. Excessive heat can build up and cause damage to close fitted engine parts. 1.
Fill fuel tank with unleaded or leaded fuel which has a minimum pump octane number of 87= (R+ M)/2.
2.
Check oil level indicated on dipstick. Add oil if necessary (Refer to Chapter 2, “Engine Oil Level” ).
3.
Drive slowly at first to gradually bring engine up to operating temperature.
4.
Vary throttle positions. Do not operate at sustained idle or sustained high speed.
5.
Perform regular checks on fluid levels, controls and all important bolt torques. Pull only light loads during initial break in.
6.
Pull only light loads during initial break-in.
7.
Change oil and oil filter after break-in period at 25 hours.
3.20
A finished cylinder should have a cross-hatch pattern to ensure piston ring seating and to aid in the retention of the fuel/oil mixture during initial break in. Hone cylinder according to hone manufacturer's instructions, or these guidelines: • Honing should be done with a diamond hone. Cylinder could be damaged if the hone is not hard enough to scratch the nicasil lining. • Use a motor speed of approximately 300-500 RPM, run the hone in and out of the cylinder rapidly until cutting tension decreases. Remember to keep the hone drive shaft centered (or cylinder centered on arbor) and to bring the stones approximately 1/2, (1.3 cm) above and below the bore at the end of each stroke. • Release the hone at regular intervals and inspect the bore to determine if it has been sufficiently de-glazed, and to check for correct cross-hatch. NOTE: Do not allow cylinder to heat up during honing. • After honing has been completed, inspect cylinder for thinning or peeling.
ENGINE If cylinder wear or damage is excessive, it will be necessary to replace the cylinder. The cylinders are lined with a nicasil coating and are not repairable. Hone only enough to de-glaze the outer layer of the cylinder bore.
Oil Pressure Test 1.
Remove blind plug/sender from left side of crankcase.
2.
Insert a 1/8 NPT oil pressure gauge adaptor into the crankcase and attach the gauge.
3.
Start engine and allow it to reach operating temperature, monitoring gauge indicator.
NOTE: Use only Polaris Premium 0W-40 Synthetic Engine Lubricant.
Example of Cross Hatch Pattern
Oil Pressure at 5500 RPM (Engine Hot): Standard: 39 PSI Minimum: 35 PSI
IMPORTANT: Clean the cylinder after honing If cylinder wear or damage is excessive, it will be necessary to replace the cylinder. The cylinders are lined with a nicasil coating and are not repairable. Hone only enough to de-glaze the outer layer of the cylinder bore.
Cleaning the Cylinder After Honing It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material. Wash the cylinder in a solvent, then in hot, soapy water. Pay close attention to areas where the cylinder sleeve meets the aluminum casting (transfer port area). Use electrical contact cleaner if necessary to clean these areas. Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris Lubricant.
Engine Lubrication Specifications
= Capacity - Approximately 2 U.S. Quarts (1.9 l) Oil Type - Polaris Premium 0W-40 Synthetic Filter Wrench - PV-43527 or equivalent - Oil Pressure Specification 35-39 PSI @ 5500 RPM, Polaris 0W-40 Synthetic, Engine at operating temperature.
3.21
3
ENGINE Oil Flow Chart This chart describes the flow of oil through the 700 engine. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through the oil filter. If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element. At this point, the oil is supplied to the main oil galley through a crankcase passage. Oil is then diverted three ways from the main oil galley, with the first path entering the camshaft bores, onto the rear balance shaft journal and then draining back into the crankcase sump. The second oil path from the main oil galley feeds the lifter bores and then drains back to the crankcase sump. The third oil path flows through a crankcase galley to the MAG side crankshaft journal and also to the front balance shaft journal and onto the crankcase sump. The oil pressure switch is fed off the main oil galley.
3.22
ENGINE ENGINE DISASSEMBLY AND INSPECTION Cylinder Head Assembly Exploded View
Rocker Arms
3 Retainer Locks (keepers)
Push Rods
Spring Retainers
Springs
Valve Seals
Valve Spring Seats
Cylinder Head Hydraulic Lifters
Valves
3.23
ENGINE Rocker Arms 1.
5.
If the push rod (A) is visibly bent, it should be replaced.
Mark or tag rocker arms in order of disassembly to keep them in order for reassembly.
A
Cylinder Head Removal Inspect the wear pad at the valve end of the rocker arm for indications of scuffing or abnormal wear. If the pad is grooved, replace the rocker arm. NOTE: Do not attempt to true this surface by grinding.
1.
3.
3.
2.
Check the rocker arm pad and fulcrum seat for excessive wear, cracks, nicks or burrs.
2.
Loosen the six cylinder head bolts evenly 1/8 turn each in a criss-cross pattern until loose. Remove bolts (A) and tap cylinder head (B) lightly with a soft face hammer until loose. CAUTION: Tap only in reinforced areas or on thick parts of cylinder head casting to avoid damaging the head or cylinder. Remove cylinder head (B) and head gasket (C) from the cylinder (D).
Push Rods 1. 2.
Clean push rods (A) in a suitable solvent. Blow dry push rods with compressed air. Use compressed air to confirm the oil passage is clear in the center of the push rod.
WARNING
A
Always wear safety glasses when working with compressed air to prevent personal injury. 3. 4.
Check the ends of the push rods (A) for nicks, grooves, roughness or excessive wear. The push rods (A) can be visually checked for straightness while they are installed in the engine by rotating them with the valve closed. Push rods can also be checked with a dial indicator or rolled across a flat surface to check for straightness.
3.24
B C D
ENGINE Cylinder Head Inspection
Valve Seal / Spring Service (On Engine)
Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon.
NOTE: The following procedure is only for servicing the top end of the valve train when replacing valve springs or replacing valve seals.
CAUTION Use care not to damage sealing surface.
In some cases the valve train can be serviced while the cylinder head is still on the engine. Keep all parts in order with respect to their location in the cylinder head.
WARNING
Cylinder Head Warp 1.
Lay a straight edge (A) across the surface of the cylinder head (B) at several different points and measure warp by inserting a feeler gauge between the straight edge and the cylinder head surface. If warp exceeds the service limit, replace the cylinder head.
Wear eye protection or a face shield during cylinder head disassembly and reassembly. 1.
Having already removed the valve cover, rocker arms and pushrods, align the cylinder to be worked on at top dead center (TDC). Install the Valve Pressure Hose (PU45652) into the spark plug hole. Hook the hose to an air compressor and supply 50 to 100 psi to the hose. This will seat the valves during valve spring removal. Do not remove air from the hose at anytime until reassembly is completed.
2.
Using the Valve Spring Compressor (PU-45257), compress the valve spring and remove the valve keepers.
A
B
3
NOTE: A small parts magnet (A) can aid in the removal of the retainers (B).
Measure at different points on the surface.
B
= In. / mm. Cylinder Head Warp Limit: .004' (.1016 mm) max
A
PU-45257 NOTE: To prevent damage to the valve seals, do not compress the valve spring more than is needed to remove the valve keepers. 3.
Remove spring retainer and spring.
4.
The valve seals are now serviceable.
3.25
ENGINE Cylinder Head Disassembly
4.
1.
IMPORTANT: It is recommended to replace seals whenever the cylinder head is disassembled. Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup.
Carefully remove the cylinder components.
5.
Remove valve guide seals.
Mark the valves with a white pen. Remove the valves from the cylinder head. This will ensure that the valves are properly placed during engine reassembly.
Mark the Valves
2.
Place the hydraulic lifters (C), pushrods (D), and rocker arms (E) in a safe, clean area.
C
D
E 3.
Measure free length of spring with a Vernier caliper. Compare to specifications. Replace spring if measurement is out of specification.
Valve Spring Free Length
= In. / mm. Valve Spring Free Length: Std: 1.735' (44.069 mm)
3.26
ENGINE Valve Inspection 1. 2.
Remove all carbon from valves with a soft wire wheel or brush. Check valve face for runout, pitting, and burnt spots. To check for bent valve stems, mount valve in a drill or use “V” blocks and a dial indicator.
= In. / mm. Valve Stem Diameter: Intake: 0.2356' + 0.00039' (5.985 + 0.01 mm) Exhaust: 0.2351' + 0.00039' (5.972 + 0.01 mm) 6.
Measure valve guide (C) inside diameter at the top middle and end of the guide using a small hole gauge and a micrometer. Measure in two directions.
C
3.
Check end of valve stem for flaring, pitting, wear or damage (A).
A
B Inspect split keeper groove for wear or flaring of the keeper seat area (B). NOTE: The valves can be re-faced or end ground, if necessary. They must be replaced if extensively worn, burnt, bent, or damaged.
= In. / mm.
4.
5.
Measure diameter of valve stem with a micrometer in three places, then rotate 90 degrees and measure again (six measurements total). Compare to specifications.
Valve Guide I.D.: 0.23672' + 0.000295' (6.0617 + 0.0075 mm) 7.
Subtract valve stem measurement from the valve guide measurement to obtain stem to guide clearance. NOTE: The valve guides cannot be replaced. Be sure to measure each guide and valve combination individually.
Measure valve stem in several places. Rotate the valve 90 degrees and measure for wear.
3.27
3
ENGINE Combustion Chamber 1.
Clean all accumulated carbon deposits from combustion chamber and valve seat area with carbon cleaner and a soft plastic scraper. IMPORTANT: Do not use a wire brush, metal scraper, or abrasive cleaners to clean the bottom of the cylinder head. Extensive damage to the cylinder head may result. Wear safety glasses during cleaning.
Combustion Area
NOTE: Valve seat width and point of contact on the valve face is very important for proper sealing. The valve must contact the valve seat over the entire circumference of the seat, and the seat must be the proper width all the way around. If the seat is uneven, compression leakage will result. If the seat is too wide, seat pressure is reduced, causing carbon accumulation and possible compression loss. If the seat is too narrow, heat transfer from valve to seat is reduced. The valve may overheat and warp, resulting in burnt valves.
Valve Seat Reconditioning
1.
Install pilot into valve guide.
NOTE: Polaris recommends that the work be done by a local machine shop that specializes in this area.
2.
Apply cutting oil to valve seat and cutter.
3.
Place 46° cutter on the pilot and make a light cut.
NOTE: The cylinder head valve guides cannot be replaced.
WARNING Wear eye protection or a face shield during cylinder head disassembly and reassembly.
Valve Seat Inspection Inspect valve seat in cylinder head for pitting, burnt spots, roughness, and uneven surface. If any of the above conditions exist, the valve seat must be reconditioned. If the valve seat is cracked the cylinder head must be replaced. Follow the manufacturers instructions provided with the valve seat cutters in the Cylinder Head Reconditioning Kit (PN 2200634). Abrasive stone seat reconditioning equipment can also be used. Keep all valves in order with their respective seat.
3.28
ENGINE 4.
Inspect the cut area of the seat:
* If the contact area is less than 75% of the circumference of the seat, rotate the pilot 180° and make another light cut.
NOTE: When using an interference angle, the seat contact point on the valve will be very narrow, and is a normal condition. Look for an even and continuous contact point all the way around the valve face (A).
* If the cutter now contacts the uncut portion of the seat, check the pilot. Look for burrs, nicks, or runout. If the pilot is bent it must be replaced.
B
* If the contact area of the cutter is in the same place, the valve guide is distorted from improper installation * If the contact area of the initial cut is greater than 75%, continue to cut the seat until all pits are removed and a new seat surface is evident. NOTE: Remove only the amount of material necessary to repair the seat surface. 5.
To check the contact area of the seat on the valve face, apply a thin coating of Prussian Blue™ paste to the valve seat. If using an interference angle (46°) apply black permanent marker to the entire valve face (A).
A
3
Proper Seat Contact on Valve Face
Bottom 60° Seat 45°
Top 30°
A
6. 7.
Insert valve into guide and tap valve lightly into place a few times. Remove valve and check where the Prussian Blue™ indicates seat contact on the valve face. The valve seat should contact the middle of the valve face or slightly above, and must be the proper width.
Seat Width
* If the indicated seat contact is at the top edge of the valve face and contacts the margin area (B) it is too high on the valve face. Use the 30° cutter to lower the valve seat. * If too low, use the 60° cutter to raise the seat. When contact area is centered on the valve face, measure seat width. * If the seat is too wide or uneven, use both top and bottom cutters to narrow the seat. * If the seat is too narrow, widen using the 45° cutter and recheck contact point on the valve face and seat width after each cut.
= In. / mm. Valve Seat Width: Intake Std: .028' (.7 mm) Limit: .055' (1.4 mm) Exhaust Std: .039I (1.0 mm) Limit: .071' (1.8 mm)
3.29
ENGINE 8.
Clean all filings from the area with hot soapy water, rinse, and dry with compressed air.
9.
Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the valve.
Cylinder Head Reassembly NOTE: Assemble the valves one at a time to maintain proper order. 1.
Apply engine oil to valve guides and seats.
NOTE: Lapping is not required with an interference angle valve job.
2.
Coat valve stem with molybdenum disulfide grease or 0W-40 Synthetic oil.
10. Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem.
3.
Install valve carefully with a rotating motion to avoid damaging valve seal.
4.
Valve seals should be installed after the valves are in the head to avoid valve seal damage. Install new valve seals on valve guides.
5.
Dip valve spring and retainer in clean engine oil and install.
6.
Place retainer on spring and install Valve Spring Compressor (PU-45257). Install split keepers with the gap even on both sides.
NOTE: A small magnet can be used to aid in the installation of the keepers.
PU-45257 11. Rotate the valve rapidly back and forth until the cut sounds smooth. Lift the valve slightly off of the seat, rotate 1/4 turn, and repeat the lapping process. Do this four to five times until the valve is fully seated, and repeat process for the other valve(s). 12. Thoroughly clean cylinder head and valves.
7.
Repeat procedure for remaining valves. When all valves are installed, tap lightly with soft faced hammer on the end of the valves to seat the split keepers.
NOTE: To prevent damage to the valve seals, do not compress the valve spring more than necessary to install the keepers.
3.30
ENGINE Valve Sealing Test
Valve Lifter Removal / Inspection
1.
1.
Clean and dry the combustion chamber area (A).
A
2. 3.
Remove the valve lifter's 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. Mark the lifters with a white pen if using the lifters for reassembly. This will ensure that the lifters are properly placed during engine reassembly.
Mark Hydraulic Lifter
2.
3.
Pour a small amount of clean solvent onto the intake port and check for leakage around each intake valve. The valve seats should hold fluid with no seepage. Repeat for exhaust valves by pouring fluid into exhaust port.
Cylinder Removal 1. 2. 3.
3
Follow engine disassembly procedures to remove rocker cover and cylinder head. Tap cylinder (A) lightly with a rubber mallet in the reinforced areas only until loose. Rock cylinder forward and backward while lifting it from the crankcase, supporting pistons and connecting rods. Support pistons with Piston Support Block (PN 2870390).
4. 5. 6.
Check the lifters for wear or scores. Check the bottom end of lifter to make sure that it has a slight convex. If the bottom surface has worn flat, it may be used with the original camshaft only.
A
Inspect Hydraulic Lifter NOTE: Lifters that are scored, worn, or if the bottom is not smooth should be replaced with new lifters and cam as an assembly. If replacing the lifters, the camshaft should also be replaced.
3.31
ENGINE Piston Removal 1.
Remove circlip (A). Mark the piston with a white pen to ensure proper orientation (if reused) during assembly.
The oil control ring is a three piece design consisting of a top and bottom steel rail and a center expander section. The top rail has a locating tab on the end which fits into a notch (B) in the upper oil ring land of the piston. To Remove: A) Remove the top rail first followed by the bottom rail. B) Remove the expander. Compression Rings Oil Ring
NOTE: If the pistons are to be reused, reassemble the pistons in the same cylinder and direction from which they were removed. NOTE: New pistons are non-directional and can be placed in either cylinder. 2.
3.
Remove piston circlip and push piston pin out of piston. If necessary, heat the crown of the piston slightly with a propane torch. CAUTION: Do not apply heat to the piston rings. The ring may lose radial tension. Remove top compression ring:
*Using a piston ring pliers: Carefully expand ring and lift it off the piston. CAUTION: Do not expand the ring more than the amount necessary to remove it from the piston, or the ring may break. *By hand: Placing both thumbs as shown, spread the ring open and push up on the opposite side. Do not scratch the ring lands.
4.
Repeat procedure for second ring.
5.
Remove the oil control ring.
3.32
B
ENGINE Cylinder Inspection 1. 2.
3.
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.
A
3 B Measure at different points on surface.
4.
Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge. Measure in two different directions, front to back and side to side, on three different levels (1/2, down from top, in the middle, and 1/ 2, up from bottom). Record measurements. If cylinder is tapered or out of round beyond .002', the cylinder must be replaced. 1/2” Down From Top of Cylinder
B A
C
= In. / mm. Cylinder Warp: .004' (0.1 mm) Max.
1/2” Up From Bottom
= In. / mm. Cylinder Taper Limit: .002' (9.05mm) Max. Cylinder Out of Round: Limit: .002' (.0 mm) Max.
700 Standard Bore Size (Both Cylinders): 3.1496' (80 mm)
3.33
ENGINE Piston-to-Cylinder Clearance
2.
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. Subtract this measurement from the maximum cylinder measurement obtained in Step 5. 5 mm
Piston Pin Measurement Locations Piston Piston Pin
Piston to Cylinder Clearance: See “700 EFI Engine Service Specifications” on page 3.11
Piston Pin O.D.: See “700 EFI Engine Service Specifications” on page 3.11 3.
Measure connecting rod small end ID.
Piston O.D.: See “700 EFI Engine Service Specifications” on page 3.11 Piston / Rod Inspection 1.
Measure piston pin bore.
Connecting Rod Small End I.D.: See “700 EFI Engine Service Specifications” on page 3.11
Piston Pin Bore: See “700 EFI Engine Service Specifications” on page 3.11
3.34
ENGINE 4.
Measure piston ring to groove clearance by placing the ring in the ring land and measuring with a thickness gauge. Replace piston and rings if ring-to-groove clearance exceeds service limits. Piston Ring
3.
If the bottom installed gap measurement exceeds the service limit, replace the rings. If ring gap is smaller than the specified limit, file ring ends until gap is within specified range. NOTE: Always check piston ring installed gap after re-boring a cylinder or when installing new rings. A re-bored cylinder should always be scrubbed thoroughly with hot soapy water, rinsed, and dried completely. Wipe cylinder bore with oil immediately to remove residue and prevent rust.
Starter Drive Bendix Removal / Inspection Feeler Gauge
See “700 EFI Engine Service Specifications” on page 3.11
1. 2.
Remove stator housing bolts and remove housing. Remove the flywheel nut and washer. Install Flywheel Puller (PN 2871043) and remove flywheel. NOTE: Do not thread the puller bolts into the flywheel more than 1/4, or stator coils may be damaged. 3.
Piston Ring Installed Gap 1.
Remove starter bendix assembly (A). Note the thrust washers located on both sides of the bendix.
Place each piston ring (A) inside cylinder (B) using piston to push ring squarely into place as shown.
A
C B
25-50 mm
A 4. 5.
Piston Ring Installed Gap See “700 EFI Engine Service Specifications” on page 3.11
Inspect the thrust washer for wear or damage and replace if necessary. After the bendix is removed, remove the two bolts retaining the starter. Tap on the starter assembly (B) with a soft faced mallet to loosen the starter from the crankcase.
B
NOTE: Ring should be installed with the mark facing upward. 2.
Measure installed gap with a feeler gauge (C) at both the top and bottom of the cylinder.
IMPORTANT: A difference in end gap indicates cylinder taper. The cylinder should be measured for excessive taper and out of round.
3.35
3
ENGINE 6. 7.
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.
C
2871043 4.
A
Use caution when removing the wire holddown (B) and the stator assembly (D). Do not tap or bump the gear /stator housing cover or the stator. This could cause the seal around the gear/stator housing cover and the crankcase to break, causing a leak.
Flywheel / Stator Removal / Inspection 1.
Remove stator housing bolts and remove housing.
D
E Remove Stator Cover
B 5.
Remove the bendix (E) if necessary.
Engine Crankcase Disassembly / Inspection 1. 2.
Remove flywheel nut and washer.
3.
Install Flywheel Puller (PN 2871043) and remove flywheel (A).
Remove the stator cover (A) and water pump cover (B).
B CAUTION Do not thread the puller bolts into the flywheel more than 1/4, or stator coils may be damaged.
A
3.36
ENGINE 2.
Remove the nylok nut (C), washer (D), and water pump impeller (E). Remove part of the water pump seal behind the impeller.
5.
Remove the starter bendix (G), wire holddown plate (H), and the woodruff key (I) from the crankshaft. The stator does not have to be removed at this point.
I E
3 G D
C
H 6.
3. 4.
Remove flywheel nut and washer. Install Flywheel Puller (PN 2871043) and remove flywheel (F).
Remove the gear/stator housing bolts and remove the gear/ stator housing cover (J) and gasket from the crankcase. Be sure to catch the excess oil from the crankcase.
CAUTION Do not thread the puller bolts into the flywheel more than 1/4, or stator coils may be damaged.
J
7.
2871043
F
Note the positions of the gears in the photo.
Camshaft Gear
Crank Gear
Counterbalance Gear
3.37
ENGINE 8.
Use a white pen to accent the timing marks on the following gears: camshaft gear (K), crankshaft gear (M), or counterbalance gear (N) This will ensure proper gear alignment and timing during reassembly of the gears. K
Water Pump Gear
Timing Marks
CAUTION Wear safety glasses at all times. Use caution when working with the top gear. The springs could cause injury or become lost should they pop out. 12. Remove all three springs using one of the tapered pins from the Tapered Pins (PU-45497-1).
M
N
NOTE: If replacing one of the gears, it is recommended that all of the gears be replaced. A gear kit is available in the parts book. 9.
Use the Cam Gear Tooth Alignment Tool (PU-45497-2) (O) to align the cam split gear assembly. With the split gear aligned, remove the bolt and cam gear assembly. NOTE: Install the Cam Gear Tooth Alignment Tool (PU-45497-2) into the assembly hole counter clockwise from the timing mark as shown.
PU-45497-1
13. With a white marking pen, accent the timing mark on the gear that contains the springs.
10. Inspect the cam gear teeth and check to make sure there is spring tension offsetting the teeth between the two gears. If there is no tension, check the springs inside of the cam gear assembly.
3 Loaded Springs
Accent Timing Marks
11. The cam gear assembly contains three loaded springs. To open the cam gear assembly: * Place the cam gear on a flat surface with the timing mark side facing up. * While holding both gears together, lightly work a small flathead screwdriver between the two gears. * Remove the top gear. The springs should stay in place.
3.38
ENGINE 14. Inspect the gear teeth and the three tabs on the gears for wear.
Inspect Teeth & Tabs
To Assemble: * Hold the spring with one finger. * Start the pointed end of the tapered pin into the cam gear hole and slowly push the dowel through the hole until the end of the dowel is almost flush with the spring. * Perform this procedure with all three tapered pins. * Do not push the pins too far through or the springs will pop out. NOTE: Do not remove the tapered pins at this time. 17. Note in the photograph that the Tapered Pins (PU-454971) are below flush with end of the springs. This helps to align the three gear tabs during the next step.
Replace 3 Springs 15. Install the new springs into the grooves of the cam gear.
Install Springs
PU-45497-1
16. Insert the pointed dowels from the Tapered Pins (PU45497-1) into the cam gear.
Cam Gear Spring Installation Tool Kit: (PU-45497) Tapered Pins: (PU-45497-1) Cam Gear Tooth Align Tool: (PU-45497-2) 18. Line up the two gears using the timing marks and the three gear tabs that were referenced earlier. Push the gears back together, using both hands and hold securely. Align Timing Marks
PU-45497-1
3.39
3
ENGINE 19. Once the gears are pressed together, firmly hold the gears together with one hand. Carefully remove the Tapered Pins (PU-45497-1) by pulling them out one at a time with the other hand.
21. To remove the balance shaft gear, the flat side of the camshaft (P) must face the balance shaft gear. To rotate the camshaft, use the Cam Spanner Wrench (PU-45498) to rotate the camshaft so the flat side of the camshaft faces the balance shaft gear.
PU-45498
P
20. After the tapered pins are removed, be sure the cam gear assembly is held together tightly. Place the cam gear assembly on a flat surface. Use the Cam Gear Tooth Alignment Tool (PU-45497-2) to align the teeth of the cam gears, as shown in the picture. NOTE: Install the Cam Gear Alignment Tool (PU45497-2) into one assembly hole counter clockwise from the timing mark.
NOTE: This Cam Spanner Wrench (PU-45498) is only needed to rotate the camshaft when the entire valve train is assembled. If the rocker arms are removed, the cam-shaft can be turned by hand. 22. Remove the bolt and nut from the balance shaft gear. Try to remove the balance shaft gear. If the gear does not come off manually, use the Flywheel Puller (PN 2871043) to remove the balance shaft gear.
2871043
PU-45497-2
NOTE: For ease of installing the Cam Gear Alignment Tool (PU-45497-2) (R), use a twisting motion when pushing down on the tool.
3.40
ENGINE 23. Inspect the crankshaft gear (Q) for broken or worn teeth. If the crankshaft gear does not need to be replaced, it does not need to be removed. If the crankshaft gear is damaged, remove the crankshaft gear with the Flywheel Puller (PN 2871043).
26. Rotate the water/oil pump gear (S), so that all four bolts are visible though the gear. Remove the four bolts with a hex wrench. Pull out the pump.
S
Q
24. Install the two puller bolts (R). Tighten the puller bolts up so that the bolts are at equal length.
3 27. Inspect the oil pump rotors for wear. Mark the rotors with a white pen to ensure upon reassembly that the correct sides of the rotors are installed and mesh with the same edges as previously installed.
Mark Rotors R
25. Install the Flywheel Puller (PN 2871043) and remove the crankshaft gear, if needed.
2871043
NOTE: If replacing the old rotors, new replacement rotors will fit into the old oil/water pump housing. 28. Use a feeler gauge to measure the clearance between the two rotors. Measure the gap between the two rotor tips as shown below. The clearance should not exceed 0.006' (0.15 mm).
Max Tip Clearance 0.006” (0.15 mm)
3.41
ENGINE 29. Remove the oil pressure relief. The oil pressure relief consists of a bolt, washer, spring, and valve (dowel). Inspect the valve (dowel) for signs of possible obstructions. Use compressed air to blow out any debris.
31. Carefully press the gear off the assembly while supporting the housing assembly.
Press Off Gear
CAUTION 30. Reinstall the valve (dowel chamfered end first). Install the spring, washer, and bolt. Torque to specification . 22 ± 2 ft. lbs. (30 ± 3 Nm).
Wear appropriate safety gear during this procedure. Protective gloves, clothing and eye wear are required. 32. Remove the snap ring from the assembly. Place the housing in a support and press out the bearing/shaft assembly. Press out shaft and bearing assembly.
Chamfer End First
Bearing
=T 22 ± 2 ft. lbs. (30 ± 3 Nm) NOTE: Be sure to place the tapered end of the valve (dowel) in first. If the valve is installed incorrectly, oil pressure and oil priming problems will occur.
Retaining Ring 33. Place the shaft in a press to remove the bearing.
Press Off Bearing
3.42
ENGINE 34. Press shaft into the new bearing.
37. Remove thrust plate (U).
U Press On Bearing
3 35. Press the bearing/shaft assembly using the bearing's outer race. Do not use the shaft to press the assembly into the housing, as bearing damage may result. Install retaining ring. Press Bearing / Shaft Assembly using outer race only
36. Press gear onto shaft while supporting the housing.
38. Remove PTO end engine mount. Remove crankcase bolts. Tap on the reinforced areas on the cases using soft hammer. Carefully separate the two crankcase halves. Separate Crankcase Halves
NOTE: Only remove the oil baffle if the baffle is damaged. When removing the oil baffle bolts, use a heat gun to heat the bolts and loosen the Loctite™. This will prevent any possible damage to the bolts or to the crankcase casting. 39. Remove and clean oil pick up (V) and oil baffle weldment (W).
W V
3.43
ENGINE 40. Remove balance shaft and crankshaft.
Camshaft Inspection 1. 2. 3.
41. Remove and inspect crankshaft main journal bearings for abnormal wear. It is recommended to replace the bearings anytime the engine is disassembled.
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.
Cam Lobe Height
= In. / mm. Cam Lobe Height (Intake & Exhaust): Std: 1.3334' (33.8674 mm) 4.
Measure camshaft journal outside diameters (O.D.).
C B A
= In. / mm. Camshaft Journal O.D. : A. (Mag): 1.654' ± .00039' (42 ± .010 mm) B. (Ctr.): 1.634' ± .00039' (41.50 ± .010 mm) C. (PTO): 1.614' ± .00039' (41 ± .010 mm)
3.44
ENGINE 5.
Measure ID of camshaft journal bores.
1.
Install oil pick up (A), if removed. Torque to specification.
= In. / mm. B
Camshaft Journal Bore I.D.: (Mag): 1.656' ± 0.00039' (42.07± 0.010 mm) (Ctr.) 1.637' ± 0.00039' (41.58 ± 0.010 mm) (PTO) 1.617' ± 0.00039' (41.07 ± 0.010 mm) 6.
A
3
Calculate oil clearance by subtracting journal O.D.'s from journal bore I.D.'s. Compare to specification.
= In. / mm.
2.
Calculated Camshaft Oil Clearance: Std: 0.0027' (.070mm) Limit: .0039' (.10 mm)
ENGINE REASSEMBLY
Torque bolts to
=T Oil Baffle Weldment & Oil Pick Up Bolt Torque: 60 ± 6 in. lbs. (6.8 ± 0.68 Nm)
NOTE: Replace camshaft if damaged or if any part is worn past the service limit. NOTE: Replace engine block if camshaft journal bores are damaged or worn excessively.
Install oil baffle weldment (B). specification.
3.
Install the balance shaft. Inspect balance shaft clearance (C) in both gearcase halves. Rotate balance shaft to ensure that there is clearance between it and oil baffle weldment.
C
Crankcase Reassembly CAUTION After any reassembly or rebuild, the engine must be primed using the Oil Priming Adapter (PU45778) and a 3/4-full oil filter before initial startup. Follow Steps 45-46 of this section to prime the engine and to help aid proper break-in. NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2870585) to remove any debris. This will ensure proper sealing when installing bolts.
NOTE: Always install new balance shaft bearings.
3.45
ENGINE 4.
Apply assembly lube to cam journals and balance shaft bearing surfaces of the MAG case halve. Install camshaft and balance shaft.
7.
Assemble the crankcase halves. Apply LocTite™ 242 (PN 2871949) to the threads and pipe sealant to the bolt flanges. Torque bolts to specification following torque pattern at beginning of this chapter.
=T Crankcase Bolt Torque: 22 + 2 ft. lbs. (30 + 3 Nm) Torque in sequence 8.
Lubricate cam lobes and valve lifters with Moly Lube Grease. Apply Moly Lube
5.
Cam Lobes
Install crankshaft assembly and apply engine oil to crank pins and rods (D). Apply assembly lube to the main journals and bearings.
Lifters 9.
Lubricate lifters with engine oil and install in the original order as removed in disassembly. Apply Lubricant or Moly Lube to the ends of the lifters. NOTE: Always replace the camshaft and lifters as a set.
D
6.
Apply Crankcase Sealant (PN 2871557) to the top gearcase halve. NOTE: Do not apply sealant to cam relief hole (E).
E
3.46
ENGINE 10. Lubricate connecting rods with 0W-40 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.
3 11. Install new cylinder gasket on crankcase. Align gasket on the dowel pins for proper gasket alignment. NOTE: To help align the pistons, slide a rod that is close to the same diameter as the wrist pin holes to properly align them in the cylinder. 14. Position cylinder and piston assemblies onto the connecting rods and push the piston pins through the piston and connecting rods.
12. Orientate the piston rings on the piston before installation into the cylinders. Set the gaps of the rings every 120° (See Illustration Below). 1
Piston Ring Orientation
2 3
1. Top Ring
2. Second Ring
Push in Piston Pins 15. Install the piston pin circlips. The circlip ends should be installed at the 12 O'clock position.
3. Oil Ring
Piston Pin Cirlcip in 12 O’clock position
3.47
ENGINE NOTE: While installing in piston circlips, cover all engine passages. The clip could fall into the engine during installation.
17. Assemble rotors as marked when disassembled. Use a cleaner to remove the marks previously made on the rotors. Line Up Marks
18. Apply assembly lube or oil to the rotors on the oil pump shaft. NOTE: The application of lubrication aids in priming the oil pump during initial engine start up. 16. Install camshaft thrust plate (G) with new bolts. Torque bolts to specification. NOTE: New bolts have patch lock on the threads and do not require Loctite™.
Lubricate Rotors
G
=T
19. Align the bolt holes and install oil pump assembly into crankcase. Rotate the rotors in the housing during installation, as this checks for binding if new rotors are used. NOTE: For assembly of the gears, the cam gear and the crankshaft gear are stamped with “This Side Out.' This indicates the side of the gear that faces outward or away from the case.
Thrust Plate Screw Torque: 115 ± 12 in.lbs. (13 ± 1.35 Nm)
NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2870585) to remove any debris. This will ensure proper sealing when installing bolts and new Loctite™.
3.48
ENGINE 20. Install oil pump housing bolts (H). The new bolts contain patch lock, so Loctite™ is not needed on the new bolts. Torque bolts to specification and follow the torque sequence at beginning of the chapter.
22. Before installing the crankshaft gear (I), heat the crankshaft gear to 250° F (121°C) on a hot plate (J).
J
I H
3 NOTE: Occasionally spin the oil pump when installing bolts to check for binding of the rotors.
=T Oil Pump Bolt Torque: 84 ± 8 in.lbs. (9.50 ± 0.90 Nm) * Torque in Sequence 21. Apply Loctite™ 242 (PN 2871949) to the crankshaft.
CAUTION The crankshaft gear is extremely hot! Severe burns or injury can occur if the gear is not handled with extreme care and caution. Follow the procedure below to help ensure safety. 23. Use extreme caution when removing the crankshaft gear from the hot plate. Use a pair of pliers and leather gloves when handling the crankshaft gear. 24. Install the crankshaft gear (I) onto the crankshaft. NOTE: For assembly of the gears, the cam gear and the crankshaft gear are stamped with This Side Out.' This indicates the side of the gear that faces outward or away from the case.
I
3.49
ENGINE 25. Install counter balance shaft gear (J) with new key, aligning timing marks with crankshaft gear (I). Install washer and bolt. Use the Gear Holder (PU-45838). Torque to specification.
NOTE: Cam Spanner Wrench (PU-45498) is only needed to rotate the camshaft when the entire valve train is assembled.
J
I
PU-45498
PU-45838
=T Balance Shaft Gear Bolt Torque: 22 ± 2 ft. lbs. (30 ± 3 Nm)
27. Reinstall the camshaft gear; so the timing marks are properly aligned. Install the washer and bolt. Torque to specification. NOTE: Be sure all of the timing marks are properly aligned.
26. Use the Cam Gear Alignment Tool (PU-45497-2) to align the teeth of the cam gear (M). Install the cam gear (M) (with the Cam Gear Alignment Tool still in place) onto the camshaft. The timing marks on the camshaft gear should align with the keyway on the balance shaft gear.
K
Water Pump Gear
Timing Marks
PU-45497-2
M
N
M
Timing Marks
NOTE: If the timing mark on the camshaft gear does not align properly, remove the camshaft gear and tool. Use the Cam Spanner Wrench (PU-45498) to rotate the cam to the proper position.
=T Counterbalance Gear and Camshaft Gear Bolt Torque: 22 ± 2 ft. lbs. (30 ± 3 Nm)
3.50
ENGINE 28. Before installing the gear / stator housing, replace the seals in the cover. Install a new water pump seal (N) into the gear / stator housing. Use the Water Pump Mechanical Seal Installer (PA-44995) to properly install the seal to the correct depth in the cover.
NOTE: Install the crankshaft seal (P) with the seal lip facing out (towards the crankcase).
P
PA-44995 O PA 99 -4 4
3
5
N
IMPORTANT: Due to seal design and construction, seals MUST be installed DRY (no lubricant) during assembly. Use of lubricants (oil, soapy water, etc.) will not allow the seal to wear-in and seal properly. Do not touch seal surface or allow seal surface to come in contact with contaminates during installation. Thoroughly clean parts, tools and hands before installation.
Seal lip goes towards the crankcase. 30. Once the crankshaft seal is installed into the gear / stator housing cover, set the direction of the paper lip by sliding the Main Crankshaft Seal Saver (PA-45658) into the crankshaft seal from the rubber lipped side to the paper lip side. (Back to Front) Remove the tool. Important: Set the direction of the paper lip seal
PU-45658
NOTE: To remove the water pump seal, the gear/ stator housing must be removed. The water pump seal cannot be removed or installed with the gear/ stator housing attached to the engine. Shaft damage will occur. NOTE: Install the water pump seal (N) with the seal lip facing out (towards the crankcase). Use of a hydraulic press is recommended for this procedure. 29. Install a new crankshaft seal (P) into the gear/stator housing cover. Use the Universal Driver Handle (PU-45543) and the Main Seal Installer (PA-45483) to seat the crankshaft seal into place. PU-45543
31. Carefully install the tapered end of the Crankshaft Seal Protection Tool (PA-45658) through the paper side of the crankshaft seal. (Back to Front) Leave the seal protector installed in the crankshaft seal. Check the crankshaft seal lips to verify they have not been rolled or damaged.
PU-45658 P
PA-45483
3.51
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. With the tools installed, carefully place the gear/stator housing cover over the protection tools.
36. Secure the gear / stator housing cover to the crankcase with the cover bolts. Torque bolts in proper sequence to specification. Remove seal protectors from the shaft ends once the cover is secure. 34. Apply Crankcase Sealant (PN 2871557) to the outside edges of the crankcase halves (See arrows), where the crankcases mate. (See photos below.) This helps to prevent coolant leakage.
PA-45401
PA-45658
=T Gear/Stator Housing Bolt Torque: 96 ± 3 in. lbs. (10.85 ± 0.35 Nm) *Torque in proper sequence
3.52
ENGINE NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2870585) to remove any debris. This will ensure proper sealing when installing bolts. 37. Install shaft seal with ceramic surface facing inward.
39. Install water pump cover (R) with new O-ring seal. Torque bolts to specification in proper sequence (See front of this chapter). Install the O-ring dry, no lubricants
R
3 96 ± 3 in. lbs. (10.85 ± 1.35 Nm)
38. Install water pump impeller (P). Secure the impeller with the washer and a new nylok nut (Q). Torque the nut to specification. P
=T Water Pump Housing Bolt Torque: 96 ± 3 in. lbs. (10.85 ± 0.35 Nm) *Torque in proper sequence 40. Sparingly apply Starter Drive Grease (PN 2871423) to the starter drive. Install the starter bendix. NOTE: There are thrust washers on both sides of starter drive.
Q
=T Water Pump Impeller Nut Torque: 108 ± 6 in. lbs. (6.8 ± 0.68 Nm)
3.53
ENGINE Flywheel / Stator Installation
=T
NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2870585) to remove any debris. This will ensure proper sealing when installing bolts. 1.
Install stator assembly (S) and bolts. Torque bolts to specification. 2. Install the wire hold down bracket (T). Install two new wire hold down bolts. New bolts contain patch-lock. Torque bolts to specification, following the proper bolt torque sequence. Coat the stator wire grommet (U) with Nyogel™ Grease (PN 2871329). NOTE: Verify stator wires are routed properly under the wire hold down bracket.
Flywheel Nut Torque 65 ± 7 ft.lbs. (88 ± 9.50 Nm) 4.
Install stator housing with new o-rings. Torque the bolts to specification and follow proper bolt torque sequence at the beginning of this chapter.
96 ± 3 in.lbs. (10.85 ± 0.35 Nm)
Replace 2 bolts with new bolts
=T T
S
Stator Housing Bolt Torque: 96 ± 3 in. lbs. (10.85 ± 0.35 Nm)
U
=T Stator Assembly Bolt Torque: 96 ± 3 in.lbs. (10.85 ± 0.35 Nm) 3.
Install the flywheel, washer, nut, and key. Torque flywheel nut to specification.
Cylinder Head Reassembly NOTE: Before reassembly, clean the bolts and bolt holes with Primer N (PN 2870585) to remove any debris. This will ensure proper sealing when installing bolts. 1.
Install the head gasket (A) on the cylinder (B).
65 ± 7 ft. lbs. (88 ± 9.50 Nm)
A
B
3.54
ENGINE 2.
Install cylinder head on cylinder.
3.
Lubricate threads and top of washers underside of bolt head with engine oil. Install head bolts (C) and torque to specification.
5.
Lubricate rockers (E) with engine oil. E
C
3 6. 7.
Verify pushrods are engaged in lifters. Install rockers. Be sure that tab of fulcrum (F) is seated in head stand-off. Torque bolts to specification.
F
=T Cylinder Head Bolt Torque: Initial setting: 35± 4 ft. lbs. (47.5 ± 5.5 Nm) Allow to set for 1 minute, then turn additional 90° (1/4 turn) *Torque Bolts In Sequence 4.
Lubricate push rods (D) and install into lifters.
=T D
Rocker Arm Bolt Torque 22 + 2 ft. lbs. (30 ± 3 Nm) 8.
Install breather reed (G) into rocker cover (H). Lightly apply black RTV sealant to the outer edges of the breather reed. The reed has a tab and will assemble one-way only. Torque the breather bolts to specification. 20 ± 5 in.lbs. (2.5 ± .55 Nm) H
G
I
3.55
ENGINE =T
11. Install thermostat (J), new O-ring, and thermostat housing. Torque to specification.
Breather Bolt Toque: 20 ± 5 in. lbs. (2.5± 0.55 Nm)
K
17 ± 2 ft. lbs. (23 ± 3 Nm)
NOTE: When applying RTV, do not get any RTV inside the reed assembly. 9.
Place a new seal (I) into the bottom of the cover. Be sure the seal is seated into the cover properly.
IMPORTANT: Before assembly, clean the bolts and bolt holes with Primer N (PN 2870585) to remove any debris. This will ensure proper sealing when installing bolts.
J 84 ± 8 in. lbs. (9.5 ± 0.9 Nm)
10. Install rocker cover. Torque bolts to specification.
=T Thermostat Housing Bolt Torque: 84 ± 8 in. lbs. (9.5± 0.9 Nm) 12. Install temperature sender (K) and torque to specification.
K
=T Rocker Cover Bolt Torque: 84 ± 8 in.lbs. (9.5 ± 0.9 Nm) Torque in Sequence
3.56
=T Temperature Sender Torque: 17 ± 2 ft.lbs. (23 ± 3 Nm)
ENGINE Oil Pump Priming 1.
After the engine is completely assembled and ready for installation, the engine must be properly primed with Polaris 0W-40 Synthetic Oil (PN 2871281). Fill the oil filter three-quarters full with Polaris 0W-40 Synthetic Oil (PN 2871281). Let the oil soak into the filter for 8-10 minutes. Install the filter onto the engine.
CAUTION After any reassembly or rebuild, the engine must be primed using the Oil Priming Adapter (PU-45778) and a 3/4-full oil filter before initial start-up. Follow the steps in this section to properly prime the engine and aid proper engine break in. Failure to perform this procedure may cause internal engine damage on initial start-up.
3
Fill 3/4 full with 0W-40
2.
Remove primer plug from the engine. Install Oil System Priming Adapter (PU-45778) into the oil plug hole. Push 3-5 oz. (approx.) of Polaris 0W-40 into the adapter or until resistance is felt. Remove the adapter. Apply sealant to the plug threads. Install the plug and torque to specification. PU-45778
=T Primer Plug Torque 18 ± 2 ft.lbs. (24.4 ± 2.71 Nm)
3.57
ENGINE TROUBLESHOOTING Engine Spark Plug Fouling
Engine Idles But Will Not Accelerate • Spark plug fouled/weak spark • Broken throttle cable • Obstruction in air intake
• Spark plug cap loose or faulty • Incorrect spark plug heat range or gap • PVT system calibrated incorrectly/ components worn or mis-adjusted • Fuel quality poor (old) or octane too high • Low compression • Restricted exhaust • Weak ignition (loose coil ground, faulty coil, stator, or ETC switch)
• Air box removed (reinstall all intake components) • Incorrect or restricted carburetor jetting • ETC switch limiting speed • Reverse speed limiter limiting speed • Incorrect ignition timing • Restricted exhaust system • Cam worn excessively
Engine Has Low Power
• ETC switch mis-adjusted
• Spark plug fouled
• Restricted air filter (main or pre-cleaner) or breather system
• Cylinder, piston, ring, or valve wear or damage (check compression)
• Improperly assembled air intake system
• PVT not operating properly
• Restricted engine breather system
• Restricted exhaust muffler
• Oil contaminated with fuel
• Cam worn excessively
Engine Turns Over But Fails To Start
Piston Failure - Scoring
• No fuel
• Lack of lubrication
• Dirt in fuel line or filter
• Dirt entering engine through cracks in air filter or ducts
• Fuel will not pass through fuel valve
• Engine oil dirty or contaminated
• Fuel pump inoperative/restricted
Excessive Smoke and Carbon Buildup
• Tank vent plugged or pinched
• Excessive piston-to-cylinder clearance
• Engine flooded
• Wet sumping
• Low compression (high cylinder leakage)
• Worn rings, piston, or cylinder
• No spark (Spark plug fouled) ignition component failure
• Worn valve guides or seals • Restricted breather
Engine Does Not Turn Over • Dead battery • Starter motor does not turn • Engine seized, rusted, or mechanical failure
Engine Runs But Will Not Idle • Restricted carburetor pilot system • Low compression • Crankcase breather restricted
3.58
• Air filter dirty or contaminated
Piston Failure - Scoring • Lack of lubrication • Dirt entering engine through cracks in air filter or ducts • Engine oil dirty or contaminated
ENGINE Excessive Smoke and Carbon Buildup • Excessive piston-to-cylinder clearance
Cooling System Overheating
• Wet sumping due to over-full crankcase
• Low coolant level
• Worn rings, piston, or cylinder
• Air in cooling system
• Worn valve guides or seals
• Wrong type/mix of coolant
• Restricted breather
• Faulty pressure cap or system leaks
• Air filter dirty or contaminated
• Restricted system (mud or debris in radiator fins causing restriction to air flow, passages blocked in radiator, lines, pump, or water jacket, accident damage)
Low Compression • Cylinder head gasket leak • No valve clearance ( cam wear ) • Cylinder or piston worn • Piston rings worn, leaking, broken, or sticking • Bent valve or stuck valve • Valve spring broken or weak • Valve not seating properly (bent or carbon accumulated on sealing surface) • Rocker arm sticking
Backfiring
• Lean mixture (restricted jets, vents, fuel pump or fuel valve) • Fuel pump output weak • Electrical malfunction • Water pump failure/ Loose impeller • Thermistor failure • Cooling fan inoperative or turning too slowly (perform current draw test) • Ignition timing mis-adjusted • Low oil level
• ETC or speed limiter system malfunction
• Spark plug incorrect heat range
• Fouled spark plug or incorrect plug or plug gap
• Faulty hot light circuit
• Exhaust system air leaks
• Thermostat stuck closed or not opening completely
• Exhaust system air leaks • Ignition system faulty: Spark plug cap cracked / broken Ignition coil faulty Ignition or kill switch circuit faulty Poor connections in ignition system Ignition timing incorrect Sheared flywheel key
Temperature Too Low • Thermostat stuck open
Leak at Water Pump Weep Hole • Faulty water pump mechanical seal (coolant leak) • Faulty pump shaft oil seal (oil leak)
• Valve sticking
3.59
3
FUEL INJECTION
CHAPTER 4 FUEL INJECTION GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 SERVICE NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 EFI SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 EFI SYSTEM COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 FUEL LINES - QUICK CONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
ELECTRONIC FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9 PRINCIPAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9 EFI OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9 INITIAL PRIMING / STARTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
ELECTRONIC CONTROL UNIT (ECU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
4
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10 ECU SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11 ECU REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11 OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11 FUEL PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12 FUEL PUMP / TANK ASSEMBLY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
FUEL PRESSURE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14 OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14 FUEL PRESSURE REGULATOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14 FUEL PRESSURE REGULATOR REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14 OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14 FUEL INJECTOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15 FUEL INJECTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
CRANKSHAFT POSITION SENSOR (CPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15 OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15 CPS TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16 CPS REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP). . . . . . . . . . . . . 4.16 OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16 T-BAP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16 T-BAP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
THROTTLE POSITION SENSOR (TPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17 OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17 TPS TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17 TPS INITIALIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18 TPS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
ENGINE COOLANT TEMPERATURE SENSOR (ECT) . . . . . . . . . . . . . . . . . . . . . . . . . 4.19 OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19 ECT SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20 ECT SENSOR REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20
GENERAL TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21 DIAGNOSTIC “BLINK CODES” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21 EFI TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22
4.1
FUEL INJECTION GENERAL INFORMATION WARNING * Gasoline is extremely flammable and explosive
under certain conditions. * EFI components are under high pressure. Verify system pressure has been relieved before disassembly. * Never drain the fuel system when the engine is hot. Severe burns may result . * Do not overfill the tank. The tank is at full capacity when the fuel reaches the bottom of the filler neck. Leave room for expansion of fuel. * Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time. * Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. * If you get gasoline in your eyes or if you should swallowgasoline,seekmedicalattentionimmediately. * If you spill gasoline on your skin or clothing, immediately wash with soap and water and change clothing. * Always stop the engine and refuel outdoors or in a well ventilated area.
Fuel Pressure Gauge Kit - PU43506-A IMPORTANT: The EFI fuel system remains under high pressure, even when the engine is not running. Before attempting to service any part of the fuel system, the pressure must be relieved. The pressure adapter has an integrated relief valve. Connect to the test valve and release the pressure.
Fuel Pressure Gauge Kit PU-43506-A
Special Tools Test Valve PART NUMBER
TOOL DESCRIPTION
PU-43506-A
Fuel Pressure Gauge Kit
PU-47063
Digital Wrench™ Diagnostic Software
PU-47471
Digital Wrench™ SmartLink Module Kit (PU-47470, PU-47469, PU-47468)
PU-47470
Digital Wrench™ PC Interface Cable
PU-47469
Digital Wrench™ Vehicle Interface Cable
PU-47468
Digital Wrench™ SmartLink Module
2201519
Throttle Position Sensor Tester
PU-47315
Throttle Body Adjustment Screwdriver (small “D” shape)
4.2
FUEL INJECTION Digital Wrench™ Diagnostic Software - PU-47063
Throttle Position Sensor Tester - PU-47082
This dealer-only software installs on laptop computers equipped with a CD drive and serial port connection, and is designed to replace multiple shop tools often used to test EFI components. It also includes step-by-step diagnostic procedures to aid technician repair and troubleshooting.
This tester allows the use of a digital multi-meter to test TPS function as well perform initialization procedures.
Digital Wrench™ SmartLink Module Kit - PU-47471 This module kit contains the necessary cables and hardware to communicate between the vehicle ECU and the Digital Wrench™ diagnostic software. Polaris dealers can also order the following separately: SmartLink Module PU-47468, Vehicle Interface Cable PU-47469 and PC Interface Cable PU-47470. This module kit is used on all 8 pin connector-based Polaris EFI systems. This kit is available to Polaris dealers through our tool supplier, SPX (1-800-328-6657).
4 Throttle Body Adjustment Screwdriver PU-47315 This tool has a special ‘D’ shaped end for adjusting the throttle stop screw during a TPS initialization procedure.
PU-47469
PU-47468 PU-47470
Digital Wrench™ - Diagnostic Connector (Located under the hood as shown below)
4.3
FUEL INJECTION Service Notes • For more convenient and accurate testing of EFI components, it is recommended dealers utilize the Digital Wrench™ Diagnostic Software (dealer only), or testing may be done manually using the procedures provided. • 80% of all EFI problems are caused by wiring harness connections. • For the purpose of troubleshooting difficult running issues, a known-good ECU from another Polaris RANGER XP EFI of the same model may be used without damaging system or engine components. • Never attempt to service any fuel system component while engine is running or ignition switch is 'on.' • Cleanliness is essential and must be maintained at all times when servicing or working on the EFI system. Dirt, even in small quantities, can cause significant problems. • Do not use compressed air if the system is open. Cover any parts removed and wrap any open joints with plastic if they will remain open for any length of time. New parts should be removed from their protective packaging just prior to installation. • Clean any connector before opening to prevent dirt from entering the system. • Although every precaution has been taken to prevent water intrusion failure, avoid direct water or spray contact with system components. • Do not disconnect or reconnect the wiring harness connector to the control unit or any individual components with the ignition 'on.' This can send a damaging voltage spike through the ECU. • Do not allow the battery cables to touch opposing terminals. When connecting battery cables attach the positive (+) cable to positive (+) battery terminal first, followed by negative (-) cable to negative (-) battery terminal. • Never start the engine when the cables are loose or poorly connected to the battery terminals. • Never disconnect battery while engine is running. • Never use a battery boost-pack to start the engine. • Do not charge battery with key switch 'on.' • Always disconnect negative (-) battery cable lead before charging battery. • Always unplug ECU from the wire harness before performing any welding on the unit.
4.4
FUEL INJECTION EFI System Exploded View 1. Electronic Control Unit (ECU) 2. Intake Air Temperature / Barometric Air Pressure Sensor (T-BAP) 3. Crankshaft Position Sensor (CPS) 4. Fuel Injectors 5. Fuel Filter 6. Fuel Pump / Regulator / Gauge Sender Asm. (Located in tank as an assembly) 7. Fuel Rail 8. Engine Coolant Sensor (ECT) 9. Throttle Position Sensor (TPS) 10. Throttle Body 11. Wire Harness (Part of main harness)
4
4.5
FUEL INJECTION EFI System Component Locations 1.
Electronic Control Unit (ECU) Located under the seat on the driver’s side.
2.
Intake Air Temperature and Barometric Air Pressure Sensor (T-BAP) Located in the rubber intake boot between the air box and throttle body.
3.
Crankshaft Position Sensor (CPS) Located in the magneto cover on the right-hand side of the engine.
4.6
4.
Fuel Injectors / Fuel Rail Attached to the fuel rail located in the intake track of the cylinder head.
5.
Fuel Pump / Regulator / Gauge Sender Assembly Located in fuel tank as an assembly.
6.
Throttle Body
Throttle Body
FUEL INJECTION 7.
Throttle Position Sensor (TPS) Located on the right-hand side of the throttle body.
TPS
8.
4
Engine Coolant Temperature Sensor (ECT) Located in the cylinder head.
4.7
FUEL INJECTION FUEL TANK Exploded View
Fuel Flow
4.8
FUEL INJECTION Fuel Lines - Quick Connect
EFI Operation Overview
RANGER EFI models use quick connect fuel lines. Refer to the steps below for fuel line removal.
The EFI system is designed to provide peak engine performance with optimum fuel efficiency and lowest possible emissions. The ignition and injection functions are electronically controlled, monitored and continually corrected during operation to maintain peak performance.
1.
Place a shop towel around the fuel line to catch any dripping fuel. Squeeze the connector tabs together and push the locking slide back.
The central component of the system is the Bosch Engine Control Unit (ECU) which manages system operation, determining the best combination of fuel mixture and ignition timing for the current operating conditions.
Squeeze Connector Tabs 2. 3. 4.
Pull on the fuel line for removal. To install the line, verify the connector and fuel tank nipple are clean and free of debris. Snap the fuel line back over the nipple and slide the locking mechanism back into place. Verify the connector tabs snap back into place.
ELECTRONIC FUEL INJECTION Principal Components The Electronic Fuel Injection (EFI) system is a complete engine fuel and ignition management design. This system includes the following principal components: • • • • • • • • • • • • •
Fuel Pump Fuel Rail Fuel Line(s) Fuel Filter(s) Fuel Injectors Pressure Regulator Throttle Body / lntake Manifold Engine Control Unit (ECU) Ignition Coils Coolant Temperature Sensor Throttle Position Sensor (TPS) Crankshaft Position Sensor (CPS) Intake Air Temperature and Barometric Air Pressure Sensor (T-BAP) • Wire Harness Assembly • Check Engine Light
An in-tank electric fuel pump is used to move fuel from the tank through the fuel line and in-line fuel filter. The in-tank fuel pressure regulator maintains a system operating pressure of 39 psi and returns any excess fuel to the tank. At the engine, fuel is fed through the fuel rail and into the injectors, which inject into the intake ports. The ECU controls the amount of fuel by varying the length of time that the injectors are 'on.' This can range from 1.5-8.0 milliseconds depending on fuel requirements. The controlled injection of the fuel occurs each crankshaft revolution, or twice for each 4-stroke cycle. One-half the total amount of fuel needed for one firing of a cylinder is injected during each injection. When the intake valve opens, the fuel/air mixture is drawn into the combustion chamber, ignited. and burned. The ECU controls the amount of fuel being injected and the ignition timing by monitoring the primary sensor signals for air temperature, barometric air pressure, engine temperature, speed (RPM), and throttle position (load). These primary signals are compared to the programming in the ECU computer chip, and the ECU adjusts the fuel delivery and ignition timing to match the values. During operation the ECU has the ability to re-adjust temporarily, providing compensation for changes in overall engine condition and operating environment, so it will be able to maintain the ideal air/fuel ratio. During certain operating periods such as cold starts, warm up, acceleration, etc., a richer air / fuel ratio is automatically calculated by the ECU.
4.9
4
FUEL INJECTION Initial Priming / Starting Procedure
ELECTRONIC CONTROL UNIT (ECU)
NOTE: The Injection system must be purged of all air prior to the initial start up, and / or any time the system has been disassembled.
Operation Overview
If the EFI system is completely empty of fuel or has been disassembled and repaired: 1.
2. 3.
Cycle the key switch from “OFF” to “ON” 6 times, waiting for approximately 3 seconds at each “ON” cycle to allow the fuel pump to cycle and shut down. Once step 1 is completed, turn the key switch to “START” until the engine starts or 5 seconds has passed. If the engine failed to start, repeat step 1 for 2 more cycles and attempt to start the engine.
The ECU is the brain or central processing computer of the entire EFI fuel/ignition management system. During operation, sensors continuously gather data which is relayed through the wiring harness to input circuits within the ECU. Signals to the ECU include: ignition (on/off), crankshaft position and speed (RPM), throttle position, engine coolant temperature, air temperature, intake manifold air pressure and battery voltage. The ECU compares the input signals to the programmed maps in its memory and determines the appropriate fuel and spark requirements for the immediate operating conditions. The ECU then sends output signals to set the injector duration and ignition timing.
If the engine fails to start, a problem may still exist, and should be diagnosed. NOTE: Accurate testing of EFI components is recommended utilizing the Digital Wrench™ Diagnostic Software (dealer only).
During operation, the ECU continually performs a diagnostic check of itself, each of the sensors, and system performance. If a fault is detected, the ECU turns on the “Check Engine” light in the speedometer and stores the fault code in its fault memory. Depending on the significance or severity of the fault, normal operation may continue, or 'Fail-Safe' operation (slowed speed, richer running) may be initiated. A technician can determine the cause of the “Check Engine” light by initiating the “Blink Code” sequence or by using Digital Wrench™. The ECU requires a minimum of 7.0 volts to operate. The memory in the ECU is operational the moment the battery cables are connected. To prevent engine over-speed and possible failure, a revlimiting feature is programmed into the ECU. If the maximum RPM limit (6200) is exceeded, the ECU suppresses the injection signals, cutting off the fuel flow. This process repeats it self in rapid succession, limiting operation to the preset maximum.
4.10
FUEL INJECTION FUEL PUMP
RANGER 700 EFI RPM Limit: Hard Limit - Injector suppression occurs • High: 6200
Operation Overview NOTE: All EFI units utilize quick connect lines.
• Low: 6200 • Neutral: 6200 • Reverse: 6200 Soft Limit - Timing suppression occurs
An electric fuel pump assembly is used to transfer fuel to the EFI system from inside the fuel tank. This assembly includes the fuel pump, regulator and fuel gauge sender. The pump is rated for a minimum output of 25 liters per hour at 39 psi and has a nonserviceable internal 60-micron filter.
• High: None Fuel pump is not replaceable, picture is for reference only.
• Low: 5900 • Neutral: 5900
4
• Reverse: 5900
ECU Service
Regulator
Never attempt to disassemble the ECU. It is sealed to prevent damage to internal components. Warranty is void if the case is opened or tampered with in any way. All operating and control functions within the ECU are pre-set. No internal servicing or readjustment may be performed. If a problem is encountered, and you determine the ECU to be faulty, contact the Polaris Service Department for specific handling instructions. Do not replace the ECU without factory authorization.
Fuel Pump
Internal 60 Micron Strainer (Bottom) Fuel Gauge Sender
The relationship between the ECU and the throttle position sensor (TPS) is very critical to proper system operation. If the TPS is faulty, or the mounting position of the TPS to the throttle body is altered, the TPS must be re-initialized. For the purpose of troubleshooting, a known-good ECU from another Polaris RANGER XP EFI of the same model may be used without system or engine component damage.
ECU Replacement 1. 2. 3.
Remove the retaining screws (2) holding the ECU. With the Ignition turned off, disconnect the wire harness from the ECU. To install, reverse the procedures and tighten screws to specification.
=T ECU Retaining Screws 10 in. lbs. (1.1 Nm)
When the key switch is turned to 'ON', the ECU activates the fuel pump, which pressurizes the system for start-up. The ECU switches off the pump preventing the continued delivery of fuel in these instances: • If the key switch is not promptly turned to the 'start' position. • If the engine fails to start, or • If the engine is stopped with the key switch 'on' (as in the case of an accident) In these situations, the “check engine” light will go on, but will turn off after 4 cranking revolutions if system function is OK. Once the engine is running, the fuel pump remains on.
4.11
FUEL INJECTION Fuel Pump Test
3.
NOTE: FUEL GAUGE SENDER TEST - To test fuel gauge sender function, refer to Chapter 10. The fuel pump/tank assembly is non-serviceable and must be replaced if determined to be faulty. If a fuel delivery problem is suspected, make certain the filters are not plugged, that the pump is being activated through the ECU, all electrical connections are properly secured, the fuses are good, and a minimum of 7.0 volts is being supplied. If during starting the battery voltage drops below 7.0 volts, the ECU will fail to operate the system.
Turn on the key switch to activate the pump and check the system pressure on the gauge. If system pressure of 39 psi ± 3 is observed, the ignition switch, ECU, fuel pump, and pressure regulator are working properly. Turn the key switch off and depress the valve button on the tester to relieve the system pressure.
Normal Fuel Pressure: 39 psi. ± 3 NOTE: If the pressure is too high or too low, replace the fuel tank assembly. 4.
WARNING Check the fuel test valve for any possible fuel seepage after performing any tests or procedures. Fuel is extremely flammable and may cause severe burns, injury, or death. Do not use any device that produces a flame or electrical devices that may spark around fuel or fuel vapors. 1.
Remove the cap from the fuel test valve.
If the pump did not activate (Step 2), disconnect the plug from the fuel pump. Connect a DC voltmeter across terminals “A” and “C” in the plug, turn on the key switch and observe if a minimum of 7 volts is present. If voltage is between 7 and 14, turn key switch off and connect an ohmmeter between the terminals “A” and “C”' on the pump to check for continuity. NOTE: If there was no continuity between the pump terminals, replace the fuel tank assembly. NOTE: If the voltage was below 7Vdc, test the battery, ignition switch, wiring harness and ECU. 5.
If voltage at the plug was good, and there was continuity across the pump terminals, reconnect the plug to the pump, making sure you have good, clean connections. Turn on the key switch and listen for the pump to activate. NOTE: If the pump starts, repeat steps 1 and 2 to verify correct pressure. NOTE: If the pump still does not operate, check for correct ECU operation by plugging in a known-good ECU of the same model. NOTE: If the pump still does not operate, replace the pump/tank assembly.
2.
Connect the pressure hose of the Polaris pressure tester (PN PU-43506) to the test valve on the fuel rail. Route the clear hose into a portable gasoline container or the equipment fuel tank.
Fuel Pump / Tank Assembly Replacement NOTE: All EFI units utilize quick connect fuel lines.
WARNING Always wear safety goggles when working with high pressure or flammable fluids. Failure to do so could result in serious injury or complications. NOTE: The fuel pump cannot be replaced as an individual part, the entire fuel pump and fuel tank is replaced as an assembly. Refer to your parts book for the proper part number.
4.12
FUEL INJECTION 1.
Disconnect the negative battery cable.
2.
Remove the seat.
3.
Disconnect the fuel line from the fuel pump.
4.
5.
6.
Remove the RH rear fender and fuel cap.
7.
Remove the two inner bolts that hold the fuel tank to the frame.
8.
Remove the two outer lower bolts that hold the fuel tank to the frame.
Disconnect the fuel pump electrical harness.
Remove the fuel tank vent hose
NOTE: A small amount of fuel may come out of the fuel line or tank. Plug the fuel line and tank inlet or use a shop towel during removal. NOTE: Properly drain fuel into a suitable container.
4.13
4
FUEL INJECTION 9.
Reinstall the fuel cap and carefully pull the fuel tank out the RH side of the frame.
Fuel Pressure Regulator Test Refer to the “FUEL PUMP TEST” procedure. See “Fuel Pump Test” on page 4.12.
Fuel Pressure Regulator Replacement The regulator is a sealed, non-serviceable assembly. If it is faulty, the pump assembly must be replaced. Refer to the Fuel Pump / Tank Assembly Replacement procedure.
FUEL INJECTORS Operation Overview WARNING Wear safety goggles while performing this procedure, failure to do so could result in serious injuries.
NOTE: All EFI units utilize quick connect fuel lines. The fuel injectors mount into the intake manifold, and the fuel rail attaches to them at the top end. Replaceable O-rings on both ends of the injector prevent external fuel leaks and also insulate it from heat and vibration.
Fuel Tank Installation 1.
Reinstall the pump/tank assembly.
2.
Reinstall the four fuel tank mounting bolts that were removed.
3.
Reconnect the electrical harness. Install the fuel line and vent line and verify they are secure.
4.
Reinstall the RH rear fender.
5.
Reconnect the negative battery cable. Test the fuel pump by turning on the key and listening for the pump to activate.
FUEL PRESSURE REGULATOR Operation Overview The fuel pressure regulator maintains the required operating system pressure of 39 psi + 3psi. A rubber-fiber diaphragm divides the regulator into two separate sections-, the fuel chamber and the pressure regulating chamber. The pressure regulating spring presses against the valve holder (part of the diaphragm), pressing the valve against the valve seat. The combination of atmospheric pressure and regulating spring tension equals the desired operating pressure. Any time the fuel pressure against the bottom of the diaphragm exceeds the desired (top) pressure, the valve opens, relieving the excess pressure, returning the excess fuel back to the tank.
4.14
When the key switch is on, the fuel rail is pressurized, and voltage is present at the injector. At the proper instant, the ECU completes the ground circuit, energizing the injector. The valve needle in the injector is opened electromagnetically, and the pressure in the fuel rail forces fuel down through the inside. The “director plate” at the tip of the injector (see inset) contains a series of calibrated openings which directs the fuel into the intake port in a cone-shaped spray pattern. The injector is opened and closed once for each crankshaft revolution, however only one-half the total amount of fuel needed for one firing is injected during each opening. The amount of fuel injected is controlled by the ECU and determined by the length of time the valve needle is held open, also referred to as the “injection duration” or “pulse width”. It may vary in length from 1.5-8 milliseconds depending on the speed and load requirements of the engine.
FUEL INJECTION Fuel Injector Service Injector problems typically fall into three general categorieselectrical, dirty / clogged, or leakage. An electrical problem usually causes one or both of the injectors to stop functioning. Several methods may be used to check if the injectors are operating.
5. 6.
Remove the fuel rail mounting screw and carefully loosen / pull the rail away from the injectors. Reverse the procedures to install the new injector(s) and reassemble. Use new O-rings any time an injector is removed (new replacement injectors include new O-rings). Lubricate O-rings lightly with oil to aid installation. Torque the fuel rail mounting screw to specification.
• With the engine running at idle, feel for operational vibration, indicating that they are opening and closing. • When temperatures prohibit touching, listen for a buzzing or clicking sound with a screwdriver or mechanic's stethoscope. • Disconnect the electrical connector from an injector and listen for a change in idle performance (only running on one cylinder) or a change in injector noise or vibration. NOTE: Do not apply voltage directly to the fuel injector(s). Excessive voltage will burn out the injector(s). Do not ground the injector(s) with the ignition on.' lnjector(s) will open/turn on if relay is energized.
=T Fuel Rail Mount Screws 16-20 ft. lbs. (22.6-27 Nm)
CRANKSHAFT POSITION SENSOR (CPS) Operation Overview The engine speed sensor is essential to engine operation, constantly monitoring the rotational speed (RPM) and position of the crankshaft.
If an injector is not operating, it can indicate either a bad injector, or a wiring/electrical connection problem. Check as follows: Injector leakage is very unlikely, but in rare instances it can be internal (past the tip of the valve needle), or external (weeping around the injector body). The loss of system pressure from the leakage can cause hot restart problems and longer cranking times. Injector problems due to dirt or clogging are unlikely due to the design of the injectors, the high fuel pressure, the use of filters and the detergent additives in the gasoline. Symptoms that could be caused by dirty/clogged injectors include rough idle, hesitation/stumble during acceleration, or triggering of fault codes related to fuel delivery. Injector clogging is usually caused by a buildup of deposits on the director plate, restricting the flow of fuel, resulting in a poor spray pattern. Some contributing factors to injector clogging include; dirty air filters, higher than normal operating temperatures, short operating intervals and dirty, incorrect, or poor quality fuel. Cleaning of clogged injectors is not recommended; they should be replaced. Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem.
Fuel Injector Replacement 1. 2. 3. 4.
Engine must be cool. Depressurize fuel system through test valve in fuel rail. Remove the front fender assembly and fuel tank. Thoroughly clean the area around and including the throttle body / manifold and the injectors. Disconnect the fuel injector harness(s) at the ECU.
A ferromagnetic 60-tooth ring gear with two consecutive teeth missing is mounted on the flywheel. The inductive speed sensor is mounted 1.0 ± 0.26 mm (0.059 ± 0.010 in.) away from the ring gear. During rotation, an AC pulse is created within the sensor for each passing tooth. The ECU calculates engine speed from the time interval between the consecutive pulses. The twotooth gap creates an “interrupt” input signal, corresponding to specific crankshaft position for PTO cylinder. This signal serves as a reference for the control of ignition timing by the ECU. Synchronization of the CPS and crankshaft position takes place during the first two revolutions each time the engine is started. This sensor must be properly connected at all times. If the sensor fails or becomes disconnected for any reason, the engine will quit running.
4.15
4
FUEL INJECTION CPS Test The crankshaft position sensor is a sealed, non-serviceable assembly. If fault code diagnosis indicates a problem within this area, test and correct as follows: 1. 2.
Disconnect main harness connector from ECU. Connect an ohmmeter between the pin terminals. A resistance value of 560Ω ± 10% at room temperature (20° C, 68° F) should be obtained. If resistance is correct, check the mounting, air gap, toothed ring gear (damage, runout, etc.), and flywheel key.
TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP) Operation Overview Mounted on the throttle body intake, the temperature and barometric air pressure sensor (T-BAP) performs two functions in one unit.
Crankshaft Position Sensor: 560Ω ± 10% (20° C, 68° F) 3.
Disconnect speed sensor connector from wiring harness. (the connector with one heavy black lead) Viewing the connector with dual aligning rails on top, test resistance between the terminals. A reading of 560Ω ± 10% should again be obtained. NOTE: If the resistance is incorrect, remove the screw securing the sensor to the mounting bracket and replace the sensor. If the resistance in step 2 was incorrect, but the resistance of the sensor alone was correct, test the main harness circuit between the sensor connector terminals and the corresponding pin terminals in the main connector. Correct any observed problem, reconnect the sensor, and perform step 2 again.
CPS Replacement 1. 2.
3.
Disconnect sensor harness connector. Using a 6 mm hex wrench, remove the retaining bolt and replace the sensor, using a light coating of oil on the o-ring to aid installation. Torque the retaining bolt to specification.
=T CPS Retaining Bolt Torque: 25 in. lbs. (2.8 Nm)
Air passing through the intake is measured by the T-BAP and relayed to the ECU. These signals, comprised of separate air temperature and barometric air pressure readings, are processed by the ECU and compared to it's programming for determining the fuel and ignition requirements during operation.
T-BAP Test The temperature and barometric air pressure sensor (T-BAP) is a non-serviceable item. If it is faulty, it must be replaced. This sensor requires a 5 Vdc input to operate, therefore the T-BAP sensor should only be tested using the Digital Wrench™ Diagnostic Software (dealer only). Refer to the EFI Diagnostic Software Manual for more information.
T-BAP Replacement 1. 2.
3.
Disconnect sensor from engine harness. Using a 10mm wrench, remove the retaining bolt and replace the sensor, using a light coating of oil on the o-ring to aid installation. Torque the retaining bolt to specification.
=T T-BAP Retaining Bolt Torque: 29 in. lbs. (3.3 Nm)
4.16
FUEL INJECTION THROTTLE POSITION SENSOR (TPS)
• Harness Test: Insert black voltmeter probe into the “Bk” test port.
Operation Overview
• Connect the red meter probe into the “R” port and verify the voltage is 4.99-5.01 Vdc. If this reading is low, verify the 9 volt battery is good or try a new 9 volt battery.
The throttle position sensor (TPS) is used to indicate throttle plate angle to the ECU. Mounted on the throttle body and operated directly off the end of the throttle shaft, the TPS works like a rheostat, varying the voltage signal to the ECU in direct correlation to the angle of the throttle plate. This signal is processed by the ECU and compared to the internal pre-programmed maps to determine the required fuel and ignition settings for the amount of engine load. NOTE: The correct position of the TPS is established and set at the factory. Do not loosen the TPS or alter the mounting position. If the TPS is repositioned, replaced or loosened it must be recalibrated.
4
TPS Test The throttle position sensor (TPS) is a non-serviceable item. If it is faulty, it must be replaced. It can be tested using the following method: NOTE: Before proceeding with any of the following measurements or tests, it’s extremely important to verify the throttle body bore is clean of any carbon build-up. Remove the intake boot and inspect the throttle body bore. If required, remove the throttle body and clean the bore. • Set up the TPS Test Adapter Harness (PU-47082), according to the instructions that accompanied the tester. Make sure that the 9 volt battery is new.
Test Procedure PU-47082 TPS Test Adapter Harness
1. 2. Use NEW 9V battery
Plug the TPS test adaptor harness in the TPS harness. Connect the red test probe in yellow test port and black test probe in the black test port and the meter to VDC. Move the throttle open and closed slowly while reading the display. The voltage should increase smoothly with no “jumps” or decreases when the throttle is applied. PU-47082 Harness
No “Jumps” in read out
VERIFY TPS TESTER REFERENCE VOLTAGE
A 5 volt reference voltage from the harness is required for the TPS test to be accurate. Refer to the instructions provided with the TPS Test Adapter Harness (PU-47082) or follow the bullet point steps to check reference voltage.
4.17
FUEL INJECTION 3.
4.
If voltage varies with throttle movement, continue on to step 3 and measure the idle air flow reading. If the sensor does not function correctly, replace it. With voltmeter still attached to the TPS Test Adapter Harness (PU-47082) as shown below, the voltmeter should read .710 ± .01 volts at idle position. TPS Tester Adapter Harness- PU-47082
• With engine off, back out air flow screw until it no longer is in contact with throttle plate cam. The throttle plate should seal off throttle bore completely. Back Air Flow Screw Out Until No Contact is Made
Should Read: .710 V .710
5.
If the voltage does not read within the specification, “TPS Initialization” will need to be performed.
TPS Initialization NOTE: The correct position of the TPS is established and set at the factory. Use this procedure only if the TPS was repositioned, replaced or loosened. STEP 1 Establishing zero offset voltage: This step is crucial as it sets the TPS position using a fixed physical stop. This will insure that the correct offset voltage is reached once the correct throttle body flow is set.
• Open and close throttle plate a couple of times to ensure full throttle closing. Do not snap closed, as this could cause unnecessary throttle plate to throttle body interference and/or damage. • Set up the TPS Test Adapter Harness (PU-47082) according to the instructions. Verify that the 9 volt battery is new. See illustration below. TPS Tester Adapter Harness- PU-47082
Should Read: .528 V .528
• Using a voltmeter attached to the TPS Tester Harness (PU-47082), check the voltage output of the TPS. It should read .528 ± .01 volts. Throttle Plate Must Be Closed
• Remove cover and disconnect throttle cable from throttle cam.
4.18
• If it does not read .528 ± .01 volts, loosen the screw holding the TPS to the throttle body. Rotate TPS until voltmeter reads .528 ± .01 volts. • Retighten TPS mounting screw, and verify the voltage did not change. If changed, repeat the previous steps.
FUEL INJECTION STEP 2
2.
Establishing correct flow: Now that the zero offset voltage has been set, you can now set the throttle body to the correct air flow value. 6.
Disconnect sensor (A) from the harness.
B
With voltmeter still attached to the TPS Test Adapter Harness (PU-47082), turn the air flow adjustment screw until the voltmeter reads .710 ± .01 volts. The throttle body is now adjusted to the correct flow value. Turn Air Flow Screw In
A 3. 4. 5.
Loosen and rotate the throttle body (B) to gain access to the retaining screw. Remove the retaining screw and replace the sensor. Refer to “TPS Initialization” for setting the TPS voltage.
ENGINE COOLANT TEMPERATURE SENSOR (ECT) Operation Overview TPS Tester Adapter Harness- PU-47082
Should Read: .710 V .710
Mounted on the cylinder head, the engine temperature sensor measures coolant temperature. The engine temperature sensor is a Negative Temperature Coefficient (NTC) type sensor, as the temperature increases the resistance decreases.
• Reconnect the TPS harness lead • Reinstall throttle cable on throttle cam and install cover. Adjust cable freeplay.
TPS Replacement The correct position of the TPS is established and set at the factory. If the TPS is repositioned, replaced or loosened it must be re-calibrated. 1.
Remove the seat base to gain access to the throttle body.
Coolant passes through the cylinder and by the sensor probe, varying a resistance reading which is relayed to the ECU. This signal is processed by the ECU and compared to it's programming for determining the fuel and ignition requirements during operation. The ECU also uses this signal to determine when to activate the fan during operation. If for any reason the engine temperature sensor circuit is interrupted, the fan will default to “ON”.
4.19
4
FUEL INJECTION ECT Sensor Test
Engine Temperature Sensor To quickly rule out other components and wiring related to the ETS, disconnect the harness from the ETS. The fan should turn on and ‘HOT’ should indicate on the instrument cluster. This indicates all other components are working properly. Refer to Chapter 10 for ECT testing. Polaris dealers can also test the sensor by using the Digital Wrench™ Diagnostic Software (dealer only). Refer to the Digital Wrench™ User Guide for more information.
ECT Sensor Resistance Readings Temperature °F (°C)
Resistance
68 °F (20 °C)
2.5 kΩ ± 6%
212 °F (100 °C)
0.186 kΩ ± 2%
ECT Sensor Replacement 1.
Drain coolant to level below sensor
2.
Disconnect sensor from engine harness.
3.
Using a wrench, remove and replace the sensor, applying a light coating of thread sealant to aid installation.
4.
Torque the sensor to 17 ft. lbs. (23 Nm).
=T ECT Retaining Bolt Torque: 17 ft. lbs. (23 Nm)
4.20
FUEL INJECTION GENERAL TROUBLESHOOTING
3.
Diagnostic “Blink Codes” NOTE: The EFI diagnostic mode is intended to quickly view the cause of the “Check Engine” light.
4.
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. The word “End” will display after all of the codes have been displayed or if no codes are present.
To recall blink codes (fail codes) from the ECU: 1.
Verify the key switch is off and the transmission is in neutral with the parking brake applied.
2.
Turn the key switch ON and OFF 3 times within 5 seconds and leave the key switch in the ON position on the third turn. The word “Wait” will appear as the ECU searches for blink codes.
NOTE: To clear codes manually, disconnect the positive battery lead for 20 seconds.
DIAGNOSTIC “BLINK CODES” CHART SAE CODE BLINK CODE P0335 P0122 P0123 P0601 P0914 P0500 P0113 P0112 P0117 P0118 P0107 P0108 P1260 P0261 P0262 P1263 P0264 P0265 P0655 P1657 P1658 P1651 P1652 P1653 P1231 P1232 P1233 P1480 P1481 P1482
21 22 22 23 25 26 41 41 42 42 45 46 51 51 51 52 52 52 54 54 54 55 55 55 56 56 56 58 58 58
NAME Loss of Synchronization TPS: Open or Short Circuit to Ground TPS: Short Circuit to Battery RAM Error: Defective ECU Transmission Input: Invalid Gear Vehicle Speed Sensor: Implausible Intake Air Temp Sensor: Open or Short Circuit to +Sensor Voltage (ECU) Intake Air Temp Sensor: Short Circuit to Ground Engine Temperature Sensor Circuit: Short To Ground Engine Temperature Sensor Circuit: Open or Short to Battery Barometric Pressure Sensor: Circuit Low Input Barometric Pressure Sensor: Circuit High Input Injector 1: Open Load Injector 1: Short Circuit to Ground Injector 1: Short Circuit to Battery Injector 2: Open Load Injector 2: Short Circuit to Ground Injector 2: Short Circuit to Battery Engine Temperature Lamp: Open Load Engine Temperature Lamp: Short Circuit to Ground Engine Temperature Lamp: Short Circuit to Battery Diagnostic Lamp: Open Load Diagnostic Lamp: Short Circuit to Ground Diagnostic Lamp: Short Circuit To Battery Pump Relay: Open Load Pump Relay: Short Circuit to Ground Pump Relay: Short Circuit to Battery Cooling Fan: Open Load Cooling Fan: Short Circuit to Ground Cooling Fan: Short Circuit to Battery
CHECK ENGINE Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
4.21
4
FUEL INJECTION EFI Troubleshooting
Poor Idle
Fuel Starvation / Lean Mixture
Symptom: Idle Too High (If greater than 1300 RPM when engine is warm)
Symptoms: Hard start or no start, bog, backfire, popping through intake / exhaust, hesitation, detonation, low power, spark plug erosion, engine runs hot, surging, high idle, idle speed erratic. • No fuel in tank • Restricted tank vent, or routed improperly
• Throttle stop screw set incorrect • Throttle cable sticking, improperly adjusted, routed incorrectly Symptom: Idle Too Low (if less than 900 RPM when engine is warm)
• Fuel lines or fuel injectors restricted
• Plugged air filter
• Fuel filter plugged
• Leaking injector (rich condition)
• Fuel pump inoperative
• Belt dragging
• Air leak in system
• Throttle stop screw tampering
• Intake air leak (throttle shaft, intake ducts, airbox or air cleaner cover) • Incorrect throttle stop screw adjustment
Symptom: Erratic Idle • Throttle cable incorrectly adjusted • Air Leaks, dirty injector
Rich Mixture
• TPS damaged or adjusted
Symptoms: Fouls spark plugs, black, sooty exhaust smoke, rough idle, poor fuel economy, engine runs rough/ misses, poor performance, bog, engine loads up, backfire.
• Tight valves • Ignition timing incorrect • Belt dragging
• Air intake restricted (inspect intake duct) • Air filter dirty/plugged • Poor fuel quality (old fuel) • Fouled spark plug • TPS setting incorrect • Injector failure
4.22
• Dirty air cleaner • Engine worn • Spark Plug fouled • Throttle stop screw set incorrectly (out of sync with ECU)
BODY / STEERING / SUSPENSION
CHAPTER 5 BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 BODY COMPONENT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 REMOVAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 LOWER BODY COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 HOOD / DASH COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 DASH INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
CAB FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 ASSEMBLY / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
CHASSIS / MAIN FRAME (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8 EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
CHASSIS / MAIN FRAME (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
SEAT / HEAD REST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10 SEAT BASE / SEAT BACK / HEAD REST ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . 5.10
STEERING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11 EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
STEERING AND SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
5
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
FRONT A-ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13 REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
FRONT STRUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14 EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14 FRONT STRUT CARTRIDGE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15 BALL JOINT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
MID AXLE A-ARM (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16 REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
REAR A-ARM (4X4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17 REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
REAR STABILIZER BAR (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19 REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
SWING ARM (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
REAR DRIVE AXLE AND SWINGARM EXPLODED VIEW (6X6) . . . . . . . . . . . . . . . . . 5.21 REAR CARGO BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22 CARGO BOX - PANELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22 CARGO BOX - TAILGATE / BOX SUPPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23 BOX REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24 BOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
STORAGE BOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
DECAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
5.1
BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS ITEM
TORQUE VALUE ft.lbs. (Nm)
Front A-Arm Attaching Bolt
30 ft. lbs. (41 Nm)
Front A-Arm Ball Joint Stud Nut
30 ft. lbs. (41 Nm)
Rear Shock Bolt (upper)
30 ft. lbs. (41 Nm)
Rear Shock Bolt (lower)
30 ft. lbs. (41 Nm)
Rear Wheel Hub Nut
110 ft. lbs. (150 Nm)
Mid Half Shaft Castle Nut (6x6)
110 ft. lbs. (150 Nm)
Wheel Nuts (Cast Rims) Wheel Nuts (Steel Rims)
90 ft. lbs. (122 Nm) 35 ft. lbs. (47 Nm)
Upper / Lower Control Arm Mounting Bolt
30 ft. lbs. (41 Nm)
Mid Axle Upper / Lower Control Arm Mounting Bolt (6x6)
35 ft. lbs. (47 Nm)
Lower Middle Wheel Bearing Carrier Bolt (6x6) Lower Rear Wheel Bearing Carrier Bolt Upper Middle Wheel Bearing Carrier Bolt (6x6)
35 ft. lbs. (47 Nm) 30 ft. lbs. (41 Nm) 35 ft. lbs. (47 Nm)
Upper Rear Wheel Bearing Carrier Bolt
30 ft. lbs. (41 Nm)
Strut Rod Retaining Nut (Top)
15 ft. lbs. (21 Nm)
Strut Casting Pinch Bolt
15 ft. lbs. (21 Nm)
Tie Rod End Jam Nut
12-14 ft. lbs. (17-19 Nm
Tie Rod End Castle Nut
40 ft. lbs. (54 Nm)
Seat Belt to Seat Base
40 ft. lbs. (54 Nm)
Steering Wheel to Shaft
25-31 ft. lbs. (34-42 Nm)
Upper Steering Shaft to U-Joint Shaft
15-19 ft. lbs. (20-26 Nm)
Lower Steering Shaft to Box
30 ft. lbs. (41 Nm)
Steering Box
14-18 ft. lbs. (19-24 Nm)
NOTE: Refer to exploded views throughout this chapter for more torque specifications, component identification, and location of components.
5.2
SPECIAL TOOLS TOOL DESCRIPTION
PART NUMBER
Strut and Ball Joint Tool Set
2870871
Shock Spanner Wrench
2870872
Shock Spring Compressor Tool
2870623
Strut Spring Compressor Tool (LH)
2871573
Strut Spring Compressor Tool (RH)
2871574
BODY / STEERING / SUSPENSION BODY COMPONENT REMOVAL Removal Procedures TO REMOVE: SEAT
PERFORM THESE STEPS: Pull up on front of seat and then pull forward 1. Remove the gear selector handle 2. Then remove the 4 screws that attach the hood to the dash
DASH
3. Remove the remaining dash screws that attach the RANGER emblem 4. Disconnect the dash component wires 5. Remove the steering wheel (1 nut) 1. Disconnect headlights
HOOD 2. Remove the 4 hinge screws 1. Remove seat back and seat base CAB
2. Remove the bolts for the front mounts 3. Remove the bolts for the rear mounts
5
1. Remove liner darts and screws HOOD LINER
2. Disconnect the wiring harnesses 3. Remove the air baffling boxes 1. Lift the hood 2. Remove the 3 front Torx screws from LH and RH wheel well panels
FRONT BUMPER 3. Remove the 2 top bumper mounting bolts 4. Remove the 3 lower bumper mounting bolts 1. Place box in the dump position 2. Remove the pin and clip from the shock at the cargo box 3. Disconnect light harnesses CARGO BOX 4. Remove (2) screws holding hinge pins 5. Tap out hinge pins 6. Lift the box off the frame with assistance 1. Raise the cargo box 2. Disconnect the vent and fuel lines (note locations) 3. Disconnect electrical connection FUEL TANK 4. Remove the RH rear fender and fuel cap 5. Remove the 2 inner bolts and 2 outer bolts that hold the tank to the frame 6. Carefully lift the tank out through the side 1. Raise the cargo box 2. Remove the (2) bottom T27 Torx screws LH STORAGE BOX
3. Remove the (2) top T27 Torx screws 4. Remove the (3) T27 Torx screws on the front edge 5. Lift the storage box outward from frame
5.3
BODY / STEERING / SUSPENSION Lower Body Components
5.4
BODY / STEERING / SUSPENSION Hood / Dash Components
T-27 4-5 ft. lbs. (5-6 Nm)
Glove Box Assembly
8-10 in. lbs. T-30 (0.9-1.0 Nm) Hinges Cup Holder
4-5 ft. lbs. (5-6 Nm)
5
T-27
Hood 4-5 ft. lbs. (5-6 Nm) T-27 Torx Grille Headlights
Hood Latch Strap
Hood Liner
5.5
BODY / STEERING / SUSPENSION Dash Instruments and Controls A. Speedometer B. Headlight Switch
A
G
C. 2WD/AWD Switch
B C
D. 12 Volt Accessory Receptacle E. Speedometer “Mode” Button F. Key Switch G. Speedometer Mount Plate
F
E
D
C
B
G
A
F
5.6
E
D
BODY / STEERING / SUSPENSION CAB FRAME Assembly / Removal 1.
Assemble the two rear cab frames at the coupler joint and secure with two 3/8' screws and nuts. Assemble the front frame in same manner. Tighten all 3/8' screws to 25-28 ft. lbs. (34-38 Nm).
2.
Assemble the center cross bracket to the rear cab frame and secure with two 5/16 hex bolts and nuts. Tighten all 5/16' bolts to 16-18 ft. lbs. (20-24 Nm).
3.
Assemble the front cab frame to the rear cab frame at both side coupler joints and secure with 3/8' screws and nuts. Tighten all 3/8' screws to 25-28 ft. lbs. (34-38 Nm).
4.
Place the assembled cab frame onto the vehicle and align the rear mount holes. Secure the rear of the frame using the two 2 1/4' bolts on the outer tubes, two 3/4' bolts on the inner mounts and nuts. Tighten all 5/16' bolts to 16-18 ft. lbs. (20-24 Nm). NOTE: Tighten all nuts finger tight, then tighten to specification.
5.
Secure the front flanges to the vehicle with 5/16 x 3/4 bolts and nuts. Tighten all 5/16' bolts to 16-18 ft. lbs. (20-24 Nm). NOTE: Tighten all nuts finger tight, then tighten to specification.
6.
Check all nuts and bolts for proper torque and installation. To remove the cab frame, reverse the installation instructions.
5 25-28 ft. lbs. (34-38 Nm) 1 3 25-28 ft. lbs. (34-38 Nm)
4 16-18 ft. lbs. (20-24 Nm) 4
2 16-18 ft. lbs. (20-24 Nm) 3
25-28 ft. lbs. 1 (34-38 Nm)
5 16-18 ft. lbs. (20-24 Nm)
4 16-18 ft. lbs. 5 (20-24 Nm)
4 16-18 ft. lbs. (20-24 Nm)
5.7
BODY / STEERING / SUSPENSION CHASSIS / MAIN FRAME (4X4) Exploded View Seat Base Frame Extension
RH Floor Support
45 ft. lbs. (61 Nm) Main Frame Front Cab Support
28-32 ft. lbs. (38-43 Nm)
Bumper Grills T-27 4-6 ft. lbs. (6-8 Nm)
5.8
13-15 ft. lbs. (17-20 Nm) 28-32 ft. lbs. (38-43 Nm)
LH Floor Support
BODY / STEERING / SUSPENSION CHASSIS / MAIN FRAME (6X6) Exploded View
Seat Base Frame Extension
Front Cab Support RH Floor Support 45 ft. lbs. (61 Nm)
5 Main Frame
28-32 ft. lbs. (38-43 Nm)
Grills
Bumper 13-15 ft. lbs. (17-20 Nm)
T-27 4-6 ft. lbs. (6-8 Nm)
LH Floor Support
28-32 ft. lbs. (38-43 Nm)
5.9
BODY / STEERING / SUSPENSION SEAT / HEAD REST Seat Base / Seat Back / Head Rest Assembly 1. 2. 3. 4. 5. 6.
After attaching the frame to the vehicle, install the two headrests onto the frame using T-27 nuts. Install the bolts loosely, then tighten to 4-6 ft. lbs. (5-8 Nm). Make sure that the chimney nuts are centered in the mounting hole of the seat back base. Place the seat back cover over the seat back base. Using the illustrations for reference, install the seat back base and seat back cover onto the cab frame. NOTE: Be sure the indented section of the seat back is positioned upward. Insert T-27 nuts through the mounting strap and into the seat back. Install all of the T-27 nuts loosely, then tighten to 4-6 ft. lbs. (5-8 Nm). Install the bolts and nuts that secure the seat belt assemblies to the rear of the seat frame. Tighten to 38-42 ft. lbs. (51-57 Nm). Check all nuts and bolts for proper torque and installation.
4-6 ft. lbs. T-27 (5-8 Nm)
Indented Section of Seat
1 Step 3
38-42 ft. lbs. (51-57 Nm) 5
T-27 4-6 ft. lbs. (5-8 Nm) 4
Step 2 5
Seat Mounting Strap
Chimney Nut
Seat Back Cushion Bolt Seat Back Base
5.10
Seat Back Cover
BODY / STEERING / SUSPENSION STEERING ASSEMBLY Exploded View
Cap 25-30 ft. lbs. (34-41 Nm) Nut Rod End & Jam Nut
Steering Wheel Bushing
Wave Washers
Screw & Lock Washer 15-22 ft. lbs. (20-30 Nm) Screw & Nut Tie Rod
Bolt 30 ft. lbs. (41 Nm)
Upper Steering Shaft
5
Lower Steering Shaft
Boots Steering Box
Tie Rod End Bolt
40-45 ft. lbs. (54-61 Nm)
5.11
BODY / STEERING / SUSPENSION STEERING AND SUSPENSION Exploded View
Always use new bolts upon reassembly
Apply LoctiteTM 242
Always use new cotter pins upon reassembly.
NOTE: To avoid damage to the tie rod ends and other steering components, be sure to install tie rod end bolts in the proper direction. The steering post arm bolt (B) points up; the rod end bolts (A) point down. Be sure inner rod ends are placed between the steering post arms. 25-30 ft. lbs. (34-41 Nm)
15-22 ft. lbs. (20-30 Nm)
30 ft. lbs. (41 Nm)
12-14 ft. lbs. (16-19 Nm)
40-45 ft. lbs. (54-61 Nm)
30 ft. lbs. (41 Nm) Front
30 ft. lbs. (41 Nm)
20-30 ft. lbs. (2-3.5 Nm)
5.12
8 ft. lbs. (11 Nm) 25 ft. lbs. (35 Nm)
BODY / STEERING / SUSPENSION FRONT A-ARM
8.
Replacement 1.
Elevate and safely support vehicle with weight removed from front wheel(s). 2. Remove cotter pin from ball joint stud at wheel end of Aarm and loosen nut until it is flush with end of stud. 3. Using a soft face hammer, tap nut to loosen A-arm from bolt. Remove nut and A-arm from hub strut assembly. 4. Loosen two bolts on A-arm bushing by alternating each about 1/3 of the way until A-arm can be removed. 5. Examine A-arm bushing and A-arm shaft. Replace if worn. Discard hardware. 6. Insert A arm bushings and A-arm shaft into new A-arm. NOTE: On AWD models, install CV joint shields. See Illustration
Attach A-arm to hub strut assembly. Tighten ball joint nut to 25 ft. lbs. (35 Nm). If cotter pin holes are not aligned, tighten nut slightly to align. Install a new cotter pin with open ends toward rear of machine. Bend both ends in opposite directions around nut.
WARNING Upon A-arm installation completion, test vehicle at low speeds before putting into regular service.
A-arm Attaching Bolt Torque: 30 ft. lbs. (41 Nm) Ball Joint Stud Nut Torque: 25 ft. lbs. (35 Nm)
7.
Install new A-arm assembly onto vehicle frame. Torque new bolts to 30 ft. lbs. (41.4 Nm).
5
WARNING The locking features on the existing bolts were destroyed during removal. DO NOT reuse old bolts. Serious injury or death could result if fasteners come loose during operation.
Vehicle Frame
Apply LoctiteTM 242
New Bolt 30 ft. lbs. (41 Nm)
Strut
Ball Joint Stud
New Bolt 30 ft. lbs. (41 Nm) A-Arm Bushing A-Arm Shaft T-20 CV Joint Shield 20-30 in. lbs. (2-3.5 Nm)
New Cotter Pin
25 ft. lbs. (35 Nm)
8 ft. lbs. (11 Nm)
5.13
BODY / STEERING / SUSPENSION FRONT STRUT Exploded View Top Pivot Ball
Nut 15 ft. lbs. (21 Nm)
Spacer Rubber Washer
Spring Retainer
Bottom Pivot Ball Spacer
Front Strut
Clamp Washer
18 ft. lbs. (24 Nm)
Spring Bolt
Strut Bumper
18 ft. lbs. (24 Nm)
Wheel Speed Sensor (Hall Effect Sensor) Washer
Bearing
Retaining Ring
5.14
BODY / STEERING / SUSPENSION Front Strut Cartridge Replacement
4. 5.
Refer to Illustration on Page 5.14. 1. 2.
Hold strut rod and remove top nut. Compress spring using strut spring compressor tools.
6. 7.
Strut Spring Compressor Tools
Remove cotter pin (A) from ball joint castlenut. Remove castle nut (B) and separate A-arm (C) from ball joint stud. Remove screws (D) and ball joint retaining plate (E). Using ball joint removal/installation tool kit (PN 2870871), remove ball joint (F) from strut housing. • Install puller guide (G) with extension cap (H).
(PN 2871573) and (PN 2871574)
• Apply grease to extension cap and threads of puller bolt to ease removal.
3. 4. 5. 6. 7. 8.
Remove upper strut pivot assembly. Remove coil spring and collapse strut cartridge. Remove two pinch bolts from strut casting. Remove strut cartridge. Install cartridge until bottomed in strut casting. Install pinch bolts with wire clamp(s). Torque pinch bolts to 15 ft. lbs. (21 Nm). 9. Reassemble spring and top pivot assembly. Be sure all parts are installed properly and seated fully. 10. Torque strut rod nut to specification. Do not over torque nut.
• Thread bolt (K) with nut (J) onto ball joint stud as shown. • Apply heat to ease removal. • Hold bolt (K) and turn nut (J) clockwise until ball joint is removed from strut housing. G
5
H J K
Strut Rod Nut Torque 15 ft. lbs. (21 Nm) Ball Joint Replacement 1. 2.
Loosen front wheel nuts slightly. Elevate and safely support machine under footrest/frame area.
To install new ball joint: • Remove extension cap and attach puller guide using short bolts provided in the kit.
CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure. 3.
8.
• Insert new ball joint (L) into driver (M).
Remove wheel nuts and wheels.
L M
C
F E
B
D A
• Slide ball joint / driver assembly into guide. • Apply heat to ease installation. • Drive new joint into strut housing until fully seated.
5.15
BODY / STEERING / SUSPENSION 9.
Apply Loctite™ 242 (PN 2871949) to threads of retaining plate screws or install new screws with pre-applied locking agent. Torque screws to 8 ft. lbs. (11 Nm). 10. Install A-arm on ball joint and torque castle nut to 25 ft. lbs. (35 Nm). 11. Reinstall cotter pin with open ends toward rear of machine.
WARNING The locking features on the existing bolts were destroyed during removal. DO NOT reuse old bolts. Serious injury or death could result if fasteners come loose during operation. 9.
Attach A-arm to wheel bearing carrier. Install the shock to the upper mid A-arm. Torque bolts as shown. 10. Locate grease fitting in center of A-arm tube and pump Aarm full of grease.
MID AXLE A-ARM (6X6) Replacement 1. 2.
3. 4.
5. 6. 7. 8.
Elevate and safely support the center of the vehicle with weight removed from center wheel(s). Remove the hub cap, cotter pin, spindle nut, wheel nuts, and wheel. Refer to Chapter 7 “MID DRIVE BEARING CARRIER / HUB REMOVAL” procedure. Remove the bolts that secure the shock to the upper and lower mid A-arms. Loosen two bolts on A-arm bushing by alternating each about 1/3 of the way until A-arm can be removed. Perform this procedure on the upper and lower mid A-arms. Examine the A-arm bushing and A-arm shaft. Replace if worn. Discard hardware. Insert A-arm bushings and A-arm shaft into new A-arm. Install new lower mid A-arm assembly onto vehicle frame. Torque new bolts to 30 ft. lbs. (41 Nm). Install a new upper mid A-arm assembly. Torque new bolts to 30 ft. lbs. (41 Nm).
Frame
WARNING Upon A-arm installation completion, test vehicle at low speeds before putting into regular service.
RANGER 6X6 Mid Drive A-arm Attaching Bolt torque: 30 ft. lbs. (41 Nm) Upper Bearing Carrier Bolt Torque: 30 ft. lbs. (41 Nm) Lower Bearing Carrier Bolt Torque: 50 ft. lbs. (68 Nm) New Bolt 30 ft. lbs. (41 Nm)
Bushing
Nut
Shaft
30 ft. lbs. (41 Nm)
Upper Mid A-arm Shock
Bushing
Mid Axle A-Arm Assy.
Shaft
Bushings
Wheel Bearing Carrier
Bushings Washer 30 ft. lbs. New Bolt (41 Nm)
5.16
Lower Mid A-Arm
50 ft. lbs. (68 Nm)
BODY / STEERING / SUSPENSION REAR A-ARM (4X4)
5.
Remove the hub and brake disc assembly by sliding it off of the axle.
6.
Remove the bolt that secures the shock and coil to the upper A-arm. Remove the bolt that secures the wheel carrier to the upper A-arm.
Replacement NOTE: Use the exploded view on the next page as reference during the procedure. 1. 2.
Elevate and safely support vehicle with weight removed from the rear wheel(s). Remove the wheel nuts, washers, and wheel.
7.
Shock Bolt NOTE: To ease the removal of the spindle bolt, remove the hub cap and loosen the spindle bolts before removing the wheel. 3. 4.
Remove the hub cap, cotter pin, spindle bolt, and washer. Remove the brake caliper. Suspend the brake caliper from the frame with a wire. NOTE: Do not let the brake caliper hang from the brake line or damage may occur.
Wheel Carrier Bolt
8.
Loosen two bolts that secure the A-arm to frame by alternating each about 1/3 of the way until A-arm can be removed. Perform this procedure on the upper A-arm. See exploded view, next page. 9. Examine the A-arm bushing and A-arm shaft. Replace if worn. Discard hardware. 10. To remove the lower control arm, the wheel bearing carrier needs to be removed. Remove the upper and lower wheel carrier bolts and slide the rear drive shaft from the carrier. (See Chapter 7 for more details).
5.17
5
BODY / STEERING / SUSPENSION 11. Remove the bottom stabilizer bar nut.
14. Install new A-arm assembly onto vehicle frame. Torque new bolts to 30 ft. lbs. (41 Nm).
WARNING Stabilizer Bar
The locking features on the existing bolts were destroyed during removal. DO NOT reuse old bolts. Serious injury or death could result if fasteners come loose during operation.
12. Loosen two bolts that secure the A-arm bushing to frame by alternating each about 1/3 of the way until the A-arm can be removed. The lower A-arm should now be free to remove.
15. Attach A-arm to wheel bearing carrier. Torque upper and lower carrier bolts as shown. 16. Install the shock and tighten shock bolt to 30 ft.lbs. (41 Nm). 17. Re-install wheel and caliper. Refer to “Chapter 2” for wheel toque specifications.
WARNING
A-Arm Installation
Upon A-arm installation completion, test vehicle at low speeds before putting into regular service.
13. Insert new A-arm bushings and new A-arm shaft into new A-arm.
Nuts
30 ft. lbs. (41 Nm)
30 ft. lbs. (41 Nm) Shaft
A-arm Bolts Bushings
Coil
Upper A-arm Shock Bushings
30 ft. lbs. (41 Nm) A-arm Bolts
30 ft. lbs. (41 Nm) Shaft Wheel Bearing Carrier
Nuts Bushings
Shaft
5.18
Bearing
Lower A-arm
Carrier Bolt 30 ft. lbs. (41 Nm) 50 ft. lbs. (68 Nm)
Caliper 18 ft. lbs. (24 Nm)
Shaft
Shaft
Snap Ring
Bushings
BODY / STEERING / SUSPENSION REAR STABILIZER BAR (4X4)
4.
Remove the two bolts that secure the stabilizer bar to the main frame, each side.
Removal / Installation 1. 2.
Elevate and safely support vehicle with weight removed from the rear wheel(s). Remove the rear wheel to gain access to the stabilizer bar, each side. Stabilizer Bar
Stabilizer Bar 5. 6. 7. 3.
Remove the stabilizer bar nut from the lower A-arm on each side.
8.
Remove the stabilizer from the frame. Inspect the stabilizer bar for straightness. Inspect the bushings and replace if needed. Inspect the rubber bushings on the linkage rod and replace if needed. Reverse the procedure for installation. Torque the stabilizer bolts to 16-18 ft.lbs. (21-25 Nm).
Inspect Bushings
16-18 ft. lbs. (21-25 Nm) Stabilizer Assembly
Inspect Bushings
5.19
5
BODY / STEERING / SUSPENSION SWING ARM (6X6) Removal A
1. Support machine on a level surface. 2. Remove rear wheels. NOTE: The rear axle may be removed to ease the removal of the swing arm. Refer to Chapter 7, “REAR AXLE HOUSING REMOVAL/INSPECTION”. 3. 4.
B
Support swing arm, remove rear axle shocks. Drive spring pin out of rear propshaft at middle angle drive using the Roll Pin Removal Tool (PN 2872608). PN 2872608
Installation 1. 2.
3. 4. 5. NOTE: Use jacks and jackstands to help remove the swing arm assembly. 5.
Remove the pivot bolt lock brackets (A), swing arm pivot bolts (B), bolts swing arm bushings, lower swing arm and rear axle.
Raise swing arm assembly and align the drive shaft to the rear gearcase splined shaft (lube splines). Insert new bushings, check pivot bolts for wear, replace if necessary, torque bolts to 150 ft. lbs (75.9 Nm). Install bolt lock brackets and bolts, torque to 30 ft. lbs. (41 Nm). Install rear coil over shocks onto swing arm, torque bolts to 30 ft. lbs (41 Nm). Install rear wheels, lower machine. Insert new spring pin on rear propshaft.
Pivot Bolt and Nut Torque: 150 ft. lbs. (75.9 Nm) Rear Shock Mount Bolt Torque: 30 ft. lbs. (41 Nm)
Swing arm U-Bolt Shock Coil Washer & Bolt Frame Rear Axle
30 ft. lbs. (41 Nm)
Bushings Pivot Bolt 150 ft. lbs. (203 Nm) 30 ft. lbs. (41 Nm)
5.20
Bolt Lock Bracket Apply LoctiteTM 271
BODY / STEERING / SUSPENSION REAR DRIVE AXLE AND SWINGARM EXPLODED VIEW (6X6) Retaining Ring
Wheel Axle Tube Bearing
Screw & Washer 60 ft. lbs. (81 Nm)
Vehicle Frame
Screw & Washer 60 ft. lbs. (81 Nm)
Swing Arm
Axle Wheel Bearing 150 ft. lbs. (203 Nm)
O - Ring Axle Tube U - Bolt Nut & Washer
40 ft. lbs. (54 Nm) Washer Rear Gearcase Assembly
Jam Nut Grease Fitting Swing Arm Bushing
U- Bolt
Bolt Lock Bracket
Pivot Bushing Swing Arm Pivot Bolt
Skid Plate
Bolt & Washer 60 ft. lbs. (81 Nm)
Rubber Pad
150 ft. lbs. (203 Nm) 30 ft. lbs. (40 Nm)
Apply LoctiteTM 242
5.21
5
BODY / STEERING / SUSPENSION REAR CARGO BOX Cargo Box - Panels
8-10 in. lbs. (0.9-1.0 Nm) Taillight T-20 8-10 in. lbs. (0.9-1.0 Nm) T-30
Tailgate Support
T-27 4-6 ft. lbs. (5-8 Nm)
T-20
T-30 8-10 in. lbs. (0.9-1.0 Nm) Seal Foam
T-20 8-10 in. lbs. (0.9-1.0 Nm)
Side Panel Front Panel
5.22
T-20 8-10 in. lbs. (0.9-1.0 Nm)
BODY / STEERING / SUSPENSION Cargo Box - Tailgate / Box Support
Tailgate Cap
Tailgate Cable
Latch
T-20 T-20 8-10 in. lbs. (0.9-1.0 Nm) Inner Panel Rod
20-25 in. lbs. (2-3 Nm)
Outer Panel
5 Tailgate Tube
Box
Box Support Box Latch Assembly Hinge Pin
Shock Pins Bolt Shock 8-10 ft. lbs. (10-13 Nm)
Heat Shield
5.23
BODY / STEERING / SUSPENSION Box Removal 1. 2. 3.
Lift the cargo box into the dump position. Disconnect the rear wire harness attached to the tail lights. Remove the upper clip and pin attaching the shock to the cargo box.
Slide Hinge Pin Out
Shock Pin
6.
With both hinge pins removed, remove the box from the frame. Two people maybe needed to remove the box from the frame.
CAUTION Use caution when removing the box. It is recommended to have two people carefully remove the box from the frame.
CAUTION Safely support the box during the remainder of the removal process. The box is not as stable with the shock removed. 4.
Remove the screw (A) that secures the hinge pin to the frame on both sides.
Box Installation 1.
If the shock was replaced, install the lower portion of the shock to the frame and secure it with the pin and clip.
A Lower Shock Pin
2. 5.
Remove the hinge pin from both sides.
CAUTION Safely support the box during the remainder of the removal process. The box is not as stable with the hinge pins removed.
5.24
3. 4. 5. 6.
Place the cargo box onto the frame. Align the hinges of the box with the bracket on the frame. Install the box hinges on both sides. Secure the box hinges with the hinge screws on both sides. With the hinges installed, attach the shock to the cargo box by inserting the pin and clip. Lower the box and secure the latch.
BODY / STEERING / SUSPENSION STORAGE BOX
DECAL REPLACEMENT
Removal
Plastic polyethylene material must be “flame treated” prior to installing a decal to ensure good adhesion. The flame treating procedure can often be used to reduce or eliminate the whitish stress marks that are sometimes left after a fender or cab is bent, flexed, or damaged.
1.
Remove the two bottom T-27 torx screws.
2.
Remove the two top T-27 torx screws.
3.
Remove the three T-27 torx screws on the front edge.
WARNING The following procedure involves the use of an open flame. Perform this procedure in a well ventilated area, away from gasoline or other flammable materials. Be sure the area to be flame treated is clean and free of gasoline or flammable residue.
Torque screws to: 4-5 ft. lbs. (5-6 Nm)
To flame treat the decal area:
4.
Lift the storage box towards the rear of the frame for removal.
Installation 1.
Install the storage box back into the frame assembly. Align all screw holes and ensure the storage box is properly fitted to the frame.
2.
Install all of the T-27 torx screws that were removed. Torque screws to 4-5 ft.lbs. (5-6 Nm).
1.
Pass the flame of a propane torch back and forth quickly over the area where the decal is to be applied until the surface appears slightly glossy. This should occur after just a few seconds of flame treating. Do not hold the torch too close to the surface. Keep the torch moving to prevent damage.
2.
Apply the decal.
NOTE: Refer to your parts manual for decal part number.
Example of Decal Placement
Decal
5.25
5
CLUTCHING
CHAPTER 6 CLUTCHING SPECIAL TOOLS AND SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 PVT SYSTEM FASTENER TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
PVT SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 GENERAL OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 DRIVE CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 DRIVEN CLUTCH OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 MAINTENANCE / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 OVERHEATING / DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
PVT SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 PVT SEALING, GUARD, AND DUCTING COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 6.5 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7 BELT DEFLECTION (TENSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7 BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7 BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8 BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
CLUTCH ALIGNMENT / OFFSET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 CLUTCH ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 CLUTCH OFFSET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
DRIVE CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11 SPRING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11 SHIFT WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12 EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13 CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13 CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14 SPIDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15 ROLLER, PIN, AND THRUST WASHER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . 6.15 BUSHING SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16 MOVEABLE SHEAVE - BUSHING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16 MOVEABLE SHEAVE - BUSHING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16 CLUTCH COVER - BUSHING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17 CLUTCH COVER - BUSHING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17 CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
6
DRIVEN CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19 EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19 CLUTCH DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19 CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22
6.1
CLUTCHING SPECIAL TOOLS AND SUPPLIES TOOL DESCRIPTION
PART NUMBER
Clutch Puller
2870506
Clutch Holding Wrench
9314177
Clutch Holding Fixture
2871358
Spider Nut Socket
2870338
Drive Clutch Spider Removal and Install Tool
2870341
Driven Clutch Puller
2870913
Roller Pin Tool
2870910
Clutch Bushing Replacement Tool Kit
2871226
Piston Pin Puller
2870386
Clutch Compression Tool
8700220
Clutch Bushing Replacement Tool Kit
2871025
Standard Clutch Alignment Tool
PA-47346
SPECIAL SUPPLIES
PART NUMBER
Loctite™ 680
2870584
RTV Silicone Sealer
2870661
Loctite Gasket Remover
2870601
TORQUE SPECIFICATIONS PVT System Fastener Torques ITEM
TORQUE VALUE ft. lbs. (Nm)
Drive Clutch Retaining Bolt
40 ft. lbs. (54 Nm)
Driven Clutch Retaining Bolt
17 ft. lbs. (23 Nm)
PVT Inner Cover Bolts
12 ft. lbs. (16 Nm)
PVT Outer Cover Bolts
45-50 in. lbs (5-5.6 Nm)
Drive Clutch Spider
200 ft. lbs. (271 Nm)
Drive Clutch Spider Lock Nut (Plastic)
15 ft. lbs. (20.3 Nm)
Drive Clutch Cover Plate
90 in. lbs. (10 Nm)
PVT SYSTEM OVERVIEW General Operation WARNING All PVT maintenance or repairs should be performed only by a certified Polaris Master Service Dealer (MSD) technician who has received the proper training and understands the procedures outlined in this manual. Because of the critical nature and precision balance incorporated into the PVT components, it is absolutely essential that no disassembly or repair be made without factory authorized special tools and service procedures. The Polaris Variable Transmission (PVT) consists of three major assemblies: 1) The Drive Clutch 2) The Driven Clutch 3) The Drive Belt The internal components of the drive clutch and driven clutch control engagement (initial vehicle movement), clutch upshift and backshift. During the development of a Polaris ATV, the PVT system is matched first to the engine power curve; then to average riding conditions and the vehicle’s intended usage. Therefore, modifications or variations of components at random are never recommended. Proper clutch setup and careful inspection of existing components must be the primary objective when troubleshooting and tuning.
Drive Clutch Operation Drive clutches primarily sense engine RPM. The two major components which control its shifting function are the shift weights and the coil spring. Whenever engine RPM is increased, centrifugal force is created, causing the shift weights to push against rollers on the moveable sheave, which is held open by coil spring preload. When this force becomes higher than the preload in the spring, the outer sheave moves inward and contacts the drive belt. This motion pinches the drive belt between the spinning sheaves and causes it to rotate, which in turn rotates the driven clutch. At lower RPM, the drive belt rotates low in the drive clutch sheaves. As engine RPM increases, centrifugal force causes the drive belt to be forced upward on drive clutch sheaves.
6.2
CLUTCHING Driven Clutch Operation
Maintenance / Inspection
Driven clutches primarily sense torque, opening and closing according to the forces applied to it from the drive belt and the transmission input shaft. If the torque resistance at the transmission input shaft is greater than the load from the drive belt, the drive belt is kept at the outer diameter of the driven clutch sheaves.
Under normal operation the PVT system will provide years of trouble free operation. Periodic inspection and maintenance is required to keep the system operating at peak performance. The following list of items should be inspected and maintained to ensure maximum performance and service life of PVT components. Refer to the troubleshooting checklist at the end of this chapter for more information.
As engine RPM and horsepower increase, the load from the drive belt increases, resulting in the belt rotating up toward the outer diameter of the drive clutch sheaves and downward into the sheaves of the driven clutch. This action, which increases the driven clutch speed, is called upshifting. Should the throttle setting remain the same and the vehicle is subjected to a heavier load, the drive belt rotates back up toward the outer diameter of the driven clutch and downward into the sheaves of the drive clutch. This action, which decreases the driven clutch speed, is called backshifting. In situations where loads vary (such as uphill and downhill) and throttle settings are constant, the drive and driven clutches are continually shifting to maintain optimum engine RPM. At full throttle a perfectly matched PVT system should hold engine RPM at the peak of the power curve. This RPM should be maintained during clutch upshift and backshift. In this respect, the PVT system is similar to a power governor. Rather than vary throttle position, as a conventional governor does, the PVT system changes engine load requirements by either upshifting or backshifting.
1.
Belt Tension, Drive to Driven Clutch Offset, Belt Width. See these sections later in chapter for each model.
2.
Drive and Driven Clutch Buttons and Bushings, Drive Clutch Shift Weights and Pins, Drive Clutch Spider Rollers and Roller Pins, Drive and Driven Clutch Springs. See these sections later in chapter.
3.
Sheave Faces. Clean and inspect for wear.
4. PVT System Sealing. Refer to appropriate illustration on the following pages. The PVT system is air cooled by fins on the drive clutch stationary sheave. The fins create a low pressure area in the crankcase casting, drawing air into the system through an intake duct. The opening for this intake duct is located at a high point on the vehicle (location varies by model). The intake duct draws fresh air through a vented cover. All connecting air ducts (as well as the inner and outer covers) must be properly sealed to ensure clean air is being used for cooling the PVT system and also to prevent water and other contaminants from entering the PVT area. This is especially critical on units subjected to frequent water forging.
6.3
6
CLUTCHING Overheating / Diagnosis During routine maintenance or whenever PVT system overheating is evident, it’s important to check the inlet and outlet ducting for obstructions. Obstructions to air flow through the ducts will significantly increase PVT system operating temperatures. The vehicle should be operated in Low when pulling or plowing heavy loads, or if extended low speed operation is anticipated. CLUTCH DRIVE BELT & COVER RELATED ISSUES: DIAGNOSIS Possible Causes Solutions / What to do Loading the vehicle into a truck or tall Shift transmission to Low during loading of the vehicle to prevent belt burning. trailer when in high range. Starting out going up a steep incline from When starting out on an incline, use Low, or dismount the vehicle after first a stopped position. applying the park brake and perform the “K” turn. Driving at low RPM or low ground speed Drive at higher speed or use Low. The use of Low is highly recommended (at approximately 3-7 MPH). for cooler PVT operating temperatures and longer component life. Insufficient warm-up of Utility Task Warm engine at least 5 min., then with transmission in neutral, advance Vehicles™ exposed to low ambient throttle to approx. 1/8 throttle in short bursts, 5 to 7 times. The belt will temperatures. become more flexible and prevent belt burning. Slow and easy clutch engagement. Fast, effective use of the throttle for efficient engagement. Towing/Pushing at low RPM/low ground Use Low only. speed. Plowing snow, dirt, etc./utility use. Use Low only. Shift the transmission to Low, carefully use fast, aggressive throttle Stuck in mud or snow. application to engage clutch. WARNING: Excessive throttle may cause loss of control and vehicle overturn. Shift the transmission to Low, carefully use fast, aggressive, brief throttle Climbing over large objects from a application to engage clutch. WARNING: Excessive throttle may cause loss stopped position. of control and vehicle overturn. Shift the transmission to neutral. Using the throttle, vary the engine rpm from Belt slippage from water or snow idle to full throttle. Repeat several times as required. During this procedure, ingestion into the PVT system. the throttle should not be held at the full position for more than 10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. For inspection of clutch components, please contact your Polaris dealer. Shift Clutch malfunction. transmission to Low during loading of the vehicle to prevent belt burning. Fouled plugs, foreign material in gas tank, fuel lines, or carburetor. Contact Poor engine performance. you dealer for further service information. Low: Heavy pulling, basic operational speeds less than 7 MPH, riding GENERAL RANGE OPERATION through rough terrain (swamps, mountains, ect.), low ground speeds. GUIDELINES: High: High ground speeds, speeds above 7 MPH.
Operating in Low Gear Low is the primary driving gear. Low should be used in ALL driving applications except for driving on hard packed level surfaces with light loads. In this circumstance, High may be used. IMPORTANT: Using High for heavy loads, hilly terrain, or in wet, muddy conditions will increase the chance of drive belt burning. RANGER 4X4 / 6X6 1. Use Low as the primary driving gear for all RANGERs.
H L
2. Use High only on hard packed, level surfaces with light loads.
N R
6.4
CLUTCHING PVT SYSTEM SERVICE PVT Sealing, Guard, and Ducting Components SEALING AND DUCTING COMPONENTS Clutch Outlet Duct Inner Cover Clamps
Inner Cover Seal Retainer Outer Cover Seal
6 Cover Bolts
PVT Outer Cover
Disassembly
6.
Install the Drive Clutch Holder (PN 9314177) (A).
Some fasteners and procedures will vary. Refer to the appropriate parts manual for proper fasteners and fastener placement.
7.
Remove drive clutch retaining bolt and remove drive clutch using the Drive Clutch Puller (PN 2870506) (B).
1. 2. 3. 4. 5.
Remove seat. Remove the LH storage box to gain access to PVT outer cover. (See Chapter 5 for removal) Remove PVT air outlet duct hose. Remove outer PVT cover screws. Mark the drive belt direction of rotation and remove drive belt. See “Drive Belt Removal”.
Drive Clutch Puller (PN 2870506) Drive Clutch Holder (PN 9314177) 8.
Remove the driven clutch retaining bolt and driven clutch. Retaining Bolt
A
B
6.5
CLUTCHING 9.
Use the Driven Clutch Puller (PN 2870913), (C) if necessary.
Assembly 1.
C
Inspect PVT inner cover-to engine seal. Replace if cracked or damaged. Apply RTV Silicone Here
Driven Clutch Puller (PN 2870913) 10. Remove driven clutch offset spacers from the transmission input shaft. Keep Spacer(s) In Order
2. 3.
4. 11. Remove screws and retainer plate.
5.
Place a new foam seal on transmission input shaft. Apply RTV silicone sealant to outside edge of inner coverto-engine seal, to ensure a water tight fit between the seal and the cover. Surfaces must be clean to ensure adhesion of silicone sealant. Reinstall cover and tighten rear cover bolts just enough to hold it in place. Fit lip of inner cover seal (A) to engine. Install seal retainer plate and tighten screws securely. B C
A
Seal outer edge to cover with RTV silicone sealant 12. Remove inner cover retaining bolts at rear of cover. 13. Remove cover along with foam seal on back of cover or shaft.
6. 7.
Torque rear inner cover bolts (B) to specification. Install clutch offset spacers on transmission input shaft. Offset Spacer(s)
6.6
CLUTCHING 8. 9. 10. 11. 12. 13.
Clean splines inside driven clutch and on the transmission input shaft. Apply a light film of grease to the splines on the shaft. Install the driven clutch, washer, lock washer, and retaining bolt. Torque to specification. Clean end of taper on crankshaft and the taper bore inside drive clutch. Install drive clutch and torque retaining bolt to specification. Reinstall drive belt noting direction of rotation. If a new belt is installed, install so numbers can be easily read.
DRIVE BELT Belt Deflection (Tension) Straight Edge Deflection Measurement See Spec Below
Toward outer cover
PVT Cover Gasket 14. Replace PVT outer cover rubber gasket with the narrow side out (C). 15. Reinstall PVT outer cover and secure with screws Torque to 45-50 in. lbs. (5-5.6 Nm). 16. Install the PVT cover outlet duct and tighten the clamps.
Belt Deflection (Tension): 1 1/8” (2.9 cm) - 1 1/4” (3.2 cm) Pinch the sheaves lightly together with clamp to prevent the belt from being pushed into the driven sheave. 1. 2. 3.
Place a straight edge on top of the belt between drive and driven clutch. Push down on drive belt until it is lightly tensioned. Measure belt deflection as shown in photo.
If belt deflection is out of specification, adjust by removing or adding shims between the driven clutch sheaves. • Remove shims to decrease belt deflection • Add shims to increase belt deflection See “Driven Clutch Service”.
Inner Cover Bolt Torque (Rear): 12 ft. lbs. (16.6 Nm) Outer Cover Bolt Torque: 45-50 in.lbs. (5-5.6 Nm) Driven Clutch Retaining Bolt Torque: 17 ft. lbs. (23.5 Nm)
At least one shim must remain between the inner and outer sheave of the driven clutch. If proper belt deflection cannot be obtained, measure drive belt width, length, and center distance of drive and driven clutch, outlined in this section; all have an effect on belt deflection.
Belt Removal 1.
Remove outer PVT cover as described in PVT Disassembly.
2.
Mark the drive belt direction of rotation so that it can be installed in the same direction.
Drive Clutch Retaining Bolt Torque: 40 ft. lbs. (55 Nm)
6.7
6
CLUTCHING NOTE: Belt is normally positioned so that part numbers are easily read.
1.
Measure belt width and replace if worn severely. Generally, belt should be replaced if clutches can no longer be adjusted to provide proper belt deflection. • The top edges have been trimmed on some drive belts. It will be necessary to project the side profiles and measure from corner to corner. • Place a straight edge on each side of the drive belt. • Place another straight edge on top of belt. • Measure the distance where the side straight edges intersect the top.
2. 3.
To remove drive belt, put transmission in gear, apply brake, pull upward and rearward on belt to open driven clutch sheaves, pull out and down on belt to slip over the driven clutch outer sheave.
3.
Inspect belt for loose cords, missing cogs, cracks, abrasions, thin spots, or excessive wear. Replace if necessary. Inspect belt for hour glassing (extreme circular wear in at least one spot and on both sides of the belt). Hour glassing occurs when the drive train does not move and the drive clutch engages the belt.
Center Distance
Clutch Center Distance: 10” + .1/-.05 (254 + 2.5 / -1.3 mm)
Belt Inspection
Belt Outer Circumference New: 41.225” (104.71 cm) Wear Limit: 41.413” (105.19 cm)
Belt Width
4.
Belt Width New: 1.188” (3.02 cm) Wear Limit: 1.157 (2.94 cm)
6.8
5.
Measure belt length with a tape measure around the outer circumference of the belt. Belts which measure longer than nominal length may require driven shimming or engine adjustment for a longer center distance to obtain proper belt deflection. Belts which measure shorter than nominal length may require driven shimming or a shorter center distance. Remember, proper belt deflection is the desired goal - not a specific center distance. Replace belt if worn past the wear limit. Belts with thin spots, burn marks, etc., should be replaced to eliminate noise, vibration, or erratic PVT operation. See Troubleshooting Chart at the end of this chapter for possible causes.
CLUTCHING NOTE: If a new belt is installed, check belt deflection.
CLUTCH ALIGNMENT / OFFSET Clutch Alignment Clutch Alignment Tool
Belt Installation 1.
Loop belt over the drive clutch and over top of the driven sheave.
(PN PA-47346)
A 1/8” +0/ - 1/16 3.2 mm +0 / -1.6 mm
2.
While pushing down on top of belt, turn the back or moveable driven sheave clockwise.
1.
Remove belt and install the Clutch Alignment Tool as shown above.
6
Clutch Alignment Tool PN: PA-47346 2.
With tool touching rear of driven clutch inner sheave, the distance at point “A” should be 1/8'.
If the distance is greater than 1/8' or less than 1/16', clutch alignment must be adjusted as follows: 3. 4. 5. 3.
The belt then should be able to be pushed down into and between the sheaves.
6.
Remove drive and driven clutch. See “PVT System Service, Disassembly.” Remove PVT inner cover. Loosen all engine mounts. Move front of engine to the right or left slightly until alignment is correct. Tighten engine mounts and verify alignment is correct. Center line
Be sure to position belt so part number is easily read.
Measure offset above and below centerline 7.
Measure belt deflection and measure offset both above and below sheave centerlines. Adjust if necessary.
6.9
CLUTCHING NOTE: On some models, minor adjustments can be made by adding shims between the frame and front lower left engine mount to increase the distance at point “A”. If a shim is present, it can be removed to decrease the distance at point “A”.
Shim Kit PN: 2200126
Clutch Offset IMPORTANT: Inspect clutch alignment and center distance before adjusting offset. 1.
Install clutch alignment tool as shown.
Offset is correct when rear of tool contacts rear of inner sheave with driven clutch pushed completely inward on shaft and bolt torqued. Adjust offset by adding or removing spacer washers between back of driven clutch and spacer as shown. Clutch Alignment Tool should contact rear edge of driven clutch sheave
Driven Clutch Offset To adjust, add or remove washers from behind the driven clutch
Spacer Washer PN: 7556401
6.10
CLUTCHING DRIVE CLUTCH SERVICE Spring Specifications The drive clutch spring has two primary functions: 1.
2.
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 upward in the drive clutch sheaves. This is referred to as drive clutch upshift.
There are other components which control upshift, but the spring is one of the primary components in insuring optimum performance. It is very important that the spring is of the correct design and is in good condition.
CAUTION Never shim a drive clutch spring to increase its compression rate. This may result in complete stacking of the coils and subsequent clutch cover failure.
6
The drive clutch spring is one of the most critical components of the PVT system. It is also one of the easiest to service. Due to the severe relaxation the spring is subject to during operation, it should always be inspected for tolerance limits during any clutch operation diagnosis or repair. With the spring resting on a flat surface, measure its free length from the outer coil surfaces as shown. Refer to the spring specification chart for specific free length measurements and tolerances. Also check to see that spring coils are parallel to one another. Distortion of the spring indicates stress fatigue, requiring replacement.
Primary Clutch Springs PART NUMBER 7041021 7041022 7041063 7041132 7041168 7041157 7042202
COLOR CODE Plain Black Purple White Green Blue/Green Blue/Gray
Secondary Clutch Springs WIRE DIAMETER .157' .140' .168' .177' .177' .177' .187'
FREE LENGTH ± .125” 4.38' 4.25' 4.37' 2.92' 3.05' 2.53' 2.55'
PART NUMBER 7041198 7041782 7041501 7041499 7041296 7041646 7043167
DESCRIPTION Red Black 5-coil Gold 6-coil Silver Blue Silver/Blue Black/Almond
6.11
CLUTCHING Shift Weights Shown below are the shift weights which have been designed for, or which may be used in the PVT system. These shift weights have many factors designed into them for controlling engagement RPM and shifting patterns. Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to sheave clearance, clutch balance and shifting pattern.
6.12
CLUTCHING Exploded View TeflonTM coated brass bushing
Drive Clutch Spring
DRIVE CLUTCH Shift Weight
TeflonTM coated brass bushing
Mark with permanent marker before disassembly
6
Clutch Inspection All PVT system maintenance repairs must be performed only by an authorized Polaris service technician who has attended a Polaris sponsored service training seminar and understands the proper procedures as outlined in this manual. Because of the critical nature and precision balance incorporated into the PVT system, it is absolutely essential that no attempt at disassembly or repair be made without factory authorized special tools and service procedures.
WARNING The clutch assembly is a precisely balanced unit. Never replace parts with used parts from another clutch assembly. 1.
Remove shift weight bolts and weights. Inspect as shown. The contact surface of the weight should be smooth and free of dents or gall marks. Inspect the weight pivot bore and pivot bolts for wear or galling. If weights or bolts are worn or broken, replace in sets of three with new bolts.
Broken
Worn
Good
NOTE: A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly. See “Roller, Pin and Thrust Washer Inspection”.
6.13
CLUTCHING Button To Tower Clearance Inspection 1.
3.
Inspect for any clearance between spider button to tower. If clearance exists, replace all buttons and inspect surface of towers. See “Spider Removal”
Inspect cover bushing (A). The outer cover bushing is manufactured with a Teflon™ coating. Bushing wear is determined by the amount of Teflon™ remaining on the bushing.
A
Cover Bushing Inspection: Replace the cover bushing if more brass than Teflon™ is visible on the bushing. Refer to bushing replacement in this chapter.
Button to Tower Clearance: 000-.001” 2.
Inspect sheave surfaces. Replace the entire service clutch if worn, damaged or cracked. 4.
Clutch Disassembly 1.
Using a permanent marker, mark the cover, spider, moveable and stationary sheaves, and steel post to the stationary sheave for reference. The X’s may not have been in alignment before disassembly.
Inspect area on shaft where bushing rides for wear, galling, nicks, or scratches. Replace clutch assembly if worn or damaged. Inspect Shaft
Mark
“X” Mark
2.
Remove cover bolts evenly in a cross pattern, and remove cover plate.
6.14
5.
Remove and inspect the clutch spring.
CLUTCHING Spider Removal
Roller, Pin, and Thrust Washer Inspection
1.
1.
Inspect all rollers, bushings and roller pins by pulling a flat metal rod across the roller. Turn roller with your finger. If you notice resistance, galling, or flat spots, replace rollers, pins and thrust washers in sets of three. Also inspect to see if roller and bushing are separating. Bushing must fit tightly in roller. Use the Roller Pin Tool (PN 2870910) to replace rollers and pins. Take care not to damage roller bushing or bearing surface of the new pin during installation.
2.
Rubber backed buttons can be used in all ATV clutches if the hollow roller pin is changed to the solid roller pin.
Install clutch in holding fixture and loosen the spider (counterclockwise) using spider removal tool.
Clutch Holding Fixture: (PN 2871358) Spider Removal Tool: (PN 2870341) It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly. Be sure to note the number and thickness of these washers.
NOTE: The rubber side of the button is positioned toward the solid roller pin.
Moveable Sheave Bushing Inspection 2.
Inspect the Teflon™ coating on the moveable sheave bushing.
TeflonTM
Moveable Sheave Bushing Inspection: Replace the cover bushing if more brass than Teflon is visible on the bushing. Refer to bushing replacement in this chapter.
6.15
6
CLUTCHING Bushing Service
4.
*Clutch Bushing Replacement Tool Kit (PN 2871226)
Insert the Number Two Adapter (#10) (PN 5020633) into the bushing from belt side as shown. With towers pointing toward vise, slide sheave and bushing onto puller rod. #10
#2
#3
#5
#10
#9
#8 Stamp
Qty.
#2
1
#3
1
#5
1
#8 #9
1 1
#10
1
Part Description P-90 Drive/Driven Clutch Bushing Install Tool Drive Clutch Cover Bushing Removal/ Installation Tool (all clutches) P-90 Driven Clutch Cover Bushing Removal Tool Main Puller Adapter Adapter Reducer Number Two Puller Adapter
Part #
5.
Install the nut removed in Step 2 onto end of puller rod and hand tighten. Turn puller barrel to increase tension on sheave if needed. Nut is left hand thread
6.
Turn sheave and puller barrel together counterclockwise on puller rod until bushing is removed. Remove nut from puller rod and set aside. Pull bushing removal tool and adapter from puller rod. Remove bushing from tool and discard.
5020628
5020629
5020631 5020632 5010279 5020633
Moveable Sheave - Bushing Removal 1.
Install handle end of the Piston Pin Puller (PN 2870386) securely into bench vise and lightly grease puller threads.
Piston Pin Puller (PN 2870386) 2. 3.
Remove nut from puller rod and set aside. Install the Main Puller Adapter (#8) (PN 5020632) onto the Piston Pin Puller (PN 2870386).
Piston Pin Puller (PN 2870386)
7. 8.
Moveable Sheave - Bushing Installation 1. 2.
Place the Main Puller Adapter (#8) (PN 5020632) onto the puller. Apply Loctite™ 680 (PN 2870584) to the back side of new bushing. Push bushing into center of sheave on tower side by hand.
Bushing (PN 3576504) Loctite™ 680 (PN 2870584) Main Puller Adaptor (#8) (PN 5020632)
6.16
3.
Insert the Clutch Bushing Installation Tool (#2) (PN 5020628) into center of sheave and with towers pointing away from vise, slide sheave onto puller rod.
CLUTCHING 4. 5.
6. 7. 8.
Install nut on puller rod and hand tighten. Turn barrel to apply additional tension if needed. Turn sheave and barrel together counterclockwise until bushing is seated.
Remove nut from puller rod and set aside. Remove sheave from puller. Remove installation tool.
4.
Install nut onto puller rod and hand tighten. Turn puller barrel to increase tension as needed.
5.
Turn clutch cover counterclockwise on puller rod until bushing is removed.
6.
Remove nut from puller rod and set aside.
7.
Remove bushing and bushing removal tool from puller. Discard bushing.
Clutch Cover - Bushing Removal 1.
Install the Main Puller Adapter (#8) (PN 5020632) onto the Piston Pin Puller (PN 2870386).
6
Clutch Cover - Bushing Installation 1.
Piston Pin Puller (PN 2870386)
Apply Loctite™ 680 (PN 2870584) to the back side of new bushing. Working from inside of cover, insert bushing and bushing installation tool into center of clutch cover.
Main Puller Adaptor (#8) (PN 5020632) 2.
From outside of clutch cover, insert the Drive Cover Bushing Remover (#3) (PN 5020629) into cover bushing.
#3
Bushing (PN 3576510) Loctite™ 680 (PN 2870584)
3.
With inside of cover toward vise, slide cover onto puller.
2.
With the Main Puller Adapter (#8) (PN 5020632) on the puller, insert cover onto puller rod, placing outside of cover toward vise.
3.
Install nut on rod and hand tighten. Turn puller barrel to apply more tension if needed.
6.17
CLUTCHING 4.
Turn clutch cover and barrel together counterclockwise on puller rod until bushing is seated.
3.
4.
Compress spider buttons for each tower and install spider, making sure that “X”, or the marks that were made earlier, on spider aligns with “X”, or the marks that were made earlier, in moveable sheave. Torque spider to specification using the holding fixture and spider tool. Torque with smooth motion to avoid damage to the stationary sheave. Refer to Page 6.2 for torque specification.
CAUTION
5.
Remove nut from puller rod and take installation tool and clutch cover off the rod.
Be sure the spider spacer washers are fully seated in the recessed area in the spider. Any misalignment will alter clutch balance. Inverting the clutch while initially tightening the spider will help position the washers. 5.
Install shift weights using new lock nuts on the bolts.
Clutch Assembly It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly. The Teflon™ bushings are self-lubricating. Do not apply oil or grease to the bushings Reassemble the drive clutch in the following sequence. Be sure the “X”, or the marks that were made earlier are aligned during each phase of assembly Nut on trailing side 6. 7. 8.
1. 2.
Reinstall clutch spring. Reinstall cover, aligning “X” mark with other marks. Torque cover bolts evenly to specification.
Install moveable sheave onto fixed sheave. Install spider spacers. Use same quantity and thickness as were removed.
Spider torque: 200 ft. lbs. (276 Nm)
Spacer washers
6.18
Rotation
Cover Screw Torque: 90 in. lbs. (10.4 Nm)
CLUTCHING DRIVEN CLUTCH SERVICE Exploded View
DRIVEN CLUTCH
Compression Spring
Spring Retainer Secondary Stationary Sheave Retaining Ring Inner Spring Retainer Moveable Inner Sheave
Clutch Disassembly / Inspection CAUTION
6 2.
With the snap ring (A) removed and spring pressure relieved, remove the outer retainer (B), spring (C), and inner retainer (D).
B
Wear eye protection when removing snap ring to prevent serious personal injury. Use caution when removing, the snap ring pressure is loaded by the compression spring. 1.
Apply and hold downward pressure on the outer spring retainer. Carefully remove the snap ring. Remember the outer spring retainer contains strong spring pressure.
A
C D
Remove Snap Ring
B A D Outer Spring Retainer
C
6.19
CLUTCHING 3.
Separate the two clutch sheaves.
4.
Inspect the helix and inner spring retainer on the moveable sheave.
6.
Check the rollers in the stationary sheave for wear. If the rollers are worn, a new driven clutch assembly may be needed.
Check Rollers for Wear Inspect For Abnormal Wear
5.
7.
Inspect the bearings inside the moveable sheave.
Inspect Bearings For Wear
Remove the inner spring retainer from the inner sheave. Inspect for wear and replace as needed.
Moveable Sheave Bearing Inspection:
Inspect For Abnormal Wear Replace the bearing if more brass than Teflon™ is visible on the bearing. 8.
Inspect the Teflon™ coating on the moveable sheave bearings.
9.
Inspect driven clutch sheave faces for wear or damage.
10. Clean and inspect splines on helix and transmission input shaft. 11. Lube splines with a light film of grease. Do not lubricate the bearings!
6.20
CLUTCHING Clutch Assembly
3.
Install spring into inner retainer.
1.
Install moveable inner spring retainer if removed. Do not apply oil or grease to the bearings.
4.
Install outer retainer on top of spring.
5.
Compress the outer retainer and install the snap ring.
2.
Align the “X” marks on each of the sheaves during reassembly.
Snap Ring
6
Reassemble Sheaves
6.21
CLUTCHING TROUBLESHOOTING Situation Engine RPM below specified operating range, although engine is properly tuned.
Probable Cause -Wrong or broken drive clutch spring.
Remedy -Replace with recommended spring.
-Drive clutch shift weight too heavy.
-Install correct shift weight kit to match engine application.
-Driven clutch spring broken or installed in wrong -Replace spring; refer to proper installation location. helix location. -Drive clutch binding. A. Disassemble drive clutch; inspect shift weights for wear and free operation. B. Clean and polish stationary shaft hub; reassemble clutch without spring to determine problem area.
Erratic engine operating RPM -Belt worn unevenly - thin / burnt spots. during acceleration or load variations. -Driven clutch malfunction.
Replace belt. A. Replace ramp buttons. B. Inspect movable sheave for excessive bushing clearance.
-Sheave face grooved. -Replace the clutch. -Incorrect drive clutch spring (too high spring rate). -Install correct recommended spring. -Drive clutch shift weights incorrect for application -Install correct recommended shift weights. (too light). -Drive clutch binding.
-Disassemble and clean clutch, inspecting shift weights and rollers. Reassemble without the spring and move sheaves through entire range to further determine probable cause.
-Driven clutch binding.
-Disassemble, clean, and inspect driven clutch, noting worn sheave bushing and ramp buttons and helix spring location.
-Converter sheaves greasy; belt slipage.
-Clean sheaves with denatured alcohol or brake cleaner, install new belt. -Replace belt.
Engine RPM above specified operating range.
-Drive belt worn too narrow. Harsh drive clutch engagement.
-Excessive belt / sheave clearance with new belt. -Perform belt / sheave clearance adjustment with shim washers beneath spider. -Wrong belt for application. -Replace with correct belt.
Drive belt turns over -Clutch alignment out of spec. -Engine mount broken or loose. -Abuse (continued throttle application when vehicle is stationary, excess load) Belt burnt, thin spots -Dragging brake
-Slow, easy clutch engagement
6.22
-Adjust alignment offset. -Inspect / adjust or replace. -Caution operator to operate machine within guidelines.
-Vehicle operated with park brake on. Inspect brake system. -Fast, effective use of throttle for efficient engagement.
CLUTCHING Troubleshooting, Continued... Situation
Probable Cause -Plugged air intake or outlet.
Remedy -Clear obstruction
-Belt slippage due to water, oil, grease, etc., rubbing -Inspect system. Clean , repair or replace as necessary. on cover. Seal PVT system ducts. PVT cover -Clutches or weight being applied to cover while in -Remove weight. Inform operator. overheating (melting) operation. -High vs. low range.
-Cover seals or ducts leaking Water ingestion
Belt slippage
PVT noise
Engagement erratic or stabby
-Operator error
-Instruct operator on guidelines for operation in proper driving range for different terrain as outlined in Owner’s Safety and Maintenance Manual. -Find leak and repair as necessary.
-Belt worn out
-Instruct operator on guidelines for operation in wet terrain as outlined in Owner’s Safety and Maintenance Manual. -Replace belt.
-Water ingestion
-Inspect and seal PVT system.
-Belt contaminated with oil or grease -Belt worn or separated, thin spots, loose belt
-Inspect and clean. -Replace belt.
6
-Broken or worn clutch components, cover hitting -Inspect and repair as necessary. clutches -Thin spots on belt, worn belt -Replace belt. Refer to belt burnt troubleshooting and instruct operator. -Drive clutch bushings stick
-Inspect and repair clutches.
6.23
FINAL DRIVE
CHAPTER 7 FINAL DRIVE SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
FRONT HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 HUB REMOVAL / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 HUBSTRUT BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4 HUB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5 FRONT HUB EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
DRIVE SHAFT / PROPSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7 EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
DRIVESHAFT / CV JOINT HANDLING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 CV JOINT / BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
FRONT PROPSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11 PROPSHAFT U-JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
FRONT GEARCASE CENTRALIZED HILLIARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14 AWD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14 CENTRALIZED HILLIARD EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15 AWD DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16 GEARCASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17 GEARCASE DISASSEMBLY / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18 GEARCASE REASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20 BACKLASH PAD (THRUST PAD) ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22 GEARCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
7
MID DRIVE HUB / BEARING CARRIER (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23 HUB DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24 HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24 HUB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25 MID DRIVE EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.26
MID DRIVE SHAFT (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27 DISASSEMBLY / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27
MID PROP SHAFT (6X6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.28 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.28
MID DRIVE GEARCASE (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.28 GEARCASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.28 GEARCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.29 GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32 GEARCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.34 MID GEARCASE EXPLODED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.35
REAR DRIVE (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.36 EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.36
7.1
FINAL DRIVE REAR HUB / BEARING CARRIER (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.36 HUB INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.36 HUB REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.36 HUB DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.37 HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.38 HUB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.38
REAR DRIVE SHAFT (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.39 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.39 CV JOINT / BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.40 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.42
REAR PROPSHAFT (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.43 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.43 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.43
REAR GEARCASE (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.44 GENERAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.44 OPERATION MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.45 DIFFERENTIAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.46 DIFFERENTIAL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.46 DIFFERENTIAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.49 DIFFERENTIAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.51 DIFFERENTIAL EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.52
REAR AXLE / GEARCASE SERVICE (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.53 REAR AXLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.53 AXLE TUBE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.54 AXLE TUBE BEARING REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.55 GEARCASE DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.55 GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.56 GEARCASE / AXLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.57 GEARCASE EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.60
7.2
FINAL DRIVE SPECIAL TOOLS
FRONT HUB
PART NUMBER
TOOL DESCRIPTION
2872608
Roller Pin Removal Tool
8700226
CV Boot Clamp Pliers
Hub Removal / Inspection 1.
Elevate front end and safely support machine under footrest / frame area.
CAUTION
TORQUE SPECIFICATIONS
Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure. Wear eye protection when removing bearings and seals.
Wheel, Hub, and Spindle Torque Table ITEM
NUT TYPE
Aluminum Wheels Lug Nut (1) (Cast) Steel Wheels (Black / Camo)
SPECIFICATION 2. 90 ft. lbs. (122 Nm)
Flange Nut (2) 35 ft. lbs. (47 Nm)
Front Spindle Nut
-
70 ft. lbs. (95 Nm)
Rear & Middle Hub Retaining Nut
-
110 ft. lbs. (150 Nm)
Check bearings for side play by grasping the tire / wheel firmly and checking for movement. Grasp the top and bottom of the tire. The tire should rotate smoothly without binding or rough spots.
7
#2
#1
Aluminum Wheel
Steel Wheel
(LE Models) 90 ft. lbs. (122 Nm)
(Standard Models) 35 ft. lbs. (47 Nm)
3.
Remove wheel nuts, washers, and wheel.
4.
Remove the two brake caliper attaching bolts. CAUTION: Do not hang the caliper by the brake line. Use wire to hang the caliper to prevent possible damage to the brake line.
7.3
FINAL DRIVE 5.
Remove hub cap, cotter pin, front spindle nut, and washer.
6.
Rotate each bearing by hand and check for smooth rotation. Visually inspect bearing for moisture, dirt, or corrosion. Replace bearing if moisture, dirt, corrosion, or roughness is evident.
Rotate Bearing
3.
Drive bearing out evenly by tapping on outer race only. Once bearing is at bottom of casting, support casting on outer edges so bearing can be removed.
NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel. While rotating bearings by hand, inspect for rough spots, discoloration, or corrosion. The bearings should turn smoothly and quietly, with no detectable up and down movement and minimal movement sideways between inner and outer race. 4.
Inspect bearing hubstrut housing for scratches, wear or damage. Replace hubstrut housing if damaged.
Bearing Installation 5.
6.
Hubstrut Bearing Replacement Bearing Removal 1.
Thoroughly clean the hubstrut housing and the outer race on the new bearing. Be sure that all oil residue has been removed from each surface. Apply Loctite® RC™ 680 to the outer circumference of the new bearing race and carefully install the new bearing into the strut housing.
Remove outer snap ring.
Apply Loctite® RC™ 680
NOTE: Use care to not allow any of the Loctite® compound to get in the bearing. 2.
From the back side, tap on the outer bearing race with a drift punch in the reliefs as shown in Step 3.
7.4
7.
Wipe the housing clean of any excess compound and install the retaining ring.
FINAL DRIVE Hub Installation
10. Install brake caliper using new bolts. Tighten bolts to specified torque.
1.
Inspect the hubstrut bearing surface for wear or damage.
2.
Apply grease to drive axle spindle.
3.
Install spindle through the backside of the hubstrut. Install the hub onto the spindle.
4.
Apply grease to washer and install with domed side out.
18 ft. lbs. (24 Nm)
Brake Caliper Bolt Torque 18 ft. lbs. (24 Nm) CAUTION New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly.
Out Cone Washer 5.
11. Install wheel, washers, wheel nuts, and tighten evenly in a cross pattern to specified torque. Refer to “Torque Specifications” on Page 7.3 Flange Nuts: Flat side against wheel
Install spindle nut and tighten to specification.
Spindle Nut Torque: 70 ft. lbs. (95 Nm) 6.
Install a new cotter pin. Tighten nut slightly if necessary to align cotter pin holes.
7.
Rotate wheel and check for smooth operation. Bend both ends of cotter pin around end of spindle in different directions.
8.
Install hub cap.
9.
Rotate hub. It should rotate smoothly without binding or rough spots or side play.
7.5
7
FINAL DRIVE Front Hub Exploded View Disc Brake
Stud Front Hub
Rim Tire
18 ft. lbs. (24 Nm) Use new bolts with pre-applied locking agent.
Wheel Nut (Spec on page 7.3)
Dust Cover
Washer Slotted Nut 70 ft. lbs. (95 Nm)
7.6
Cotter Pin
FINAL DRIVE DRIVE SHAFT / PROPSHAFT Exploded View RANGER Front Driveshaft CV Joint
30g Grease Packet
30g Grease Packet
Plunging Joint
Inner Clamps
Boots
Clamp
Circlip
Clamp
RANGER Front Propshaft
Joint Kit
Grease Zerk O-ring
7 Shaft Yoke
Front Yoke
RANGER 4X4 & 6X6 Rear Propshaft Spring Pin O-ring
O-ring
4X4
6X6
Grease Zerk
Cross & Bearing Kit Cross & Bearing Kit
Cross & Bearing Kit Spring Pin
7.7
FINAL DRIVE DRIVESHAFT / CV JOINT HANDLING TIPS
2.
Check bearings for side play by grasping tire / wheel firmly and checking for movement. It should rotate smoothly without binding or rough spots.
3.
Remove wheel nuts, washers, and wheel.
4.
Remove the two brake caliper attaching bolts. CAUTION: Do not hang the caliper by the brake line. Use wire to hang the caliper to prevent possible damage to the brake line.
Removal
5.
Remove the hub spindle nut.
1.
6.
Remove hub.
Care should be exercised during driveshaft removal or when servicing CV joints. Driveshaft components are precision parts. Cleanliness and following these instructions is very important to ensure proper shaft function and a normal service life. • The complete driveshaft and joint should be handled by getting hold of the interconnecting shaft to avoid disassembly or potential damage to the driveshaft joints. • Over-angling of joints beyond their capacity could result in boot or joint damage. • Make sure surface-ground areas and splines of shaft are protected during handling to avoid damage. • Do not allow boots to come into contact with sharp edges or hot engine and exhaust components. • The driveshaft is not to be used as a lever arm to position other suspension components. • Never use a hammer or sharp tools to remove or to install boot clamps. • Be sure joints are thoroughly clean and that the proper amount and type of grease is used to refill when joint boots are replaced and when joints are cleaned. Refer to text for grease capacity of CV joints and CV joint boots.
FRONT DRIVE SHAFT Elevate front end and safely support machine under footrest / frame area.
CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure. Wear eye protection when removing bearings and seals.
7.8
FINAL DRIVE 7.
8.
Remove cotter pin and nut from lower A-arm ball joint. Remove lower A-arm from ball joint.
CV Joint / Boot Replacement 1.
Remove wheel, brake caliper and wheel hub. Refer to “Front Hub Removal” for procedure.
2.
Remove cotter pin and castle nut from A-arm ball joint.
3.
Disconnect A-arm from ball joint using a tie rod fork.
Pull strut assembly out while pivoting front drive shaft downward until it clears strut assembly.
7 9.
With short sharp jerks, remove drive shaft from front gearcase. 4.
Slide strut off end of drive shaft and tie it up out of the way of the shaft.
5.
Remove clamps from rubber boot using the proper boot clamp pliers.
CV Boot Clamp Pliers: Earless Type - 8700226
7.9
FINAL DRIVE 6.
Remove the large end of the boot from the CV joint, slide the boot back and separate the wheel spindle and CV joint assembly from the axle shaft by pulling the shaft sharply outward, away from the CV joint. It may be necessary to tap the CV joint assembly outward with a soft faced hammer.
FRONT DRIVE SHAFT
Boot Capacity 30 Grams
Retaining Ring
Joint Capacity* 30 Grams
Pull shaft to remove from CV joint 7.
Remove small clamp and boot from driveshaft. If the vehicle has been operated with a damaged boot, the CV joint grease may be contaminated. Inspect the grease carefully for contamination, and clean the joint thoroughly if necessary. Front drive axle outer boot replacement requires 30g of grease. Inner boot replacement requires 20g of grease. If either of the joints are cleaned, double the amount of grease is required. Refer to information below and illustration to the right.
Boot Replacement Grease Requirement: Outer CV Joint Grease - 30g PN 1350046 Inner Plunging Joint Grease - 20g PN 1350059 8.
Before installing the new boot, remove all grease from the boot area and shaft.
NOTE: It is very important to use the correct type and quantity of grease by using the grease contained in the boot kit. DO NOT use a substitute grease and DO NOT overfill or underfill the CV joint. 9.
Slide the new clamp and boot (small end first) over the splined shaft, then slide (tap) the CV joint into the splines of the axle. Install small boot clamp.
10. Add grease through large end of boot. 11. Position large end of boot on CV joint, purge excess air by partially compressing axle into CV bell, lift one edge of boot to let out excess air Secure the CV boot with clamp.
7.10
Joint Capacity** 20 Grams Boot Capacity 20 Grams
*CV joint capacity: 30g if boot is replaced only. Another 30g (60g total) if joint is cleaned. **Plunging joint capacity: 20g if boot is replaced only. Another 20g (40g total) if joint is cleaned.
FINAL DRIVE FRONT PROPSHAFT REMOVAL
Installation 1.
Install new spring ring on drive shaft. Apply an anti-seize compound to splines. Align splines of drive shaft with front gearcase and install by lightly tapping on drive shaft with rubber faced hammer.
1.
Elevate front end and safely support machine under footrest / frame area.
CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure. Wear eye protection when removing bearings and seals.
2.
Install drive shaft in strut.
3.
Install the lower A-arm onto the lower ball joint, torque nut to 25 ft. lbs. (35 Nm) and install new cotter pin.
2.
Remove wheel nuts and wheel.
3.
Remove cotter pin and nut from lower A-arm ball joint. Remove lower A-arm from ball joint. (See below)
7 4.
Cotter Pin
4.
25 ft. lbs. (35 Nm)
Use the Roll Pin Removal Tool (PN 2872608), to remove the roll pin from prop shaft at the front housing. Slide prop shaft back and away from front housing. Pull sharply forward to remove from transmission shaft.
NOTE: The roll pin can also be accessed through the hole in the skid plate shown in the photo below.
Install hub and tighten spindle nut to 70 ft. lbs. (95 Nm).
Front Spindle Nut Torque 70 ft. lbs. (95 Nm)
Roll Pin Removal Tool (PN 2872608)
7.11
FINAL DRIVE NOTE: Remove the drive shaft floor cover to help align the roll pin removal tool to the roll pin for removal. The drive shaft can be removed through the floor covering.
2.
Support inner yoke as shown and drive outer yoke down (bearing cap out) with a soft face hammer.
3.
Support U-joint in vise as shown and drive inner yoke down to remove remaining bearing caps.
4.
Force U-joint cross to one side and lift out of inner yoke.
PROPSHAFT U-JOINT SERVICE Disassembly 1.
Remove internal or external snap ring from all bearing caps.
CAUTION Always wear eye protection.
NOTE: If yoke or bearing is removed, cross bearing must be replaced. Note orientation of grease fitting and mark inner and outer yoke for correct repositioning during installation.
7.12
FINAL DRIVE Assembly 1.
2.
4.
Install outer disassembly.
yoke,
aligning
marks
made
before
5.
Repeat Steps 1-3 to install bearing caps on outer yoke.
6.
Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown.
Install new bearing caps in yoke by hand. Carefully install U-joint cross with grease fitting properly positioned inward toward center of shaft. Take care not to dislodge needle bearings upon installation of cross joint. Tighten vise to force bearing caps in.
Using a suitable arbor, fully seat bearing cap in one side. Continually check for free movement of bearing cross as bearing caps are assembled.
7 7.
3.
When installation is complete, yokes must pivot freely in all directions without binding. If the joint is stiff or binding, tap the yoke lightly to center the joint until it pivots freely in all directions.
Install snap ring to contain bearing cap just installed. Repeat procedure for other side.
7.13
FINAL DRIVE FRONT GEARCASE CENTRALIZED HILLIARD
CAUTION
AWD Operation Engaging Front Gearcase: The AWD switch may be turned on or off while the vehicle is moving. Initially, the vehicle’s electronic system will not enable the AWD until the engine RPM is below 3100. Once enabled, the AWD remains while the front gearcase is moving, it will not disengage until the rear wheels regain traction. Engage the AWD switch before getting into conditions where the front wheel drive may be needed. If the rear wheels are spinning , release the throttle before switching to AWD.
If the rear wheels are spinning, release the throttle before turning the AWD switch on. If AWD is engaged while the wheels are spinning, severe drive shaft and clutch damage could result. Roller Cage and Roller’s Rotate Inward and Grip the Output hub for AWD Engagement Output Hub
Rollers
CAUTION Switching to AWD while the rear wheels are spinning may cause severe drive shaft and gearcase damage. Always switch to AWD while the rear wheels have traction or are at rest. Normal Operation: With the AWD switch off the vehicle drives only the rear wheels (2 wheel drive). When the AWD switch is activated it engages the Hilliard, locking both front axles into All Wheel Drive. Roller Cage
Armature plate design may differ from what is shown
Output Hub
Armature Plate
Coil
Cover
4X4 Engagement: When the AWD switch is activated, a 12 VDC current charges the central coil which creates a magnetic field. This magnetic field attracts an armature plate keyed to a roller cage that contains 14 rollers and roller cam. The difference in rpm by input shaft and front axles the forces the rollers up the external cam. The rollers engage themselves to the output hubs that link both front axles, resulting in True All Wheel Drive.
7.14
Roller Cage & Bearings Disengagement: As the front and rear wheels gain traction, rotating very close to the same speed, the front wheels “overdrive” the output hubs and the rollers are forced outward, disengaging the AWD. The vehicle is now back to rear wheel drive until the next loss of traction.
FINAL DRIVE Centralized Hilliard Exploded View
1
2
3 17 ft. lbs. (23 Nm)
4
15
9
5 6
14
11
8
7
10 6
15 17 ft. lbs. (23 Nm)
20
12 13
7
14 26
24
16
25 18 23
17
19 22
14
10 ft. lbs. (14 Nm)
21 8-30 ft. lbs. (11-41 Nm)
7 REF#
DESCRIPTION
QTY
REF#
DESCRIPTION
QTY
1
Set Screw
1
14
Seal Kit (Includes O-Rings and Seals)
1
2
Cover Plate Asm.
1
15
Screw
11
3
Thrust Button
1
16
Input Cover
1
4
Thrust Plate
1
17
Roller Ball Bearing
1
5
Armature Plate Shim
1
18
Pinion Shaft, 11T
1
6
Roller Ball Bearing
2
19
Bushing
1
7
Race / Output Hub Asm.
1
20
Gearcase LH
1
8
Dowel Pin
1
21
Oil Fill Plug
1
9
Clutch Housing / Ring Gear
1
22
Drain Plug Asm. (Includes Plug and Washer) 1
10
Roll Cage Asm (Includes H-Springs)
1
23
Roller Thrust Needle Bearing
1
11
Rollers
14
24
Clutch Asm.
1
12
Bushing
1
25
Internal Retaining Ring
1
13
Vent Fitting
1
26
Armature Plate
1
7.15
FINAL DRIVE AWD Diagnosis Possible Wear Ring on Armature Plate
Symptom: AWD Will Not Engage. 1.
Check the gearcase coil resistance. To test the gearcase coil resistance. Test between the Grey & Brown / White wires. The gearcase coils should measure between 22.8 ohms and 25.2 ohms.
OK Condition
Front Gearcase Coil Resistance: 22.8--25.2 Ohms 2.
Check the minimum battery voltage at the Gray & Brown / White wires that feed the hub coil voltage. There should be a minimum of 11.0-12.0 Volts present for proper operation. Bad Condition (Wear from coil on armature plate) 4.
Check to make sure the coil is seated in the U-shaped insert that is pressed into the gearcase cover. The top of the coil should be seated below the U-shaped insert. The U-shaped insert controls the pole gap. If the top of the coil is above the surface of the U-shaped insert it raises the armature plate, thereby increasing pole gap. If the pole gap increases the coil will not be strong enough to engage the AWD system. If this is the cause order a new Plate Cover Assembly. Gearcase Cover
3.
Inspect the armature plate for a consistent wear pattern. There should one or two distinct wear bands (one band inside the other). If only one band of wear is present (or if there is wear between the two bands, inspect the coil area as indicated in Step 4. A band with an interrupted wear mark may indicate a warped plate, which may cause intermittent operation. See the following illustrations.
Coil
U-shaped insert Armature Plate Armature plate design may differ from what is shown
Check for wear bands
7.16
Side cutaway view of Centralized Hilliard cover
FINAL DRIVE 5.
Inspect the rollers for nics and scratches. The rollers must slide up and down and in and out freely within the roll cage sliding surfaces.
8.
The front gearcase and drive shafts can be accessed from both sides of the vehicle and limited access from the top.
Rollers
Top View - From under hood 9.
Remove the access panel on the side of the vehicle. T-25 screws secure the panel to the frame.
Gearcase Removal 1. 2. 3.
Stop engine, place machine in gear and set parking brake. Loosen right front wheel nuts slightly. Elevate and support machine under footrest/frame area.
Left Side Panel
CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure. Wear eye protection when removing and installing bearings and seals. 4. 5.
Remove right wheel nuts and wheel. Remove cotter pin, lower ball joint nut, and A-arm from ball joint.
6. 7.
Repeat Step 1 through Step 5 on the opposite side. Pull each axle out from the front gearcase, refer to the 'FRONT DRIVE SHAFT REMOVAL' procedure earlier in this chapter.
7 10. Remove the roll pin from the front drive shaft.Remove the front drive shaft from the front gearcase splines. 11. Remove bolts securing bottom of gearcase to frame. Remove vent line. Remove gearcase from right side of frame.
Remove 4 Bolts
7.17
FINAL DRIVE Gearcase Disassembly / Inspection 1. 2.
Remove the roll cage assembly, rollers, and H-springs.
7.
Thoroughly clean all parts. Inspect the rollers (A) for nicks and scratches. The rollers must slide up and down freely within the roller cage surfaces (B). Inspect the ring gear (C) for consistent wear patterns. The surfaces should be free of nicks and scratches.
Drain and properly dispose of used oil. Remove any metal particles from the drain plug magnet. Remove bolts and output shaft cover.
3.
Check the gearcase coil resistance. The resistance value should meet the specifications listed below. NOTE: To test the gearcase coils resistance, use the coil harness. The gearcase coils should measure between 22.8 ohms and 25.2 ohms. 4.
6.
8.
B
Remove output shaft assembly
C A 9.
NOTE: Be careful not to misplace the thrust bearing located between the two output shafts. 5.
Clean all parts and inspect spacers for wear. Inspect ring gear for chipped, broken, or missing teeth.
7.18
Inspect roll cage (B) sliding surface. This surface must be clean and free of nicks, burrs or scratches. Remove and inspect the H-springs. B
H-Spring
FINAL DRIVE 10. Use a flat head screwdriver to remove the retaining ring from the output cover. Retaining Ring
13. Remove the output hub (G) from the cover. remove the thrust bearing (F) from the output hub (G). Inspect the thrust bearing (F) and the dowel (H). G
H
F 11. Remove the spacer washer (D), armature plate (E), and rubber O-ring from the output cover. D
O-Ring
E
14. Inspect the magnetic coil (I) in the output housing. NOTE: See 'FRONT GEARCASE DIAGNOSIS' earlier in this chapter for more details on the coil. 15. Inspect the back lash pad (J) for excessive wear. NOTE: The backlash for the centralized hilliard is set at the factory. No adjustment is required, unless the front cover needs to be replaced, or the back lash pad screw is removed. See the 'Backlash Pad Adjustment” procedure later in this chapter for details on backlash setting. J
7
12. Inspect the armature plate (E) for a consistent wear pattern. Uneven wear of the armature plate (E) indicates a warped plate, which may cause intermittent operation. NOTE: See 'FRONT GEARCASE DIAGNOSIS' earlier in this chapter for more details. E I
Armature plate design may differ from what is shown
7.19
FINAL DRIVE 16. Remove the other output hub (K) from the main gearcase. Inspect the inner bearing (L) for wear. If there is excessive wear, replace bearing as needed.
19. Install new seals into the gearcase housing and use new Orings for the gearcase input and output covers.
K
L
17. Remove the input cover (M), bearing (N), and the pinion gear (O). Inspect the pinion gear (O) for chipped, broken, or missing teeth. Replace the input cover O-ring.
Gearcase Reassembly / Inspection 1.
N
M
O
As mentioned in the disassembly section, replace all Orings, seals, and worn components. 2. Press the pinion shaft seal into the pinion cover, until the seal is flush with the sealing surface. 3. Inspect bearings on output and pinion shafts. To replace, press new bearing on to shaft. NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel. While rotating bearings by hand, inspect for rough spots, discoloration, or corrosion. The bearings should turn smoothly and quietly, with no detectable up and down movement and minimal movement side to side. 4.
Install pinion shaft, bearing, and input cover with new oring and torque bolts to 17 ft. lbs. (23 Nm).
18. Inspect the output shaft bushing. Replace as needed. Clean the inside surfaces of both gearcase halves.
Input Cover Bolts Torque: 17 ft. lbs. (23 Nm)
7.20
FINAL DRIVE 5.
Install the output hub (A) into the gearcase housing. The output hub should spin freely.
8.
Install the retaining ring (F) into the output cover. Be sure the retaining ring is properly seated into the cover.
A F
6.
Install the other output hub (B) and thrust bearing (C) into the output cover. Apply a small amount of grease onto the thrust bearing.
9.
Install the ring gear (G) onto the output hub on the output cover. G
B
C
7.
Install the armature plate (D) and spacer washer (E) into the output cover.
7 10. Install the rollers and roll cage into the ring gear. Insert the rollers as the roll cage is installed.
E
D
Backlash Plate NOTE: Be sure backlash plate is in place.
7.21
FINAL DRIVE 11. Install the output cover assembly onto the main gearcase.
Backlash Pad (Thrust Pad) Adjustment 1. 2.
Lay the gearcase on the side with the output cover facing up. The backlash screw is loctited into place. Use a heat gun to lightly heat up the loctite on the screw (A).
A
NOTE: Be sure armature plate tabs are placed into the slots on roll cage. (See Reference Photo) Photo for reference only
3.
Using a hex wrench, turn the back-lash screw out 3-4 turns. Re-apply red loctite onto the bottom screw threads.
4.
Turn the screw in until it is lightly seated, then turn the screw out 1/4 turn. Set the gearcase upright. Rotate the pinion shaft at least 4 times. This ensures the ring gear completes one full rotation.
Armature plate tabs fit into roll cage slots
Armature plate design may differ from what is shown
NOTE: This photo is for reference only, the armature plate is actually installed in the output cover. 12. Install output cover with new O-ring and torque bolts to 17 ft. lbs. (23 Nm). NOTE: Be sure the square O-ring is placed flat on the cover surface. If the O-ring is twisted fluid leakage may occur.
Cover Bolts Torque: 17 ft. lbs. (23 Nm)
7.22
5.
FINAL DRIVE 6.
If a tight spot is felt during rotation, loosen the backlash screw another 1/8 turn. Perform the previous step again. Repeat this procedure until the pinion shaft rotates smoothly 4 times (1 revolution of ring gear).
MID DRIVE HUB / BEARING CARRIER (6X6) Removal
Gearcase Installation 1.
To install gearcase, reverse removal procedure.Use new spring pin in front prop shaft.
2.
Torque mounting bolts to 30 ft.lbs. (41 Nm).
1.
Lock the emergency parking brake. Safely raise the center of the machine with a floor jack. Raise the machine just enough to remove the middle wheel.
2.
Remove the four wheel nuts and wheel.
3.
Remove the hub cap and cotter pin.
4.
Remove the hub nut, domed washer, and flat washer.
4 Bolts 30 ft. lbs. (41 Nm)
Front Housing Mount Bolt Toque: 30 ft. lbs. (41 Nm) 3.
7
Add the proper lubricant to the front gearcase. Check drain plug for proper torque. Refer to Chapter 2 for fluid fill and change information.
Premium Front Drive Hub Fluid (PN 2871654) Hub Nut & Washers
Front Housing Capacity 5 fl. oz. (148 ml) 5.
Remove the hub from the axle shaft.
7.23
FINAL DRIVE 6.
Remove the upper and lower control arm bolts. Upper Bolt
NOTE: Drive bearing out evenly by tapping on outer race only. Once bearing is at bottom of casting, support casting on outer edges so bearing can be removed.
Lower Bolt
7.
Remove the bearing carrier from the A-arm assembly. Figure 7.24 3.
Inspect the bearing.
NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel. While rotating bearings by hand, inspect for rough spots, discoloration, or corrosion. The bearings should turn smoothly and quietly, with no detectable up and down movement and minimal movement sideways between inner and outer race. 4.
Inspect bearing housing for scratches, wear or damage. Replace housing if damaged.
Hub Disassembly 1.
Remove outer snap ring (A). A
Hub Assembly 1.
Support bottom of bearing carrier housing. (A) Bearing Carrier Housing; (B) Bearing; (C) Snap Ring A
B
C 2.
From the back side, tap on the outer bearing race with a drift punch in the reliefs as shown in Figure 7.24.
7.24
FINAL DRIVE 2.
Hub Installation
Start bearing (B) in housing (A). B A
3.
1.
Install hub carrier to lower A-arm. Hand tighten lower Aarm bolt.
2.
Slide mid drive shaft through the hub carrier.
3.
Install upper A-arm bolt and torque both upper and lower bolts.
Press bearing into place until outer race bottoms on housing.
CAUTION Use an arbor and press only on the outer race, as bearing damage may occur.
Lower Control Arm Bolt Torque: 35 ft. lbs. (47 Nm) Upper Control Arm Bolt Torque: 35 ft. lbs. (47 Nm)
4.
4.
Pull drive shaft outward and install hub onto driveshaft splines. Apply Anti-Seize compound to the axle splines.
5.
Install the flat washer (A) and cone washer (B) with domed side facing outward. (Refer to next photo)
Install snap ring into groove.
Out Cone Washer
7.25
7
FINAL DRIVE 6.
Install the castle nut (C), wheel, and wheel nuts.
7.
Remove jackstand and torque mid hub nut to 110 ft. lbs. (149 Nm) and wheel nuts to 35 ft. lbs. (47 Nm).
Mid Hub Nut Torque: 110 ft. lbs. (149 Nm) Mid Wheel Nut Torque 35 ft. lbs. (47 Nm) B
A
C
8.
Install a new cotter pin. Tighten nut slightly to align holes if required.
9.
Install hub cap.
Mid Drive Exploded View 35 ft. lbs. (47 Nm)
BUSHING SHAFT MID UPPER A-ARM 35 ft. lbs. (47 Nm)
MID DRIVE AXLE BEARING CARRIER
35 ft. lbs. (47 Nm)
BEARING
SHAFT
HUB
BUSHING MID LOWER A-ARM
7.26
SNAP RING 35 ft. lbs. (47 Nm)
BUSHING
FINAL DRIVE MID DRIVE SHAFT (6X6)
Installation
Removal
1.
1.
Repeat Steps 1-7 in the “Mid Drive Hub / Bearing Carrier Removal” section.
2.
Slide the middle axle out of the bearing carrier by pulling the bearing carrier assembly outward and down.
B
2.
3.
Apply Anti-Seize compound onto the mid gearcase output shaft splines. Slide mid drive shaft (A) onto the mid gearcase output shaft (B). A
Install the outer end of the mid drive shaft into the hub carrier (C).
Pull the middle axle straight out from the frame. The axle will slide off the mid gearcase splined output shaft.
C
7 3.
Lift hub carrier into place and install bolt to upper control arm. Torque bolt to 35 ft. lbs. (47 Nm). Upper Bolt
Disassembly / Assembly NOTE: For mid drive shaft service information, see “REAR DRIVE SHAFT (4X4) - CV Joint / Boot Replacement”
4.
Pull drive shaft outward and install hub onto driveshaft splines. Apply Anti-Seize compound to the axle splines.
5.
Install the flat washer (A) and cone washer (B) with domed side facing outward. (Refer to next photo)
7.27
FINAL DRIVE 6.
Install the castle nut (C), wheel, and wheel nuts.
8.
Install a new cotter pin. Tighten nut slightly to align holes if required.
9.
Install hub cap.
MID PROP SHAFT (6X6) Removal
A
7.
B
1.
Use the Roll Pin Removal Tool (PN 2872608), to remove the roll pin from prop shaft at rear of transmission.
2.
The transmission or middle differential mounting will have to be loosened to allow the propshaft to slide off of the transmission output shaft.
C
Remove jackstand and torque mid hub nut to 110 ft. lbs. (149 Nm) and wheel nuts to 35 ft. lbs. (47 Nm).
Mid Hub Nut Torque: 110 ft. lbs. (149 Nm) Mid Wheel Nut Torque 35 ft. lbs. (47 Nm)
MID DRIVE GEARCASE (6X6) Gearcase Removal
PIN
MID DRIVE GEARCASE REAR DRIVE SHAFT
PIN TRANSMISSION COUPLER
MOUNTING BOLTS & WASHERS
7.28
MID DRIVE SHAFT
FINAL DRIVE NOTE: To ease the removal of the middle axle gearcase, remove the box from the frame. Refer to the Box Removal Procedure in Chapter 5. 1.
Remove the vent line clamp and vent line (A) from the top of the mid drive gearcase (B). A
D
Gearcase Disassembly 1.
Drain the oil from the mid drive gearcase. Properly dispose of the oil.
2.
Remove the output cover bolts (A) and the output cover (B).
B
B
D
C
A
2.
Remove the mid drive shafts (D). Repeat steps 1-3 in the “Mid Drive Shaft Removal” section.
3.
Remove the O-ring (C) and two shims (D) from the output cover.
3.
Remove the parking brake caliper (C), refer to Chapter 9, “Parking Brake Caliper Service - Caliper Removal”.
NOTE: The two shims are different of thickness. Be sure to note the placement of the shims as they are removed from the output cover for later installation.
4.
Use the Roll Pin Removal Tool (PN 2872608) to remove the roll pins that secure the rear prop shaft and middle prop shaft to the mid drive gearcase.
C
7
Roll Pin Removal Tool 2872608
D
NOTE: If the rear drive shaft does not slide off the mid gearcase output shaft, compress the rear suspension and the rear driveshaft will move back. 5.
Remove the four bolts and washers that secure the gearcase to the frame. The bolts are accessible through the skid plate on the bottom of the frame.
6.
With the drive shafts removed from the mid gearcase, lift the gearcase out of the frame.
7.29
FINAL DRIVE 4.
Remove the output shaft and ring gear assembly (E) from the gearcase. Inspect the ring gear for abnormal wear, broken, or chipped teeth. Inspect and spin the bearings (F), the bearings should rotate smoothly.
7.
Remove the input cover bolts (I). Remove the input cover (H) and pinion gear assembly from the gearcase.
E
H
F 5.
F
8.
Remove the wave spring (G) from the gearcase assembly.
I
Remove the pinion gear assembly (J) from the front cover (H). If the pinion gear does not come loose from the front cover, use the following steps to aid in removal: • Hold the pinion gear assembly • Use a rubber mallet to lightly tap around the bearing cup of the front cover • Tap the front cover in an X pattern (follow the pattern in the photo on the right), until the pinion gear assembly comes loose J
H
1 G 4 6.
3
Remove the bolts from the input cover (H). H 2
7.30
FINAL DRIVE 9.
Inspect the pinion gear (K) and 26T output gear (L) for nics or uneven wear. Inspect the bearing (M), the bearing should spin smoothly. Replace the parts as needed. L
K
12. Carefully pull the output thru shaft (Q) through the gearcase.
M
Q 10. Remove the rear output seal (N). 13. Remove the retaining ring (O), shim (P), and input gear (R) from the output shaft (Q). Inspect the input gear for abnormal wear, broken, or chipped teeth.
N
Q
P
7
O 11. Remove the retaining ring (O) and shim (P) from the rear output thru shaft.
14. Inspect the two flange bearings (S) inside the gearcase. Inspect the pinion shaft bushing (T) for wear that is inside the gearcase.
O T
P
S
7.31
FINAL DRIVE 2.
Install the 26T input gear (D), shim (E), and a new retaining ring (F) onto the output shaft.
E S
D F 15. Replace all O-ring, seals, and worn components. Replace the seals as shown in the photo.
3.
Assemble the pinion shaft assembly (if previously disassembled). Install the 26T gear (G) and bearing (H) onto the pinion shaft (I). NOTE: When replacing the 26T output, be sure the step of the gear is facing towards the bearing (see below). Pinion Shaft Assembly Step Of Gear
I
Gearcase Assembly 1.
G H
Install the shim (A) and a new retaining ring (B) onto the output end of the output shaft (C). Install the output thru shaft into the gearcase.
Pinion Shaft Assembly Assembled
C
A&B
4.
Install the pinion shaft assembly into the input cover.
NOTE: Alignment of the pinion shaft bearing into the input cover maybe be difficult. If needed, use the following steps to aid in installation (refer to photo on right):
7.32
FINAL DRIVE • Hold the pinion gear assembly
7.
• Use a rubber mallet to lightly tap on the front of the input cover, around the bearing cup
L
• Tap the front cover in an X pattern (follow the pattern in the photo on the right), until the pinion gear assembly comes loose 3
1
2
4
8.
5.
Install the wave spring (L) into the gearcase assembly. Be sure the wave spring is fully seated into the bearing cup of the gearcase.
Install the output shaft and ring gear into the gearcase. Be sure the 10T input pinion gear and the output pinion gear mesh smoothly.
Apply Polaris Crankcase Sealant (PN 2871557) to the inside surface of the input cover (J). J
7 9.
Sealant
6.
Install the pinion shaft assembly and input cover onto the gearcase. Install the input cover bolts (K). Torque the bolts to 18 - 23 ft. lbs. (24 - 31 Nm).
Install the shims (M) into the output cover (N). Install the shims in the order that they were removed during the disassembly process. M
N K
7.33
FINAL DRIVE 10. Install a new O-ring (O) onto the output cover.
Middle Gearcase Specifications: Capacity: 6.75 oz. (200 ml) Specified Lubricant: ATV Angle Drive Fluid (PN 2871653) Fill Plug Torque: 14 ft. lbs. (19 Nm) O
Gearcase Installation 11. Carefully install the output cover onto the gearcase. Install the output cover bolts. Torque the bolts to 18 - 23 ft. lbs. (24 - 31 Nm).
1.
Place the middle gearcase in the frame assembly. A
B
D
D
C
2.
Attach the mid and rear prop shafts to the mid gearcase, but do not install the new roll pins yet.
3.
Install the four middle drive gearcase bolts. Torque the bolts to 30 ft. lbs. (41 Nm) in a cross pattern.
18 - 23 ft. lbs. (24 - 31 Nm)
4.
Install a new roll pins into the mid and rear prop shafts and middle gearcase input and rear output shafts.
12. Remove the fill plug (P) and fill the mid gearcase with 6.75 oz. (200 ml) of Polaris ATV Angle Drive Fluid (PN 2871653). Torque the fill plug to 14 ft. lbs. (19 Nm).
5.
Install the mid drive shafts (D) onto the mid gearcase (B).
6.
Install the vent tube (A) and clamp.
7.
Lift bearing carrier into place and install bolt to upper control arm. Torque bolt to 35 ft. lbs. (47 Nm). Refer to the “MID DRIVE SHAFT INSTALLATION” section for more details.
8.
Install hub, flat washer, domed washer (domed side out) and nut. Torque center nut to 110 ft. lbs. (149 Nm). Install new cotter pin and hub cap.
9.
Install rear wheel and torque wheel nuts to specification.
Input Cover Bolt Torque:
P
7.34
10. Install the parking brake caliper (C), refer to Chapter 9, “Parking Brake Caliper Service - Caliper Installation”
FINAL DRIVE Mid Gearcase Exploded
18-23 ft. lbs. (24-31 Nm) 18-23 ft. lbs. (24-31 Nm)
30 ft. lbs. (41 Nm)
7 REF#
DESCRIPTION
QTY
REF#
DESCRIPTION
QTY
1
Screw (5/16-18 x 1.0)
12
16
Washer, Thrust
2
2
Plug, Square Socket
3
17
Bearing, Plain Flanged
2
3
Seal, Dual Lip
2
18
Gearcase
1
4
Tube, Vent 1/4” Hose
1
19
Bushing
1
5
Cover, Output
1
20
Pinion, 10T
1
6
Shim
1
21
Gear, 26T Output
1
7
Bearing, Ball
1
22
Bearing, Ball
1
8
Gear, Ring 37T
1
23
Shaft, Output Thru
1
9
Shaft, Output
1
24
Gear, 26T Input
1
10
Bearing, Ball
1
25
Cover, Input
1
11
Spring, Wave
1
26
Seal, Triple Lip
1
12
O-Ring
1
30
Bolt, (5/16-18 x 1.25)
3
13
Pipe, Knock
4
31
Bracket, Caliper Mount
1
14
Seal, Triple Lip
1
32
Ring, Hog
2
15
Ring, Retaining
2
7.35
FINAL DRIVE REAR DRIVE (4X4) Exploded View 30 ft. lbs. (41 Nm)
Rear Gearcase
Coil
A-arm bolts Shaft Bushings
Shock Upper A-arm Bushings
Rear Drive Axle
30 ft. lbs. (41 Nm) Caliper 18 ft. lbs. (24 Nm)
A-arm bolts Nuts Bushings
Bearing
Lower A-arm Carrier Bolt Shaft
30 ft. lbs. (41 Nm)
Shaft
Snap Ring
Bushings
REAR HUB / BEARING CARRIER (4X4) Hub Inspection
Hub Removal
1.
Support machine securely with rear wheels elevated.
1.
2.
Grasp wheel / hub and check for movement.
Elevate rear end and safely support machine under main frame area.
3.
If movement is detected, inspect hub, hub nut torque and bearing condition and correct as necessary.
2.
Check bearings for side play by grasping the tire / wheel firmly and checking for movement. Grasp the top and bottom of the tire. The tire should rotate smoothly without binding or rough spots.
3.
Remove wheel nuts and wheel.
CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure. Wear eye protection when removing bearings and seals.
7.36
FINAL DRIVE 4.
5.
Remove the two brake caliper attaching bolts. CAUTION: Do not hang the caliper by the brake line. Use wire to hang the caliper to prevent possible damage to the brake line.
Remove hub cap, cotter pin, front spindle nut, and washer.
7.
Remove the upper and lower control arm bolts from the rear hub / bearing carrier.
8.
Remove the bearing carrier. Inspect the bearing again for smoothness and side to side movement, replace as needed.
Hub Disassembly 1.
Remove outer snap ring (A). A
7 6.
Slide the rear hub from the rear drive axle. 2.
From the back side, tap on the outer bearing race with a drift punch in the reliefs as shown. NOTE: Drive bearing out evenly by tapping on outer race only. Once bearing is at bottom of casting, support casting on outer edges so bearing can be removed.
7.37
FINAL DRIVE 3. Inspect the bearing. NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel. While rotating bearings by hand, inspect for rough spots, discoloration, or corrosion. The bearings should turn smoothly and quietly, with no detectable up and down movement and minimal movement sideways between inner and outer race. 4.
Inspect bearing housing for scratches, wear or damage. Replace housing if damaged.
Hub Assembly 1.
Support bottom of bearing carrier housing. (A) Bearing Carrier Housing; (B) Bearing; (C) Snap Ring
4.
Install snap ring into groove.
Hub Installation A
1.
Start the wheel bearing carrier onto the drive shaft.
2.
Align the bottom of carrier housing and lower control arm. Slide the lower control arm bushings into place. Secure with the lower control arm bolt.
3.
With the driveshaft placed in the wheel bearing carrier, align the carrier with the top control arm. Secure with the upper control arm bolt.
B
C
NOTE: The lower shock bolt may need to be removed to allow the upper A-arm to move more freely. 2.
Start bearing (B) in housing (A). B A
3.
Press bearing into place until outer race bottoms on housing.
CAUTION Use an arbor and press only on the outer race, as bearing damage may occur.
7.38
FINAL DRIVE 4.
Torque the top and bottom A-arm bolts as shown in the photo.
REAR DRIVE SHAFT (4X4) Removal 1.
Repeat all of the steps in the “Rear Hub / Bearing Carrier, Hub Removal” section.
2.
Remove upper carrier bolt. Slide the rear drive shaft out of the bearing carrier by pulling the bearing carrier assembly outward and tipping it down to remove the shaft.
3.
Pull the rear drive shaft straight out of the frame. Use short sharp jerks to free the circlip from the gearcase. The circlip holds the drive shaft in the gearcase.
30 ft. lbs. (41 Nm)
5.
Install the hub assembly onto the rear drive axle.
6.
Install the washer with domed side out. Install the spindle retainer nut.
7 7.
Install the wheel, washers, and wheel nuts. Torque wheel nuts to specification. See “Torque Specifications” table on page 7.3.
8.
Lower the vehicle. Torque the spindle retaining nut to 110 ft.lbs. (149 Nm). Install a new cotter key and the hub cap. 4.
Inspect the axle splines and CV boots for any damage.
110 ft. lbs (149 Nm)
7.39
FINAL DRIVE CV Joint / Boot Replacement 1.
Remove clamps from rubber boot(s) using the CV Boot Clamp Pliers (PN 8700226) (A). A
NOTE: When replacing a damaged boot, check the grease for contamination by rubbing it between two fingers. A gritty feeling indicates contamination. If the grease is not contaminated, the boot can be replaced without cleaning the CV joint. Use the recommended amount of grease for boot replacement only. 4. 5.
Remove boot from the shaft. Thoroughly clean and dry the CV joint and inspect ball tracks and cages for wear, cracks or other damage. NOTE: Shiny areas in ball tracks and on the cage spheres are normal. Do not replace CV joints because parts have polished surfaces. Replace CV joint only if components are cracked, broken, worn or otherwise unserviceable.
CV Boot Clamp Pliers: Earless Type - 8700226 2.
6.
Remove the large end of the boot from the CV joint and slide the boot back.
Place a new snap ring in the groove of the CV joint inner hub, with tabs facing the shaft as shown. Tabs face the shaft
Snap ring located in recessed area Snap ring
NOTE: Photo above is shown without shaft for clarity. Wipe grease away from recess in CV joint inner hub to locate snap ring 3.
Open the snap ring using a snap ring pliers or small needle nose pliers. Tap CV housing off shaft with a soft faced hammer while holding snap ring open. Spread ends of snap ring to remove joint from shaft
7.
7.40
Before you assemble the CV joint, slide the new boot (small end first) and clamp over the splined shaft.
FINAL DRIVE 8.
Refit CV joint on the shaft by tapping with a plastic hammer on the joint housing. Take care not to damage threads on the outboard CV joint. The joint is fully assembled when the snap ring is located in the groove on the shaft. Tap joint onto shaft
NOTE: It is very important to use the correct type and quantity of grease by using the grease contained in the boot kit. DO NOT use a substitute grease and DO NOT overfill or underfill the CV joint. 9.
Fill the CV joint and/or boot with the recommended type and amount of grease. Rear drive shaft inner or outer boot replacement requires 50g of grease if the CV joints were not disassembled. NOTE: If the joints were disassembled and cleaned, refer to the call-out below or Figure 7-31 for the correct amount of grease required.
11. While pulling out on the CV shaft, fully extend the CV joint and slide a straight O-ring pick or a small slotted screw driver between the small end of the boot and the shaft. This will allow the air pressure to equalize in the CV boot in the position that the joint will spend most of its life. Before you remove your instrument, be sure the small end of the boot is in its correct location on the axle.
12. Install the small clamp on the boot. REAR SHAFT CV Joint Joint Capacity* 25 Grams Retaining Ring
7
Large Clamp
Boot Replacement Grease Requirement: Inner Plunging Joint Grease - PN 1350047 Only boot replacement - 50g Boot replacement w/joint cleaning - 100g Outer CV Joint Grease - PN 1350047 Only boot replacement - 50g Boot replacement w/joint cleaning - 75g 10. Remove excess grease from the CV joint's external surfaces and position the boot over the housing, making sure the boot is seated in the groove. Position clamp over the large boot end and make sure clamp tabs are located in slots. NOTE: Before tightening boot clamp on inboard joint, make sure any air pressure which may have built up in joint boot has been released. The air should be released after the plunging joint has been centered properly. Tighten boot clamp using boot clamp pliers.
Grease PN 1350047 Boot Capacity 50 Grams
Boot
Small Clamp Boot Capacity 50 Grams
Boot Grease PN 1350047
Large Clamp Retaining Ring
Joint Capacity* 50 Grams
Plunging Joint Spring Ring
Figure 7-31
7.41
FINAL DRIVE Installation 1.
4.
Lift bearing carrier into place and install the bolt into the upper control arm. Torque bolt to 30 ft. lbs. (41 Nm).
Slide the rear drive axle into the bearing carrier hub.
30 ft. lbs. (41 Nm)
5. 2.
Install a new circlip onto the rear drive shaft. Apply AntiSeize Compound onto the rear driveshaft splines (both ends).
Install hub, domed washer (domed side out) and nut. Torque rear spindle nut to 110 ft. lbs. (149 Nm). Install new cotter pin and hub cap.
Apply Anti-Seize
New Circlip
3.
Reinstall the rear driveshaft into the rear gearcase. Be sure the circlip is securely fit into the rear gearcase. Use a rubber mallet to tap on the outboard end of the driveshaft if necessary.
Rear Hub Nut Torque: 110 ft. lbs. (149 Nm) 6.
Install rear wheel and torque washers and wheel nuts to specification. See “Torque Specifications” on page 7.3. 110 ft. lbs. (149 Nm)
Wheel Nut (4)
Out Cone Washer
7.42
Cone washer dome to outside
Flat washer
FINAL DRIVE REAR PROPSHAFT (4X4)
4.
Slide the propshaft off the transmission shaft and rear gearcase input shaft. Orientate the shaft so that it’s parallel with the frame supports as shown below.
5.
Remove the shaft by placing the brake disc over the top of the rear frame support and under the front frame support.
Removal 1.
Remove the pin clips from upper and lower cargo box shock pins and remove shock. Carefully allow cargo box to rest in the dump position as you remove the propshaft.
Rear Frame Support
WARNING Support the cargo box while the shock is removed to prevent injury or damage. 2.
Front Frame Support
Use the Roll Pin Removal Tool (PN 2872608), to remove the roll pin from prop shaft at rear of transmission.
7
Installation
3.
1.
When installing the propshaft, ensure that the shaft is touching the rear frame support and reinstall the shaft the same way it was removed with the brake disc over the top of the rear frame support and under the front frame support.
2.
Slide the shaft onto the rear gearcase input shaft and then slide it onto the transmission shaft. Install a new roll pin into the propshaft Install the parking brake caliper and torque mounting bolts to 18 ft. lbs. (24 Nm). Install cargo box shock, mounting pins and pin clips.
Remove the two bolts that secure the rear parking brake caliper. Suspend the brake caliper assembly from the frame with a piece of wire. (Refer to Chapter 9 for more information on the rear parking brake)
3. 4. 5.
7.43
FINAL DRIVE REAR GEARCASE (4X4) General Operation The RANGER rear gearcase has three traction operational modes: AWD, Differential Lock, and Differential Unlock. Locking the rear differential is beneficial in low traction and rough terrain conditions. Unlocking the rear differential makes maneuvering easier and minimizes damage to turf and sensitive terrains.
AWD
When the clutch gear is unlocked the rear axle becomes a differential. When it’s locked it becomes a solid rear axle increasing traction. (See images below) Clutch Gear
Shift Yoke
Shift yoke slides clutch gear to lock and unlock the rear differential
Differential - Locked Clutch Gear Differential - Unlocked
When the “Unlocked” option is chosen on the selector, the rear differential becomes unlocked for tighter turns. An electrical solenoid mounted on the rear axle housing actuates the shift yoke and slides the clutch gear to lock and unlock the rear axle housing. When switch position is set to “Unlock”, the solenoid is powered and the plunger extends to disengage the clutch gear and unlock the axle housing.
Locked Mode Clutch Gear
IRS Axle
Locked Locked
Unlocked Mode IRS Axle
Clutch Gear Unlocked
7.44
FINAL DRIVE Operation Modes
Differential Unlocked
Differential Locked
Both rear wheels rotate at same speed.
Rear wheels can rotate at different speeds. (Allow for sharper turning)
AWD Mode
7
Rear Wheels rotate as same speed. Front Wheels rotate as same speed when AWD activated.
7.45
FINAL DRIVE Differential Removal
Differential Disassembly
1.
Follow “Rear Drive Shaft Removal” procedure to remove the drive axles from each side of the rear differential.
2.
Disconnect the differential solenoid 2 wire harness.
3.
Remove the four bolts that secure the rear differential brackets to the frame.
IMPORTANT: The pinion gear assembly is NOT intended to be disassembled from the case, as it requires special OEM tooling in order to properly reassemble. If there is any damage to the pinion gear, bearings or case, the assembly must be replaced. Pinion and ring gear shimming information is NOT provided due to OEM manufacturing requirements. 1. 2.
Drain and properly dispose of used gearcase fluid. If necessary, remove the rear differential mount brackets from the rear differential.
3.
Remove the bolts that secure the carrier cover (A) bolts to the carrier housing (B).
Remove 2 bolts from each side
4.
Carefully pull the rear differential case assembly from the frame. Let the rear propshaft slide off of the rear differential.
Remove Cover Bolts
B
A
7.46
FINAL DRIVE 4.
Remove the differential assembly (C) from the housing. Inspect the bevel gear teeth for chipped, worn, or broken teeth.
6.
Remove the differential lock solenoid (F) from the carrier housing by turning the solenoid counterclockwise. F
C
7.
5.
Remove the bearings from each side of the carrier assembly (C). Inspect the bearings (D) for smoothness and wear. Be sure to keep the shims (E) together for reassembly.
Inspect the tip of the solenoid (F) for wear. If the tip of the solenoid is flat the solenoid may need to be replaced.
F
C
7
D E
8.
Remove the clutch gear (G) from the carrier cover (B) and shift yoke (H).
B
C
G
J K D
H
E
7.47
FINAL DRIVE 9.
Inspect the shift yoke (H), shift lever (J), and shift lever return spring (K).
K
12. Thread the bolt into the shift yoke pivot shaft (L).
J
H
13. Carefully pull the shift yoke pivot shaft (L) out of the carrier cover. 10. Remove the set screw.
11. Remove the shift yoke pivot shaft (L) Use a 1/4 in.- 20 coarse thread bolt approximately 3 in. long to thread into the pivot shaft.
L
14. Remove the shift lever (M) and springs (N) from the shift yoke (H). Inspect the components for wear and replace as needed. M
L N
7.48
H
FINAL DRIVE 15. Remove the pinion shaft seal (P) using a seal puller.
2.
Install the original shims (A) onto the differential assembly (B) on both sides. Install the bearings (C), replace with new bearings if needed. B
P
A
16. SPECIAL NOTE: The Pinion assembly is NOT intended to be disassembled, as it requires special OEM tooling in order to properly assemble the pinion assembly. If there is any damage to the pinion gear, bearings or case, the assembly must be replaced.
C
B
C
A
7 3.
Install the differential assembly into the carrier housing.
4.
Install the spring lever and shift yoke into the carrier cover, if previously removed.
Differential Assembly 1.
Replace all O-rings, seals, and worn components. Replace the O-ring and oil seal on the carrier housing.
NOTE: Grease all seals and O-rings with Polaris All Season Grease (PN 2871322) upon assembly.
7.49
FINAL DRIVE 5.
Assemble the shift yoke (D), shift lever (G), spring lever (F), and return spring (E).
8.
Install the new lightly greased O-ring (K) onto the carrier cover.
H Carrier Cover
F E 6.
G
D
Use the bolt that was used to remove the shift yoke pivot shaft (H) to reinsert the shaft into the carrier cover. Place the shift yoke assembly into the carrier cover and secure with the shift yoke pivot shaft (H). Install Shift Yoke Assembly
7.
Install the differential lock solenoid into the carrier cover. Torque solenoid to 30-40 ft. lbs. (41-54 Nm).
K 9.
Install the carrier cover bolts. Tighten and torque the bolts in a criss cross pattern to 25-35 ft.lbs. (34-48 Nm). 25-35 ft. lbs. (34-48 Nm)
10. Install the rear differential mount brackets from the rear differential onto the rear differential. Torque the bracket to differential bolts to 26-33 ft.lbs. (35-45 Nm)
30-40 ft. lbs. (41-54 Nm) 26-33 ft. lbs. (35-45 Nm) Bracket to Differential
7.50
FINAL DRIVE Differential Installation 1.
Place the differential assembly into the frame. Torque the bracket to frame bolts to 38-42 ft.lbs. (35-45 Nm).
Bracket to Frame 38-42 ft. lbs. (35-45 Nm)
2.
Slide the rear propshaft onto the rear differential input shaft.
3.
Reverse the removal procedure for the rest of the installation.
4.
Add Polaris ATV Angle Drive Fluid (PN 2871653) to rear carrier. Refer to maintenance information in Chapter 2 for more details. Torque drain plug to 30-45 in.lbs. (3-5 Nm). Torque fill plug to 40 ft.lbs. (54 Nm).
7
Fill Plug 40 ft. lbs. (54 Nm)
Drain Plug 30-45 in. lbs. (3-5 Nm)
Rear Gearcase capacity: 18 fl. oz. (532 ml) or 0.75” (1.9 cm) below bottom of fill plug hole threads - See Chapter 2
7.51
FINAL DRIVE Differential Exploded View 8
30-45 in. lbs. (3-5 Nm)
9
10
ft. lbs. 11 40 (54 Nm)
7
3 1
5
4
20
12
6
13
12
2
19 18
14 15 16
37
17
38
25-35 ft. lbs. (34-48 Nm)
21 22 23
36 3
24
31
25-35 ft. lbs. (34-48 Nm)
35
4 25
34
29 33
REF#
DESCRIPTION
QTY
32
ft. lbs. 30 30-40 (41-52 Nm)
REF#
27
26
28
DESCRIPTION
QTY
1
Pinion Oil Seal
1
20
Flanged Hex Nut
3
2
Pinion Nut
1
21
Flanged Hex Bolt
3
3
Pinion Bearing Cone
2
22
Vent Tube
1
4
Pinion Bearing Cup
2
23
Differential Case Half Cover
1
5
Pinion Spacer
AR
24
Flanged Hex Bolt
6
6
Pinion Bearing Spacer
1
25
Clutch Gear
1
7
Drain Plug
1
26
Shift Yoke
1
8
Oil Seal Shaft
1
27
Shift Spring Lever
1
9
O-Ring
1
28
Shift Lever
1
10
Carrier Half Cover
1
29
Shift Return Spring
2
11
Fill / Check Plug
1
30
Diff. Lock Solenoid
1
12
Gear-Side, Differential
2
31
Hex Bolt
8
13
Gear-Pinion, Mate, Differential
2
32
Differential Case Half
1
14
Differential Case Half Cover
1
33
Differential Cross-Pin
1
15
Differential Bearing Spacer
AR
34
Differential Roll-Pin
1
16
Tapered Roller Bearing
1
35
Pinion Spacer
AR
17
O-Ring, Housing Halves
1
36
Differential Bearing Spacer
AR
18
Shift Yoke Pivot Shaft
1
37
Differential Bearing Cup
1
19
Set Screw
1
38
Differential Bearing Cone
1
7.52
FINAL DRIVE REAR AXLE / GEARCASE SERVICE (6X6)
7.
Remove the bottom shock bolts and shocks (both sides).
8.
Remove the two bolts that secure the rear axle housing to the frame.
Rear Axle Removal 1.
Jack up vehicle and support on frame and swing arm.
CAUTION Serious injury could occur if machine tips or falls. 2.
Remove rear wheels.
3.
Remove the brake calipers. Suspend the brake calipers from the frame with wire (both sides).
Brake Calipers
7 9. 4.
Remove the hub cover, cotter pin, spindle nut and washer (both sides).
5.
Pull the hub off of the axle.
Mark the positions of the four U-bolts that secure the axle to the frame. This will aid with proper U-bolt and axle placement during reassembly.
Mark U-bolt Positions
6.
Remove the hose clamp from the rear gearcase breather hose. Remove the breather hose.
7.53
FINAL DRIVE 10. Loosen the four U-bolts. Loosen each U-bolt nut a few turns at a time, this will reduce stress on all of the U-bolts during U-bolt removal.
Axle Tube Removal 1.
Place the rear axle assembly on a clean surface.
2.
Remove the bolts that secure the rear gearcase to the axle tubes and remove the rear gearcase skid plate
3.
Remove the axle and axle tube’s from the rear gearcase. Note the placement of the axle spacer seals for placement during reassembly.
4.
Slide the axles out of each axle tube.
Loosen U-bolts 11. With the U-bolts removed, carefully lower the rear axle assembly from the frame. Pull the axle assembly out from the frame. NOTE: The drive shaft yolk (A) slides off of the rear gearcase.
A
NOTE: Use caution when removing the rear axle assembly. Extra jacks maybe needed to lower the rear axle assembly safely.
NOTE: Make note of the side each axle was removed. 5.
7.54
Inspect the splines on the axle ends and the splines on rear gearcase for chips or wear. Replace as needed.
FINAL DRIVE Axle Tube Bearing Replacement
Gearcase Disassembly / Inspection
1.
1.
Drain and properly dispose of used oil.
2.
Remove the differential housing cover bolts and the gearcase housing cover.
3.
Remove the shim and O-ring from the differential cover.
2.
Remove the retaining ring from the axle tube.
Remove the bearings from the axle tube with a bearing puller. Inspect the bearing contact surfaces in the axle tube.
O-Ring Shim
3.
7
Install the new bearing using a press.
4.
Remove the output shaft and ring gear from the differential. Inspect the ring gear for abnormal wear, broken, or chipped teeth. Inspect the bearings for wear. Spin the bearings by hand, the bearings should roll smoothly. Replace the bearings if needed. Bearings
NOTE: The bearing should be properly lubricated before installation. 4.
Reinstall the retaining ring.
7.55
FINAL DRIVE 5.
Remove the wave spring from the differential assembly.
8.
Inspect the pinion shaft bushing for wear.
Wave Spring
6.
Remove the four bolts that secure the pinion gear cover to the differential. Remove the pinion gear cover and O-ring.
Gearcase Assembly
Pinion Gear Cover
1.
Replace all O-rings, seals, and worn components.
2.
Install the pinion shaft into the differential housing.
4 Bolts O-Ring 7.
Remove the pinion shaft from the differential. Inspect for abnormal wear, broken, or chipped teeth.
7.56
FINAL DRIVE 3.
Replace the pinion shaft cover O-ring and install the cover. Install the four pinion shaft cover bolts and torque the bolts to 26 ft. lbs. (35 Nm).
NOTE: The O-ring is a smaller diameter than the gearcase. Use two hands to work the O-ring onto the gearcase lip. New O-Ring
Pinion Gear Cover
26 ft. lbs. (35 Nm) New O-Ring
Pinion Shaft Cover Bolt Torque:
7. 8.
26 ft. lbs. (35 Nm) 4.
Install the wave spring into the differential assembly. Be sure to properly seat the wave spring into the differential.
Install the output cover onto the differential assembly. The output cover must be properly aligned and installed straight with the differential when installed. This will ensure that the O-ring is not damaged during output cover installation. This also helps to prevent any gearcase leaks after assembly.
7
9. 5.
Torque the output cover bolts to 30 ft. lbs. (41 Nm).
Reinstall the output shaft and ring gear.
Output Cover Bolt Torque 30 ft. lbs. (41 Nm)
Gearcase / Axle Installation 1. 2.
3. 6.
Install a new O-ring onto the lip of the gearcase housing.
Lube the splines of the rear gearcase with anti-seize. Reinstall the axle spacer seals. Reinstall the axle onto the rear gearcase (both sides) Reinstall the axle tube over the axle and attach it to the gearcase. Install and tighten the four bolts onto the right side of the gearcase. Install and tighten the two bottom bolts to the left side of the gearcase. Do not torque the bolts.
7.57
FINAL DRIVE NOTE: The two top gearcase / axle tube bolts (B) on the left side are installed into the frame later in this assembly procedure.
6.
Install the four U-bolts. Align the U-bolts with the white marks previously made on the axle tube for proper rear axle alignment.
NOTE: Use a floor jack to help align the rear axle assembly for the U-bolt installation.
B
2 Bolts
4 Bolts
B 4.
U-bolt Alignment Marks
Fit the rear axle assembly up to the frame. Slide the rear driveshaft yoke (A) onto the rear gearcase input shaft.
A
Fit the rear axle assembly up to frame. Attach the rear axle assembly to the shocks. Leave the shock bolts finger tight until assembly is complete. NOTE: Use a jack or another person to assist with the rear axle assembly installation.
7.
Install the U-bolt nuts, but do not tighten the nuts.
8.
Install the two frame to gearcase bolts (B). Torque the gearcase bolts on both sides of the gearcase to 60 ft. lbs. (81 Nm).
5.
NOTE: Use caution when removing the rear axle assembly. Extra jacks maybe needed to raise the rear axle assembly safely.
7.58
B
Axle Tube to Gear Case Bolt Torque: 60 ft. lbs. (81 Nm)
FINAL DRIVE 9.
Torque the U-bolts nuts to 40 ft. lbs. (54 Nm).
U-Bolt Nut Torque: 40 ft. lbs. (54 Nm) 10. Torque the rear shock bolts to 25 ft. lbs. (35 Nm). 25 ft. lbs. (35 Nm)
13. Install the brake caliper. Torque the bolts to 18 ft. lbs. (24.8 Nm).
Brake Caliper Torque: 18 ft. lbs. (24.8 Nm) 14. Install the tire and four wheel nuts. Torque the castle nut and the wheel nuts to specifications.
7 Rear Coil Over Shock Bolt Torque 25 ft. lbs. (35 Nm) 11. Reinstall the vent hose and clamp to the rear gearcase housing. 12. Apply anti-seize to the splines of the axle. Reinstall the hub onto the axle. Reinstall the domed washer, and spindle nut onto the axle.
Rear Hub Nut Torque 110 ft. lbs. (149 Nm) Rear Wheel Nut Torque 35 ft. lbs. (47 Nm) 15. Install a new cotter pin. Tighten nut slightly to align holes if required. Install the hub cap.
7.59
FINAL DRIVE Gearcase Exploded View
26 ft. lbs. (35 Nm) 30 ft. lbs. (41 Nm)
REF#
DESCRIPTION
QTY
REF#
DESCRIPTION
QTY
1
Seal, Triple Lip
1
12
O-Ring
1
2
Screw (5/16-18 x 1.0)
12
13
Spring, Wave
1
3
Cover, Input
1
14
Bearing, Ball
1
4
O-Ring
1
15
Shaft, Output
1
5
Bearing, Ball
1
16
Gear, Ring 37T
1
6
Pinion, 10T
1
17
Bearing, Ball
1
7
Bearing, Plain
1
18
Shim
1
8
Plug, Square Socket
2
19
Plug, Expansion
1
9
Seal, Dual Lip
2
20
Tube, Vent 1/4” Hose
1
10
Gearcase, Rear Housing
1
21
Cover, Output
1
11
Pipe, Knock
1
7.60
TRANSMISSION
CHAPTER 8 TRANSMISSION TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
SHIFT LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
TRANSMISSION SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10 TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15 TROUBLESHOOTING CHECKLIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.15
TRANSMISSION EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16 EXPLODED VIEW (4X4, 6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16
8
8.1
TRANSMISSION TORQUE SPECIFICATIONS
3.
ITEM
TORQUE VALUE
Transmission Fill Plug
10-14 ft. lbs. (14-19 Nm)
Transmission Drain Plug
10-14 ft. lbs. (14-19 Nm)
Transmission Case Bolts
27-34 ft. lbs. (37-46 Nm)
Bell Crank Nut
12-18 ft. lbs. (16-24 Nm)
Bell Crank Gear Cover
7-9 ft. lbs. (10-12 Nm)
Transmission Mounting Bolts
25 ft. lbs. (35 Nm)
Transmission Lubricant / Amount
AGL Gearcase Lube 15.2 oz. (450 ml)
Remove the shift lever cover and then remove the screw. Pull off the shifter knob. Shift Lever
Shift Lever Location 4.
Lift the gear shift selector out of mounting bracket and away from frame.
Installation 1.
Repeat the steps in reverse order to install the gear shift selector.
SHIFT LEVER Removal
SHIFT LINKAGE
1.
Disconnect linkage cable from shifter.
Inspection
2.
Remove one bolt attaching the gear shift selector mount to machine frame.
Linkage rod adjustment is necessary when symptoms include: • No All Wheel Drive light
Cover
• Noise on deceleration
Screw Shifter knob
Cable
• Inability to engage a gear • Excessive gear clash (noise)
Bearing
• Shift selectors moving out of desired range NOTE: Remove necessary components to gain access to shift linkage cable ends (i.e. exhaust heat shield, exhaust pipe, etc.).
Shifter Grommet Shift Lever Breakdown
8.2
Bolt
1.
Inspect shift linkage cable, clevis pins, and pivot bushings and replace if worn or damaged.
2.
Be sure idle speed is adjusted properly.
TRANSMISSION Adjustment
TRANSMISSION SERVICE
1.
Transmission Removal
Place gear selector in neutral. Make sure the transmission bell crank is engaged in the neutral position detents.
1.
Remove the PVT system from the left side of the transmission.
2.
Drive roll pin from rear driveshaft yoke.
NOTE: On the 4x4 & 6x6 transmission the front output shaft yolk slides off during the transmission removal.
Neutral Position
4x4 Shown Roll Pin Removal Tool 2.
With two wrenches loosen the outside jam nut counterclockwise. Turn the outside jam nut 1 1/2 turns. Perform this procedure on the shift lever end, also. Inside Jam Nut
Roll Pin Removal Tool (PN 2872608) 3. Outside Jam Nut 3.
4. 5.
After turning the outside jam nut 1 1/2 turns. Hold the outside jam nut with a wrench and tighten the inside jam nut clockwise, until it is tight against the bracket. Repeat Step 4 and Step 5 until the proper adjustment is made for the transmission cable. Use this procedure to loosen or tighten the shift linkage cable as needed.
Remove the air intake hose from the air box that is located above the transmission. Place the hose to the side, this eases the transmission removal. Remove the vent hose from the top of the transmission. Vent Tube & Air Intake Hose
8
Clockwise Inside Jam Nut
Outside Jam Nut Counterclockwise
8.3
TRANSMISSION 4.
Disconnect the transmission switch.
7.
Remove the mounting bolts from the transmission mounting on both sides of the transmission. General Transmission Mounting
Transmission Switch
5.
Remove the cotter pin from the shift linkage rod. Remove the shift linkage rod and a washer from the bellcrank. 8.
Remove the four bottom transmission to frame bolts.
9.
Remove the rear transmission to frame bolt.
10. Remove front transmission-to-engine mount bolt. 11. Remove transmission from right side of frame.
6.
Loosen the jam nuts for the transmission cable. Remove the cable from the mounting bracket. Jam Nuts
8.4
TRANSMISSION Transmission Disassembly
5.
NOTE: The following disassembly procedure shows the 4x4 transmission disassembly. Follow the same procedure for the 6x6 transmission disassembly. The transmissions are very similar. Refer to the exploded view at the end of this chapter.
NOTE: It may be helpful to place a mark just above the keyed spline.
1. 2.
Mark the detent gear with a white pen. Remove the detent gear from the case.
Detent Gear
Place the bellcrank in neutral position. Remove the nut, and washer that secure the bell crank. Remove the bellcrank.
6.
Mark the lockout disc, this will indicate which side of the disc faces outward during assembly. Remove the disc.
NOTE: It may be helpful to place a mark just above the keyed spline. Note the raised edge on the detent. 3.
Remove the five bolts that secure the cover and remove the cover from the transmission.
Cover
Lockout Disc
8 7. 4.
Remove the shift shaft and detent lever.
Remove the detent spring.
Spring
8.5
TRANSMISSION 8.
Note the transmission gear position and mark the two shift gears before removing them to aid with reassembly. Remove the shift gears from the case.
NOTE: Depending on what gear the transmission is in upon disassembly, the stamped timing marks may not be lined up. To avoid confusion, mark the two gears as described in Step 8. 9.
NOTE: You may have to tap the shift drum from the backside of the case to aid in removal.
12. Remove the upper gear cluster and shift forks. You may need to move the assembly back and forth to aid in removal
Remove the bolts on the LH transmission case cover. Tap the cover off with a soft face hammer if necessary.
13. Set the upper gear cluster on a flat surface and inspect the components.
10. Lift shift rail 0.5”-1” (12.70-25.40 mm). Then rotate the shift rail / forks and shift drum, so the forks’ pins disengage from the drum.
11. Remove the shift drum.
8.6
TRANSMISSION 14. Remove the shift forks from the assembly. Note the correct position of each fork.
17. Remove the bearing from the input shaft with a puller.
Shift Fork
18. Remove the snap ring and washer from the reverse shaft. NOTE: The picture above depicts a transmission with a “park dog” on the end of the shaft instead of a regular “shift dog”. The transmission will have a regular shift dog in the location indicated by the arrow in the photo. 15. Remove the bearing from the reverse shaft with a puller.
19. Remove low gear (33T) and the needle bearing.
8 16. Remove the park lock engagement dog. Remove the wave spring and reverse engagement dog.
Engagement Dogs
20. Remove the reverse gear shaft.
8.7
TRANSMISSION 21. Remove the rest of the bearings from the shafts.
24. Remove the gear, split bearing, and washer from the reverse shaft.
22. Use a press to remove the gear from the shaft. 25. Slide off the shift dogs and wave springs.
23. Make note of the direction of the gear and hub location. 26. Remove the snap ring, washer, gear, and split bearing.
8.8
TRANSMISSION 27. Remove bearing and the helical gear.
30. Remove the front housing cover, shim, thrust button, and thrust button shim.
28. Remove the pinion shaft retainer plate and the pinion shaft. 31. Remove the shafts as an assembly.
29. Remove the front housing cover screws. 32. Remove the silent chain from the assembly for shaft inspection. 33. Clean all components in a parts washer and inspect for wear. 34. Inspect engagement dogs of gears and replace if edges are rounded. 35. Inspect gear teeth for wear, cracks, chips or broken teeth. Note the location of the hubs on the gear. Note Location of Hubs
8.9
8
TRANSMISSION 36. Remove seals from transmission case.
3.
IMPORTANT: New seals should be installed after the transmission is completely assembled.
Before installing the cover make sure the sealing surfaces are clean and dry, and shafts are fully seated in the transmission case. Apply Polaris Crankcase Sealant to the mating surfaces.
37. Inspect bearings for smooth operation. Check for excessive play between inner and outer race.
Transmission Assembly 1.
Reinstall the chain onto the front output shaft and rear output shaft.
Crankcase Sealant (PN 2871557) 4.
2.
Install front and rear output shafts into the case.
Reinstall the thrust button shim, thrust button, and other shims into the cover. Reinstall cover and torque bolts in a criss-cross pattern in 3 steps to 27-34 ft. lbs. (37-46 Nm).
NOTE: Make sure that the case locating pins (knock pipes) are in place.
Front Cover Bolt Torque: 27-34 ft. lbs. (37-46 Nm)
8.10
5.
Apply grease to the seal lips. Apply electricians tape or somehow cover the splines of the shaft to protect the seal lips during installation. Install new front and rear output shaft seals.
6.
Install pinion shaft with bearing.
7.
Install retainer plate with flat side toward bearing.
TRANSMISSION 8.
Apply Loctite™ 262 (Red) (PN 2871951) to screw threads and torque screws to 6-12 ft. lbs. (8-16 Nm).
Pinion Retainer Plate Bolt Torque: 6-12 ft. lbs. (8-16 Nm) 9.
11. Slide the reverse shaft assembly through the silent chain.
12. Install a new needle bearing, the low gear, the thrust washer and the snap ring. Use of a new snap ring is recommended. 13. Install the engagement dogs, wave springs, and bearing. 14. Install the ball bearing onto the end of the input shaft.
Install a new needle bearing, the 24T reverse sprocket, washer, and a new snap ring. Install the shift dogs and wave spring. Install the washer, a new needle bearing and the high gear. Install the press fit gear and ball bearing.
10. Install a new snap ring at this time. When installing the new snap ring, open the snap ring just far enough to go over the shaft, to avoid stressing the snap ring. If the snap ring is overstressed it could come off the shaft and cause internal damage to the transmission. 15. As the engagement dogs are installed onto the shaft, place the wave springs into the spring groove. Keep the spring in place while the fork is being installed on the shaft and while placing the shafts into the case. NOTE: Use caution when installing the fork, the spring can easily fall out.
NOTE: Installing the shift rail will aid in keeping the shift forks, shift dogs, and the springs in place.
8.11
8
TRANSMISSION 16. Carefully install the shaft assembly and gear cluster as a unit into their respective bearing case recesses. Tap with a soft face hammer to seat shaft assemblies.
17. Position the shift forks up and so the pins point toward the 9 o’clock position, before installing the shift drum assembly.
20. Lift the shift rail slightly and rotate the rail/fork assembly so it meshes with the tracks on the shift drum. Be sure the wave springs are properly in place and that the shift rail is seated into the pocket on the backside of the case.
21. Install the helical gear and bearing onto the pinion shaft. 22. Clean the mating surfaces of the case and cover. Apply Crankcase Sealant (PN 2871557) to the mating surfaces. Be sure the locating pins (knock pipes) are in place. Reinstall cover and torque bolts in a criss-cross pattern in 3 steps to 27-34 ft. lbs. (37-46 Nm). 23. Reinstall the mounting bracket if previously removed.
18. Replace and grease the O-ring’s on the shift drum before installation.
Front Cover Bolt Torque: 27-34 ft. lbs. (37-46 Nm) 24. Grease the seal lips of the input shaft seal. Apply electricians tape or somehow cover the splines of the shaft to protect the seal lips during installation. Install new input shaft seal. 19. Install the shift drum into the case. NOTE: Make sure shift shaft pins are properly positioned in the slot on selector arms.
8.12
TRANSMISSION 25. Install drain plug with a new sealing washer. Torque drain plug to 10-14 ft. lbs. (14-19 Nm).
28. Install the lockout disc with the raised edge facing outward. Use the white mars that was previously applied for reference.
Transmission
Lockout Disc Drain Plug 10-14 ft. lbs. (14-19 Nm)
Drain Plug Torque: 10-14 ft. lbs. (14-19 Nm) 26. Place a small amount of grease (PN 2871551) into the pocket before installing the sector gear. Install the shift gear (16T) on the shift drum shaft. Install the sector gear in the bushing pocket on the left side. Align the timing marks you made on the gears during disassembly.
29. Install the detent gear with the raised edge facing outward. Note the keyed spline on the end of the shaft. 30. Install the detent lever spring. Install a new o-ring onto the shift shaft after the detent lever is assembled to the shaft. Place a small amount of grease on the small O-ring on the shift shaft and on the detent gear. Grease the o-ring on the end of the shift drum. Detent Gear
8
Detent Lever Spring
IMPORTANT: Note the location of the skip tooth on the splines. Apply a light coating of grease on the gear teeth.
31. Install the cover and hand tighten all of the bolts. Tighten the bolt indicated in the picture below first and torque the bolt to 7-9 ft. lbs. (10-12 Nm). This helps to align the cover and shaft to ensure smoother shifting. 7-9 ft. lbs. (10-12 Nm)
27. Install the shift shaft along with the detent lever.
Tighten This Bolt First
8.13
TRANSMISSION 32. Torque the remaining bolts to 7-9 ft.lbs. (10-12 Nm).
Cover Bolt Torque: 7-9 ft. lbs. (10-12 Nm) 33. Install a new bellcrank onto the shift shaft. Note the keyed spline on the bellcrank and shaft. Install the washer and nut. Torque the bellcrank nut to 12-18 ft. lbs. (16-24 Nm).
Transmission Installation 1.
Install transmission from right side of vehicle.
2.
Position transmission in frame.
3.
Loosely install the front transmission to frame bolts.
4.
Loosely install the rear transmission to frame bolt.
5.
Loosely install the three bottom transmission to frame bolts.
6.
Tighten mounting fasteners in order A-D as shown.
Keyed Spline
Bellcrank Nut Torque: 12-18 ft. lbs. (16-24 Nm) Transmission Mounting Bolts Torque 25 ft. lbs. (34.5 Nm)
34. Install transmission and add Polaris AGL Gearcase Lubricant (PN 2872602).
NOTE: Be sure to tighten the lower transmission bolts first, this ensures that the transmission is tight against the lower frame and helps to properly align the transmission. NOTE: Align clutches as outlined in Chapter 6.
= AGL Gearcase Lube 15.2 oz. (450 ml)
8.14
7.
Align the front input shaft to the front propshaft yoke on the vehicle.
8.
Align rear output shaft to rear propshaft yoke and roll pin hole.
9.
Slide rear output shaft and into propshaft yoke. Drive the roll pin into the driveshaft yolk.
10. Reinstall the shift linkage rod, the air intake hose, and the vent hose on top of the transmission.
TRANSMISSION TROUBLESHOOTING Troubleshooting Checklist Check the following items when shifting difficulty is encountered. • Idle speed adjustment • PVT alignment • Transmission oil type/quality • Transmission torque stop adjustment (where applicable) • Engine torque stop adjustment (where applicable) • Drive belt deflection • Loose fasteners on rod ends • Loose fasteners on selector box • Worn rod ends, clevis pins, or pivot arm bushings • Linkage rod adjustment and rod end positioning • Shift selector rail travel • *Worn, broken or damaged internal transmission components NOTE: To determine if shifting difficulty or problem is caused by an internal transmission problem, isolate the transmission by disconnecting linkage rod from transmission bellcrank. Manually select each gear range at the transmission bellcrank, and test ride vehicle. If it functions properly, the problem is outside the transmission. If transmission problem remains, disassemble transmission and inspect all gear dogs for wear (rounding), damage. Inspect all bearings, circlips, thrust washers and shafts for wear.
8
8.15
TRANSMISSION TRANSMISSION EXPLODED VIEW Exploded View (4x4, 6x6) 27-34 ft. lbs. (37-46 Nm)
GREASE
6-12 ft. lbs. (8-16 Nm)
27-34 ft. lbs. (37-46 Nm)
7-9 ft. lbs. (10-12 Nm) 12-18 ft. lbs. (16-24 Nm) 15-19 ft. lbs. (20-26 Nm) 10-14 ft. lbs. (14-19 Nm)
FOR REASSEMBLY Apply White Lithium Based Grease. Apply Polaris Crankcase Sealant. Apply LoctiteTM 262 to the bolt threads.
8.16
TRANSMISSION Exploded View (4x4, 6x6), Cont. Ref.
Qty.
Description
Ref.
Qty.
Description
1
Asm., 4x4 Transmission
35.
1
22T Sprocket
1.
1
Nut
36.
1
19T Sprocket
2.
1
Shift Drum Bellcrank
37.
1
Silent Chain
3.
5
Cover Screws
38.
1
Front Main Output Shaft
4.
1
Sector Cover
39.
1
Gear Set - 10T / 31T
6.
1
O-ring
40.
1
Ball Bearing
7.
1
Detent Pawl
41.
1
Spacer
8.
1
Compression Spring
42.
1
Retaining Ring
9.
1
Shift Shaft
43.
1
Bearing Center Drive Cover
10.
1
31T Sector Gear
44.
4
Torx Screws
11.
2
Hollow Hex Plug
45.
1
56T Mid Output Helical Gear (6x6: 60T Gear)
12.
2
Triple Lip Seal
46.
4
Ball Bearing
13.
1
Gearcase, Main
47.
1
Reverse Shaft
14.
1
Vent Tube
48.
1
Needle Cage Bearing
15.
1
O-Ring
49.
1
24T 6 Face Sprocket
16.
1
Shift Drum
50.
1
Washer
17.
1
External Retaining Ring
51.
2
External Retaining Ring
18.
1
6-Pin Switch
52.
4
6 Face Engagement Dog
19.
1
O-ring
53.
2
Wave Spring
20.
1
Detent Star
54.
1
Washer
21.
1
Lockout Disc
55.
2
Needle Cage Bearing
22.
1
16T Sector Gear
56.
1
28T 6 Face Gear (6x6: 23T Gear)
23.
2
Lock Nut
57.
1
51T Mid Output Helical Gear (6x6: 47T Gear)
24.
4
Dowel Pin
58.
1
Shift Shaft Rail
25.
4
Ball Bearing
59.
2
Shift Fork w/Pin
26.
1
Thrust Washer
61.
1
Silent Chain
27.
1
Vent Plug Cap
62.
1
Input Shaft Assy.
28.
1
Output Shaft
63.
1
LH Main Cover
29.
1
Shim
64.
1
Dual Lip Seal
30.
1
Thrust Button
65.
1
Transmission Mount Bracket
31.
1
Shim
66.
2
Hex Screw
32.
1
Output Cover
67.
1
33T 6 Face Gear
33.
15
Screw
68.
1
Washer
34.
1
Plain Bearing
69.
1
Label
8
8.17
BRAKES
CHAPTER 9 BRAKES GENERAL SPECIFICATIONS / TORQUE SPECIFICATIONS / SPECIAL TOOLS . . . . . BRAKE SYSTEM SERVICE NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE NOISE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC BRAKE SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MASTER CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2 9.3 9.3 9.4 9.5 9.6
REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
FOOT BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6 PEDAL REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
BRAKE BLEEDING / FLUID CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
PARKING BRAKE CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10 EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10 CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10 CALIPER DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11 NEW BRAKE PAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12 CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
PARKING BRAKE DISC SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12 DISC REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
FRONT BRAKE PADS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13 PAD REMOVAL / DISASSEMBLY / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13 PAD ASSEMBLY / INSTALLATION / ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
FRONT CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15 FRONT CALIPER EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15 CALIPER REMOVAL / DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15 CALIPER INSPECTION / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16 CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
FRONT BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18 DISC INSPECTION / REMOVAL / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
REAR BRAKE PAD (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18 PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18 PAD INSPECTION / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
REAR BRAKE PAD (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20 PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20 PAD INSPECTION / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
9
REAR CALIPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22 REAR CALIPER EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22 CALIPER REMOVAL (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22 CALIPER REMOVAL (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23 CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23 CALIPER INSPECTION / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24 CALIPER INSTALLATION (4X4, 6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
REAR BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26 BRAKES SQUEAL / POOR BRAKE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . 9.26 PEDAL VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26 CALIPER OVERHEATS (BRAKES DRAG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26 BRAKES LOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
9.1
BRAKES GENERAL SPECIFICATIONS FRONT BRAKE SYSTEM Item
Standard
Service Limit
Front Brake Pad Thickness
.298 ± .007' / 7.56 ± .178 mm
.180' (4.6 mm)
Front Brake Disc Thickness
.150 -.165' ( 3.810 - 4.19mm)
.140' (3.56mm)
-
.010' (.254mm)
Front Brake Disc Runout
REAR BRAKE SYSTEM Item
Standard
Service Limit
Rear Brake Pad Thickness
.298 ± .007'/ 7.56 ± .178 mm
.180' (4.6 mm)
Rear Brake Disc Thickness
.150-.165' (3.81-4.19 mm)
.140' (3.56 mm)
Park Brake Pad Thickness
Inboard - .304” (7.72 mm) Outboard - .360” (9.14 mm)
.240' (6.1 mm) .310” (7.87 mm)
Park Brake Disc Thickness
0.150” - 0.164” (3.81 - 4.16 mm)
.140' (3.56 mm)
-
.010' (.254 mm)
Rear Brake Disc Runout
TORQUE SPECIFICATIONS
SPECIAL TOOLS
Item
Torque ft. lbs.
Torque Nm
Front Caliper Mounting Bolts
18
24
Rear Caliper Mounting Bolts
18
24
Parking Brake Mounting Bolts
18
24
Parking Brake Assembly Bolts
25
34
12-15
16-20
Brake Line Banjo Bolts (Caliper Attachment)
15
2
Brake Line Banjo Bolt (Master Cylinder Attachment)
15
20
Front Brake Disc to Hub Bolts
18
24
Brake Switch
12-15
16-21
Master Cylinder Clevis Nut
9-13
12-18
Brake Line Flare
9.2
Part Number
Tool Description
2870975
Mity Vac™ Pressure Test Tool
BRAKES BRAKE SYSTEM SERVICE NOTES Disc brake systems are light weight, low maintenance, and perform well in the conditions ATVs routinely encounter. There are a few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function and maximum pad service life. • Optional pads are available to suit conditions in your area. Select a pad to fit riding style and environment. • Do not over-fill the master cylinder fluid reservoir. • Make sure the brake lever and pedal returns freely and completely. • Adjust stop pin on front caliper after pad service. • Check and adjust master cylinder reservoir fluid level after pad service. • Make sure atmospheric vent on reservoir is unobstructed. • Test for brake drag after any brake system service and investigate cause if brake drag is evident. • Make sure caliper moves freely on guide pins (where applicable). • Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely. • Perform a brake burnishing procedure after installing new pads to maximize service life. • DO NOT lubricate or clean the brake components with aerosol or petroleum products. Use only approved brake cleaning products.
BRAKE NOISE TROUBLESHOOTING Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise (squeal caused by vibration). If cleaning does not reduce the occurrence of brake noise, Permatex™ Disc Brake Quiet (PN 2872113) can be applied to the back of the pads. Follow directions on the package. This will keep pads in contact with caliper piston(s) to reduce the chance of squeaks caused by dirt or dust. Brake Noise Troubleshooting Possible Cause Dirt, dust, or imbedded material on pads or disc Pad(s) dragging on disc (noise or premature pad wear) Improper adjustment Insufficient lever or pedal clearance Master cylinder reservoir overfilled Master cylinder compensating port restricted Master cylinder piston not returning completely Caliper piston(s) not returning Operator error (riding the brake / park brake applied)
Remedy Spray disc and pads with CRC Brakeleen™ or an equivalent non-flammable aerosol brake cleaner. Remove pads and/or disc hub to clean imbedded material from disc or pads.
9
Adjust pad stop (front calipers) Check position of controls & switches. Set to proper level Clean compensating port Inspect. Repair as necessary Clean piston(s) seal Educate operator
Loose wheel hub or bearings
Check wheel and hub for abnormal movement.
Brake disc warped or excessively worn
Replace disc
Brake disc misaligned or loose
Inspect and repair as necessary
Noise is from other source (axle, hub, disc or wheel)
If noise does not change when brake is applied check other sources. Inspect and repair as necessary
Wrong pad for conditions
Change to a softer or harder pad
9.3
BRAKES HYDRAULIC BRAKE SYSTEM OPERATION Typical Hydraulic Brake System
Compensating port compensates for temperature changes by allowing fluid back to master cylinder.
E
Must be clear to allow proper diaphragm movement
C F
A
B
Movable G Brake Pad
D
The Polaris brake system consists of the following components or assemblies: brake pedal; master cylinder; hydraulic hose; brake calipers (slave cylinder); brake pads; and brake discs, which are secured to the drive line. When the foot activated brake lever (A) is applied it contacts a piston (B) within the master cylinder. As the master cylinder piston moves inward it closes a small opening (compensating port) (C) within the cylinder and starts to build pressure within the brake system. As the pressure within the system is increased, the piston (D) located in the brake caliper moves outward and applies pressure to the moveable brake pad. This pad contacts the brake disc and moves the caliper in its floating bracket, pulling the stationary side pad into the brake disc. The resulting friction reduces brake disc and vehicle speed. As the lever pressure is increased, the braking affect is also increased. The friction applied to the brake pads will cause the pads to wear. As these pads wear, the piston within the caliper moves further outward and becomes self adjusting. Fluid from the reservoir fills the additional area created when the caliper piston moves outward. Brake fluid level is critical to proper system operation. Too little fluid will allow air to enter the system and cause the brakes to feel spongy. Too much fluid could cause brakes to drag due to fluid expansion. Located within the master cylinder is the compensating port (C) which is opened and closed by the master cylinder piston assembly. The port is open when the lever is released and the master cylinder piston is outward. As the temperature within the hydraulic system changes, this port compensates for fluid expansion (heated fluid) or contraction (cooled fluid). During system service, be sure this port is open. Due to the high temperatures created within the system during heavy braking, it is very important that the master cylinder reservoir have adequate space to allow for fluid expansion. Never overfill the reservoir! Do not fill the reservoir past the MAX LEVEL line! This system also incorporates a diaphragm (E) as part of the cover gasket; and a vent port (F) located between the gasket and the cover. The combination diaphragm and vent allow for the air above the fluid to equalize pressure as the fluid expands or contracts. Make sure the vent is open and allowed to function. If the reservoir is over filled or the diaphragm vent is plugged the expanding fluid may build pressure in the brake system leading to brake failure. When servicing Polaris brake systems use only Polaris DOT 4 Brake Fluid (P/N 2872189). Polaris brake fluid is sold in 12 oz. bottles. WARNING: Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws. Do not store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture. This causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of serious injury.
9.4
BRAKES BRAKE SYSTEM EXPLODED VIEW Caliper Banjo Style Fittings:
1 15 ft. lbs. (20 Nm).
All Caliper Bleed Screws:
2 30-60 in. lbs. (3.4-6.8 Nm) All Flare Style Fittings:
3 12-15 ft. lbs. (16-20 Nm) 1
LH Front Brake Line
LH Rear Line
Master Cylinder 3
1
3
2
3 LH Rear Caliper
2
LH Front Caliper 3
MC Rear Brake Line
1
MC Front Brake Line
3
2
Brake Switch 1
Cross Fitting 1 RH Rear Line 2 RH Rear Caliper Master Cylinder Side View
RH Front Brake Line
RH Front Caliper
15 ft. lbs. (20 Nm)
9
9.5
BRAKES MASTER CYLINDER
FOOT BRAKE PEDAL
Removal
Pedal Removal
1. 2.
1. 2.
Open the hood. Locate the master cylinder. Remove the nut and bolt (A) from the brake pedal. C
Open the hood. Locate the master cylinder. Remove the nut, bushing, tube, and bolt from the brake pedal. Master Cylinder
A
Bolt
Tube
Bushing
Clevis Pin
A 9-13 ft. lbs.
Nut
(12-18 Nm)
Bushing
Cotter Key
Brake Pedal
9-13 ft. lbs. (12-18 Nm)
3. 20-22 ft. lbs. (27-30 Nm)
Remove the clevis pin and cotter key from the master cylinder to remove the brake pedal.
B
Pedal Installation 3.
Place a container to catch brake fluid under the master cylinder brake line banjo bolts (B). NOTE: Dispose of brake fluid properly and do not re-use.
CAUTION Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact with finished surfaces. 4.
Loosen the banjo bolts (B) for the brake lines and allow fluid to drain. NOTE: Make note of front and rear brake line locations to master cylinder. 5.
Remove the two mounting bolts (C) that secure the master cylinder to the frame.
Installation 1.
Reverse Steps 1-5 for master cylinder installation. Refer to the torque specifications in the illustration. After installing the foot brake check pedal freeplay. Pedal freeplay should not exceed .090” (2.286 mm).
9.6
1.
Reverse Steps 1-3 for foot brake installation. Torque the clevis nut to 9-13 ft. lbs. (12-18 Nm). After installing the foot brake check pedal freeplay. Pedal freeplay should not exceed .090” (2.28 mm).
Brake Pedal Freeplay: .090” (2.28 mm)
BRAKES BRAKE BLEEDING / FLUID CHANGE NOTE: When bleeding the brakes or replacing the fluid always start with the furthest caliper from the master cylinder.
CAUTION Always wear safety glasses.
CAUTION Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact with finished surfaces. This procedure should be used to change fluid or bleed brakes during regular maintenance. 1. 2.
Clean reservoir cover thoroughly. Remove cover from reservoir.
3.
If changing fluid, remove old fluid from reservoir with a Mity Vac™ pump or similar tool.
Mity Vac™ (PN 2870975) 4.
Add brake fluid to the indicated MAX level of reservoir.
Polaris DOT 4 Brake Fluid (P/N 2872189) 5.
6.
7.
Hold brake pedal on to maintain pedal pressure, and open bleeder screw. Close bleeder screw and release foot pedal. NOTE: Do not release foot pedal before bleeder screw is tight or air may be drawn into master cylinder. 8.
Repeat procedure until clean fluid appears in bleeder hose and all air has been purged. Add fluid as necessary to maintain level in reservoir.
CAUTION Maintain at least 1/2'(1.27 cm) of brake fluid in the reservoir to prevent air from entering the master cylinder. 9. Tighten bleeder screw securely and remove bleeder hose. 10. Repeat procedure Step 5 through Step 9 for the remaining calipers. 11. Add brake fluid to MAX level inside reservoir.
Master Cylinder Fluid Level Between the MIN and MAX line shown on the reservoir.
9
12. Install master cylinder reservoir cover. 13. Field test machine at low speed before putting into service. Check for proper braking action and pedal reserve. With pedal firmly applied, pedal reserve should be no less than 1/2'(1.3 cm). 14. Check brake system for fluid leaks.
Begin bleeding procedure with the caliper that is farthest from the master cylinder. Install a box end wrench on caliper bleeder screw. Attach a clean, clear hose to fitting and place the other end in a clean container. Be sure the hose fits tightly on fitting. Slowly pump foot pedal until pressure builds and holds.
9.7
BRAKES PARKING BRAKE Exploded View Park Brake Handle / Lever
Mount Cotter Pin Washer Spring
Washer
Nut
Bushings Park Brake Sensor Switch
Handle
Spring Pin Clip
Pin Park Brake Lever
Grommet
Latch Washer Brake Release
Park Brake Assembly Bolt
Parking Brake Assembly
Pin
Washer Clip Pin
Clip Pin
Park Brake Caliper Assembly
Cable
Mount Bolt
Rear Prop Shaft / Park Brake Disc
9.8
BRAKES Inspection 1.
2.
Inspect the springs and bushings on the parking brake lever assembly.
3. 4.
Bushings
After 2 to 3 clicks the wheels should not rotate when turning by hand. After 10 full clicks of lever travel, the vehicle should not roll while parked. If the vehicle moves, adjustment is necessary. Adjust the parking brake where the cable attaches to the lever assembly on the rear brake caliper.
Adjustment Procedure 1. 2. Springs
3.
Place the vehicle in neutral on a flat level surface. Carefully lift the rear of the vehicle off the ground and stabilize on jack stands. Locate the parking brake cable located under the front hood and under the dash on the driver side. Parking Brake Switch
2.
Inspect the parking brake cable and brake pads on the caliper assembly located on the rear propshaft. See “Parking Brake Caliper Service” for brake pad replacement information. 4x4 Model Shown
Inboard Pad
Parking Brake Cable Adjustment NOTE: See Chapter 10 for more information on the parking brake switch. 4.
Front
Outboard Pad 5. 6.
Adjustment 1.
Use two wrenches to loosen the bottom jam nut (C). Hold the top jam nut (D) with one wrench. Turn the bottom jam nut (C) 1 1/2 turns counterclockwise to loosen. Now hold the bottom jam nut (C) and turn the top jam nut (D) clockwise, until the jam nut is tight against the bracket. Repeat Step 4 and Step 5 until the proper adjustment is made for the park brake cable.
Push the parking brake (A) down with your foot.
To Parking Brake Pedal
D Top of Bracket
C A
To Parking Brake Caliper
9.9
9
BRAKES PARKING BRAKE CALIPER SERVICE Exploded View Hex Nut
Pad & Holder Pad & Holder 18 ft. lbs. (24 Nm)
Plain Washer
Sleeve
Hex Head Mount Bolt
Thrust Washer
Shim Pack (4 Shims)
Nut
Lever Asm. Bolt 25 ft. lbs. (34 Nm)
Spring Pin Compression Spring
Caliper Removal NOTE: Do no get oil, grease, or fluid on the park brake pads. Damage to or contamination of the pads may cause the pads to function improperly. 1.
Remove the clip pin and pin (A) from the park brake cable. 4x4 Model Shown
A
NOTE: Be sure the park brake is not engaged.
9.10
Steel Balls (3) 2.
Stationary Actuator Figure 9.10
If replacing the brake pads, slightly loosen the caliper assembly bolts before removing the complete caliper assembly. This will ease the caliper disassembly procedure later. 4x4 Model Shown
BRAKES 3.
Loosen the two brake caliper mount bolts (B) in equal increments.
Slide the brake pads and springs from the assembly.
NOTE: Retain the lever and ball bearings for reassembly.
4x4 Model Shown B
4.
6.
Remove the bolts from the frame and lift park brake assembly out.
7.
Inspect the brake pads linings for excessive wear. Replace as needed.
8.
Check the three steel balls for any signs of cracking. Replace as needed.
9.
Check ball seats in lever and stationary actuator. excessively worn, replace parts as needed.
If
10. Measure the thickness of the rear caliper parking brake pads. Replace assembly or pads as needed. See illustration below for proper readings. Inboard pad thickness New .304” (7.72 mm) Limit: 0.24” (6.1 mm)
4x4 Model Shown Inboard Pad
Outboard Pad
Outboard Pad Thickness New 0.360” (9.14 mm) Limit: 0.31” (7.87 mm) Installed Disc to Park Brake 0.375” (0.953 cm)
Caliper Disassembly / Inspection NOTE: The rear park brake caliper assembly is replaced as an assembly. Refer to your parts book for information. 5.
New Rotor Disc Thickness 0.150” - 0.164 (3.81 - 4.16 mm)
Remove the two caliper assembly nuts (C) that were previously loosened during Step 2 of “Caliper Removal”.
9
C
9.11
BRAKES New Brake Pad Installation
Caliper Installation
NOTE: Parking Brake Pads can be replaced by ordering one of the following kits: PN 2203148 - Brake Pad and Shim Kit PN 2203147 - Brake Pad Kit There may be more parts in the service kit than your brake requires. Check the parts list included with the kit for the exact quantities.
1.
1.
18 ft. lbs. (24 Nm)
Using the stationary actuator, assemble the caliper components as shown below. Do not install the springs or shims yet. Measure the gap for the brake disc. Disassemble and add shims between thrust washer and the inside brake pad as needed to close the gap to 0.203”0.193” (5.156-4.902 mm). For shim location, see Figure 9.10 on page 10. Add shims until gap measures 0.203”- 0.193” (5.156 - 4.902 mm)
Install the park brake assembly into place. Tighten the two mounting bolts in increments for proper installation.
4x4 Model Shown 2.
Torque the two mounting bolts to 18 ft. lbs. (24 Nm).
=T Parking Brake Caliper - Mounting Bolts: 18 ft. lbs. (24 Nm) 3.
2.
Once you have determined the correct amount of shims to use, install the assembly bolts through the sleeves. Install the nuts and the correct amount of shims, the inner brake pad, springs, and outer brake pad. Torque the assembly nuts to 25 ft. lbs. (34 Nm).
=T Parking Brake Caliper - Assembly Bolts: 25 ft. lbs. (34 Nm) 3.
Ensure the park brake assembly functions properly by actuating the lever before reinstallation.
Install the cable, pin, and clip pin. Test the park brake for proper function.
PARKING BRAKE DISC SERVICE Disc Removal / Inspection 1.
2.
Measure the park brake disc with a micrometer. The minimum allowable thickness of the disc should be .161” (4.09 mm). If the thickness of the disc is less than specified, replace the rear propshaft / disc assembly. Follow the “Rear Prop Shaft Removal (4x4 & 6x6)” procedure in Chapter 7 to remove the rear prop shaft / disc assembly. 4x4 Shaft Shown Remove Bolts
Minimum Disc Thickness: 0.140” (3.56 mm) New Disc: 0.150” - 0.164” (3.81 - 4.16 mm)
9.12
BRAKES FRONT BRAKE PADS
4.
Push caliper piston into caliper bore slowly using a Cclamp or locking pliers with pads installed.
Pad Removal / Disassembly 1.
Elevate and support front of machine.
CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. 2.
Remove the front wheel. Loosen pad adjuster screw 2-3 turns. Pad Adjuster Screw
NOTE: Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper. Remove excess fluid from reservoir as required. 5.
3.
Push upper pad retainer pin inward and slip outer brake pad past edge. Remove the pad.
Remove the two caliper bolts and caliper from mounting bracket.
Pad Inspection 1.
Measure the thickness of the pad material. Replace pads if worn beyond the service limit.
Measure Thickness
9.13
9
BRAKES 4.
Front Brake Pad Thickness: New: 298” (7.56 mm) + .007” (.178 mm)
Slowly pump the brake pedal until pressure has been built up. Maintain at least 1/2'(12.7 mm) of brake fluid in the reservoir to prevent air from entering the brake system.
Pad Adjustment Service Limit: .180”/4.6 mm
1.
Pad Assembly / Installation 1.
Install the adjuster screw and turn clockwise until stationary pad contacts disc, then back off 1/2 turn (counterclockwise). Pad Adjuster Screw
Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease, and install rubber dust boots.
2.
Be sure fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap.
Master Cylinder Fluid Polaris Premium All Season Grease (PN 2871423) 2.
3.
Compress mounting bracket and make sure dust boots are fully seated. Install pads with friction material facing each other. Be sure pads and disc are free of dirt or grease. Install caliper on hub strut, and torque mounting bolts.
Up to MAX line inside reservoir 3. 4.
Install wheels and torque wheel nuts. It is recommended that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise. Start machine and slowly increase speed to 30 mph. Gradually apply brakes to stop machine. Repeat procedure 10 times.
Front Wheel Nut Torque: 37 ft. lbs. (50 Nm)
18 ft. lbs. (24 Nm)
Front Caliper Mounting Bolts Torque 18 ft. lbs. (24 Nm)
9.14
BRAKES FRONT CALIPER Front Caliper Exploded View DURING ASSEMBLY
FRONT CALIPER EXPLODED VIEW
4
4 4
Bleeder Screw 30-60 in. lbs. (3.4-6.8 Nm)
Square O-rings Dust Boots Pads
Adjuster Screw (Finger Tight) Caliper Body 4 Piston
Caliper Mount
Caliper Removal
Caliper Disassembly
1.
1.
Remove brake pad adjuster screw (A).
2.
Push upper pad retainer pin inward and slip brake pads past edge, if pads are still installed.
3.
Remove mounting bracket (B) and dust boot (C)
Elevate and support front of machine.
CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. 2. 3.
F
Remove the front wheel. Remove brake line from the caliper. Place a container under caliper to catch fluid draining from brake line.
D
B
9
A E C Figure 9.15
4.
Remove brake caliper mounting bolts and caliper.
9.15
BRAKES 4.
Remove piston (D) and square O-rings (E) from the caliper body (F). See Figure 9.15.
2.
Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol. NOTE: Be sure to clean seal grooves in caliper body.
Inspect piston for nicks, scratches, wear or damage. Measure diameter and replace if damaged or worn beyond service limit.
5.
Front Caliper Piston O.D. Std. 1.4985-1.5000” (38.062 - 38.10 mm) Service Limit 1.4980” (38.049 mm)
Caliper Inspection 1.
Inspect caliper body for nicks, scratches or wear. Measure bore size and compare to specifications. Replace if damage is evident or if worn beyond service limit.
3.
Inspect the brake disc and pads as outlined for brake pad replacement in this chapter.
Caliper Assembly 1.
Install new square O-rings (A) in the caliper body. Be sure that the grooves are clean and free of residue or brakes may drag.
4 B
Front Caliper Piston Bore I.D. Std. 1.5050-1.5040” (32.27-30.202 mm) Service Limit 1.5060” (38.252 mm)
A 2.
9.16
Coat the piston with clean Polaris DOT 4 Brake Fluid (P/N 2872189). Install piston (B) with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance.
BRAKES 3.
Lubricate the mounting bracket pins with Polaris Premium All Season Grease (PN 2871423), and install the rubber dust seal boots.
3.
Install the adjuster screw and turn until stationary pad contacts disc, then back off 1/2 turn. Pad Adjuster Screw
CAUTION Do not allow grease to come into contact with the piston and seals. Damage may occur to the components.
4. 5.
Follow brake bleeding procedure outlined earlier in this chapter. Install wheels and torque wheel nuts to specification.
Front Wheel Nut Torque: 37 ft. lbs. (50 Nm)
4.
Compress the mounting bracket and make sure the dust seals are fully seated. Install the brake pads. Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt, oil or grease.
NOTE: If new brake pads are installed, it is recommended that a burnishing procedure be performed to extend pad service life and reduce noise. Start machine and slowly increase speed to 15 mph. Gradually apply brakes to stop machine. Repeat procedure 10 times.
Caliper Installation 1.
Install caliper on hub strut, and torque mounting bolts.
9 18 ft. lbs. (24 Nm)
Front Caliper Mounting Bolt Torque: 18 ft. lbs. (24 Nm) 2.
Install brake line and tighten securely with a flare nut wrench.
9.17
BRAKES FRONT BRAKE DISC
Disc Removal / Replacement
Disc Inspection
1.
1. 2.
Remove bolts and disc. Bolts
Visually inspect the brake disc for nicks, scratches, or damage. Measure the disc thickness at 8 different points around the pad contact surface using a 0-1'micrometer. Replace disc if worn beyond service limit.
18 ft. lbs. (24 Nm)
Disc Hub 2. 3. 4.
Clean mating surface of disc and hub. Install disc on hub. Install new bolts and tighten to 18 ft.lbs. (24 Nm).
CAUTION Brake Disc Thickness New .150-.165” (3.81 - 4.19 mm) Service Limit .140”/3.56 mm
Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal.
REAR BRAKE PAD (4X4) Brake Disc Thickness Variance Pad Removal Service Limit .002” (.051 mm) difference between measurements 3.
1.
CAUTION
Mount dial indicator as shown to measure disc runout. Slowly rotate the disc and read total runout on the dial indicator. Replace the disc if runout exceeds specifications.
Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. 2.
Brake Disc Runout Service Limit .010” (.254 mm)
9.18
Elevate and support rear of machine.
Remove the rear wheel. Loosen pad adjuster screw 2-3 turns.
BRAKES 3.
Clean caliper area before removal.
Pad Inspection
4.
Remove caliper mounting bolts and lift caliper off of disc.
1. 2.
NOTE: When removing caliper, be careful not to damage brake line. Support caliper so as not to kink or bend brake line.
Clean the caliper with brake cleaner or alcohol. Measure the thickness of the pad material. Replace pads if worn beyond the service limit.
Measure Thickness Remove Caliper Bolts 5.
Push caliper piston into caliper bore slowly with pads installed.
NOTE: Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper. Remove excess fluid from reservoir as required. 6.
Rear Brake Pad Thickness New .298 + .007” (7.56 + .178 mm) Service Limit .180” (4.6 mm) Pad Installation 1.
Install new pads in caliper body.
Remove the brake pads.
9 2.
Install caliper and torque mounting bolts.
18 ft. lbs. (24 Nm)
9.19
BRAKES Rear Brake Caliper Mounting Bolt: Torque 18 ft. lbs. (24 Nm)
3. 4.
3.
Clean caliper area before removal.
4.
Remove caliper mounting bolts and lift caliper off of disc.
NOTE: When removing caliper, be careful not to damage brake line. Support caliper so as not to kink or bend brake line.
Turn adjuster screw back in finger tight using a hex wrench. Slowly pump the brake pedal until pressure has been built up. Maintain at least 1/2'(12.7 mm) of brake fluid in the reservoir to prevent air from entering the master cylinder.
Remove Caliper Bolts
Do not bend or kink
5. Pump the Brake Pedal
REAR BRAKE PAD (6X6) 1.
Elevate and support rear of machine.
CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. 2.
Remove the rear wheel. Loosen pad adjuster screw 2-3 turns. Adjuster Screw
9.20
NOTE: Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper. Remove excess fluid from reservoir as required. 6.
Pad Removal
Push caliper piston into caliper bore slowly with pads installed.
Remove the brake pads.
BRAKES Pad Inspection
Pad Installation
1.
Clean the caliper with brake cleaner or alcohol.
1.
Install new pads in caliper body.
2.
Measure the thickness of the pad material. Replace pads if worn beyond the service limit.
2.
Install caliper and torque mounting bolts.
Measure Thickness
Rear Brake Pad Thickness New .298 + .007” (7.56 + .178 mm) Service Limit .180” (4.6 mm)
18ft. lbs. (24 Nm)
Rear Brake Caliper Mounting Bolt: Torque 18 ft. lbs. (24 Nm) 3.
Turn adjuster screw back in finger tight using a hex wrench.
4.
Slowly pump the brake pedal until pressure has been built up. Maintain at least 1/2'(12.7 mm) of brake fluid in the reservoir to prevent air from entering the master cylinder.
Pump the Brake Pedal
9.21
9
BRAKES REAR CALIPER Rear Caliper Exploded View DURING ASSEMBLY 4
4
Bleeder Screw 30-60 IN. LBS. (4-6.5 NM)
4 Piston Caliper Body
4 Square O-rings
Pads Caliper Mount
Adjuster Screw (Finger Tight)
Dust Boots
Caliper Removal (4x4) 1.
3.
After the fluid has drained into the container, remove the two caliper mounting bolts and remove caliper.
4.
Clean disc, caliper body, and pistons with brake cleaner or alcohol.
Safely support the rear of the machine.
CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. 2.
Use a wrench to remove the brake line. Place a container to catch brake fluid draining from brake lines.
9.22
BRAKES Caliper Removal (6x6)
Caliper Disassembly
1.
1.
Remove brake pad adjuster screw (A).
2.
Push upper pad retainer pin inward and slip brake pads past edge, if pads are still installed.
3.
Remove mounting bracket (B) and dust boot (C)
Safely support the rear of the machine.
CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. 2.
B F
Use a wrench to remove the brake line. Place a container to catch brake fluid draining from brake lines.
Pads
C D
Remove Banjo Bolt
E A
3.
4.
Remove piston (D) and square O-rings (E) from the caliper body (F).
5.
Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol.
After the fluid has drained into the container, remove the two caliper mounting bolts and remove caliper.
Remove Caliper Bolts
NOTE: Be sure to clean seal grooves in caliper body. 4.
Clean disc, caliper body, and pistons with brake cleaner or alcohol.
9.23
9
BRAKES Caliper Inspection
Caliper Assembly
1.
1.
Inspect caliper body for nicks, scratches or wear. Measure bore size and compare to specifications. Replace if damage is evident or if worn beyond service limit.
Install new square O-rings (A) in the caliper body. Be sure that the grooves are clean and free of residue or brakes may drag. A
4
2.
Coat the piston with clean Polaris DOT 4 Brake Fluid (P/N 2872189). Install piston (B) with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance.
3.
Lubricate the mounting bracket pins with Polaris Premium All Season Grease, and install the rubber dust seal boots.
Rear Caliper Piston Bore I.D. Std. 1.2550” (3.227 mm) Service Limit 1.256” (31.902 mm) 2.
B
Inspect piston for nicks, scratches, wear or damage. Measure diameter and replace if damaged or worn beyond service limit.
Polaris Premium All Season Grease (PN 2871423) Rear Caliper piston O.D. Std. 1.250” (31.75 mm) Service Limit 1.2495” (31.737 mm) 3.
Inspect the brake disc and pads as outlined for brake pad replacement in this chapter.
9.24
4.
Compress the mounting bracket and make sure the dust seals are fully seated. Install the brake pads. Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt, oil or grease.
BRAKES Caliper Installation (4x4, 6x6)
REAR BRAKE DISC
1.
Install the rear caliper with the mounting bolts. Torque mounting bolts to 18 ft.lbs. (24 Nm).
Disc Inspection
2.
Install brake line banjo bolt. Torque banjo bolt to 15 ft. lbs. (21 Nm).
1.
18 ft. lbs. (24 Nm)
2.
4X4
Visually inspect disc for scoring, scratches, or gouges. Replace the disc if any deep scratches are evident. Use a 0-1'micrometer and measure disc thickness at 8 different points around perimeter of disc. Replace disc if worn beyond service limit. Rear Brake Disc
15 ft. lbs. (21 Nm)
18 ft. lbs. (24 Nm)
6X6
Rear Brake Disc Measure Thickness
15 ft. lbs. (21 Nm) 3.
Front View of Brake Disc
Brake Disc Thickness New .150-.165” (3.81-4.19 mm) Service Limit .140” (3.56 mm)
Install the rear wheel and wheel nuts. Carefully lower the vehicle.
Brake Disc Thickness Variance Service Limit .002” (.051 mm) difference between measurements 3.
9
Mount dial indicator and measure disc runout. Replace the disc if runout exceeds specifications.
Brake Disc Runout Service Limit .010” (.254 mm) 4. 5. 6.
Install brake line and tighten with a flare nut wrench. Follow bleeding procedure outlined earlier in this chapter. Field test unit for proper braking action before putting into service. Inspect for fluid leaks and firm brakes. Make sure the brake is not dragging when pedal is released. If the brake drags, re-check assembly and installation.
9.25
BRAKES TROUBLESHOOTING Brakes Squeal / Poor Brake Performance • Air in system • Water in system (brake fluid contaminated) • Caliper/disc misaligned • Caliper dirty or damaged • Brake line damaged or lining ruptured • Worn disc and/or friction pads • Incorrectly adjusted stationary pad • Worn or damaged master cylinder or components • Damaged break pad noise insulator
Pedal Vibration • Disc damaged • Disc worn (runout or thickness variance exceeds service limit)
Caliper Overheats (Brakes Drag) • Compensating port plugged • Pad clearance set incorrectly • Parking brake lever incorrectly adjusted • Brake pedal binding or unable to return fully • Parking brake left on • Residue build up under caliper seals • Operator riding brakes
Brakes Lock • Alignment of caliper to disc • Caliper pistons sticking • Improper assembly of brake system components
9.26
ELECTRICAL
CHAPTER 10 ELECTRICAL GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 UNDER-HOOD COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
SWITCHES / CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 AWD / REAR DIFFERENTIAL SWITCH (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 DIFFERENTIAL SOLENOID (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 BRAKE LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 PARKING BRAKE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 RIDER INFORMATION DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 STANDARD DISPLAY MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 DIAGNOSTIC DISPLAY MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 VIEWING DIAGNOSTIC CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 INSTRUMENT CLUSTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11 INSTRUMENT CLUSTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
INSTRUMENT CLUSTER TROUBLESHOOTING TESTS . . . . . . . . . . . . . . . . . . . . . . 10.12 TEST 1 - NO ALL WHEEL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 TEST 2 - NO DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13 TEST 3 - WHEEL SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13 TEST 4 - NO AWD HUB SAFETY LIMITER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14 TEST 5 - FUEL GAUGE DISPLAY NOT WORKING . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15 TEST 6 - SHIFT INDICATOR NOT WORKING (TRANSMISSION SWITCH) . . . . . . . 10.15
ALL WHEEL DRIVE (AWD) COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16 OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16 DIAGNOSING SYSTEM FAILURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
GEAR POSITION INDICATOR SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16 TEST DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
HEAD LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17 HIGH BEAM HEADLIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17 HEADLAMP BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17 HEADLAMP HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17 HEADLAMP HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
TAIL LIGHT / BRAKE LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18 LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19 COOLING SYSTEM BREAK-OUT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19 FAN CONTROL CIRCUIT OPERATION / TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20 FAN CONTROL CIRCUIT BYPASS TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20 COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
EFI DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
10
EFI COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
FUEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
RELAYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
FUSES / CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
10.1
ELECTRICAL CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22 CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22 CHARGING SYSTEM “BREAK EVEN” TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23 CHARGING SYSTEM ALTERNATOR TESTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23 CHARGING SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
BATTERY TERMINAL BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26 BATTERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26 BATTERY TERMINALS / BOLTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26 BATTERY IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
CONVENTIONAL BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27 BATTERY ACTIVATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27 BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27 BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28 BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28 CONVENTIONAL BATTERY TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28 OCV - OPEN CIRCUIT VOLTAGE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28 SPECIFIC GRAVITY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28 LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29 OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29 CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
LOW MAINTENANCE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30 BATTERY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30 BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30 BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30 BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31 BATTERY TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31 OCV - OPEN CIRCUIT VOLTAGE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31 LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31 OFF-SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32 BATTERY CHARGING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33 VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33 STARTER MOTOR REMOVAL / DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33 BRUSH INSPECTION / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34 ARMATURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35 STARTER REASSEMBLY / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35 STARTER SOLENOID BENCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36 STARTER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36 STARTER EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37
STARTER SYSTEM TESTING FLOW CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38 ELECTRIC BOX LIFT ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39 DIAGNOSIS (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
10.2
ELECTRICAL GENERAL INFORMATION
• When measuring resistance of a component that has a resistance value under 10 Ohms, remember to subtract meter lead resistance from the reading. Connect the leads together and record the resistance. The resistance of the component is equal to tested value minus the lead resistance.
Special Tools Part Number
Tool Description
PV-43568
Fluke™77 Digital Multimeter
2870630
Timing Light
2870836
Battery Hydrometer
2460761
Hall Sensor Probe Harness
2871745
Static Timing Light Harness
• Become familiar with the operation of your meter. Be sure leads are in the proper jack for the test being performed (i.e. 10A jack for current readings). Refer to the Owner’s manual included with your meter for more information.
PU-47063
Digital Wrench™ Diagnostic Software
PU-47471
Digital Wrench™ SmartLink Module Kit
• Voltage, amperage, and resistance values included in this manual are obtained with a Fluke™ 77 Digital Multimeter (PV-43568). This meter is used for when diagnosing electrical problems. Readings obtained with other meters may differ.
Electrical Service Notes
• Pay attention to the prefix on the multimeter reading (K, M, etc.) and the position of the decimal point.
Keep the following notes in mind when diagnosing an electrical problem.
• For resistance readings, isolate the component to be tested. Disconnect it from the wiring harness or power supply.
• Refer to wiring diagram for stator and electrical component resistance specifications.
Under-Hood Components H
C
A B G
10 A. Voltage Regulator / Rectifier B. Starter Solenoid C. Terminal Block
E D
D. Positive Battery Cable E. Negative Battery Cable
F
F. Battery G. Starter Motor Positive Lead H. Relays
10.3
ELECTRICAL SWITCHES / CONTROLS Headlamp Switch 1.
Lift the front hood.
2.
The wires are located on the back side of the instrument panel.
3.
Disconnect the headlamp switch harness (Brown, Green, and Yellow), by depressing the connector lock and pulling on the connector. Do not pull on the wiring.
4.
Test the switch connections and check for continuity at the following pins as shown in the illustration.
4.
Test the switch connections and check for continuity at the following pins shown in the illustration. AWD / REAR DIFFERENTIAL SWITCH
HEADLAMP SWITCH
BACK VIEW OF SWITCH (INTERNAL CONNECTIONS)
Differential Solenoid (4x4)
BACK VIEW OF SWITCH (INTERNAL CONNECTIONS)
The differential solenoid is located on the rear gear case. The solenoid actuates the carrier, which locks and unlocks the rear carrier. (Refer to Chapter 7 for more information on rear carrier operation.) Solenoid
AWD / Rear Differential Switch (4x4) 1.
Lift the front hood.
2.
The wires are located on the back side of the instrument panel.
3.
Disconnect the switch harness (Grey, Orange/White, Brown, White/Green), by depressing the connector lock and pulling on the connector. Do not pull on the wiring.
10.4
ELECTRICAL Differential Solenoid Circuit Operation
If the rear carrier fails to switch from operational modes:
When the switch is pushed to activate “Turf” mode, the White/ Green wire is connected to ground via the Brown wire at the AWD / Diff-Lock Switch and signals the ECU to energize the Rear Diff Solenoid Relay.
• Check the connector located under the left rear fender. Look for loose wires or bad connections. • Check for power from the connector, to ensure the solenoid has power to be activated.
Depending on vehicle speed and gear position criteria, the ground path is then sent from the ECU to the Rear Diff Solenoid Relay. This activates the solenoid and sends 12 volt “Key On” power from the RD/WH wire to the OR/WH wire of the Differential Solenoid.
• Check the operator’s switch wires for loose connections. • Remove solenoid from carrier and ensure the solenoid plunger is actuating.
Rear Differential Solenoid Circuit
CAUTION
AWD / Diff-Lock Switch
Do not power the solenoid with 12 Volts for more than 1 second, or damage may occur to the solenoid.
Brake Light Switch 1.
The brake light switch is located near the steering gearbox along the frame. The brake pressure switch is installed into this block.
Key-On Power
Brake Switch
2.
Disconnect wire harness from switch.
3.
Connect an ohmmeter across switch contacts. Reading should be infinite (•).
4.
Apply foot brake and check for continuity between switch contacts. If there is no continuity or greater than .5 ohms resistance when the brake is applied with slight pressure, first clean the switch contacts and re-test. Replace switch if necessary.
10.5
10
ELECTRICAL Parking Brake Switch
TESTING PARK BRAKE SWITCH
The parking brake switch is located under the dash or under the hood. Follow the parking brake lever under the dash to locate the switch.
1.
Disconnect the Orange/Red wire and Red/White wire from the switch.
2.
Place the ohmmeter leads onto terminal leads A and C. The reading should be infinite (•).
Parking Brake Switch
RD/WH OG/RD
The switch remains in the “open” position when the park brake lever is not applied.
3.
Apply the parking brake. There should be continuity between the switch terminals. If no continuity exists when the park brake is applied, try to clean the switch terminals and re-test. Replace switch if necessary.
Park Brake Indicator
P
Parking Brake Not Applied
The switch makes contact when the park brake is applied and sends voltage to the ECU and Speedometer to illuminate the “Park Brake Indicator” near the top-center of the instrument cluster.
Key-On Power
Parking Brake Applied
10.6
ELECTRICAL INSTRUMENT CLUSTER
Rider Information Display
Overview
The rider information display is located in the instrument cluster. All segments will light up for 2.5 seconds at start-up.
The RANGER instrument cluster senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as time, hours of operation and engine RPM. Park Brake Indicator
Speedometer
NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. 6 3 4 5 7 8
Speedometer Needle 2
1
Rider Information Display
NOTE: In addition to showing vehicle speed, the speedometer needle flashes when a low fuel condition exists.
1.
Gear Indicator - This indicator displays gear shifter position. H = High Gear L = Low Gear N = Neutral R = Reverse Gear
2.
AWD Indicator - This indicator illuminates when the AWD switch is in the AWD position.
3.
Engine Hour Display Indicator
4.
Service Interval / Diagnostic Mode Indicator
5.
Low Battery and Over Voltage - This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged. It may also occur when the engine is at idle and high electrical load (lights, cooling fan, accessories) is applied. Drive at a higher RPM or recharge the battery to clear the warning.
6.
Odometer/Tachometer/Tripmeter/ Hour Meter/Clock
7.
Fuel Gauge - The segments of the fuel gauge show the level of fuel in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments will flash, FUEL will display in the LCD, and the speedometer needle will blink. Refuel immediately.
NOTE: Use the “Mode Button” shown below to toggle between Instrument Cluster display screens. Instrument Cluster
Ignition Switch
8. Mode Button
Check Engine Warning Indicator - This indicator serves two purposes. The word HOT displays if the engine overheats. It also appears if an EFI-related fault occurs. Do not operate the vehicle if this warning appears. Serious engine damage could result.
10.7
10
ELECTRICAL Standard Display Modes
Clock Screen
Use the yellow mode button located under the speedometer to toggle through the mode options. Odometer Mode The odometer records the miles traveled by the vehicle. Trip Meter Mode The trip meter records the miles traveled by the vehicle on each trip if it's reset before each trip. To reset the trip meter, select the trip meter mode. Press and hold the mode button until the total changes to 0.
To reset the clock:
NOTE: In the Rider Information Display, the trip meter display contains a decimal point, but the odometer displays without a decimal point.
1. 2. 3.
Hour Meter Mode
4.
This mode logs the total hours the engine has been in operation. Tachometer Mode
5.
The engine RPM is displayed digitally. NOTE: Small fluctuations in the RPM from day to day may be normal because of changes in humidity, temperature and elevation. Clock Mode
6. 7.
Enter the diagnostic mode. Toggle to the clock screen. Press and hold the mode button until the hour display flashes. Release the button. Press and release the mode button once to advance the setting by one hour. Press and hold the mode button to advance the hours quickly. When the desired hour is displayed, wait approximately four seconds, until the minute display flashes. When the display stops flashing, the mode has been set. Use the same procedure to reset the minutes.
Battery Voltage Screen View this screen to check battery voltage level.
The clock displays time in a 12-hour format. To reset the clock, see “Clock Screen” in the “Diagnostic Display Mode” section.
Diagnostic Display Mode The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any movement of the tires will also cause the gauge to exit the diagnostic mode. To enter the diagnostics mode: 1.
Turn the key switch off and wait 10 seconds.
2.
Lock the parking brake.
3.
Place the transmission in neutral.
4.
Hold the mode button and turn the key switch to the “ON” position. Release the mode button as soon as the display is activated.
5.
Use the mode button to toggle through the diagnostic screens.
Tachometer Screen View the tachometer to check engine speed.
10.8
ELECTRICAL AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the AWD coil.
NOTE: A 10 - 20% variance from these readings is within normal parameters. Programmable Service Interval Gear Circuit Diagnostic Screen This screen displays the resistance value (in ohms) being read at the gear switch input of the gauge.
When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. When this feature is enabled, it provides a convenient reminder to perform routine maintenance.
10 NOTE: The service interval is programmed at 50 hours at the factory.
10.9
ELECTRICAL To enable or disable the service interval: 1.
Enter the diagnostic mode.
2.
Toggle to the service interval screen.
3.
Press and hold the mode button for about seven (7) seconds, until either ON or OFF appears in the Rider Information Display, depending on your preference.
To reset the service interval: 1.
Enter the diagnostic mode.
2.
Toggle to the service interval screen.
3.
Press and hold the mode button for 2-3 seconds, until the wrench icon flashes. Release the button.
Viewing Diagnostic Codes
4.
Press and release the mode button once to advance the setting by one hour. Press and hold the mode button to advance the hours quickly.
Use the following procedure to view diagnostic blink codes (failure codes) from the EFI module. NOTE: See Page 4.21 for a complete list of Diagnostic Blink Codes
NOTE: If you scroll past the intended number, press and hold the button until the hours cycle back to zero.
1.
Engage the parking brake.
2.
Stop the engine.
5.
3.
Turn the key switch to the ON position.
4.
Turn the key switch off and on three times in less than five seconds, then leave the switch on. The word “Wait” will appear on the screen along with a flashing “Check Engine” light.
When the desired setting is displayed, wait until the wrench icon stops flashing. The new service interval is now programmed.
Miles / Kilometers Toggle The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement. 1.
Enter the diagnostic mode.
2.
Toggle to the screen that displays either kilometers (KM) or miles (MP).
3.
Press and hold the mode button until the letters flash, then press and release the button once. When the display stops flashing, the mode has been set.
10.10
ELECTRICAL 5.
Any blink code numbers stored in the EFI module will display, one at a time, on the screen. Example below shows a Blink Code of “42”.
2.
Push the instrument cluster out from the back side of the dash panel, while securely holding the panel and rubber mount. Dash Panel
Push Instrument Cluster Outward 6.
The number “61” and/or the word “End” displays after all codes have been transmitted. Rubber Mount
Bezel
Instrument Cluster
NOTE: Do not remove the rubber mount from the dash panel. Only remove the rubber mount if necessary. The bezel is a snap-on assembly and is a serviceable part.
Instrument Cluster Installation Instrument Cluster Removal
1.
NOTE: Do not allow alcohol or petroleum products to come in contact with the instrument cluster lens. 1.
Spray a soap and water mixture onto the outer surface area of the instrument cluster. This will help the instrument cluster slide into the rubber mount more easily.
Lift the hood and disconnect the wire connectors from the back side of the instrument cluster.
10 2.
Be sure the rubber mount inside the pod is fully installed and that the indexing key on the rubber mount is lined up with the keyway in the dash panel.
3.
Hold the dash panel securely and insert the instrument cluster into the dash panel. Twist the instrument cluster gently in a clockwise motion to properly seat the instrument cluster into the pod assembly. Apply pressure on the bezel while pressing down on the instrument cluster.
10.11
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