2008 RANGER 500 2X4 / 4X4 EFI SERVICE MANUAL FOREWORD This service manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position. Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools as specified. Comments or suggestions about this manual may be directed to: Service Publications Dept. @ Polaris Sales Inc. 2100 Hwy 55 Medina Minnesota 55340.
2008 Service Manual PN 9921267 Š Copyright 2007 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS Throughout this manual, important information is brought to your attention by the following symbols:
WARNING
SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle.
CAUTION
SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.
CAUTION
CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage. NOTE: NOTE provides key information by clarifying instructions. IMPORTANT: IMPORTANT provides key reminders during disassembly, assembly and inspection of components.
TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL: Loctite, Registered Trademark of the Loctite Corporation Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity-Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries FOX, Registered Trademark of FOX RACING SHOX RydeFX, Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www.polarisindustires.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer.
GENERAL INFORMATION
1
MAINTENANCE
2
ENGINE
3
CARBURETION / EFI
4
BODY / STEERING / SUSPENSION
5
CLUTCHING
6
FINAL DRIVE
7
TRANSMISSION
8
BRAKES
9
ELECTRICAL
10
GENERAL INFORMATION
CHAPTER 1 GENERAL INFORMATION
1
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 GENERAL: 2008 RANGER 2X4 / 4X4 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 DETAILED: 2008 RANGER 2X4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 DETAILED: 2008 RANGER 4X4 EFI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 VEHICLE IDENTIFICATION Model Identification The machine model number must be used with any correspondence regarding warranty or service.
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Machine Model Number Identification R 08 RB 50 AA Emissions & Model Option
Model Year Designation Basic Chassis Designation
Engine Designation
Engine Designation Number EH50PLE ..........................................................................................Single, L/C, SOHC 4 Stroke, Electric Start
VIN Identification World Mfg. ID
Vehicle Identifier
Vehicle Description
}
}
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A R B 50 A * 8 P 0 0 0 0 0 0 Model Year
Engine Body Style 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 flywheel housing on the right side of engine.
A Engine Serial Number
1.2
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 2X4, 4X4
75 in. 190.50 cm
RANGER 2X4, 4X4
10 in. 25.4 cm
58 in. 147 cm
1.4
GENERAL INFORMATION VEHICLE DIMENSIONS
1 RANGER 2X4, 4X4 113 in. 287 cm
58 in. 147 cm
76 in. 193 cm
1.5
GENERAL INFORMATION GENERAL SPECIFICATIONS MODEL: 2008 RANGER 2X4 MODEL NUMBER: R08RB50AA ENGINE MODEL: EH50PLE 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 in. / 27.9 cm Turning Radius 148 in. / 376 cm Dry Weight 1105 lbs. / 501 kg Gross Vehicle Weight 2755 lbs. / 1250 kg Cargo Box Capacity 1000 lbs. / 454 kg 54 x 36.5 x 11.5 in. Cargo Box Dimensions (137 x 92.7 x 29.2 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: 2008 RANGER 4X4 EFI MODEL NUMBER: R08RH50AF, AR, AT ENGINE MODEL: EH50PLE 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 in. / 27.9 cm Turning Radius 148 in. / 376 cm Dry Weight 1185 lbs. / 538 kg Gross Vehicle Weight 2835 lbs. / 1286 kg Cargo Box Capacity 1000 lbs. / 454 kg 54 x 36.5 x 11.5 in. Cargo Box Dimensions (137 x 92.7 x 29.2 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
1.6
GENERAL INFORMATION MODEL: 2008 RANGER 2X4
Drivetrain
MODEL NUMBER: R08RB50AA ENGINE MODEL: EH50PLE
Transmission Type
Polaris Automatic PVT 4.43:1 10.08:1 6.87:1
Platform
Fuji Single Cylinder, 4-Stroke, SOHC, Liquid Cooled
Transmission Gear Ratio: High Low Reverse
Engine Model Number
EH500PLE169
Final Drive Ratio
3.70:1
Engine Displacement
499 cc
Shift Type
In Line Shift - H / L / N / R
Number of Cylinders
1
Transmission Oil Requirements
Bore & Stroke
92 x 75 mm
Polaris Synthetic AGL 15.2 oz. (450 ml)
Compression Ratio
10.2:1
Rear Gearcase Oil Requirements
Polaris Premium ADF 18 oz. (532 ml)
Compression Pressure
70-90 psi
Engine Idle Speed
1200 ± 200 RPM
Valve Clearance Int./Exh.
0.006 in. (0.152 mm)
Engine Hot Light
Dash Light
Lubrication
Pressurized Dry Sump
Oil Requirements
0W-40
Oil Capacity
2 qts. (1.9 L)
Coolant Capacity
3.25 qts. (3.08 L)
Exhaust System
Single Pipe / Canister Style
Engine
Carburetion Carburetor model
Mikuni BST 34mm CV
Main Jet
135
Pilot Jet
42.5
Jet Needle
4MB32-3
Needle Jet
P-6 (829)
Pilot Screw
2.5 Turns Out (Initial starting point, settings may vary)
Pilot Air Jet
Belt
3211077
Drive Belt Deflection
1.125 in. (28.58 mm)
Center Distance
10 in. (254 mm)
Clutch Offset
0.5 in. (12.7 mm)
Steering / Suspension Front Suspension
MacPherson Strut
Front Travel
8 in. (20.3 cm)
Rear Suspension
Independent Rear Suspension
Rear Travel
9 in. (22.9 cm)
Rear Shock Preload Adjustment
Cam Adjustment
Toe Out
1/8 - 1/4 in. (3.2 - 6.35 mm) Wheels / Brakes
Front Wheel Size
12 x 6 / 10 gauge
Rear Wheel Size
12 x 8 / 10 gauge
Front Tire Make / Model / Size
Titan / AT489 / 25x10-12
160
Rear Tire Make / Model / Size
Titan / AT489 / 25x11-12 8 - 12 psi
Float Height
0.51 ± 0.40 in. (13 ± 1 mm)
Tire Air Pressure - Front / Rear
Fuel Delivery
Electric Fuel Pump (External)
Brakes - Front / Rear
4 Wheel Hydraulic Disc
Fuel Capacity / Requirement
9 gal. (34 L) 87 Octane (minimum)
Parking Brake
Hand Actuated (in dash)
Brake Fluid
DOT 4
Electrical Alternator Max Output
250 watts @ 5000 RPM
Lights : Main Headlights
2 - Single Beam 50w / Halogen
Tail
5 watts x 2
Brake
5 watts x 2
Indicator Panel Lights
1 watt (ea.)
Starting System
Electric Start
Ignition System
12V DC/CDI
RPM Limit
6600 RPM
Ignition Timing
30° ± 2° BTDC @ 5000 RPM
Spark plug / Gap
NGK BKR5E / .036 in. (0.9 mm)
Battery / Model / Amp Hr
Yuasa YB30L-B Conventional / 30 Amp Hr. / 12 Volt
Instrument Panel Type
Indicator Lights / Hour Meter
DC Outlet
Standard
JETTING CHART Ambient Temperature Altitude
Meters (Feet)
Below 40° F Below 5° C
+40° F TO +80° F +5° C TO +28° C
0-1500 (0-5000)
140 (3130527)
135 (3130563)
above 1500 (above 5000)
132.5 (3130562)
127.5 (3130560)
CLUTCH CHART Altitude
Meters (Feet)
0-1500 (0-5000)
Shift Weight
Drive Spring
Driven Spring
Driven Helix
10 MH Blu/Grn Black 45° (5630513) (7041157) (7041782) (5131446)
1500-3700 10 WH Blu/Grn Black 45° (5000 - 12000) (5630710) (7041157) (7041782) (5131446)
1.7
1
GENERAL INFORMATION MODEL: 2008 RANGER 4X4 EFI
Drivetrain
MODEL NUMBER: R08RH50AF, AR, AT ENGINE MODEL: EH50PLE Engine Platform
Fuji Single Cylinder, 4-Stroke, SOHC, Liquid Cooled
Engine Model Number
EH500PLE224
Engine Displacement
499 cc
Number of Cylinders
1
Bore & Stroke (mm)
92 x 75 mm
Compression Ratio
10.2:1
Compression Pressure
70-90 psi
Engine Idle Speed
1200 ± 200 RPM
Valve Clearance Int./Ext.
0.006 in. (0.152 mm)
Transmission Type
Polaris Automatic PVT
Transmission Gear Ratio: Front / Rear High Low Reverse
4.43:1 / 3.83:1 10.08:1 / 8.71:1 6.87:1 / 5.94:1
Final Drive Ratio
3.70:1
Drive Ratio - Front
3.818:1
Shift Type
In Line Shift - H / L / N / R
Front Gearcase Oil Requirements
Polaris Demand Drive LT Premium Fluid 5 oz. (150 ml)
Transmission Oil Requirements
Polaris Synthetic AGL 15.2 oz. (450 ml)
Rear Gearcase Oil Requirements
Polaris Premium ADF 18 oz. (532 ml)
Engine Hot Light
Dash Light
Lubrication
Pressurized Dry Sump
Oil Requirements
0W-40
Belt
3211077
Oil Capacity
2 qts. (1.9 L)
Drive Belt Deflection
1.125 in. (28.58 mm)
Coolant Capacity
3.25 qts. (3.08 L)
Center Distance
10 in. (254 mm)
Single Pipe / Canister Style
Clutch Offset
0.5 in. (12.7 mm)
Exhaust System
Steering / Suspension
Fuel System
Front Suspension
MacPherson Strut
Fuel System Type
Visteon Electronic Fuel Injection
Fuel Delivery
Electronic Fuel Pump (in tank)
Front Travel
8 in. (20.3 cm)
Fuel Pressure
39 psi
Rear Suspension
Independent Rear Suspension
Fuel Filters
30 micron (in tank)
Rear Travel
9 in. (22.9 cm)
9 gal. (34 L) 87 Octane (minimum)
Rear Shock Preload Adjustment
Cam Adjustment
Toe Out
1/8 - 1/4 in. (3.2 - 6.35 mm)
Fuel Capacity / Requirement
Wheels / Brakes
Electrical 500 watts @ 3000 RPM
Front Wheel Size
12 x 6 / 10 gauge
Lights : Main Headlights
2 - Single Beam 50w / Halogen
Rear Wheel Size
12 x 8 / 10 gauge
Tail
2 - 5 watts
Titan / AT489 / 25x10-12
Brake
2 - 5 watts
Front Tire Make / Model / Size
Indicator Panel Lights
1 watt (ea.)
Rear Tire Make / Model / Size
Titan / AT489 / 25x11-12
Tire Air Pressure - Front / Rear
8 - 12 psi
Alternator Max Output
Starting System
Electric Start
Ignition System
Visteon EFI (ECU Controlled)
Ignition Timing
10° ± 1° BTDC @ 1150 RPM
Spark plug / Gap
NGK BKR5E / .035 in. (0.9 mm)
Battery / Model / Amp Hr
Yuasa YB30L-B Conventional / 30 Amp Hr. / 12 Volt
Instrument Panel Type
Indicator Lights / Hour Meter
DC Outlet
Standard
Relays
Fan / ECU / Ignition Coil & Fuel Pump
1.8
Circuit Breakers
Fan Motor: 10 Amp
Fuses
Main Chassis: 20 Amp Accessory: 20 Amp ECU Relay: 15 Amp ECU Relay: 5 or 6 Amp
Brakes - Front / Rear
4 Wheel Hydraulic Disc
Parking Brake
Hand Actuated (in dash)
Brake Fluid
DOT 4
CLUTCH CHART Altitude
Meters (Feet)
0-1500 (0-5000)
Shift Weight
Drive Spring
Driven Spring
Driven Helix
10 MH Blu/Grn Black 45° (5630513) (7041157) (7041782) (5131446)
1500-3700 10 WH Blu/Grn Black 45° (5000 - 12000) (5630710) (7041157) (7041782) (5131446)
GENERAL INFORMATION VEHICLE INFORMATION
1
Publication Numbers Model
Model No.
Owner’s Manual PN
Parts Manual PN
2008 RANGER 2x4
R08RB50AA
9921264
9921265
2008 RANGER 4x4 EFI
R08RH50AF, AR, AT
9921272
9921273
NOTE: When ordering service parts be sure to use the correct parts manual. NOTE: Polaris factory publications can be found at www.polarisindustries.com or purchased from www.purepolaris.com.
Paint Codes Painted Part
Color Description
Polaris Number
Frame / Cab
Medium Gloss Black
P-067
RANGER 2x4, 4x4 EFI - Plastic - Hood / Dash
Dark Green
P-195
RANGER 4x4 EFI - Plastic - Hood / Dash
Solar Red
P-342
RANGER 4x4 EFI - Plastic - Hood / Dash
Midnight Blue
P-485
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#
Part Number
20
4010278
21
4010278
22
4010321
23
4010321
27
4010321
28
4010321
31
4110141
32
4110148
67
4010278
68
4010278
SPECIAL TOOLS Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, by phone at 1-800-328-6657 or on-line at http://polaris.spx.com/.
1.9
GENERAL INFORMATION MISC. SPECIFICATIONS AND CHARTS Conversion Table
°C to °F: 9/5(°C + 32) = °F
1.10
°F to °C: 5/9(°F - 32) = °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
NOTES
1.14
MAINTENANCE
CHAPTER 2 MAINTENANCE PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 PERIODIC MAINTENANCE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 PRE-RIDE - 25 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 50 - 100 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 100 - 300 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2
GENERAL COMPONENT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 RH SIDE AND DASH VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 LH SIDE AND REAR VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
SERVICE PRODUCTS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 MAINTENANCE REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 POLARIS LUBRICANT SYMBOL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 COMPONENT FLUID TYPE AND USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 COMPONENT LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 (CARB MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14 VENT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14 THROTTLE PEDAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14 THROTTLE FREEPLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15 THROTTLE CABLE ADJUSTMENT (CARB MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . 2.15 CHOKE ADJUSTMENT (CARB MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15 IDLE SPEED ADJUSTMENT (CARB MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16 PILOT SCREW (CARB MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16 PILOT SCREW ADJUSTMENT (CARB MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17 CARBURETOR DRAINING (CARB MODELS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17 AIR INTAKE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18 AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
FUEL SYSTEM (EFI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19 COMPRESSION AND LEAKDOWN TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19 BREATHER FILTER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20 BREATHER HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20 FLYWHEEL HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20 ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20 ENGINE OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 OIL PUMP PRIMING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22 VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23 INTAKE / EXHAUST VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 2.24 EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
TRANSMISSION AND GEARCASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 FRONT GEARCASE LUBRICATION (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26 REAR GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
2.1
MAINTENANCE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29 LIQUID COOLING SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29 COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29 RADIATOR COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29 COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30 COOLING SYSTEM PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30 COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30 COOLANT DRAIN / RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
FINAL DRIVE / WHEEL AND TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31 WHEEL AND HUB TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31 CV SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31 WHEEL REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32 TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32 TIRE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33 BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33 BATTERY FLUID LEVEL (CONVENTIONAL BATTERY) . . . . . . . . . . . . . . . . . . . . . . . 2.33 BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33 BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34 BATTERY STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34 BATTERY CHARGING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34 SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34 ENGINE TO FRAME GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35
STEERING AND SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35 TIE ROD END / STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35 CAMBER AND CASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35 WHEEL TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36 TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36 FRONT SUSPENSION / REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37 REAR SUSPENSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37 REAR SPRING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38
BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38 BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38 BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38 BRAKE PAD / DISC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39 PARKING BRAKE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39 PARKING BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39
2.2
MAINTENANCE PERIODIC MAINTENANCE CHART Periodic Maintenance Overview Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Pure Polaris parts available from your Polaris dealer. NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations. Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently. Severe Use Definition • Frequent immersion in mud, water or sand • Racing or race-style high RPM use • Prolonged low speed, heavy load operation • Extended idle • Short trip cold weather operation Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.
Break-In Period The break-in period consists of the first 25 hours of operation, or the time it takes to use 14 gallons (53 liters) of fuel. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components. • Drive vehicle slowly at first while varying the throttle position. Do not operate at sustained idle. • Pull only light loads. • Perform regular checks on fluid levels and other areas outlined on the daily pre-ride inspection checklist. • Change both the engine oil and filter after 25 hours or one month. • See “Owner’s Manual” for additional break-in information.
Maintenance Chart Key The following symbols denote potential items to be aware of during maintenance: = CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an authorized Polaris dealer.
= SEVERE USE ITEM: See information provided above. E = Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.
WARNING Improperly performing the procedures marked could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.
2.3
2
MAINTENANCE Pre-Ride - 25 Hour Maintenance Interval
Item Steering
Front Suspension Rear Suspension
Maintenance Interval (whichever comes first) Miles Hours Calendar (KM) Pre-Ride -
Remarks
-
Pre-Ride
-
-
Pre-Ride
-
-
Pre-Ride
-
Brake Fluid Level Brake Pedal Travel
-
Pre-Ride
-
-
Pre-Ride
-
Brake Systems Wheels / Fasteners Frame Fasteners
-
Pre-Ride Pre-Ride Pre-Ride
-
Engine Oil Level
-
Pre-Ride
-
Air Filter / Pre-Filter
-
Daily
-
Inspect;clean often
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
-
-
Inspect; adjust tension after first 25 hours
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
Tires
E
E
E
Air Filter, E
Main Element
Brake Pad Wear / Inspect Parking Brake Pads Battery
Parking Brake Cable Adjustment Front Gearcase Oil (if equipped)
Middle Gearcase Oil (if equipped) Rear Gearcase Oil
(if equipped) Transmission Oil Engine Breather
E Filter (if equipped)
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
Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.
2.4
MAINTENANCE 50 - 100 Hour Maintenance Interval
Item
Maintenance Interval (whichever comes first) Miles Hours Calendar (KM)
Remarks
50 H
6M
-
Lubricate all grease fittings, pivots, cables, etc. Inspect, lubricate, adjust
Steering
50 H
6M
-
Lubricate
Front Suspension Rear Suspension
50 H
6M
-
Lubricate
50 H
6M
-
Lubricate
50 H
6M
-
Drain bowl periodically and prior to storage
50 H
6M
-
50 H
6M
-
General Lubrication Shift Linkage
50 H
3M
-
Carburetor Float Bowl (if applicable) Throttle Cable / Throttle Pedal Choke Cable (if applicable) Carburetor / Throttle Body Air Intake Ducts / Flange Drive Belt
50 H
6M
-
Inspect ducts for proper sealing/air leaks
50 H
6M
-
Cooling System
50 H
6M
-
Inspect; adjust; replace as needed Inspect coolant strength seasonally; pressure test system yearly
100 H
-
-
Inspect; adjust tension as needed
Engine Oil Change
100 H
6M
-
Perform a break-in oil change at 25 hours/ one month
Oil Filter Change
100 H
6M
-
Replace with oil change
100 H
12 M
-
Inspect routing, condition
100 H
12 M
-
Inspect; adjust
E E E
Parking Brake Cable Adjustment E E
Oil Tank Vent Hose E (if applicable)
Valve Clearance E
Inspect; adjust; lubricate; replace if necessary Inspect; adjust; lubricate; replace if necessary
Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.
2.5
2
MAINTENANCE 100 - 300 Hour Maintenance Interval
Item
Maintenance Interval (whichever comes first) Miles Hours Calendar (Km)
Remarks
Fuel System E
100 H
12M
-
Check for leaks at tank cap, lines, fuel valve, filter, pump, carburetor, replace lines every two years
Fuel Filter E
100 H
12M
-
Replace yearly
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
-
Inspect
100 H
12M
-
Clutches (Drive and Driven) 100 H Front Wheel Bearings 100 H E Idle Speed (Carb Models) 100 H
12M 12M
-
24M 36M
-
Radiator Cooling Hoses Engine Mounts Exhaust Muffler / Pipe Spark Plug E Ignition Timing E
Wiring
Toe Adjustment
100 H
Brake Fluid Spark Arrestor
200 H 300 H
Auxiliary Brake
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 Adjust as needed Inspect periodically; adjust when parts are replaced Change every two years (DOT 4) Clean out
-
Inspect daily; adjust as needed
-
Adjust as needed
Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.
2.6
MAINTENANCE GENERAL COMPONENT LOCATION RH Side and Dash View
2 Power Distribution Module (PDM)
Front Gearcase (Behind Radiator) Rear Gearcase Gas Tank
(4X4)
Engine (under seat)
Dash Components 8 1. Indicator Lights 2. Gear Shifter 3. Ignition Key 4. Choke 5. 12V accessory 6. Hourmeter 7. AWD / Differential Switch 8. Light Switch 9. Glove Box 1
2
3
7
4
6
5
9
2.7
MAINTENANCE LH Side and Rear View
Battery
Rear Prop Shaft
PVT Cover Front Prop Shaft (4x4) Transmission
Tail Gate Latch
Air Cleaner
Muffler 2" Hitch
2.8
Drive Shafts (2x4, 4x4)
MAINTENANCE SERVICE PRODUCTS AND LUBRICANTS 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)
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) 2872189 DOT 4 Brake Fluid (12 Count) 2871557 Crankcase Sealant, 3-Bond 1215 (5oz.) 2872893 Engine Degreaser (12oz.) (12 Count) NOTE: The number count indicated by each part number in the table above indicates the number of units that are shipped with each order.
2.9
2
MAINTENANCE MAINTENANCE REFERENCES Polaris Lubricant Symbol Identification
Polaris Brake Fluid
Polaris Synthetic Gearcase Lube
Polaris Synthetic OW-40 Oil
Polaris Demand Drive Hub Fluid
Polaris ATV Angle drive Fluid
Polaris All Season Grease
Polaris U-Joint Lube
Engine Lubrication Item 1. 4-Stroke Engine Oil
Lube Rec. Polaris 0W-40 Synthetic (PN 2871281)
Method Add oil to proper level.
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.
RANGER 500
Oil Filter
* More often under severe use, such as operated in water or under severe loads.
2.10
Engine Oil Dipstick
MAINTENANCE Component Fluid Type and Use Item
Lube Rec.
2. Brake Fluid
DOT 4 (PN 2872189)
3. Transmission
Polaris AGL Gearcase Lubricant (PN 2873602)
4. Front Gearcase 5. Rear Gearcase
Premium Demand Drive Hub Fluid (PN 2871654) ATV Angle Drive Fluid (PN 2871653)
Method Fill reservoir between MAX and Min lines.
Frequency* As required. Change fluid every 2 years. Change annually. Change more Add lube to bottom of fill plug often if used in severe threads. conditions. Drain completely. Add lube to Change annually** specified quantity. Drain completely. Add lube to Change annually** specified quantity.
* More often under severe use, such as operated in water or under severe loads. **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
Transmission Fill Plug
Brake Master Cylinder
3. Transmission
2. Brake Master Cylinder
Fill Plug 4. Front Gearcase (4x4)
Fill Plug
5. Rear Gearcase
Drain Plug
2.11
2
MAINTENANCE Component Lubrication Points Item
Lube Rec.
6. Hubsrut Assembly (Both Sides)
Polaris All Season Grease (PN 2871423)
7. Front Prop Shaft Yoke (4x4)
Polaris Premium U-Joint Lube (PN 2871551)
Method Frequency* Locate grease fitting on the underside of the hubstrut Semi-annually*** assembly and grease with grease gun. Locate fittings and grease with Semi-annually*** grease gun.
* 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) Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or Mobilegrease Special
Yoke
6. Front Hubstrut
7. Front Prop Shaft (4x4)
Transmission End Front Hub Strut Assy.
2.12
MAINTENANCE GENERAL VEHICLE INSPECTION AND MAINTENANCE
Shift Linkage Inspection / Adjustment Linkage rod adjustment is necessary when symptoms include: • No All Wheel Drive light
Pre-Ride / Daily Inspection
• Noise on deceleration Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.
2
• Inability to engage a gear • Excessive gear clash (noise)
• Tires - check condition and pressures
• Shift selectors moving out of desired range • Fuel and oil tanks - fill both tanks to their proper level; Do not overfill oil tank • All brakes - check operation and adjustment (includes auxiliary brake)
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.
Inspect shift linkage cable, clevis pins, and pivot bushings and replace if worn or damaged.
• Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners
2.
Be sure idle speed is adjusted properly.
3.
Place gear selector in neutral. Make sure the transmission bell crank is engaged in the neutral position detents.
4.
With two wrenches loosen the outside jam nut counterclockwise. Turn the outside jam nut 1 1/2 turns. Perform this procedure on the shift lever end, also.
• Engine coolant - check for proper level at the recovery bottle • Check all rear suspension components for wear or damage.
Inside Jam Nut
Outside Jam Nut
Frame, Nuts, Bolts, and Fasteners Periodically inspect the torque of all fasteners in accordance with the maintenance schedule. Check that all cotter pins are in place. Refer to specific fastener torques listed in each chapter.
Shift Cable Adjustment 5.
After turning the outside jam nut 1 1/2 turns. Hold the outside jam nut with a wrench and tighten the inside jam nut clockwise, until it is tight against the bracket.
6.
Repeat Step 4 and Step 5 until the proper adjustment is made for the transmission cable.
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