2011 Evinrude E tec 40 50 60 65 75 90 Hp Repair Manual – PDF Download by www.heydownloads.com

GENERAL INFORMATION

CHAPTER 1 GENERAL INFORMATION VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . 1.3

PUBLICATIONS AND REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 MODEL: 2011-2013 RANGER DIESEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 MODEL: 2012-2013 RANGER DIESEL CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7

GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 VEHICLE CONTROLS / GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9

FUEL INFORMATION, USAGE AND RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 FUEL INFORMATION / RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 BIO-DIESEL FUELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 B5 DIESEL FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 BIO-FUEL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 B6 TO B20 BIO-DIESEL FUEL BLEND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 ENGINE WARRANTY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 COLD WEATHER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 BLOCK HEATER USAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11

MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 STANDARD BOLT TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 METRIC BOLT TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14

1.1

GENERAL INFORMATION VEHICLE IDENTIFICATION Model Number Designation Example: R13TH90DG GROUP

MODEL YEAR

CHASSIS

DRIVELINE

1st digit

2/3rd digit

4th digit*

5th digit*

11 12 13

C = Sportsman 6x6 D = Sportsman Tour E = Trail Boss F = Sportsman Youth G = Sport H = RANGER 6x6 J = RZR XP K = Sport Youth M = Sportsman N = Trail Blazer P = Phoenix R = RANGER Midsize S = RZR T = Sportsman X2 /  RANGER Fullsize U = RANGER Fullsize V = RZR W = Multi-pass RGR X = Multi-pass RZR Z = Sportsman XP

A = ATV R = RANGER

ENGINE 6th digit*

7th digit*

Category

Check Digit

Model Year *

Mfg. Location

Vehicle Identifiers

Chassis

Vehicle Descriptors

World Mfg. ID

Individual Serial No.

* Model Year: A = 2010; B = 2011; C = 2012; D = 2013

1.2

GENERAL INFORMATION

Engine Number Designation 3TNM72 - APL........................................................................................3-Cylinder, Liquid Cooled, Diesel, Electric Start

Vehicle and Engine Serial Number Locations Whenever corresponding about a Polaris RANGER utility vehicle, be sure to refer to the vehicle identification number (VIN) and the engine model number and serial number. The VIN can be found stamped on the lower frame rail on the front LH side of the vehicle (see Figure 1-1). The engine model and serial number can be found on a decal applied to the engine cylinder head and stamped on the side of the engine block.(see Figure 1-2).

Figure 1-2

Figure 1-1

Engine Serial Number VIN Number

1.3

GENERAL INFORMATION PUBLICATIONS AND REPLACEMENT KEYS Publication Numbers Model

Model No.

Owner’s Manual PN

Parts Manual PN

2011 RANGER DIESEL

R11TH90DG

9923138

9923139

2012 RANGER DIESEL

R12TH90DG

9923514

9923517

2012 RANGER DIESEL CREW

R12WH90DG

9923514

9923528

2013 RANGER DIESEL

R13TH90DG

9924088

9924095

2013 RANGER DIESEL CREW

R13WH90DG

9924088

9924105

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.

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

4010278

4010321

4110141

4110148

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/.

1.4

GENERAL INFORMATION

GENERAL SPECIFICATIONS MODEL: 2011-2013 RANGER DIESEL MODEL NUMBER: R11TH90DG (2011) R12TH90DG (2012) R13TH90DG (2013) ENGINE MODEL: 3TNM72-APL Category

Dimension / Capacity

Length

114 in. / 289.6 cm

Width (cargo box)

60 in. / 152.4 cm

Width (tires)

58 in. / 147.3 cm

Height

76 in. / 193 cm

Wheel Base

76 in. / 193 cm

Ground Clearance

12 in. / 30.5 cm

Turning Radius

158 in. / 401.3 cm

Dry Weight

1435 lbs. / 690 kg

Cargo Box Capacity

1000 lbs. / 454 kg

Cargo Box Dimensions (inside dimensions)

36.5 x 54 x 11.5 in. (93 x 137 x 29 cm)

Vehicle Payload

1500 lbs. / 680 kg (Includes weight of operator, passenger, cargo and accessories.

Hitch Towing Capacity

2000 lbs. / 907 kg

Hitch Tongue Capacity

150 lbs. / 68 kg

1.5

GENERAL INFORMATION MODEL: 2011-2013 RANGER DIESEL Engine Platform

Yanmar 3-Cylinder, Liquid Cooled, Diesel

Engine Model Number

3TNM72-APL

Engine Displacement

904 cc

Number of Cylinders

Bore & Stroke (mm)

72 x 74 mm

Compression Ratio

23.5 : 1

Compression Pressure

470 ± 15 psi

Engine Idle Speed

1075 ± 50 RPM

Engine Max Operating Speed

3600 RPM

Lubrication

Pressurized Wet Sump

Oil Requirements

Polaris DIESEL Oil

Oil Capacity

1.8 qts. (1.7 L)

Coolant Capacity

6.2 qts. (5.9 L)

Overheat Warning

Instrument Cluster Indicator

Exhaust System

Canister Style

Starting Aid

Glow Plugs / Opt. Block Heater Fuel System

Drivetrain Transmission Type

Polaris Automatic PVT

Shift Type

In Line Shift - H / L / N / R

Front Gearcase Lubricant Requirements

Demand Drive Plus 6.75 oz. (200 ml)

Rear Gearcase Lubricant Requirements

ATV Angle Drive Fluid 22 oz. (650 ml)

Transmission Lubricant Requirements

Polaris AGL plus 32 oz. (946 ml)

Drive Belt

3211135

Steering / Suspension Toe Out

1/8 - 1/4 in. (3.2 - 6.35 mm)

Front Suspension

Dual A-arm

Front Travel

9.6 in. (24.4 cm)

Rear Suspension

Independent (IRS)

Rear Travel

9 in. (22.9 cm)

Shock Preload Adjustment

Cam Adjustment

Wheels / Brakes Front Wheel Size / Type

12 x 6 / Steel

Rear Wheel Size / Type

12 x 8 / Steel

Front Tire Make / Model / Size

AT489 / 25 x 10 R12

Fuel Injection Unit (non-serviceable)

Yanmar MC Fuel Injection Pump

Fuel Transfer System

Electric Fuel Pump (in-line)

Rear Tire Make / Model / Size

AT489 / 25 x 11 R12

Fuel Pump Pressure

1-5 psi

Tire Air Pressure

8-12 psi

Fuel Capacity

9 gal. (34 L)

Brake System Type

4 Wheel Hydraulic Disc

Fuel Requirement

Low Sulfur / Ultra Low Sulfur

Brake Fluid

DOT 4

Parking Brake

Hand Actuated (in dash)

Electrical Alternator Max Output

55A, 742Watts @ 3000 RPM

Main Headlights

50 Watt / Halogen x 2

Tail Lights

0.3 Watts / L.E.D. x 2

Brake Lights

3.1 Watts / L.E.D. x 2

1.6

Starting System

Electric Start

Glow Plugs

Yanmar Quick Type

Battery

Low-Maintenance / Sealed

Instrumentation

Multifunction Speedometer

DC Outlets

(2) - Front

Relays

Chassis / Glow Plug / Fan / Fuel Pump / Differential / Brake Light

Circuit Breaker

Fan Motor: 15 Amp

Fuses

Main: 20 Amp Accessory: 20 Amp Lights: 15 amp Fuel Pump: 30 Amp Glow Plugs: 30 Amp Fuel Pump: 30 Amp Auxiliary Lights: 20 Amp

GENERAL INFORMATION

GENERAL SPECIFICATIONS MODEL: 2012-2013 RANGER DIESEL CREW MODEL NUMBER: R12WH90DG (2012) R13WH90DG (2013) ENGINE MODEL: 3TNM72-APL Category

Dimension / Capacity

Length

145 in. / 386 cm

Width (cargo box)

60 in. / 149.8 cm

Width (tires)

58 in. / 147.3 cm

Height

76 in. / 193 cm

Wheel Base

108 in. / 274 cm

Ground Clearance

11.5 in / 29 cm

Turning Radius

255 in. / 648 cm

Dry Weight

1685 lbs. / 764.3 kg

Cargo Box Capacity CREW

1000 lbs. / 454 kg

Cargo Box Dimensions (inside dimensions)

36.5 x 54 x 11.5 in. (93 x 137 x 29 cm)

Vehicle Payload

1750 lbs. / 794 kg (Includes weight of operator, passenger, cargo and accessories.

Hitch Towing Capacity

2000 lbs. / 907 kg

Hitch Tongue Capacity

150 lbs. / 68 kg

1.7

GENERAL INFORMATION MODEL: 2012-2013 RANGER DIESEL CREW Drivetrain Engine Platform

Yanmar 3-Cylinder, Liquid Cooled, Diesel

Engine Model Number

3TNM72-APL

Engine Displacement

904 cc

Number of Cylinders

Bore & Stroke (mm)

72 x 74 mm

Compression Ratio

23.5:1

Compression Pressure

470 ± 15 psi

Engine Idle Speed

1075 ± 50 RPM

Engine Max Operating Speed

3600 RPM

Lubrication

Pressurized Wet Sump

Oil Requirements

Polaris DIESEL Oil

Oil Capacity

1.8 qts. (1.7 L)

Coolant Capacity

6.64 Qts (6.28 L)

Overheat Warning

Instrument Cluster Indicator

Exhaust System

Canister Style

Starting Aid

Glow Plugs / Opt. Block Heater Fuel System

Fuel Injection Unit (non-serviceable)

Yanmar MC Fuel Injection Pump

Fuel Transfer System

Electric Fuel Pump (in-line)

Fuel Pump Pressure

1-5 psi

Fuel Capacity

9 gal. (34 L)

Fuel Requirement

Low Sulfur or Ultra Low Sulfur Electrical

Polaris Automatic PVT

Shift Type

In Line Shift - H / L / N / R

Front Gearcase Lubricant Requirements

Demand Drive Plus 6.75 oz. (200 ml)

Rear Gearcase Lubricant Requirements

ATV Angle Drive Fluid 22 oz. (650 ml)

Transmission Lubricant Requirements

Full Synthetic Transmission Fluid 32 oz. (946 ml)

Drive Belt

3211135

Steering / Suspension Toe Out

1/8 - 1/4 in. (3.2 - 6.35 mm)

Front Suspension

Dual A-arm

Front Travel

9.6 in. (24.4 cm)

Rear Suspension

Independent (IRS)

Rear Travel

9 in. (22.9 cm)

Shock Preload Adjustment

Cam Adjustment

Wheels / Brakes Front Wheel Size / Type

12 x 6 / Steel

Rear Wheel Size / Type

12 x 8 / Steel

Front Tire Make / Model / Size

Carlisle / PXT / 26 x 9 R12

Rear Tire Make / Model / Size

Carlisle / PXT / 26 x 11 R12

Tire Air Pressure

Front: 12 PSI (83 kPa) Rear: 16 PSI (110 kPa)

Brake System Type

4 Wheel Hydraulic Disc

55A, 742 Watts, @ 3000 RPM

Brake Fluid

DOT 4

Main Headlights

50 Watt / Halogen x 2

Parking Brake

Hand Actuated (in dash)

Tail Lights

0.3 Watts / L.E.D. x 2

Alternator Max Output

1.8

Transmission Type

Brake Lights

3.1 Watts / L.E.D. x 2

Starting System

Electric Start

Glow Plugs

Yanmar Quick Type

Battery

Low-Maintenance / Sealed

Instrumentation

Multifunction Speedometer

DC Outlets

2 front / 1 rear

Relays

Chassis/ Glow Plug / Fan / Fuel Pump / Differential/ Brake Light

Circuit Breaker

Fan Motor: 15 Amp

Fuses

Main: 20 Amp Accessory: 20 Amp Lights: 15 amp Fuel Pump: 30 Amp Glow Plugs: 30 Amp Fuel Pump: 30 Amp Auxiliary Lights: 20 Amp

GENERAL INFORMATION

GENERAL SPECIFICATIONS Vehicle Controls / Gauges Parking Brake Lever

Gear selector (shifter)

Switches & Indicator lights Speedometer / MFD

12V Outlets

Low Oil Pressure Indicator

Ignition Switch

Wait-to-start (Glow plug) Indicator

Head lamp Switch

Speedometer

MFD

Ignition Switch Off / On / Start

Mode Button

1.9

GENERAL INFORMATION FUEL INFORMATION, USAGE AND RECOMMENDATIONS Fuel Information / Recommendations CAUTION

• Ash content must not exceed 0.01% by volume. • Carbon residue content must not exceed 0.35% by volume. Less than 0.1% is preferred. • Total aromatics content should not exceed 35% by volume. Less than 30% is preferred. • PAH (poly cyclic aromatic hydrocarbons) content should be below 10% by volume.

NEVER use an engine starting aid such as ether. Engine damage will result. NOTE: For the best engine performance, to prevent engine damage and to comply with EPA/ARB warranty requirements, use ONLY the recommended diesel fuels. Use only CLEAN low sulfur or ultra low sulfur #2 or #1 Diesel fuel. Diesel fuel should comply with the following specifications. The table lists several worldwide specifications for diesel fuels:

DIESEL FUEL SPECIFICATION

LOCATION

ASTM D975 No. 1D S15, S500 No. 2D S15, S500

USA

EN590:96

European Union

ISO 8217 DMX

International

BS 2869-A1 or A2

United Kingdom

JIS K2204 Grade No. 2

Japan

KSM-2610

Korea

GB252

China

Additional Technical Fuel Requirements • The fuel cetane number should be equal to 45 or higher. • The sulfur content must not exceed 0.5% by volume. Less than 0.5% is preferred. Especially in the U.S.A. and Canada, Low Sulfur (300 to 500 ppm (mg/kg) or Ultra Low Sulfur fuel should be used.

• Metal content of Na, Mg, Si and Al should be equal to or lower than 1 mass ppm (test analysis method JPI-5S-44-95). • Lubricity: Wear mark of WS1.4 should be Max. 0.018 in. (.457 mm) at HFRR test.

Bio-Diesel Fuels NOTE: Never use bio-diesel blended fuel containing more than 5% bio-diesel in this vehicle. In Europe and in the United States, as well as some other countries, non-mineral oil based fuel resources such as RME (Rapeseed Methyl Ester) and SOME (Soybean Methyl Ester), collectively known as FAME (Fatty Acid Methyl Esters), are being used as extenders for mineral oil derived diesel fuels. YANMAR approves the use of bio-diesel fuels that do not exceed a blend of 5% (by volume) of FAME with 95% (by volume) of approved mineral oil derived diesel fuel. Such bio-diesel fuels are known in the marketplace as B5 diesel fuels.

B5 Diesel Fuel Requirements 1. The bio-fuels must meet the minimum specifications for the country in which they are used. • In Europe, bio-diesel fuels must comply with the European Standard EN14214 • In the United States, bio-diesel fuels must comply with the American Standard ASTMD-6751.2 2. Bio-fuels should be purchased only from recognized and authorized diesel fuel suppliers.

• NEVER mix kerosene, used engine oil or residual fuels with the diesel fuel. • Water and sediment in the fuel should not exceed 0.05% by volume. • Keep the fuel tank and fuel-handling equipment clean at all times. • Poor quality fuel can reduce engine performance and/or cause engine damage. • Fuel additives are not recommended. Some fuel additives may cause poor engine performance.

1.10

GENERAL INFORMATION

Bio-Fuel Precautions

Engine Warranty

1. Free methanol in FAME may result in corrosion of aluminum and zinc FIE components.

Damages, performance or service concerns determined to be caused by the use of bio-diesel fuel not meeting the specifications outlined above are not considered to be defects in material or factory workmanship and are not covered under warranty. The same applies to damages or other concerns induced by not complying with the recommended operating conditions of YANMAR engines with bio-diesel fuel.

2. Free water in FAME may result in plugging of fuel filters and increased bacterial growth. 3. High viscosity at low temperatures may result in fuel delivery problems, injection pump seizures, and poor injection nozzle spray atomization. 4. FAME may have adverse effects on some elastomers (seal materials) and may result in fuel leakage and dilution of the engine lubricating oil. 5. Even bio-diesel fuels that comply with a suitable standard as delivered, will require additional care and attention to maintain the quality of the fuel in the equipment or other fuel tanks. It is important to maintain a supply of clean, fresh fuel. Regular flushing of the fuel system, and/or fuel storage containers, may be necessary. 6. The use of bio-diesel fuels that do not comply with the standards as agreed to by the diesel engine manufacturers and the diesel fuel injection equipment manufacturers, or bio-diesel fuels that have degraded as per the precautions and concerns above, may affect the warranty coverage of your engine.

B6 to B20 Bio-Diesel Fuel Blend B6 to B20 bio-diesel is not approved for this POLARIS application. Approved Engines

Cold Weather Operation Cold weather operation can result in fuel gelling if the incorrect fuel type is used. Use the fuel blending guideline table below to prevent this from occurring.

Block Heater Usage If this vehicle will be operated when temperatures are in the +30° to -25° F. (-1° to -32° C) range, a block heater must be installed. Please see your dealer to purchase a block heater kit. NOTE: A block heater kit is recommended for use below 30 degrees F.

Cold Weather Fuel Usage Table: Temperature

NO. 2 Diesel NO. 1 Diesel

Above 15° F (9° C)

100%

Down to -20° F (-29° C)

50%

Below -20° F (-29° C)

100%

Only the YANMAR TNM engine series 3TNM72 may operate with bio-diesel fuel concentrations up to B5 for POLARIS applications. Approved Fuel IMPORTANT: Raw pressed vegetable oils are not considered bio-diesel, and are unacceptable for use as fuel in any concentration in YANMAR engines. Bio-diesel fuel blends up to B5 must comply with the following standards: • EN14214 (European standard) and/or ASTM D6751 (American standard) • All applicable engines may operate with bio-diesel fuel up to a maximum B5 (5% bio-diesel blend) concentration

1.11

GENERAL INFORMATION MISC. SPECIFICATIONS AND CHARTS Conversion Table

°C to °F: 9/5(°C + 32) = °F

1.12

°F to °C: 5/9(°F - 32) = °C

GENERAL INFORMATION

Standard Bolt Torque Specification

Grade 2

Grade 8

Grade 5

Bolt Size 1/4-20

Grade 2 ft-lbs (Nm)

Grade 5 ft-lbs (Nm)

Grade 8 ft-lbs (Nm)

5 (7)

8 (11)

12 (16)

1/4-28

6 (8)

10 (14)

14 (19)

5/16-18

11 (15)

17 (23)

25 (35)

5/16-24

12 (16)

19 (26)

29 (40)

3/8-16

20 (27)

30 (40)

45 (62)

3/8-24

23 (32)

35 (48)

50 (69)

7/16-14

30 (40)

50 (69)

70 (97)

7/16-20

35 (48)

55 (76)

80 (110)

1/2-13

50 (69)

75 (104)

110 (152)

1/2-20

55 (76)

90 (124)

120 (166)

Metric Bolt Torque Specification

GRADE

Bolt Size

4.6

4.8

8.8/8.9 FT-LBS

.3/.5

.5/.7

10.9

12.9

1.5/2

/ NM (DRY THREADS) 1/1.3

.8/1.1

1/1.5

2/3

3/4.5

4/5

1.5/2.5

2/3

4.5/6

6.5/9

7.5/10

3/4

4/5.5

7.5/10

11/15

13/18

7/9.5

10/13

18/25

26/35

33/45

M10

14/19

18/25

37/50

55/75

63/85

M12

26/35

33/45

63/85

97/130

110/150

M14

37/50

55/75

103/140

151/205

177/240

M16

59/80

85/115

159/215

232/315

273/370

M18

81/110

118/160

225/305

321/435

376/510

1.13

GENERAL INFORMATION SAE Tap / Drill Sizes

Decimal Equivalents

Metric Tap / Drill Sizes

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 - 50 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 50 - 100 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 100 - 300 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 GREASE LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

SERVICE PRODUCTS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 FLUID MAINTENANCE REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 COMPONENT QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 COMPONENT QUICK REFERENCE, CONTINUED...... . . . . . . . . . . . . . . . . . . . . . . . . . 2.9

GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 2.10 PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 SHIFT CABLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10 SHIFT CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10

FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 VENT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 THROTTLE PEDAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 THROTTLE FREEPLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12 ENGINE AIR INTAKE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 PVT AIR INTAKE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14 AIR INTAKE EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15

FUEL FILTER / WATER SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16 GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16 FUEL FILTER / WATER SEPARATOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16 FUEL FILTER / WATER SEPARATOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 2.16

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17 COMPRESSION AND LEAKDOWN TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17 ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18 ENGINE OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18 EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20

TRANSMISSION AND GEARCASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 FRONT GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22 REAR GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 LIQUID COOLING SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26 COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26 RADIATOR INSPECTION / CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27 RADIATOR REMOVAL (2011) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27 RADIATOR REMOVAL (2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

2.1

MAINTENANCE FINAL DRIVE / WHEEL AND TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31 WHEEL AND HUB TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31 CV SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31 WHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32 WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32 TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32 TIRE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32

ELECTRICAL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33 BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33 BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33 BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34 BATTERY STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34 BATTERY CHARGING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34 ENGINE GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35 STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35 TIE ROD END / STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35 WHEEL TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35 TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36

SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37 SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37 SPRING PRE-LOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37 SHOCK POSITION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37

BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38 BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38 BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38 BRAKE PAD / DISC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38 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 • Frequent or prolonged operation in dusty environments • 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 50 hours of operation. 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 50 hours. • See “Owner’s Manual” for additional break-in information.

Maintenance Chart Key The following symbols denote potential items to be aware of during maintenance:  = CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an authorized Polaris dealer. = SEVERE USE ITEM: See information provided above. E = Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.

WARNING Improperly performing the procedures marked < could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.

2.3

MAINTENANCE Pre-Ride - 25 Hour Maintenance Interval Make adjustments / changes as needed. See Pre-Ride Checklist on Page 2.10. Maintenance Interval (whichever comes first)

Item Hours

Calendar

Miles (KM)

 Steering

Pre-Ride

 Front Suspension

Pre-Ride

 Rear Suspension

Pre-Ride

 Brake Pedal Travel

Pre-Ride

 Brake System and Fluid

Pre-Ride

Wheels / Fasteners

Pre-Ride

Frame Fasteners

Pre-Ride

Tires

 Engine Oil Level E

Remarks

Make adjustments / changes as needed.  See Pre-Ride Checklist on Page 2.10.

 Fuel Filter / Water Separator E

Pre-Ride

Fuel filter / water separator should be drained every 50 hours (normal conditions with quality fuel) OR drained daily (severe conditions / poor fuel quality). Fuel filter / water separator should be replaced every 150 hours OR 12 months OR 2000 miles (3200KM). WHICHEVER COMES FIRST.

Air Filter / Pre-Filter  (Located Behind LF E Headlamp)

Daily

Inspect;clean often

 Air Box Sediment Tube E

Daily

Drain deposits when visible

Coolant Level

Daily

Check level daily, change coolant every 2 years

Head Lamp / Tail Lamp

Daily

Check operation; apply dielectric grease if replacing

Weekly

Inspect; replace as needed or replace every 150 hours.

10 H

100 (160)

Inspect periodically

20 H

200 (320)

Check terminals; clean; test

 Parking Brake Cable  Adjustment

25 H

 Front Gearcase Fluid

25 H

250 (400)

Initial fluid level inspection

25 H

250 (400)

Initial fluid level inspection

25 H

250 (400)

Initial fluid level inspection

 Air Filter, E Main Element  Brake Pad Wear / Inspect  Parking Brake Pads Battery



Mid Gearcase Fluid (if equipped)

 Transmission Fluid

Inspect; adjust tension after first 25 hours

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 Maintenance Interval (whichever comes first)

Item

 Engine Oil Change  E (Break-In Period)

Hours

Calendar

Miles (KM)

50 H

Remarks

Perform a break-in oil and filter change

 Separator

50H

300 (480)

 General Lubrication

50 H

500 (800)

Lubricate all grease fittings, pivots, cables, etc.

50 H

500 (800)

Inspect, lubricate, adjust

 Steering

50 H

500 (800)

Lubricate (if applicable)

 Front Suspension  Rear Suspension

50 H

500 (800)

Lubricate (if applicable)

50 H

500 (800)

Lubricate (if applicable)

 Throttle Cable / Throttle E Pedal

50 H

500 (800)

Inspect; adjust; lubricate; replace if necessary

Throttle Body Air Intake Ducts / Flange

50 H

500 (800)

Inspect ducts for proper sealing/air leaks

Drive Belt

50 H

500 (800)

Inspect; adjust; replace as needed Inspect coolant strength seasonally; pressure test system yearly

Fuel Filter / Water

Shift Linkage

Cooling System

50 H

500 (800)

100 H

1000 (1600)

Inspect; adjust tension as needed

 Engine Oil Change

100 H

1000 (1600)

Perform a break-in oil change at 50 hours or after one month of operation.

 Oil Filter Change

100 H

1000 (1600)

Replace during engine oil change

 Front Gearcase Fluid

100 H

12 M

1000 (1600)

Change fluid

100 H

12 M

1000 (1600)

Change fluid

100 H

12 M

1000 (1600)

Change fluid

24 M

 Parking Brake Cable  Adjustment E E

Mid Gearcase Fluid

 (if equipped)  Transmission Fluid  Fuel System E

Replace fuel lines every 2 years.

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

MAINTENANCE 100 - 300 Hour Maintenance Interval Maintenance Interval (whichever comes first)

Item

Remarks

Hours

Calendar

Miles (Km)

 Fuel System E

100 H

12 M

1000 (1600)

Check for leaks at tank cap, fuel lines, fuel pump, and fuel rail.  Replace lines every two years.

 Radiator  Cooling Hoses  Engine Mounts

100 H

12 M

1000 (1600)

Inspect; clean external surfaces

100 H

12 M

1000 (1600)

Inspect for leaks

100 H

12 M

1000 (1600)

Inspect

100 H

12 M

1000 (1600)

Inspect

Exhaust Silencer / Pipe

Inspect; replace as needed. See chapter 11 for maintenance interval.

 Alternator Belt

 Wiring

100 H

12 M

1000 (1600)

Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.

 Clutches   (Drive and Driven)

100 H

12 M

1000 (1600)

Inspect; clean; replace worn parts

 Front Wheel Bearings

100 H

12 M

1000 (1600)

Inspect; replace as needed Fuel filter / water separator should be drained every 50 hours (normal conditions with quality fuel) OR drained daily severe conditions / poor fuel quality). Fuel filter / water separator should be replaced every 150 hours OR 12 months OR 2000 miles (3200KM). WHICHEVER COMES FIRST.

 Fuel/Water Separator 

150 H

12 M

2000 (3200)

 Air Filter

150 H

12 M

 Brake Fluid

200 H

24 M

2000 (3200)

Change every two years (DOT 4)

300 H

36 M

3000 (4800)

Clean out

Spark Arrestor  Toe Adjustment Headlight Aim

Replace air filter. Inspect / replace more often if vehicle is subject to severe use.

Inspect periodically; adjust when parts are replaced

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.

Grease Lubrication Points There is a grease fitting on the front propshaft yoke. Item Front Propshaft Yoke

2.6

Recommended Lube

Method

Grease fittings Polaris Premium U-Joint Grease (3 pumps maximum)

Frequency Grease before long periods of storage, and after pressure washing or submerging the vehicle.

MAINTENANCE SERVICE PRODUCTS AND LUBRICANTS Polaris Lubricants, Maintenance and Service Products Part No.

Description

NOTE: Each item can be purchased separately at your local Polaris dealer. Part No.

Description Additives / Sealants / Thread Locking Agents / Misc.

Engine Lubricant 2878473

Diesel 15w40 Engine Oil (Quart)

2878471

15w40 Oil Change Kit - Summer

2871950

Loctite™ Threadlock 242  (6 ml.) (12 count)

2878474

Diesel 10w30 Engine Oil (Quart)

2872189

DOT 4 Brake Fluid (12 count)

2878472

10w30 Oil Change Kit - Winter

2871557

Crankcase Sealant, 3-Bond 1215 (5 oz.)

Gearcase / Transmission Lubricants

NOTE: The number count indicated by each part number indicates the minimum order quantity.

2877922

Demand Drive Plus  (Quart)

2877923

Demand Drive Plus  (2.5 Gallon)

SPECIAL TOOLS

2878068

AGL plus Synthetic Gearcase Lube (Quart)

SPX Corp: 1-800-328-6657 or http://polaris.spx.com

2878069

AGL plus Synthetic Gearcase Lube  (Gallon)

2876160

ATV Angle Drive Fluid (Quart) (12 count)

2872276

ATV Angle Drive Fluid  (2.5 Gallon) (2 Count)

2870465

Oil Pump for 1 Gallon Jug Grease / Specialized Lubricants

2871322

Premium All Season Grease  (3 oz. cartridge) (24 Count)

2871423

Premium All Season Grease  (14 oz. cartridge) (10 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)

2.7

MAINTENANCE FLUID MAINTENANCE REFERENCES Component Quick Reference III. #

Item

Lube Rec.

Method

Frequency*

Engine Oil

Polaris Diesel Engine Oil

Add oil to proper level on dipstick

Change after 1st month or first 50 hours of operation, 100 hours thereafter.

Engine Coolant

Polaris 60/40 Coolant

Maintain coolant level in coolant reservoir bottle.

Check level daily, change coolant every 2 years

Brake Fluid

Maintain fluid level between Polaris DOT 4 Brake Fluid “MAX and “MIN” lines on the master cylinder reservoir

Check level during pre-ride inspection; change fluid every two years

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

1. Engine Oil

2. Brake Fluid

(Under seat base)

(Front LH wheel well)

Reservoir

Dip stick location

Master cylinder

3. Engine Coolant* Recovery bottle

*Open front hood to add coolant

MAX MIN

View level through front RH wheel well

2.8

Radiator cap

MAINTENANCE Component Quick Reference (continued) III. #

Item

Lube Rec.

Method

Frequency*

Add lubricant until it is visible at the fill hole threads

Initial fluid level inspection at 25 hours; change fluid yearly

Front Gearcase Polaris Demand Drive Plus

Rear Gearcase

Polaris ATV Angle Drive Fluid (ADF)

Add lubricant until it is visible at the fill hole threads

Initial fluid level inspection at 25 hours; change fluid yearly

Transmission

Add lubricant until it is visible Polaris Full Synthetic Gearcase Lubricant (AGL) at the fill hole threads

Initial fluid level inspection at 25 hours; change fluid yearly

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

4. Front Gearcase

6. Transmission

(Front of vehicle)

(Rear of vehicle)

Check / Fill plug

5. Rear Gearcase (Rear of vehicle) Check / Fill plug Drain plug

Check / Fill plug

2.9

MAINTENANCE GENERAL VEHICLE INSPECTION AND MAINTENANCE

Inspect shift cable, clevis pins, and pivot bushings and replace if worn or damaged.

Shift Cable Adjustment

Pre-Ride / Daily Inspection Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance. • Tires - check condition and pressures • Fuel tank - fill tank to proper level • All brakes - check operation, fluid level and adjustment (includes parking brake)

NOTE: The shift cable should be adjusted at the rear adjustment point located near the transmission. If adjustment is needed beyond that, remove the dash panel to access the shift cable adjustment point located underneath the shift lever. 1. Place gear selector in neutral. Make sure the transmission bell crank is engaged in the neutral position detents.

• Throttle - check for free operation and closing • Headlight/Taillight/Brakelight - check operation of all indicator lights, instrument cluster and switches

Adjustment Point

• Ignition switch - check for proper function • Wheels - check for tightness of wheel nuts and axle nuts; check to be sure axle nuts are secured by cotter pins • Air cleaner element - check for dirt; clean or replace • Steering - check for free operation noting any unusual looseness in any area • Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners • Engine coolant - check for proper level at the recovery bottle • Check all suspension components for wear or damage

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.

2. Locate the shift cable adjustment point at the engineto-transmission mount bracket. 3. With two open-end wrenches, loosen the outside jam nut counterclockwise. Turn the outside jam nut 1 1/2 turns. 4. 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. 5. Repeat Step 3 and Step 4 until the proper adjustment is made to the shift cable. 6. Use this procedure to loosen or tighten the shift linkage cable as needed.

Shift Cable Inspection Shift cable adjustment is necessary when symptoms include: • Noise on deceleration • Inability to engage a gear • Excessive gear clash (noise) • Gear selector is moving out of desired range

2.10

MAINTENANCE FUEL SYSTEM AND AIR INTAKE

Vent Lines

Fuel System

1. Check fuel tank vent lines for signs of wear, deterioration, damage or leakage. Replace every two years.

WARNING • Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel outdoors or in a well-ventilated area. • Always turn off the engine before refueling. • Do not overfill the tank. Do not fill the tank neck. • Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. • If gasoline spills 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 cause loss of consciousness or death in a short time. • 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.

2. Be sure vent line is routed properly and secured with cable ties.

CAUTION Make sure vent line is not kinked or pinched.

Throttle Pedal Inspection If the throttle pedal has excessive play due to cable stretch or cable misadjustment, it will cause a delay in throttle speed and the throttle may not open fully. If the throttle pedal has no play, it 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.

Throttle Freeplay Adjustment Inspection 1. Apply the parking brake. 2. Put the gear shift lever in the N (Neutral) position. 3. Start the engine, and warm it up thoroughly. 4. Measure the distance the throttle pedal moves before the engine begins to pick up speed. Free play should be 1/16” - 1/8” (1.5 - 3 mm).

Fuel Lines 1. Check fuel lines for signs of wear, deterioration, damage or leakage. Replace if necessary. Be sure fuel lines are routed properly.

CAUTION Make sure lines are not kinked or pinched. 2. Replace all fuel lines every two years.

2.11

MAINTENANCE Adjustment

Air Filter Service

1. Remove the seat. 2. Locate the throttle cable adjuster on RH side of engine.

It is recommended the air filter be replaced every 150 hrs. When riding in extremely dusty or wet conditions, or at wide open throttle for extended periods, replacement is required more often.

3. Squeeze the end of the rubber boot and slide it far enough to expose the end of the inline cable adjuster.

The filter should be inspected before each ride, using the following procedure. Removal 1. Lift the rear cargo box to access the airbox cover.

Boot

Lock Nut

Adjuster

4. Loosen the adjuster lock nut. 5. Rotate the boot to turn the adjuster until 1/16” to 1/8” (1.5 - 3 mm) of freeplay is achieved at the throttle pedal. NOTE: While adjusting, lightly flip the throttle pedal in and out. 6. Tighten the lock nut. 7. Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position. 8. Start the engine. 9. Disengage the parking brake and field test unit to ensure proper throttle operation.

Airbox Cover

2. Unhook the 4 clips from airbox cover and remove cover. Inspect the cover seal. It should adhere tightly to the cover. 3. Remove the air filter assembly by using a pulling/ twisting motion. Be sure not to damage the filter element. 4. Inspect the air filter and replace if necessary. IMPORTANT: If the filter has been soaked with fuel or oil it must be replaced. Do not attempt to wash the air filter. If cleaning is required, replace the filter. Cover Seal

Airbox

Filter

2.12

Clips

MAINTENANCE Installation

Engine Air Intake Inspection

5. Clean airbox of any oil or water deposits and apply a small amount of grease to the sealing surfaces of the filter.

1. Open the hood to access the engine intake air baffle box (A).

Plastic Ring

2. 2011-2012 models only: Remove headlight bulb from RH front headlamp assembly (B). 3. Loosen hose clamp (C) and remove hose from intake baffle box. 4. Remove intake baffle box from the vehicle. 2013

. Polaris All Purpose Grease to Apply inner sealing area.

2011-2012

B A

Be sure tab and notch are in alignment

6. Reinstall the air filter into the airbox container. Be sure the filter fits tightly in the air box and engage the 4 clips onto the airbox.

C 5. Remove the filter element from the baffle box. Be careful not to damage / cut the foam. 6. If the filter element is dirty, clean it with a high flash point solvent, followed by hot soapy water. Rinse and dry the filter element thoroughly. Inspect element for tears or damage. Replace if necessary. 7. Reinstall the filter element into the air baffle box. 8. Reinstall the baffle box, hose clamp and headlamp bulb.

2.13

MAINTENANCE PVT Air Intake Inspection 1. Lift the cargo box to access the PVT air intake baffle box. 2. Remove the filter element (A) from the baffle box.

3. If the filter element is dirty, clean it with a high flash point solvent, followed by hot soapy water. Rinse and dry the filter element thoroughly. Inspect element for tears or damage. Replace if necessary. 4. Reinstall the filter element into the air baffle box.

2.14

MAINTENANCE Air Intake Exploded View

Airbox

Clamp

Filter

Engine Air Intake Baffling Box (front) 2011-2012 2013

Hose (lower)

To Engine Intake

Clamp

Filter

Hose (front)

PVT Intake Seal

Engine Intake Duct

Clamp

CREW Models

PVT Air Intake Baffling Box

Clamp

(located behind front seat)

To PVT PVT Intake Hose

2.15

MAINTENANCE FUEL FILTER / WATER SEPARATOR General Information The fuel filter / water separator assembly is located under the seat on the RH side of the vehicle, in-between the engine and the fuel tank. The filter should be:

5. Reach under the fuel filter and unscrew the black drain valve until fuel starts to drain out of the bottom of the valve. (1/2 to 1 turn) Do not unscrew the drain valve completely. The drain valve has standard rotation threads. Fuel filter drain valve as viewed from under filter. Tighten Valve

• Inspected daily. • Drained every 50 hours (normal conditions with quality fuel) OR drained daily (severe conditions / poor fuel quality). • Replaced every 150 hours OR 12 months OR 2000 miles (3200KM). WHICHEVER COMES FIRST.

Fuel Filter / Water Separator Draining

Loosen Valve

1. See chapter 4 of this manual for safety information. 2. Be sure engine is cool and the battery is disconnected. 3. Remove seat.

Fuel Drain 6. Wait for fuel and water to stop draining from the valve and firmly retighten valve hand tight only. 7. Clean up any excess fuel properly.

4. Place container / drain pan / shop towels under fuel filter area to catch any excess fuel.

8. Reconnect battery. 9. Turn key switch ON for 10-15 seconds. 10. Start engine and verify that no fuel leaks are present. 11. Dispose of shop towels and drained fuel properly.

Fuel Filter

Fuel Filter / Water Separator Replacement 1. Follow Steps 1-7 from the “Fuel Filter / Water Separator Draining” Procedure.

Drain Valve

2. Unscrew fuel filter / water separator from the filter mount using a commercially available filter wrench if it is not removable by hand. The filter has standard rotation threads. 3. Properly drain and dispose of fuel filter / water separator. 4. Lightly lubricate the rubber gasket of the new fuel filter / water separator with fresh engine oil. Thread new filter onto the filter mount until the gasket lightly touches the filter housing. Tighten filter 1/2-3/4 of a turn after initial contact of the rubber gasket to the filter mount. Be sure that the drain valve on the bottom of the filter is snug and did not loosen up during filter installation. 5. Clean up any excess fuel properly.

2.16

MAINTENANCE 6. Reconnect battery.

ENGINE

7. Turn key switch ON for 10-15 seconds to prime the fuel system.

Compression and Leakdown Test

8. Start engine and verify that no fuel leaks are present. 9. Dispose of shop towels and drained fuel properly.

NOTE: This engine does NOT have decompression components. Compression readings will vary in proportion to cranking speed during the test. Refer to Yanmar Engine Service Chapter 11 for the proper tools and procedures. A smooth idle generally indicates good compression. Low engine compression is rarely a factor in running 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 the manufacturer's instructions to perform a cylinder leak-down test. Cylinder Compression Standard: 470 Âą 15 PSI Cylinder Leakdown Service Limit 15% (Inspect for cause if test exceeds 15%)

Special Tools PART NUMBER

TOOL DESCRIPTION

PU-50529

Diesel Engine Compression Tester and Adapter

PU-50531

Diesel Oil Pressure Adapter

PU-50530

Diesel Injection Timing Tool

PU-50532

Diesel Fuel Injector Tester

SPX Corp: 1-800-328-6657 or http://polaris.spx.com/

2.17

MAINTENANCE Engine Oil Level This 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: A rising oil level between checks in cool weather driving can indicate contaminants such as fuel or moisture collecting in the crankcase. If the oil level is over the full mark, change the oil immediately.

1. Park machine on a level surface and set the parking brake.

Engine Oil and Filter Change

2. Stop the engine. Allow the oil level to settle for 3 minutes before removing the dipstick.

It is important to use oil viscosities that will work efficiently in the ambient temperature the vehicle will be operated in for extended periods. Please refer to the viscosity chart for proper oil usage.

IMPORTANT: Do not check oil immediately after engine operation.

Oil Viscosity Requirement vs. Temperature

3. Remove the seat base. Remove the dipstick (A) and wipe dry with a clean cloth. A

= Recommended Engine Oil:

4. Reinstall dipstick and ensure it seats completely. NOTE: Make certain the dipstick is inserted all the way into the filler tube to produce consistent oil level readings. 5. Remove dipstick and check that the oil level is in the SAFE range. Add oil as indicated by the level on the dipstick. Do not overfill.



Use only Polaris Diesel oil 15W40 Summer or 10W30 Winter. (CI-4 rated)

2878471 Diesel Oil Change Kit, Summer 15W40 2878472 Diesel Oil Change Kit, Winter 10W30  2878473 Diesel Oil 2 qt. Summer 15W40 2878474 Diesel Oil 2 qt. Winter 10W30

1. Place vehicle on a level surface and allow the engine to run for two to three minutes until warm. Stop engine.

Maintain Oil Level In SAFE Range DO NOT Overfill the Engine

NOTE: Use only Polaris Diesel oil 15W40 Summer or 10W30 Winter.

2.18

MAINTENANCE 2. Clean the area around the drain plug (B) at the bottom of the crankcase. Drain plug is accessible through the skid plate.

8. Place shop towels beneath oil filter (C). Using Oil Filter Wrench (PU-50105), turn the filter counter-clockwise to remove it.

B C

WARNING

Oil Filter Wrench: PU-50105: 2.5â&#x20AC;? (64 mm)

Personal injury can occur when handling used oil. Hot oil can cause burns or skin damage.

9. Using a clean, dry cloth, clean filter sealing surface on crankcase.

3. Place a drain pan beneath the crankcase and remove drain plug.

10. Lubricate gasket area on new oil filter with a film of fresh engine oil. Check to make sure the sealing areas are in good condition.

4. Allow oil to drain completely.

11. Install new filter and turn to specification.

5. Clean sealing area of drain plug and oil pan. NOTE: The sealing surface on the drain plug should be clean and free of burrs, nicks or scratches. 6. Reinstall drain plug and torque to specification.

=T Engine Crankcase Drain Plug: 25 ft-lbs (33.9 Nm) 7. Remove the seat base.

=T Oil Filter: Turn by hand until filter gasket contacts sealing surface, then turn an additional 1/23/4 turn. 12. Fill the sump with Polaris Diesel Engine Oil to the recommended level through the oil filler access on top of the valve cover. 13. Place gear selector in neutral and set parking brake. 14. Start the engine and let it idle for one to two minutes. Stop the engine and inspect for leaks. 15. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick. 16. Dispose of used oil and oil filter properly.

2.19

MAINTENANCE Exhaust Pipe

3. If some carbon is expelled, cover the exhaust outlet and lightly tap on the pipe around the clean out plugs with a rubber mallet while revving the engine several more times.

WARNING Do not perform clean out immediately after the engine has been run, as the exhaust system becomes very hot. Serious burns could result from contact with exhaust components. To reduce fire hazard, make sure that there are no combustible materials in the area when purging the spark arrestor. Wear eye protection. Do not stand behind or in front of the vehicle while purging the carbon from the spark arrestor.

4. If particles are still suspected to be in the muffler, back the machine onto an incline so the rear of the machine is one foot higher than the front. Set the parking brake, block the wheels and repeat Steps 2 and 3.

Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas. Do not go under the machine while it is inclined. Set the hand brake and block the wheels to prevent roll back. Failure to heed these warnings could result in serious personal injury or death. The exhaust pipe must be periodically purged of accumulated carbon as follows: 1. Remove the clean out plug located on the bottom of the muffler as shown below. 5. If particles are still suspected to be in the muffler, drive the machine onto the incline so the front of the machine is one foot higher than the rear. Set the parking brake, block the wheels and repeat Steps 2 and 3. Clean Out Plug 2. Set the parking brake and start the engine. Purge accumulated carbon from the system by momentarily revving the engine several times.

2.20

6. Repeat steps 2 through 5 until no more particles are expelled when the engine is revved. 7. Stop the engine and allow the arrestor to cool. 8. Reinstall the clean out plug.

MAINTENANCE TRANSMISSION AND GEARCASES

4. Reinstall the fill plug and torque to specification.

Transmission Lubrication

NOTE: It is important to follow the transmission maintenance intervals described in the Periodic Maintenance Chart. Regular fluid level inspections should be performed as well. The transmission lubricant level should be checked and changed in accordance with the maintenance schedule. • Be sure vehicle is positioned on a level surface when checking or changing the lubricant. • Check vent hose to be sure it is routed properly and unobstructed.

Drain / Fill Plug: 12 ft-lbs (16 Nm) Transmission Lubricant Change The drain plug is located on the right side of the transmission. Access the drain plug from the rear righthand side of the vehicle. 1. Remove the fill plug (refer to “Transmission Lubricant Level Check”).

Transmission Lubricant Level Check

2. Place a funnel into the skid plate hole and under the transmission drain plug.

The fill plug is located on the right side of the transmission. Access the fill plug from the rear right-hand side of the vehicle. Maintain the fluid level even with the bottom threads of the fill plug hole.

3. Place a drain pan under the vehicle at the location of the funnel.

1. Position vehicle on a level surface. Raise the cargo box for easier access if required.

4. Remove the drain plug and allow lubricant to drain completely.

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

12 ft-lbs (16 Nm) Transmission Drain

5. Clean the drain plug magnetic surface. Reinstall drain plug with a new O-ring and torque to specification. Add lubricant until even with bottom of threads 3. If lubricant level is not even with the bottom threads, add the recommended lubricant as needed. Do not overfill.

6. Add the recommended amount of lubricant through the fill plug hole. Maintain the lubricant level at the bottom of the fill plug hole when filling the transmission. Do not overfill.

= Recommended Transmission Lubricant: Synthetic AGL Plus (PN 2878608) (Quart) Capacity: 32 oz. (946 ml)

2.21

MAINTENANCE 7. Reinstall fill plug with a new O-ring and torque to specification.

4. Remove the (3) bolts from the lower portion of the bumper. 5. Remove the fasteners from each side of the upper portion of the bumper.

6. Carefully remove the bumper from the vehicle.

Drain / Fill Plug Torque: 12 ft-lbs (16 Nm)

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

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

Front Gearcase Lubrication

Fill Plug ft-lbs 12 Nm)

NOTE: It is important to follow the front gearcase maintenance intervals described in the Periodic Maintenance Chart. Regular fluid level inspections should be performed as well. The front gearcase fluid level should be checked and changed in accordance with the maintenance schedule. • Be sure vehicle is positioned on a level surface when checking or changing the fluid. • Check vent hose to be sure it is routed properly and unobstructed.

Add lubricant until even with bottom of threads

Drain Plug ft-lbs (12 Nm)

8. If fluid level is not even with the bottom threads, add the recommended fluid as needed. Do not overfill.

Front Gearcase Fluid Level Check The fill plug is located on the front left side of the front gearcase. Access the fill plug from the front of the vehicle. Maintain the fluid level even with the bottom threads of the fill plug hole.

9. Reinstall the fill plug and torque to specification.

1. Position vehicle on a level surface. 2. Begin by removing the front bumper to gain access to the gearcase fill plug. 3. Remove the (2) T27 Torx-head screws retaining the fascia screen and remove the screen. Remove Remove

Drain / Fill Plug: 9 ft-lbs (12 Nm) Front Gearcase Fluid Change: The drain plug is located on the bottom side of the front gearcase. Access the drain plug through the skid plate. 1. Remove the fill plug (refer to “Front Gearcase Fluid Level Check”). 2. Place a drain pan under the front gearcase drain plug. 3. Remove the drain plug and allow fluid to drain completely.

T27 Screws

4. Clean the drain plug magnetic surface. 5. Reinstall drain plug with a new O-ring and torque to specification. Remove

2.22

MAINTENANCE 6. Add the recommended amount of fluid through the fill hole. Maintain the fluid level even with the bottom threads of the fill plug hole.

12. Install the (2) T27 Torx-head screws retaining the fascia screen. Torque screws to specification.

=T = Recommended Front Gearcase Fluid: Polaris Demand Drive Plus (PN 2877922) (Quart) Capacity: 6.75 oz. (200 ml) 7. Reinstall fill plug with a new O-ring and torque to specification.

Upper Bumper Fasteners: 30 ft-lbs (41 Nm) Lower Bumper Bolts: 14 ft-lbs (19 Nm) Fascia Screen Screws: 5 ft-lbs (7 Nm)

Rear Gearcase Lubrication NOTE: It is important to follow the rear gearcase maintenance intervals described in the Periodic Maintenance Chart. Regular fluid level inspections should be performed as well. The rear gearcase lubricant level should be checked and changed in accordance with the maintenance schedule.

=T Drain / Fill Plug: 9 ft-lbs (12 Nm)

• Be sure vehicle is positioned on a level surface when checking or changing the lubricant.

8. Check for leaks. Dispose of used fluid properly. 9. Reinstall the front bumper.

• Check vent hose to be sure it is routed properly and unobstructed. Rear Gearcase Lubricant Level Check:

30 ft-lbs 41 Nm) 30 ft-lbs (41 Nm)

The fill plug is located on the left side of the rear gearcase. Maintain the lubricant level even with the bottom threads of the fill plug hole. 1. Position the vehicle on a level surface. 2. Remove the fill plug and check the lubricant level.

5 ft-lbs 7 Nm)

Gearcase lubricant flush with bottom of threaded area 14 ft-lbs 19 Nm) 10. Install the fasteners on each side of the upper portion of the bumper. Torque fasteners to specification. 11. Install the (3) bolts in the lower portion of the bumper. Torque bolts to specification.

3. If lubricant level is not even with the bottom threads, add the recommended lubricant as needed. Do not overfill.

2.23

MAINTENANCE 4. Reinstall fill plug and torque to specification.

6. Add the recommended amount of lubricant through the fill hole. Maintain the lubricant level even with the bottom threads of the fill plug hole.

Fill Plug: 25 ft-lbs (34 Nm) Drain Plug: 38 in-lbs (4.3 Nm) NOTE: The rear gearcase lubricant must be checked and filled when the gearcase is properly mounted in the vehicle and the vehicle resting on level ground. Rear Gearcase Lubricant Change: The drain plug is located on the bottom right side of the rear gearcase. Access the drain plug from the rear of the vehicle through the skid plate.

= Recommended Rear Gearcase Lubricant: ATV Angle Drive Fluid (PN 2876160) Capacity: 22 oz. (650 ml) 7. Reinstall fill plug with a new O-ring and torque to specification. 8. Check for leaks. Dispose of used lubricant properly.

1. Remove the fill plug (refer to “Rear Gearcase Lubricant Level Check”). 2. Place a drain pan under the rear gearcase drain plug. 3. Remove the drain plug and allow the lubricant to drain completely.

Drain Plug 38 in-lbs 4.3 Nm) 4. Clean the drain plug magnetic surface. 5. Reinstall drain plug with a new O-ring and torque to specification.

=T Fill Plug: 25 ft-lbs (34 Nm) Drain Plug: 38 in-lbs (4.3 Nm)

2.24

MAINTENANCE COOLING SYSTEM

Coolant Level Inspection

Liquid Cooling System Overview

The recovery bottle and radiator pressure cap are located under the hood.

NOTE: Use ethylene glycol coolant / anti-freeze only. Do not mix coolant types. The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the recovery bottle (A), radiator filler neck, radiator pressure cap (B) and connecting hose. As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle. As engine coolant temperature decreases the contracting (cooled) coolant is drawn back up from the tank past the pressure cap and into the radiator.

1. Position the vehicle on a level surface with the engine at operating temperature 2. Check the coolant level in the recovery bottle, located on the ride side of the machine. The coolant level must be maintained between the “MAX” and “MIN” levels indicated on the recovery bottle Recovery Bottle

MAX MIN

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.

3. If the coolant level is below the “MIN” mark, open the hood to access the radiator pressure cap and recovery bottle cap. 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.

WARNING Escaping steam can cause burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap. 4. Remove the pressure cap. Using a funnel, add coolant to the top of the radiator filler neck. 5. Reinstall the pressure cap. NOTE: Use of a non-standard pressure cap will not allow the recovery system to function properly. 6. Remove the recovery bottle cap.

2.25

MAINTENANCE 7. Fill the recovery bottle to the “MAX” mark with Polaris Premium 60/40 Anti-Freeze/Coolant or a 50/50 mixture of antifreeze/coolant and distilled water as required for freeze protection in your area.

Cooling System Hoses 1. Inspect all hoses for cracks, deterioration, abrasion or leaks. Replace if necessary. Recovery Bottle

8. Reinstall the recovery bottle cap. 9. start engine and check for leaks. NOTE: Make sure radiator fins are clean to prevent overheating.

Hose To thermostat)

Coolant Strength / Type Test the strength of the coolant using an antifreeze hydrometer. Hose 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. Straight water or antifreeze may cause the system to freeze, corrode, or overheat.

2011 SHOWN

2. Check tightness of all hose clamps.

CAUTION Do not over-tighten hose clamps at radiator, or radiator fitting may distort.

=T Radiator Hose Clamp: 36 in-lbs (4 Nm)

Recommended Anti-Freeze/Coolant: Polaris 60/40 Anti-Freeze/Coolant (PN 2871534) (Quart)

2.26

(To water pump)

MAINTENANCE Radiator Inspection / Cleaning

Radiator Removal (2011)

1. Check radiator air passages for restrictions or damage.

1. Remove the push rivets and front RH wheel well panel to access the radiator drain valve.

Flush radiator in this direction

Fan Motor

2. Place a suitable drain pan underneath the radiator. 3. Allow the vehicle to cool down if recently operated.

WARNING

Radiator

Shroud 2011 SHOWN

2. Carefully straighten any bent radiator fins. 3. Remove any obstructions with compressed air or low pressure water.

Escaping steam can cause burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap. 4. Open the hood and slowly open the radiator pressure cap to relieve system pressure. 5. Open the drain valve on the front side of the radiator and allow the coolant to completely drain. Properly dispose of the used coolant.

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

Drain valve

6. Remove the (2) T25 screws that retain the recovery bottle to the frame bracket. Set the recovery bottle out of the way.

2.27

MAINTENANCE 7. Remove the push rivets and front LH wheel well panel. 8. Remove the upper and lower coolant lines from the radiator.

12. Remove the recovery bottle return line (see Figure 226). 13. Carefully lift the radiator straight up and out of the vehicle. Take care not to damage the cooling fins.

9. Remove the (4) bolts that retain the fan motor and shroud to the radiator. Installation 14. Reverse removal procedure for installation. 15. Upon installation, be sure the lower radiator mounts are placed properly in the frame support.

10. Remove the (2) mounting screws that secure the upper portion of the radiator to the frame (see Figure 2-26). Figure 2-26

Spring Support

16. After the radiator is installed, be sure the mounts have remained in place. 17. After installation and reassembly, remove the pressure cap and fill the radiator and recovery bottle with coolant. 18. Refer to the “Cooling System Bleeding Procedure” in Chapter 3.

Radiator

Recovery bottle return line

11. Remove the (2) lower hood latch screws and remove the lower hood latch spring support (see Figure 2-26).

2.28

MAINTENANCE Radiator Removal (2012) 1. Open the hood and disconnect the headlights.

4. Remove the (2) screws that retain the front cab assembly to the hood liner.

2. Remove the (4) upper screws that retain the hood to the frame.

5. Remove the (11) remaining screws and (6) push rivets retaining the front cab.

3. Remove the (8) fasteners retaining the front bumper assembly and remove the bumper from the vehicle.

6. Lift up on the front cab and slide it up the cab frame far enough to access the hood liner. Support the front cab to keep it from sliding down. 7. Disconnect and remove the battery from the vehicle. 8. Loosen the hose clamp and remove the engine air intake baffle box located behind the RF headlamp area.

2.29

MAINTENANCE 9. Remove the (4) screws that retain the hood liner to the frame.

14. Allow the vehicle to cool down if recently operated.

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. 15. Slowly open the radiator pressure cap to relieve system pressure. 16. Remove the lower coolant hose and drain the coolant from the radiator and hose. Allow the coolant to completely drain. Properly dispose of the used coolant. 10. Carefully lift up on the hood liner far enough to allow radiator removal. NOTE: Turn coolant pressure cap to allow the hood liner to clear the cap. 11. Remove the (2) screws retaining the upper portion of the radiator to the frame.

17. Remove the upper coolant hose. 18. Remove the recovery bottle return line from the radiator. 19. Disconnect the fan motor electrical connector. 20. Carefully lift the radiator/fan motor from the vehicle as an assembly. Take care not to damage the cooling fins. 12. Remove the push rivets and front LH wheel well panel to access the lower coolant hose at the radiator. 13. Place a suitable drain pan under the LH side of the radiator.

2.30

MAINTENANCE 21. Remove the (4) bolts that retain the fan motor assembly and service radiator or fan as needed.

FINAL DRIVE / WHEEL AND TIRE Wheel and Hub Torque Table ITEM

NUT TYPE

SPECIFICATION

Lug Nut

30 ft-lbs (41 Nm) plus 90° (1/4 turn)

Steel Wheels

Flange Nut

35 ft-lbs (47 Nm)

Front Hub Nut

80 ft-lbs (108 Nm)

Mid / Rear Hub Retaining Nut

110 ft-lbs (150 Nm)

Aluminum Wheels

CV Shaft Boot Inspection

Installation 22. Reverse this procedure for installation.

Inspect the CV shaft boots in the front and rear 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.

23. Upon installation, be sure the lower radiator mounts are placed properly in the frame support.

Inspect Boots

24. After the radiator is installed, be sure the mounts have remained in place.

Inspect Boots

25. After installation and reassembly, remove the pressure cap and fill the radiator and recovery bottle with coolant. 26. Refer to the “Cooling System Bleeding Procedure” in Chapter 3.

2.31

MAINTENANCE Wheel Removal

Tire Inspection • Improper tire inflation maneuverability.

Wheel Nuts (4)

may

affect

vehicle

• When replacing a tire always use original equipment size and type. • The use of non-standard size or type tires may affect vehicle handling.

Front Hub Nut 80 ft-lbs (108 Nm)

Tire Tread Depth Always replace tires when tread depth is worn to 1/8” (3 mm) or less.

Mid/Rear Hub Nut 110 ft-lbs (150 Nm)

Tread Depth 1/8” (3 mm)

1. Stop the engine, place the transmission in gear and lock the parking brake. 2. Loosen the wheel nuts slightly. 3. Elevate the side of the vehicle by placing a suitable stand under the footrest frame. 4. Remove the wheel nuts and washers and remove the wheel.

Wheel Installation 1. With the transmission in gear and the parking brake locked, place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation. 2. Install the washers (if applicable) and wheel nuts and finger tighten them. 3. Lower the vehicle to the ground. 4. Securely tighten the wheel nuts to the proper torque listed in the torque table at the beginning of this section.

CAUTION If wheels are improperly installed it could affect vehicle handling and tire wear. On vehicles with tapered rear wheel nuts, make sure tapered end of nut goes into taper on wheel.

2.32

WARNING Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury. Always maintain proper tire pressure. When replacing tires, always use original equipment size and type.

Tire Pressure Tire Pressure Inspection (PSI - Cold) Model

Front / Rear

RANGER DIESEL

8-12 psi / 8-12 psi

RANGER DIESEL CREW

12 psi / 16 psi

MAINTENANCE ELECTRICAL SYSTEM

Battery Removal

Battery Maintenance

1. Remove the seat base.

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.

2. Remove the under-seat storage container on the drivers side.

Be careful not to allow cleaning solution or tap water into the battery.

WARNING CALIFORNIA PROPOSITION 65 WARNING: Batteries, battery posts, terminals and related accessories contain lead and lead compounds, and other chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. WASH HANDS AFTER HANDLING.

3. Disconnect the black (-, negative) battery cable.

Battery electrolyte is poisonous. It contains acid! Serious burns can result from contact with the skin, eyes, or clothing.

6. Lift the battery out of the vehicle, being careful not to tip it sideways and spill any electrolyte (if applicable).

4. Disconnect the red (+, positive) battery cable. 5. Remove the hold-down strap from the battery.

ANTIDOTE

CAUTION

External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call a physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention.

Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last.

Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in closed space. Always shield eyes when working near batteries. Keep out of reach of children. 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.

2.33

MAINTENANCE Battery Installation

Battery Charging

NOTE: 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 procedures before installing the battery.

1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging.

1. Verify that the battery is fully charged.

2. Charge the battery with a charging output no larger than 1/10 of the batteryâ&#x20AC;&#x2122;s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater.

2. Place the battery in the battery holder.

3. Reinstall the battery.

3. Install battery hold down strap. 4. Coat the terminals with dielectric grease or petroleum jelly. 5. Connect and tighten the red (+, positive) cable first. 6. Connect and tighten the black (-, negative) cable last.

Engine Ground Inspect engine ground cable connection (A). Be sure it is clean and tight. The ground cable runs from the LH engine block to the terminal block. Located under the seat next to the battery.

7. Verify that cables are properly routed and install the hold-down strap. 8. Reinstall the under-seat storage container. 9. Reinstall the seat base. Use Polaris corrosion resistant Nyogelâ&#x201E;˘ grease (PN 2871329) on battery terminals.

=T Battery Terminal Pinch Bolt: 12.5 ft-lbs (17 Nm)

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.

2.34

MAINTENANCE STEERING Steering Inspection 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.

Wheel Toe Alignment Inspection 1. Place machine on a smooth level surface and set steering wheel in a straight ahead position. Secure the steering wheel in this position. 2. Place a chalk mark on the center line of the front tires approximately 10” (25.4 cm) from the floor or as close to the hub/axle center line as possible.

WARNING Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized Polaris MSDcertified technician when replacing worn or damaged steering parts. Use only genuine Polaris replacement parts.

Tie Rod End / Steering Inspection

Measure here Mark (A), measure, then roll forward and measure (B).

• To check for play in the tie rod end, grasp the steering tie rod, pull in all directions feeling for movement. • Replace any worn steering components. Steering should move freely through entire range of travel without binding.

10”

NOTE: It is important the height of both marks be equally positioned to get an accurate measurement. 3. Measure the distance between the marks and record the measurement. Call this measurement “A”. 4. Rotate the tires 180° by moving the vehicle forward. Position chalk marks facing rearward, even with the hub/axle center line.

2.35

MAINTENANCE 5. Again measure the distance between the marks and record. Call this measurement “B”. Subtract measurement “B” from measurement “A”. The difference between measurements “A” and “B” is the vehicle toe alignment. The recommended vehicle toe tolerance is 1/8”, to 1/4”, (.3 to .6 cm) toe out. This means the measurement at the front of the tire (A) is 1/8”, to 1/4”, (.3 to .6 cm) wider than the measurement at the rear (B).

= In. / mm.

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.

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

Toe Adjustment If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell you which tie rod needs adjusting. NOTE: Be sure steering wheel is straight ahead before determining which tie rod needs adjustment.

• Loosen jam nuts at both end of the tie rod. • Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified in “Wheel Toe Alignment”. • IMPORTANT: When tightening the tie rod end jam nuts, the rod ends must be held parallel to prevent rod end damage and premature wear. Damage may not be immediately apparent if done incorrectly. • After alignment is complete, torque jam nuts to specification.

=T Tie Rod Jam Nut: 13 ft-lbs (18 Nm)

Measure Distances (Measurements should be equal)

2.36

MAINTENANCE SUSPENSION

Shock Position Adjustment

Suspension Inspection

The front and rear shock position may be adjusted to provide a stiffer suspension if necessary.

Compress and release the suspension. Damping should be smooth throughout the range of travel.

1. Elevate the vehicle and safely support the main frame.

• Check all suspension components and mounting fasteners for wear or damage.

CAUTION

• Inspect each shock body for leakage.

Spring Pre-Load Adjustment The front and rear shock absorber springs are adjustable. Rotate the adjuster cam either direction to increase or decrease spring tension. Always adjust both left and right sides equally.

Use care when supporting vehicle so that it does not tip or fall. Serious injury may occur if vehicle tips or falls. 2. Remove the top shock mounting bolts on each side. 3. Reposition the shocks to the outside mounting holes. Front Shock Position Adjustment

Inside (Soft) Highest amount of spring pre-load

Lowest amount of spring pre-load

Shock Pre-Load Adjustment Vehicle loads effect suspension spring pre-load requirements. Use Spanner Wrench (PN 2871095) to adjust pre-load as necessary to avoid bottoming of the shocks. Shock Spanner Wrench: PN 2871095

Outside Stiff) Rear Shock Position Adjustment Outside (Stiff)

Inside (soft)

2.37

MAINTENANCE 4. Reinstall the shock mounting bolts and torque to specification.

=T Shock Mounting Bolt: 30 ft-lbs (41 Nm)

BRAKE SYSTEM

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.

Brake Pad / Disc Inspection 1. Check the brake pads for wear, damage, or looseness. 2. Inspect the brake pad wear surface for excessive wear.

Brake Fluid Inspection Always check the brake pedal travel and inspect the brake fluid reservoir level before each operation. If the fluid level is low, add DOT 4 brake fluid only.

3. Pads should be changed when the friction material is worn to .040â&#x20AC;? (1 mm).

Brake fluid should be changed every two years. The fluid should also be changed anytime the fluid becomes contaminated, the fluid level is below the minimum level, or if the type and brand of the fluid in the reservoir is unknown. The brake master cylinder reservoir can be accessed through the front left wheel well.

Measure Pad Material Thickness

Service Limit: .040" (1 mm)

1. Position the vehicle on a level surface. 2. Place the transmission in Neutral (N) and set the parking brake.

4. Check surface condition of the brake discs.

3. View the brake fluid level in the reservoir. The level should be between the MAX and MIN level lines.

5. Measure the thickness of the front and rear brake discs.

4. If the fluid level is lower than the MIN level line, add brake fluid until it reaches the MAX level line.

6. The disc(s) should be replaced if thickness is less than the specified service limit (see Chapter 9 for specifications).

5. Install the reservoir cap and apply the brake pedal forcefully for a few seconds and check for fluid leakage around the master cylinder fittings and the brake caliper fittings.

Measure Brake Disc Thickness

Front Disc

Master Cylinder

2.38

Rear Disc

MAINTENANCE Parking Brake Cable Adjustment

Parking Brake Pad Inspection

NOTE: Inspect the parking brake cable tension after the first 25 hours of operation and every 100 hours of operation afterwards to ensure proper cable tension.

Measure the thickness of the rear caliper parking brake pads. Replace assembly as needed. See illustration below for proper readings.

Loss of tension in the parking brake cable will cause illumination of the parking brake light and activation of the limiting feature. If this occurs, inspect and adjust parking brake cable tension. If performing this service is difficult due to conditions or location, open the hood and temporarily disconnect the parking brake connector. Reconnect the connector as soon as practicable and adjust the parking brake cable to proper tension.

Inboard Pad New .304” (7.72 mm) Limit: 0.24” (6.1 mm) Inboard Pad

Outboard Pad

1. Pull back on the parking brake lever (located in the dash). 2. After 3 to 4 clicks the “P” light should illuminate on the instrument cluster and the wheels of the vehicle should not rotate when turning by hand. After 8 full clicks of lever travel, the vehicle should not roll while parked.

Outboard Pad 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 0.169 +/- .008” (4.29 +/- .20mm) Replace at .150” (3.81mm) or less

3. If the vehicle moves, adjustment is necessary. 4. Adjust the parking brake cable where the cable attaches to the caliper mount bracket. The mount bracket is located on the left-hand side of the transmission behind the outer PVT cover. Adjustment Procedure: Refer to Chapter 9 “Brakes” for complete adjustment procedure.

2.39

MAINTENANCE

NOTES

2.40

ENGINE

CHAPTER 3 ENGINE SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 GENERAL ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 ACCESSIBLE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 OIL PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 ENGINE/TRANSMISSION ASSEMBLY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5

ENGINE / TRANSMISSION MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 ENGINE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 COOLING SYSTEM SPECIFICATIONS AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 COOLING FAN ON/OFF & HOT LIGHT ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 COOLING SYSTEM BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11

REFER TO YANMAR ENGINE SERVICE CHAPTER 11 FOR ENGINE REPAIR INFORMATION

3.1

ENGINE SPECIAL TOOLS

Engine Lubrication Specifications

Special Tools

Oil Viscosity Requirement vs. Temperature

PART NUMBER

TOOL DESCRIPTION

PU-50529

Diesel Engine Compression Tester and Adapter

PU-50531

Diesel Oil Pressure Adapter

PU-50530

Diesel Injection Timing Tool

PU-50532

Diesel Fuel Injector Tester

SPX Corp: 1-800-328-6657 or http://polaris.spx.com/

GENERAL ENGINE SERVICE Accessible Components

The following components can be serviced or removed with the engine installed: • Alternator

Recommended Engine Oil: Polaris 15W40 Diesel Summer / Polaris 10W30 Diesel Winter (CI-4 rated)

• Starter Motor/Drive • Camshaft • Cylinder Head

Capacity: Approximately 1.8 U.S. Quarts (1.7 l)

• Valvetrain Components

2878471 - Diesel Oil Change Kit, Summer 15W40 2878472 - Diesel Oil Change Kit, Winter 10W30 2878473 - Diesel Oil 2Qt Summer 15W40 2878474 - Diesel Oil 2Qt Winter 10W30

• Fuel Injection Pump • Glow Plugs • Injectors • Water Pump

Oil Pressure Test

• Oil Pump

1. Remove oil pressure switch (A) from right side of the cylinder block.

• Timing Geartrain The following components require engine removal for service: • Connecting Rods • Crankshaft • Crankshaft Main Bearings • Cylinder Block • Flywheel (transmission removal) • Piston / Rings

2. Insert special adapter tool PU-50531 into cylinder block. Use oil pressure test kit PV-43531-B. 3. Start engine and allow it to reach operating temperature, while monitoring the gauge. Check for oil leaks.

3.2

ENGINE NOTE: Use only Polaris Diesel oil 15W40 Summer or 10W30 Winter.

7. Disconnect battery (-) negative cable from the engine block.

Oil Pressure at 3600 RPM (Engine Hot): MIN: 34 PSI MAX: 64 PSI Oil Pressure at IDLE RPM (Engine Hot): MIN: 8 PSI 4. Using thread sealant, reinsert oil pressure switch and tighten sufficiently upon completion of test.

Engine/Transmission Assembly Removal IMPORTANT: For efficiency, it is recommended that the engine and transmission be removed as an assembly anytime the engine requires complete disassembly or rebuilding. This makes the transmission / engine coupling and placement process more efficient.  Some engine repair procedures can be performed without removing the engine. Refer to “Accessible Components” for further information. NOTE: Use a mechanical hoist to remove the engine and transmission as an assembly from the vehicle to prevent personal injury or damage to other vehicle components.

WARNING Always wear safety glasses and use the proper tools when performing the procedures in this manual. Failing to do so may lead to  possible injury or death. 1. Thoroughly clean the engine / transmission and chassis before removal.

8. Remove the cab frame support and lower seat frame as an assembly (refer to Chapter 5).

Remove as an assembly

FRAME

9. Disconnect the harness / wires attached to the alternator.

2. Drain the engine oil (refer to Chapter 5). 3. Drain the engine coolant into a catch container by removing the lower radiator hose. TIP: Remove additional engine coolant from the system by sealing the lower radiator fitting and introducing low-pressure compressed air into the system. Additional coolant will flow from the lower radiator hose into the catch container. 4. Disconnect cargo box harness. Remove Cargo box and cargo box shock. 5. Remove the seat base. 6. Disconnect the battery positive (+) and negative (-) cables.

3.3

ENGINE 10. Disconnect the harness / wires attached to the starter.

18. Disconnect the glow plug harness connector (A) and the stop solenoid connector (B).

B 11. Remove the springs from exhaust pipe.

19. Disconnect the oil pressure sensor connector.

12. Remove the exhaust pipe nuts from the manifold and remove the pipe. 13. Remove belt guard. 14. Place a small catch-container under the fuel filter / water separator and fuel supply and return lines. Disconnect fuel lines on fuel tank and engine. Carefully remove and plug the fuel supply and return lines. Remove fuel filter mount and lines as an assembly from the frame. Store in safe, clean area. NOTE: Dispose of all fluids properly. 15. Remove the radiator hoses from the water pump. 16. Disconnect and remove the throttle cable.

17. Remove the air intake filter housing and engine intake hose assembly. Place a shop towel into the engine intake to prevent dirt from entering the intake port.

3.4

20. Disconnect the crankshaft position sensor (CPS) harness located on the bell housing.

21. Disconnect the gear position switch harness from the transmission (Refer to chapter 8), located on top of the transmission.

ENGINE 22. Disconnect the speed sensor harness from the rear of the transmission.

29. Using a hoist, carefully remove the engine/ transmission assembly verticality from the chassis frame using the supplied lifting eyes on the engine.

3 Lifting Points

23. Verify that ALL electrical harness connections are disconnected from the engine and transmission. 24. Disconnect the shift cable and remove the shift cable bracket assembly from the frame (refer to chapter 8). 25. Remove the parking brake to allow rear propshaft removal (refer to Chapter 9). 26. Remove the rear propshaft from the transmission (refer to Chapter 7). 27. Remove the front propshaft from the transmission (refer to Chapter 7). 28. Remove the engine and transmission fasteners from underside of the frame.

mount

Remove all 8 lower mount bracket bolts. NOTE: Access holes in skid plate.

30. Place engine / transmission assembly on suitable flat working area. Separate engine and transmission if needed. See page 3.11 and chapter 8 for more details when removing transmission from engine. NOTE: Use extreme caution when lifting the engine out of the frame. Always use an engine lift or other heavy-duty lifting apparatus.

Engine Installation Reverse the removal steps. After the engine is installed in the frame, review the following and perform all steps that apply: General Items 1. Properly torque all fasteners. Use general torque guide in Chapter 1 if no specifications are supplied. Torques values can be found at the end of chapter 3 and in chapter 8 2. Install previously removed components using new gaskets, seals, and fasteners where applicable. 3. Verify proper throttle operation. 4. Verify the engine ground is installed on the cylinder block. 5. Verify the alternator belt is properly tensioned. NOTE: Properly route all electrical harnesses and reattach any fasteners or protective tubing. Check for any possible rubbing points of electrical wires. 6. Perform regular checks on fluid levels, controls, and all other areas of the vehicle as outlined in the daily pre-ride inspection checklist (refer to Chapter 2). PVT System 1. Check the clutch offset, clutch alignment, and belt deflection if required (see Chapter 6 “Clutching”).

3.5

ENGINE 2. Clean the clutch sheaves thoroughly and inspect inlet and outlet ducts for proper routing and sealing (see Chapter 6). Transmission 1. Inspect transmission operation and adjust the shift cable if necessary. Refer to Chapter 2 and Chapter 8. Exhaust 1. Replace exhaust gaskets as part of preventative maintenance. Seal connections with high temp silicone sealant if required. 2. Verify all exhaust springs are in good condition. Bleed Cooling System NOTE: Follow coolant bleeding procedure outlined in this chapter Engine Break-In Period The break-in period for a Polaris RANGER diesel engine is defined as the first 50 hours of engine operation. 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 engine life. Perform the following procedures carefully:

CAUTION Use only Polaris Diesel engine oil or an approved equivalent. Do not operate at full throttle or high speeds for extended periods during the first 50 hours of use. Excessive heat can build up and cause damage to close fitted engine parts. 1. Fill fuel tank with clean fuel. 2. Check oil level indicated on dipstick. Add oil if necessary (Refer to Chapter 2). 3. Drive slowly at first to gradually bring engine up to operating temperature. 4. Vary throttle positions during vehicle operation. Do not operate at sustained idle or sustained high speed. 5. Perform regular checks on fluid levels, controls and all important bolt torques during the break in period. 6. Pull only light loads during initial break-in. 7. Change oil and oil filter after break-in period of 50 hours.

3.6

ENGINE ENGINE / TRANSMISSION MOUNTING Exploded View / Torque Values 25 ft-lbs (34 Nm) 62 ft-lbs (84 Nm) 30 ft-lbs (40 Nm)

25 ft-lbs (34 Nm)

18 ft-lbs (25 Nm)

25 ft-lbs (34 Nm)

30 ft-lbs (40 Nm)

18 ft-lbs (25 Nm)

17 ft-lbs (23 Nm)

18 ft-lbs (25 Nm)

Gasket 55 ft-lbs (75 Nm)

Rubber Coupler

3.7

ENGINE ENGINE EXHAUST SYSTEM Exploded View - Engine Exhaust System

18 ft-lbs (24 Nm)

5 ft-lbs (7 Nm)

18 ft-lbs (24 Nm)

3.8

ENGINE ENGINE COOLING SYSTEM

Radiator Cap Pressure Test

Cooling System Specifications and Testing

1. Open the front hood (see Warning under “Cooling System Pressure Test”).

CONDITION

SPECIFICATION

Thermostat begins to open

approx.160° F (71° C)

Thermostat fully open

approx. 185° F (85° C)

Radiator Cap Pressure

13 PSI

SYSTEM CAPACITY RANGER DIESEL

6.2 Qts. (5.9 L)

RANGER DIESEL CREW

6.64 Qts (6.28 L)

Polaris Premium Antifreeze 2871534 - Quart 2871323 - Gallon Recommended Coolant Use only high quality antifreeze/coolant mixed with distilled water in a 50/50 or 60/40 ratio, depending on freeze protection required in your area. Use only ethylene glycol coolant; do not mix coolant types.

2. Remove radiator pressure cap and test using a cap tester (commercially available). 3. The radiator cap relief pressure is 13 lbs. Replace cap if it does not meet this specification.

Cooling Fan on/off & HOT Light on/off The cooling fan and HOT light are both controlled by the VCM via the coolant temp sensor. FAN

HOT LIGHT

ON 194 ° F (90 ° C)

ON 221° F (105° C)

OFF 179 ° F (82 ° C)

OFF 212° F (100° C)

NOTE: If the coolant temperature sensor or circuit malfunctions the radiator fan will default “ON”. NOTE: See chapter 10 for more information.

IMPORTANT: 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 Antifreeze/ Coolant is recommended for use. Cooling System Pressure Test 1. Open the front hood.

WARNING Escaping steam can cause burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap. 2. Remove the pressure cap from the radiator and pressure test the cooling system using a commercially available tester. 3. The system must retain 10 psi for five minutes or longer. If pressure loss is evident within five minutes, check radiator, all cooling system hoses and clamps and water pump seal for leakage.

3.9

ENGINE

3.10

ENGINE Cooling System Bleeding Procedure

NOTE: If system is partially filled, steps 4 to 8 may be unnecessary and can be skipped to step 9. 4. Cooling system empty - Completely unscrew the rear bleed screw on the thermostat housing.

WARNING Always wear safety glasses and proper shop clothing when performing the procedures in this manual. Failing to do so may lead to possible injury or death.

Coolant Bleed Screw

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 recovery bottle. NOTE: Use this procedure when overheating occurs and no apparent leaks in the cooling system are found.

5. Cooling system empty - Place rags around the bleed hole area to absorb any coolant that may escape during the radiator fill process.

1. Place the vehicle in Neutral and set the parking brake.

6. Cooling system empty - Slowly add coolant to the radiator while monitoring the thermostat housing bleed hole. This process purges the air from the system.

CAUTION Escaping steam can cause burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap. 2. Remove the radiator cap. 3. Verify the recovery bottle is filled between the “MIN” and the “MAX” line with coolant. Add coolant if required.

MAX MIN

Recovery Bottle

7. Cooling system empty - Squeeze coolant hoses gently by hand during initial fill to help purge the system of air. 8. Cooling system empty - When coolant appears at the bleed hole, replace the bleed screw and tighten, but do not fully torque at this time. 9. Continue to fill radiator with coolant to the filler neck. 10. Loosen the bleed screw on the thermostat housing (approximately 2 turns or more) and allow any remaining trapped air to escape. If no air is present, a steady stream of coolant will be present. If air is present, the screw area will bubble and sputter as air escapes. 11. Once a steady stream of coolant appears at the bleed screw, tighten the bleed screw to specification on the thermostat housing.

=T Coolant Bleed Screw: 70 in-lbs (8 Nm) 12. Add coolant to the radiator fill neck. 13. Remove rags from the thermostat housing and dispose of properly.

3.11

ENGINE 14. Place appropriate drain pan under radiator. Start the engine and allow it to reach operating temperature with the radiator cap removed from the radiator. Be sure thermostat has opened before installing the cap back onto the radiator. (Cooling fan should cycle at least once) Install radiator cap. 15. Stop the engine and allow it cool. Any air remaining in the system should continue to bleed out through the recovery bottle during operation.

CAUTION Use caution when performing these procedures. Coolant may be hot and may cause severe injury or burns. 16. Top off the radiator (A) and recovery bottle (B) with coolant if required. Fill the radiator first before filling the recovery bottle.

A B

17. Repeat this procedure if you are still having difficulty bleeding the system. 18. It may be necessary to lift the front of the vehicle higher that the rear of the vehicle to aid in the bleeding procedure. Use a suitable vehicle hoist or vehicle lift to raise the front of the vehicle safely.

3.12

FUEL SYSTEM

CHAPTER 4 FUEL SYSTEM GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 DIESEL SERVICE NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 FUEL TANK EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 FUEL INJECTION SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 FUEL SYSTEM COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 FUEL LINE REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5

FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 PRINCIPAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 INITIAL PRIMING / STARTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6

FUEL TRANSFER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 FUEL PUMP TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 FUEL PUMP REPLACEMENT / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 FUEL TANK ASSEMBLY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 FUEL TANK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8

FUEL FILTER / WATER SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9 FUEL FILTER / WATER SEPARATOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9 FUEL FILTER / WATER SEPARATOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . 4.9

FUEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10 FUEL SENDER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10 FUEL SENDER REPLACEMENT / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10

GENERAL TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11

REFER TO YANMAR ENGINE SERVICE CHAPTER 11 FOR ENGINE FUEL INJECTION SYSTEM INFORMATION

4.1

FUEL SYSTEM GENERAL INFORMATION

Diesel Service Notes • 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 fuel 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 connection before opening to prevent dirt from entering the system. • Although every precaution has been taken to prevent water intrusion failures, avoid high pressure spray contact with system components. • 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. • Do not charge battery with key switch "on."

Special Tools PART NUMBER

TOOL DESCRIPTION

PU-50326

PFA Nut Tool

SPX Corp: 1-800-328-6657 or http://polaris.spx.com/ PFA Nut Tool - PU-50326

• Always disconnect negative (-) battery cable lead before charging battery. IMPORTANT: The fuel system remains under pressure, even when the engine is not running. Before attempting to service any part of the fuel system, pressure must be relieved (if applicable). NOTE: This vehicle has both low and high fuel pressure systems. The low pressure system is covered in this chapter (4) and the high pressure system is covered in chapter 11.

Refer to Yanmar Engine Service - Chapter 11 for more information on fuel system special tools.

4.2

FUEL SYSTEM Fuel Tank Exploded View PFA Nut

Fuel Return Fuel Sender ssembly To Fuel Pump

Float / Arm ssembly

PFA Gasket Vent Fuel Tank Assembly

Fuel Flow

Bypass / Return Flow

Injection lines

Fuel Tank Fuel Pump

Fuel Injection Unit

Fuel Injectors

Fuel Filter / Water Separator

4.3

FUEL SYSTEM Fuel Injection System Exploded View 1. Fuel Transfer Pump  2. Fuel Filter / Water Separator  3. Fuel Injection Unit  4. Fuel Injector High Pressure Lines 5. Fuel Injector  6. Low Pressure Return Line Assembly (A) 7. Fuel Inlet / Lines (B)  8. Fuel Injection Drive Gear  9. Cylinder Head 



A 7

B 5

B A

4.4

FUEL SYSTEM Fuel System Component Locations

Fuel Line Removal / Installation

1. Fuel Transfer Pump (item #1) Located above fuel tank as an assembly.

CAUTION Verify fuel system has been depressurized before performing this procedure. Refer to the steps for fuel line removal / installation: 1. Thoroughly clean the hose connection area and place a shop towel around the fuel line to catch any excess fuel. 2. Squeeze the clamp tabs together with a suitable pliers and slide the clamp down the fuel line approx. 2 inches.

4 2. Fuel Filter / Water Separator (item #2) Located on the frame by the fuel tank, under the seat. 3. Fuel Injection Unit (Item #3) Located on the engine under the seat. Refer to Yanmar Engine Service - Chapter 11.

3. Gently pull and twist the fuel line to remove from the fuel pump outlet. 4. When installing the fuel hose, verify the hose and fuel return inlet are clean and free of debris.

4. Fuel Injectors / Fuel Rail (item #4) Attached by high pressure fuel lines to the fuel injection unit. Located on the cylinder head.

5. Slide the hose fully onto the fuel tank outlet. Squeeze the clamp tabs with suitable pliers and slide clamp onto hose connection area. See photo above for proper positioning.

5. Fuel Gauge Sender Assembly Located in fuel tank as an assembly.

4.5

FUEL SYSTEM FUEL INJECTION

FUEL TRANSFER PUMP

Principal Components

Operation Overview

The fuel system is a complete engine fuel management design. This system includes the following principal components:

The electric fuel transfer pump is used to supply fuel from the tank to the fuel injection system. The main in-line components for fuel transfer include the fuel pump and fuel/water separator. The pump is rated for a 1-5 psi output.

• Fuel Pump • Fuel Filter / Water Separator Assembly • Fuel Injection unit (Refer to the Yanmar Engine Service Section - Chapter 11) • The fuel system contains both high and low pressure systems. (Supply and Injection)

Operation Overview The fuel injection system is designed to provide peak engine performance with optimum fuel efficiency and lowest possible emissions. The injection functions are mechanically controlled and governed. NOTE: The fuel injection unit is not serviceable. (Refer to the Yanmar Engine Service Section - Chapter 11) It must be serviced by an authorized FIE repair facility. An in-line electric fuel pump is used to move fuel from the tank through the fuel line and in-line fuel filter/water separator. The fuel pump maintains a system operating pressure of 1-5 psi. Any excess fuel returns to the tank via the return line attached to the injection system. At the engine, fuel is fed to the fuel injection control unit, which operates the injectors. A precise amount is injected into the pre combustion chambers.

Initial Priming / Starting Procedure NOTE: The injection system must be purged of all air prior to the initial start up, and / or any time the system has been disassembled.

When the key switch is turned to "ON", 12Vdc power activates the fuel pump, which pressurizes the system for start-up. The fuel pump is activated any time the key switch is turned to "ON" position.

Fuel Pump Test NOTE: The fuel transfer pump is non-serviceable and must be replaced if determined to be faulty. If a fuel delivery problem is suspected, make certain the fuel pump is being activated by key ‘ON’, all electrical connections are properly secured, the fuses are good, and a minimum of 12.0 Vdc is being supplied.

WARNING

If the fuel system is completely empty of fuel or has been disassembled and repaired: 1. Turn the key switch to the ON position for 10-15 seconds. 2. Turn the key switch to “START” until the engine starts or 5 seconds has passed. 3. If the engine failed to start, repeat steps one and two. If the engine fails to start, a problem may still exist, and should be diagnosed.

Fuel is extremely flammable and may cause severe burns, injury, or death. Do not use any device that produces a flame or electrical devices that may spark around fuel or fuel vapors. 1. Cover the fuel line connection with a shop towel and disconnect the fuel line from the fuel pump where it connects to the engine. 2. Install a commercially available low pressure test gauge on the fuel line between the fuel pump and the fuel filter / water separator assembly.

4.6

FUEL SYSTEM 3. Turn on the key switch to activate the pump and check the system pressure on the gauge. If system pressure of 1-5 psi is observed, the ignition switch and fuel pump are working properly. Turn the key switch off and relieve the system pressure. Fuel Pump Pressure: 1-5 psi NOTE: If the pressure is too low, check in-tank fuel filter. If in-tank fuel filter is ok, replace the fuel pump assembly.

Fuel Pump Replacement / Installation WARNING Always wear safety goggles when working with high pressure or flammable fluids. Do not use any device that produces a flame or electrical devices that may spark around fuel or fuel vapors. 1. Disconnect the electrical harness at the fuel pump.

4. If the pump did not activate (Step 3), disconnect the plug from the fuel pump. Connect a DC voltmeter across terminals in the plug on the vehicle harness side. Turn on the key switch and observe voltage to ensure a minimum of 12 Vdc is present.

2. Cover the fuel line connections with a shop towel and disconnect the fuel lines from the fuel pump.

NOTE: If the voltage was below 12 Vdc, test battery, ignition switch, relay(s), wiring harness and ECM.

4. Install the new pump onto the frame, and reinstall the bracket fasteners. Tighten fasteners securely.

5. If the reading is around 12 Vdc, turn key switch off and connect an ohmmeter between the power terminal on the pump and to frame ground to check for continuity within the fuel pump.

5. Install the fuel lines and spring clamps securely.

NOTE: If there was no continuity, replace the fuel pump assembly. 6. If voltage at the plug is within the specified range, and there is continuity across the pump terminals, reconnect the plug to the pump, making sure you have clean connections. Turn on the key switch and listen for the pump to activate.

3. Remove the bracket fasteners and remove the pump from the frame.

6. Reconnect the electrical harness. 7. Turn the ignition key ON for 10-15 seconds. 8. Test pump and check for leaks. 9. Start engine and check for fuel leaks. 10. Properly dispose of shot towels and excess fuel properly.

NOTE: If the pump starts, verify you have the correct amount of fuel pressure. NOTE: If the pump starts but still does not operate, check the fuel tank assembly for line blockage or no fuel. Replace the pump if no blockage is found.

9924084 - 2011-2013 RANGER DIESEL / CREW ÂŠ 2012 Polaris Sales Inc.

4.7

FUEL SYSTEM Fuel Tank Assembly Removal

6. Remove the (4) bolts retaining the fuel tank to the frame support.

WARNING

Fuel Tank

Always wear safety goggles when working with high pressure or flammable fluids. Failure to do so could result in serious injury.

Remove

1. Remove the seat base. 2. Disconnect the negative (-) battery cable. 3. Disconnect the fuel lines and electrical harness from the fuel tank.

Remove

Return Line

7. Carefully remove the fuel tank out the RH side of the frame.

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. 4. Remove the fuel tank vent hose. 5. Remove the right rear fender/rocker panel assembly and the fuel cap. Reinstall the fuel cap after the fender/ rocker panel has been removed. RH Rear Fender / ocker Panel

NOTE: Properly drain fuel into a suitable container.

Fuel Tank Installation 1. Reinstall the fuel tank assembly. 2. Reinstall the (4) fuel tank mounting bolts. 3. Reconnect the fuel sender electrical harness. 4. Install the fuel line and vent line, and verify they are secure and unobstructed. 5. Reinstall the right rear fender/rocker panel assembly and install the fuel cap. 6. Reconnect the negative battery cable. Test the fuel pump by turning the ignition key to ‘On’ and listening for the pump to activate.

4.8

FUEL SYSTEM FUEL FILTER / WATER SEPARATOR General Information The fuel filter / water separator assembly is located under the seat on the RH side of the vehicle, in-between the engine and the fuel tank. The filter should be:

Fuel Filter / Water Separator Draining 1. See chapter 4 of this manual for safety information. 2. Be sure engine is cool and the battery is disconnected.

Loosen Valve Fuel Drain

3. Remove seat.

6. Wait for fuel and water to stop draining from the valve and firmly retighten valve hand tight only.

4. Place container / drain pan / shop towels under fuel filter area to catch any excess fuel.

7. Clean up any excess fuel properly. 8. Reconnect battery. 9. Turn key switch ON for 10-15 seconds. 10. Start engine and verify that no fuel leaks are present. 11. Dispose of shop towels and drained fuel properly.

Fuel Filter

Fuel Filter / Water Separator Replacement 1. Follow Steps 1-7 from the “Fuel Filter / Water Separator Draining” Procedure.

Drain Valve

4.9

FUEL SYSTEM FUEL SENDER

6. Loosen and remove the PFA nut using Special Tool PU-50326.

Fuel Sender Test If the fuel gauge reading on the instrument cluster is not working, or if the display reading differs in large comparison to the fuel in the tank, perform a resistance test on the fuel sender. Disconnect the sending unit connection and measure the resistance at the connector wires (see chapter 10 for further details). If out of specification, replace the sender assembly.

Special Tool: PU-50326 - PFA Nut Tool 7. Remove the old sender and discard the PFA gasket. 8. Install a new sender and new PFA gasket onto the tank assembly, using care not to damage or bend the float arm. 9. Install the PFA nut using Special Tool PU-50326. Torque the PFA nut to specification. Fuel Sender Resistance Specifications: Full: 102 ± 2  Empty: 7 ± 2 

=T PFA Nut: 75 ft-lbs (101 Nm)

Fuel Sender Replacement / Installation If the fuel gauge sender is broken, replace the sender as an assembly (Refer to exploded view on Page 4.3). 1. Remove the seat base. 2. Thoroughly clean the top of the fuel tank before disassembly.

10. Reconnect the sender harness and return fuel line. 11. Reconnect the negative battery cable. Test the fuel gauge sender by turning the ignition key to ‘On’ and watch for the gauge to indicate your present fuel level.

3. Disconnect the negative battery cable. 4. Disconnect the return flow fuel line. 5. Disconnect the fuel sender harness connector.

4.10

FUEL SYSTEM GENERAL TROUBLESHOOTING Fuel System Troubleshooting - Refer to

Yanmar Engine Service Chapter 11 for more troubleshooting information

Fuel Starvation Symptoms: Hard start or no start, bog, backfire, hesitation, low power, surging, high idle, idle speed erratic and low idle: • No fuel in tank / Low fuel • Restricted tank vent, or routed improperly • Fuel lines or fuel injectors restricted • Fuel filter plugged / gelled • Fuel pump inoperative

• Air leak in system • Intake air leak (intake ducts, airbox) Rich Mixture Symptoms: Excessive exhaust smoke, rough idle, poor fuel economy, engine runs rough, poor performance, bog, engine loads up. • Air intake restricted (inspect intake duct) • Air filter dirty/plugged • Poor fuel quality (old fuel) • Fouled injectors • TPS setting incorrect • Injector dirty / worn Poor Idle Symptom: Idle Too High • Throttle stop screw set incorrect • Throttle cable sticking, improperly adjusted, routed incorrectly Symptom: Idle Too Low • Plugged air filter • Low Fuel • Leaking injector (rich condition) • PVT Belt dragging Symptom: Erratic Idle • Throttle cable incorrectly adjusted or sticking • Low Fuel • Air Leaks, dirty injector • Tight valves • Timing incorrect • PVT Belt dragging • Dirty air cleaner • Engine worn

4.11

FUEL SYSTEM

NOTES

4.12

BODY / STEERING / SUSPENSION

CHAPTER 5 BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 DECAL REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 CAB FRAME / SEAT BACK / PVT AIR INTAKE BOX (NON CREW) . . . . . . . . . . . . . . . . . . . . . 5.4 CAB FRAME / SEAT BACK / PVT AIR INTAKE BOX (CREW). . . . . . . . . . . . . . . . . . . . . . . . . . 5.6 CHASSIS / MAIN FRAME (NON CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8 CHASSIS / MAIN FRAME (CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 BODY EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10 DASH INSTRUMENTS / CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.10 HOOD / DASH / FRONT FENDERS / FRONT FASCIA . . . . . . . . . . . . . . . . . . . . . . . . .5.11 FLOOR / REAR FENDERS (2011 NON CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.12 FLOOR / REAR FENDERS (2012-2013 NON CREW) . . . . . . . . . . . . . . . . . . . . . . . . . .5.13 FLOOR / REAR FENDERS (CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.14 SEAT MOUNTING / SEAT BELTS (NON CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.15 SEAT MOUNTING / SEAT BELTS (CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.16 CARGO BOX - PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.17 CARGO BOX - TAILGATE / BOX SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.18

BODY COMPONENT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19

BOX REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.19 BOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.20 LOWER SEAT BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.20 WHEEL WELL PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.21 FRONT BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.21 FRONT FASCIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.21 FRONT FENDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.21 HOOD / DASH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.22 GLOVE BOX / STORAGE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.22

STEERING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23 EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.23 STEERING WHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.24 STEERING SHAFT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.24 STEERING SHAFT BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.25

FRONT A-ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26 BALL JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27 SERVICE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.27 BALL JOINT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.28 BALL JOINT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.28

REAR A-ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.29 REMOVAL / REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.29 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.31 EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.32

REAR STABILIZER BAR / LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33 SHOCKS / SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.34

5.1

BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS

SPECIAL TOOLS

Torque Specifications

Special Tools

ITEM

TORQUE VALUE

Front Frame to Rear Frame Support Fasteners (CREW)

39 ft-lbs (53 Nm)

Front Upper / Lower A-Arm Bolts

30 ft-lbs (41 Nm)

Rear Upper / Lower A-Arm Bolts

30 ft-lbs (41 Nm)

Front Ball Joint Pinch Bolts

23 ft-lbs (31 Nm)

Rear Lower Bearing Carrier

30 ft-lbs (41 Nm)

Rear Upper Bearing Carrier

30 ft-lbs (41 Nm)

Upper / Lower Shock Bolts

30 ft-lbs (41 Nm)

Stabilizer Bar to Frame

17 ft-lbs (23 Nm)

Stabilizer Bar Linkage Bushings

17 ft-lbs (23 Nm)

Front Wheel Hub Castle Nut

80 ft-lbs (108 Nm)

Rear Wheel Hub Castle Nut

110 ft-lbs (150 Nm)

Wheel Nuts (Cast Rims) Wheel Nuts (Steel Rims)

PART NUMBER 2871095

Shock Spanner Wrench

2870623

Shock Spring Compressor Tool

2876389

Multi-Function Pliers

SPX Corp: 1-800-328-6657 or http://polaris.spx.com/

Multi-Function Pliers Included in the tool kit, the multi-function pliers is designed to remove the plastic push rivets used to fasten body components.

30 ft-lbs (41 Nm) + 90° (1/4) turn 35 ft-lbs (47 Nm)

Outer Tie Rod to Bearing Carrier

40 ft-lbs (54 Nm)

Tie Rod End Jam Nut

13 ft-lbs (18 Nm)

Seat Belt to Cab Frame

38 ft-lbs (51 Nm)

Seat Belt to Seat Base

40 ft-lbs (54 Nm)

Steering Wheel to Shaft

28 ft-lbs (38 Nm)

Upper Steering Shaft to U-Joint Shaft

17 ft-lbs (23 Nm)

Lower Steering Shaft to Steering Box

30 ft-lbs (41 Nm)

Steering Box

17 ft-lbs (23 Nm)

NOTE: Refer to exploded views throughout this chapter for more torque specifications, component identification, and location of components.

Pliers

Push Rivet

5.2

TOOL DESCRIPTION

BODY / STEERING / SUSPENSION DECAL REPLACEMENT

To flame treat the decal area:

WARNING The following procedure involves the use of an open flame. Perform this procedure in a wellventilated 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. Do not flame treat components that are installed on the vehicle. Remove the component from the vehicle before flame treating.

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 (2-3 inches from the flame tip is recommended). Keep the torch moving to prevent damage. 2. Apply the decal on one edge first. Slowly lay down remainder of the decal while rubbing lightly over the decal surface to eliminate any air bubbles during the application.

The side panels, front and rear fender cabs are plastic polyethylene material. Therefore, they must be “flame treated” prior to installing a decal to ensure good adhesion. A bonus of the flame treating procedure is it can be used to reduce or eliminate the whitish stress marks that are sometimes left after a fender or cab is bent, flexed, or damaged.

CAUTION Do not flame treat painted plastic components. Painted plastic surfaces should only be wiped clean prior to decal adhesion.

5.3

BODY / STEERING / SUSPENSION CAB FRAME / SEAT BACK / PVT AIR INTAKE BOX (NON CREW)

Tighten the hose clamp to specification.

Exploded View / Assembly 1. Assemble the RH and LH cab frame side hoops by sliding the tube over the rear coupler. Secure using (2) 5/16” bolts and nuts. Line up the front side hoop couplers with the front frame couplers and secure using (4) 3/8” screws and nuts. Leave all fasteners finger tight. 2. Attach the front cab frame cross tube to the side hoops using (4) M10 bolts. Attach the rear cab frame cross tube to the side hoops using (4) M10 bolts. Leave all fasteners finger tight. 3. Loosely install the rear cab frame X brace to the side hoops using (8) M8 bolts and nuts. Leave all fasteners finger tight. 4. Tighten the (8) front and rear cab frame cross tube fasteners installed during Step 2 to specification.

Hose Clamp: 18 in-lbs (2 Nm) 9. Attach the clutch air intake box to the seat back using (4) #14 self-tapping screws. Tighten fasteners to specification.

=T #14 Self-Tapping Screws: 19 in-lbs (2.1 Nm) 10. Attach each headrest to the rear cab frame using four 1/4” self-tapping fasteners. Place washers between the fastener head and headrest as shown below. Torque fasteners to 10 in-lbs (1 Nm).

=T Rear Cab Frame Cross Tube Fasteners: 27 ft-lbs (36 Nm) 5. Tighten the (2) 5/16” fasteners installed during Step 1 to specification and the (4) 3/8” fasteners to specification.

=T 5/16” Fasteners: 17 ft-lbs (22 Nm) 3/8” Fasteners: 27 ft-lbs (36 Nm) 6. Tighten the (8) M8 X brace fasteners installed during Step 3 to specification.

=T M8 X Brace Fasteners: 17 ft-lbs (22 Nm) 7. Fasten the seat back to the X brace using (8) #14 selftapping screws. Tighten fasteners to specification.

=T #14 Self-Tapping Screws: 19 in-lbs (2.1 Nm) 8. Place the 2.5” hose clamp over the clutch air inlet hose and slide the clutch intake box assembly into the hose.

5.4

Fasteners: 10 in-lbs (1 Nm)

BODY / STEERING / SUSPENSION 27 ft-lbs (36 Nm)

17 ft-lbs (22 Nm)

27 ft-lbs (36 Nm)

19 in-lbs (2.1 Nm) 10 in-lbs (1 Nm)

17 ft-lbs (22 Nm)

19 in-lbs (2.1 Nm)

27 ft-lbs (36 Nm)

5.5

BODY / STEERING / SUSPENSION CAB FRAME / SEAT BACK / PVT AIR INTAKE BOX (CREW) 1. Assemble the RH and LH front cab frame side hoops by sliding the tube over the rear coupler. Secure using (2) 5/16” bolts and nuts. Line up the front side hoop couplers with the front frame couplers and secure using (4) 3/8” screws and nuts. Leave all fasteners finger tight. 2. Attach the front cab frame cross tube to the side hoops using (4) M10 screws. Install the rear cab frame cross tube to the side hoops using (4) M10 screws. Leave all fasteners finger tight. 3. Loosely install the rear cab frame K brace to the side hoops using (8) M8 screws and nuts. Leave all fasteners finger tight.

and the (4) M10 fasteners to specification.

=T 5/16” Fasteners: 17 ft-lbs (22 Nm) M10 Fasteners: 27 ft-lbs (36 Nm) 11. Tighten the (4) rear cab frame cross tube fasteners installed during Step 8 to specification.

=T Rear Cab Frame Cross Tube Fasteners: 27 ft-lbs (36 Nm) 12. Tighten the (8) M8 X brace fasteners installed during Step 9 to 17 ft-lbs (22 Nm).

4. Tighten the (8) front and rear cab frame cross tube fasteners installed during Step 2 to specification.

=T M8 X Brace Fasteners: 17 ft-lbs (22 Nm)

Rear Cab Frame Cross Tube Fasteners: 27 ft-lbs (36 Nm) 5. Tighten the (2) 5/16” fasteners installed during Step 1 and the (4) 3/8” fasteners to specification.

13. Fasten the seat back to the rear cab frame X brace using (8) #14 self-tapping screws. Tighten fasteners to specification. Repeat this step to attach the front seat back to the mid-cab frame K brace. 14. Place the 2.5” hose clamp over the clutch air inlet hose and slide the clutch intake box assembly into the hose. Tighten the hose clamp to specification.

=T 5/16” Fasteners: 17 ft-lbs (22 Nm) 3/8” Fasteners: 27 ft-lbs (36 Nm) 6. Tighten the (8) M8 K brace fasteners installed during Step 3 to specification.

15. Attach the clutch air intake box to the seat back using (4) #14 self-tapping screws. Tighten fasteners to specification. 16. Attach the headrest to the rear cab frame using (4) 1/ 4” self-tapping fasteners. Place washers between the fastener head and headrest as shown below. Torque fasteners to specification.

M8 K Brace Fasteners: 17 ft-lbs (22 Nm) 7. Assemble the RH and LH rear cab frame side hoops by sliding the tube over the rear coupler. Secure using (2) 5/16” bolts and nuts. Line up the front upper rear hoop couplers with the rear cab frame cross tube holes and secure using (2) M10 screws and nuts. Leave all fasteners finger tight.

=T Hose Clamp: 18 in-lbs (2 Nm) #14 Self-Tapping Screws: 19 in-lbs (2.1 Nm) 1/4” Self-tapping Fasteners: 10 in-lbs (1 Nm)

8. Install the rear cab frame cross tube to the rear side hoops using (4) M10 screws. Leave all fasteners finger tight. 9. Loosely install the rear cab frame X brace to the rear side hoops using (8) M8 screws and nuts. Leave all fasteners finger tight. 10. Tighten the (2) 5/16” fasteners installed during Step 7

5.6

BODY / STEERING / SUSPENSION 27 ft-lbs (36 Nm)

27 ft-lbs (36 Nm)

27 ft-lbs (36 Nm) 10 in-lbs (1 Nm)

17 ft-lbs (22 Nm) 19 in-lbs (2.1 Nm)

27 ft-lbs (36 Nm)

17 ft-lbs (22 Nm) 17 ft-lbs (22 Nm)

19 in-lbs (2.1 Nm)

17 ft-lbs (22 Nm)

5.7

BODY / STEERING / SUSPENSION CHASSIS / MAIN FRAME (NON CREW) Exploded View

Seat Base

Dash Support RH Floor Support

Main Frame

Cap Fascia Screen

30 ft-lbs (41 Nm) 30 ft-lbs (41 Nm)

T27 Screws 5 ft-lbs (7 Nm)

Cap 14 ft-lbs (19 Nm)

Bumper Screen

Bumper Guard Bracket Bumper

5.8

LH Floor Support

BODY / STEERING / SUSPENSION CHASSIS / MAIN FRAME (CREW) Exploded View

Rear Seat Base

Front Seat Base Dash Support Rear Frame

5 RH Floor Support

39 ft-lbs (53 Nm)

30 ft-lbs (41 Nm)

Cap

Frame Supports

30 ft-lbs (41 Nm)

39 ft-lbs (53 Nm)

Fascia Screen

LH Floor Support

Front Frame 14 ft-lbs (19 Nm) T27 Screws 5 ft-lbs (7 Nm)

Bumper Screen

Bumper

5.9

BODY / STEERING / SUSPENSION BODY EXPLODED VIEWS Dash Instruments / Controls A. Instrument Cluster (Speedo) B. Speedometer “Mode” Button C. Headlight Switch D. 2WD/AWD Switch E. 12 Volt Accessory Receptacle (2) F. Rubber Mount G. Key Switch H. Grommet I. Push Rivet J. Wait to Start / Low Oil Pressure Indicator K. Dash Panel

K D

F I H G E

5.10

BODY / STEERING / SUSPENSION Hood / Dash / Front Fenders / Front Fascia T27 Screws 5 ft-lbs (7 Nm)

T30 Screws Hood Front RH Fender

Dash T20 Screws

Push Rivets

Hinge T27 Screws 5 ft-lbs (7 Nm) Cup Holder T27 Screw 5 ft-lbs (7 Nm)

Front Fascia

T27 Screws

T27 Screws 5 ft-lbs (7 Nm)

Front LH Fender

T27 Screws

U-Type Speed Nut

Push Rivets

U-Type Speed Nut

T27 Screws 5 ft-lbs (7 Nm)

Hood Liner

T27 Screws Fascia Screen

5.11

BODY / STEERING / SUSPENSION Floor / Rear Fenders (2011 NON CREW)

Rear RH Fender Rocker Panel T27 Screws 5 ft-lbs (7 Nm)

T27 Screws 5 ft-lbs (7 Nm) U-Type Speed Nut Storage Container

Push Rivets

Rear Floor Floor Cover U-Type Speed Nut

T27 Screws 5 ft-lbs (7 Nm)

Main Floor

T27 Screws

Push Rivets

Push Rivets Rear LH Fender Rocker Panel

Wheel Well Panels Push Rivets

Skid Plate

Screws 6-8 ft-lbs (8-10 Nm)

5.12

T27 Screws 5 ft-lbs (7 Nm)

BODY / STEERING / SUSPENSION Floor / Rear Fenders (2012-2013 NON CREW)

T27 Screws 5 ft-lbs (7 Nm)

Rear RH Fender Rocker Panel T27 Screws 5 ft-lbs (7 Nm)

Foil Heat Shield

Push Rivets Storage Container

Floor Cover

U-Type Speed Nut

5 Rear Floor

Main Floor

T27 Screws 5 ft-lbs (7 Nm)

Block Off Panel

T27 Screws

Push Rivets

T27 Screws 5 ft-lbs (7 Nm)

Rear LH Fender Rocker Panel

Wheel Well Panels Push Rivets

Screws 7 ft-lbs (9 Nm)

Skid Plate

5.13

BODY / STEERING / SUSPENSION Floor / Rear Fenders (CREW) Storage Container

Underseat Storage box

Foil

Heat Shield

Rear Floor

Floor Cover

T27 Screws 5 ft-lbs (7 Nm)

U-Type Speed Nut

Rear Floor Main Floor

Mid Floor

Rear Lower Floor

U-Type Speed Nut

RH Fenders Rocker Panels

U-Type Speed Nut

T27 Screws 5 ft-lbs (7 Nm)

T27 Screws

Push Rivets

U-Type Speed Nut

Push Rivets T27 Screws 5 ft-lbs (7 Nm) Wheel Well Panels Block Off Panel

Front LH Fender Rocker Panel

Push Rivets Skid Plates Screws 7 ft-lbs (9 Nm)

5.14

Rear LH Fender Rocker Panel

BODY / STEERING / SUSPENSION Seat Mounting / Seat Belts (NON CREW) Bolt 37 ft-lbs (50 Nm)

RH 3-Point Seat Belt

Bolt 37 ft-lbs (50 Nm)

T30 Screws 19 in-lbs (2.1 Nm)

Seat Back

LH 3-Point Seat Belt

Foil

5 2011 2012 2013 Heat Shield RH 3-Point Seat Belt Bolt 40 ft-lbs (54 Nm)

Seat Base

Lab Belt Bolt 40 ft-lbs (54 Nm)

Grommet

Bolt 40 ft-lbs (54 Nm)

LH 3-Point Seat Belt Seat Base Frame Grommet

Bolt 40 ft-lbs (54 Nm)

5.15

BODY / STEERING / SUSPENSION Seat Mounting / Seat Belts (CREW) T30 Screws 19 in-lbs (2.1 Nm)

Bolt 37 ft-lbs (50 Nm) Seat Back RH 3-Point Seat Belt (x2)

Foil

T30 Screws 19 in-lbs (2.1 Nm)

Seat Base

Heat Shield

Bolt 37 ft-lbs (50 Nm)

LH 3-Point Seat Belt (x2)

Front Seat Supports

Bolt 40 ft-lbs (54 Nm)

Grommet

RH 3-Point Seat Belt (x2)

Lab Belt Pad

Bolt 40 ft-lbs (54 Nm) Grommet

Seat Base Frame

5.16

Bolt 40 ft-lbs (54 Nm) LH 3-Point Seat Belt (x2)

Bolt 40 ft-lbs (54 Nm)

BODY / STEERING / SUSPENSION Cargo Box - Panels

RH Box Panel Latch

T30 Screws

Tailgate Support

Latch

5 T20 Screws

Cargo Box

T20 Screw

Foil

T20 Screws

Front Box Panel

T30 Screws

LH Box Panel

5.17

BODY / STEERING / SUSPENSION Cargo Box - Tailgate / Box Support Tailgate Cap

Outer Panel Tailgate Bracket Latch

Tailgate Cable

Rod T30 Screws T20 Screws Rod Inner Panel

Tailgate Cable

T27 Screws 5 ft-lbs (7 Nm)

T27 Screw Tailgate Tube

T30 Screws Box Support

Nut (M10) Box Latch

Hinge Bolt (M10) Bumper Bushings

Springs

Shock Pins Clip

Screw

Clip

5.18

BODY / STEERING / SUSPENSION BODY COMPONENT REMOVAL

frame on both pivot points.

Box Removal 1. Lift the cargo box into the raised dump position.

2. Disconnect the rear wire harness attached to the tail light harness. 3. Remove the upper clip and pin attaching the shock to the cargo box. Box Shock Pin and Retaining Clip

CAUTION

Tail Light Harness

Safely support the box during the remainder of the removal process. The box is not as stable with the hinge pins removed. 6. With both hinge bolts removed, lift the box from the frame. Two people or an approved hoist may be needed to 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 lower clip and pin attaching the shock to the vehicle frame.

CAUTION Use caution when removing the box. It is recommended to have two people carefully remove the box from the frame.

Box Shock Pin and Retaining Clip

5. Remove nut (A) and bolt (B) that secure the box to the

5.19

BODY / STEERING / SUSPENSION Box Installation

Lower Seat Base

1. If the shock was replaced, install the lower portion of the shock to the frame and secure it with the pin and clip.

1. Lift up on the front of the seat base to disengage the seat from the rubber grommets.

Lower Shock Pin

Rubber rommets 2. Place the cargo box onto the frame. Align the hinges of the box with the bracket on the frame. 3. Install box hinge bolts on both sides.

2. Pull the seat base forward to disengage the rear tabs and remove the seat base from the vehicle.

4. Install hinge bolt nuts on both sides and torque to ď&#x20AC; specification.

=T Rear Box Hinge Bolt Nuts: 30 ft-lbs (41 Nm) 5. With the hinge bolts installed, attach the shock to the cargo box by inserting the pin and clip. 6. Connect tail light harness connector. 7. Lower the box and secure the latch.

5.20

BODY / STEERING / SUSPENSION Wheel Well Panels

Front Fascia

1. Using the multi-function pliers, remove the (6) push rivets from the LH panel and the (5) push rivets from the RH panel.

1. Remove the (2) T27 Torx-head screws retaining the fascia screen and remove the screen. 2. Remove the (6) remaining T27 Torx-head screws retaining the front fascia.

Remove all T27 screws shown 2. Pull both panels out from the wheel wells. 3. Turn the headlight bulbs counter-clockwise 90° and remove the bulbs from the head lamps.

Front Bumper 1. Remove the (2) T27 Torx-head screws retaining the fascia screen and remove the screen.

4. Carefully remove the fascia from the vehicle.

Front Fenders 1. Remove the lower T27 Torx-head screws retaining the front fascia (see “Front Fascia”).

Remove Remove

T27 crews

Remove 2. Remove the (3) bolts from the lower portion of the bumper. 3. Remove the fasteners from each side of the upper portion of the bumper.

T27 Screws (See “Front Fascia”)

4. Carefully remove the bumper from the vehicle.

Push Rivets

2. Remove the (4) push rivets retaining the front fender and remove the fender from the vehicle. 3. Repeat this procedure to remove the other front fender.

5.21

BODY / STEERING / SUSPENSION Hood / Dash 1. Remove the front fascia (see “Front Fascia” removal). 2. Unlatch the hood and remove the (4) T27 Torx-head screws to remove the hood assembly. T27 Screws

9. Remove the (2) push rivets from the dash panel (see “Dash Instruments/Controls”). Unhook all electrical components to allow the panel to be completely removed. 10. Carefully remove the dash assembly from the vehicle.

Glove Box / Storage Panel 1. Remove the hood / dash (see “Hood / Dash”).

3. Remove the front portion of the cab frame on each side to allow dash removal (see “Cab Frame Exploded View”). 4. Remove the (2) T25 Torx-head screws retaining the front of the dash to the hood liner. 5. Open the glove box and remove the (4) T20 Torxhead screws from the dash. Remove front cab frame from each side of dash

T25 Screws

Remove 2V outlets 2. Remove the (7) T27 Torx-head screws retaining the glove box storage panel. 3. Disconnect 12V power outlets and remove the assembly.

T20 Screws T27 Screws

Remove fasteners and rivets

6. Remove the (5) T27 Torx-head screws retaining the rear portion of the dash. 7. Remove the (8) fasteners from each side of the dash where it attaches to the front and rear fenders. 8. Remove the rubber boots from around the parking brake and shift lever.

5.22

BODY / STEERING / SUSPENSION STEERING ASSEMBLY Exploded View Cap Steering Wheel 28 ft-lbs (38 Nm)

Thick Washer Thin Washer Bearing

23 ft-lbs (31 Nm) Pivot Tube

Spacer Bearing Spacer Thin Washer Thick Washers Thin Washer

7 ft-lbs (10 Nm)

Bushing

23 ft-lbs (31 Nm)

Steering Shaft

12 ft-lbs (16 Nm)

Oil Locking Shock Asm.

40 ft-lbs (54 Nm)

13 ft-lbs (18 Nm) Gear Box Asm.

30 ft-lbs (41 Nm)

Boot

40 ft-lbs (54 Nm) Tie Rod

17 ft-lbs (23 Nm)

13 ft-lbs (18 Nm)

Rod End

Cotter Pin

5.23

BODY / STEERING / SUSPENSION Steering Wheel Removal

Steering Shaft Removal 1. Remove the pinch bolt retaining the lower portion of the steering shaft to the steering gear box assembly.

CAUTION This procedure should NOT be used on EPS models. Using this procedure on an EPS model can permanently damage the EPS unit and cause a Power Steering Fault.

Steering Shaft Pinch Bolt

1. Remove the steering wheel cap. 2. Loosen the nut and back it half way off the steering shaft. 3. With a glove on your hand, place it under the steering wheel. Lift upward on the inner portion of the steering wheel while using a hammer to strike the steering shaft nut. IMPORTANT: If the steering wheel will not pop loose, proceed to “Steering Shaft Removal”.

Gear Box Asm.

Figure 5-16

2. Remove the fastener retaining the upper portion of the steering wheel tilt shock to the pivot tube. Figure 5-17

4. Once the steering wheel pops loose, completely remove the nut and lift the steering wheel off the shaft.

Pivot Tube

Tilt Shock

3. Remove the (2) fasteners that retain the pivot tube. 4. Remove the steering shaft, pivot tube and steering wheel from the vehicle as an assembly. 5. Refer to steps 11-13 of the “Steering Shaft Bearing Replacement” procedure for installation.

5.24

BODY / STEERING / SUSPENSION Steering Shaft Bearing Replacement IMPORTANT: Replacement pivot tube assembly comes with new upper and lower bearings installed. Use this procedure if replacing just the bearings only. 1. Perform the “Steering Shaft Removal” procedure. 2. Remove the steering wheel cap and retaining nut.

9. Reinstall the upper washers and spacers in the order in which they were removed. 10. Install the steering wheel and hand tighten the nut. 11. Reinstall the steering shaft assembly in the vehicle. Install the lower portion of the steering shaft onto the steering gear box assembly (see Figure 5-16). Torque the lower pinch bolt to specification.

3. Press steering shaft out of the steering wheel and pivot tube.

4. Note the order and location of the washers and spacers between the steering wheel and pivot tube. 5. Drive the bearings out of the pivot tube using a drift punch.

Lower Pinch Bolt: 30 ft-lbs (41 Nm) 12. Install the (2) fasteners that retain the pivot tube (see Figure 5-17). Torque fasteners to specification.

6. Inspect the pivot tube bearing surfaces for signs of excessive wear or damage.

7. Apply Loctite® 271™ (Red) to the outer circumference of the new lower bearing race. Slide the new lower bearing onto the steering shaft and install the steering shaft through the pivot tube.

Pivot Tube Fasteners: 23 ft-lbs (31 Nm)

NOTE: Use care not to allow any of the Loctite® to get in the bearing.

13. Install the fastener retaining the upper portion of the steering wheel tilt shock to the pivot tube (see Figure 5-17). Torque fastener to specification.

Thick Washer

Spacer Pivot Tube Cap Nut Thin Washer

Spacer

Bearing

Upper Tilt Shock Fastener: 7 ft-lbs (10 Nm) 14. Be sure the front wheels are facing straight forward. Remove the steering wheel and align as needed. Torque the steering wheel nut to specification.

Thick Washers

=T Bearing

Thin Washers

NOTE: Be sure the lower washers and spacers are still on the steering shaft. 8. Apply Loctite® 271™ (Red) to the outer circumference of the new upper bearing race. Slide the new upper bearing onto the steering shaft and press it into the pivot tube by hand.

Steering Wheel Nut: 28 ft-lbs (38 Nm) 15. Wipe the pivot tube clean of any excess Loctite®. 16. Install steering wheel cap and field test steering operation.

NOTE: Use care not to allow any of the Loctite® to get in the bearing. NOTE: Bearings will be seated in the pivot housing upon tightening the steering wheel nut in step 14.

5.25

BODY / STEERING / SUSPENSION FRONT A-ARMS

18. If not replacing the A-arm, thoroughly clean the A-arm and pivot tubes.

Removal / Replacement

19. Install new ball joint into A-arm. Refer to “Ball Joint Replacement” section.

The following procedure details upper and lower A-arm removal and replacement on one side of the vehicle. 1. Elevate and safely support the front of the vehicle and remove the front wheel. 2. Remove the lower shock fastener (A) from the upper A-arm.

20. Insert new A-arm bushings and pivot tubes into new A-arm. 21. Install new lower A-arm assembly onto vehicle frame. Torque new bolts (E) to specification.

3. Remove the brake line clamp from the A-arm.

22. Insert lower A-arm ball joint end into the bearing carrier. Install the lower ball joint pinch bolt (D) into the bearing carrier and torque bolt to specification.

4. Remove the upper ball joint pinch bolt (B) from the front bearing carrier.

23. Upon A-arm installation completion, test vehicle at low speeds before putting into service.

5. Using a soft face hammer, tap on bearing carrier to loosen the upper A-arm ball joint end while lifting upward on the upper A-arm. Completely remove the ball joint end from the bearing carrier. 6. Loosen and remove the upper A-arm through-bolt fasteners (C) and remove the upper A-arm from the vehicle.

=T Upper/Lower A-arm Retainer Bolt: 30 ft-lbs (41 Nm) Ball Joint Pinch Bolt: 23 ft-lbs (31 Nm) Lower Shock Mounting Bolt: 30 ft-lbs (41 Nm)

7. Examine A-arm bushings and pivot tubes (see “Exploded View”). Replace if worn. Discard hardware.

WARNING

Remove Clamp

Fastener has a pre-applied locking agent which is destroyed upon removal. Always use new fastener upon assembly. 8. If not replacing the A-arm, thoroughly clean the A-arm and pivot tubes.

B D

9. Install new ball joint into A-arm. Refer to “Ball Joint Replacement” section. 10. Insert new A-arm bushings and pivot tubes into new A-arm.

E E

11. Install new upper A-arm assembly onto vehicle frame. Torque new bolts (C) to specification. 12. Insert upper A-arm ball joint end into the bearing carrier. Install the upper ball joint pinch bolt (B) into the bearing carrier and torque bolt to specification. 13. Attach shock to A-arm with fastener (A). Torque lower shock bolt to specification. 14. Remove the lower ball joint pinch bolt (D) from the front bearing carrier. 15. Using a soft face hammer, tap on bearing carrier to loosen the lower A-arm ball joint end while pushing downward on the lower A-arm. Completely remove the ball joint end from the bearing carrier. 16. Loosen and remove the lower A-arm through-bolt fasteners (E) and remove the lower A-arm from the vehicle. 17. Examine A-arm bushings and pivot tubes (see “Exploded View”). Replace if worn. Discard hardware.

5.26

BODY / STEERING / SUSPENSION BALL JOINT SERVICE

Exploded View

Service Preparation

30 ft-lbs (41 Nm)

IMPORTANT: Do not reuse a ball joint if it has been removed. If removed, it must be replaced. Use this removal procedure only when replacing the ball joint.

Pivot Tube

Nuts

Upper A-arm

Bushings

30 ft-lbs (41 Nm)

Ball Joint

NOTE: Ball joint tool PU-50506 will allow the upper and lower ball joints to be replaced with the A-arm installed on the vehicle. PU-50506

Press Asm. (C)

Removal Adapter (B)

Pivot Tube

Nuts

Bearing Pinch Carrier Bolts 23 ft-lbs (31 Nm)

Bushings 30 ft-lbs (41 Nm)

30 ft-lbs (41 Nm)

Installation Adapter (D) Ball Joint

Spacer (A)

The A-arm does not need to be removed to perform this procedure if ball joint tool PU-50506 is used. 1. Properly lift and support the vehicle by the frame. 2. Remove the appropriate front wheel.

Screws CV Shield

Lower A-arm

3. To service the upper ball joint:  - Remove and discard the two front brake caliper mounting bolts and remove the caliper from the brake disc (see “Brakes” chapter).  - Remove and discard the upper ball joint pinch bolt.  - If necessary, remove the lower front shock fastener from the A-arm to gain enough clearance to install ball joint tool (PU-50506) on the upper ball joint. 4. To service the lower ball joint:  - Remove and discard the lower ball joint pinch bolt.  - If necessary, remove the lower front shock fastener from the A-arm to gain enough clearance to install ball joint tool (PU-50506) on the lower ball joint.

5.27

BODY / STEERING / SUSPENSION Ball Joint Removal

Ball Joint Installation

1. Remove the retaining ring from the ball joint.

1. By hand, install the NEW ball joint into the A-arm.

Picture For Reference Only

Ball Joint

2. Position the Installation Adapter (D) over the face of the ball joint.

D Upper A-arm

Retaining Ring 2. Install Spacer (A) over the top of the ball joint face. A

Ball Joint Face

A-arm

3. Position the Spacer (A) over the shaft of the ball joint so it is against the A-arm.

A A-arm

4. Install the Press Asm. (C) onto the A-arm to engage the Installation Adapter and Spacer. 5. Tighten the Press Asm. screw and fully install the ball joint into the arm.

B C

3. Place Removal Adaptor (B) over the ball joint shaft. 4. Install the Press Asm. (C) onto the A-arm to engage the ball joint Removal Adapter.

IMPORTANT: Be sure the Press Asm. opening is only contacting the Spacer (A) and not the ball joint face. 5. Tighten the Press Asm. screw and fully remove the ball joint from the A-arm.

Ball Joint Removal

5.28

Ball Joint Installation

BODY / STEERING / SUSPENSION 6. After the new ball joint is fully installed into the A-arm, install a new retaining ring. Picture For Reference Only

Ball Joint

REAR A-ARMS Removal / Replacement The following procedure details upper and lower A-arm removal and replacement on one side of the vehicle. Repeat the following steps to remove the A-arm(s) from the opposite side. NOTE: Use the exploded view in this section as a reference during the procedure. 1. Elevate and safely support the rear of vehicle off the ground and remove the rear wheel.

Upper A-arm

Retaining Ring 7. Repeat the ball joint service procedure for any additional A-arm ball joint replacements. 8. Insert upper / lower A-arm ball joint end into the bearing carrier. Install new pinch bolts and nuts. Torque to specification.

9. If needed, install new brake caliper mounting bolts and torque to specification.

CAUTION New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly. 10. Install wheel and (4) wheel nuts. Torque wheel nuts to specification.

Upper A-arm Removal 2. Remove the fastener retaining the lower portion of the shock and stabilizer linkage to the upper A-arm.

=T Front Ball Joint Pinch Bolts: 44 ft-lbs (60 Nm) Front Shock Mounting Bolts: 45 ft-lbs (61 Nm) Front Caliper Mounting Bolts: 40 ft-lbs (54 Nm) Wheel Nuts (Alum): 30 ft-lbs (41 Nm) + 90Â° (1/4 turn) Wheel Nuts (Steel): 27 ft-lbs (37 Nm)

5.29

BODY / STEERING / SUSPENSION 3. Remove the fastener attaching the upper A-arm to the bearing carrier.

4. Remove the fasteners attaching the upper A-arm to the frame and remove the upper A-arm from the vehicle.

5. Examine A-arm and bearing carrier bushings and pivot tubes (see “Exploded View”). Replace if worn. Discard hardware.

WARNING Fastener has a pre-applied locking agent which is destroyed upon removal. Always use new fastener upon assembly. 6. If not replacing the A-arm, thoroughly clean the a-arm and pivot tubes. 7. Insert new A-arm bushings and pivot tubes into the new A-arm.

5.30

Lower A-arm Removal 8. Remove the fastener attaching the lower A-arm to the bearing carrier.

9. Remove the fasteners attaching the lower A-arm to the frame and remove the lower A-arm from the vehicle.

10. Examine A-arm and bearing carrier bushings and pivot tubes (see “Exploded View”). Replace if worn. Discard hardware.

WARNING Fastener has a pre-applied locking agent which is destroyed upon removal. Always use new fastener upon assembly. 11. If not replacing the A-arm, thoroughly clean the a-arm and pivot tubes. 12. Insert new A-arm bushings into pivot tubes into the new A-arm.

BODY / STEERING / SUSPENSION Installation 1. Install lower A-arm assembly onto vehicle frame. Torque new fasteners to specification. 2. Attach lower A-arm to bearing carrier. Torque new fastener to specification. 3. Route the brake line over the top of the lower A-arm and secure it in the retainer. Retainer

4. Install upper A-arm assembly onto vehicle frame. Torque new fasteners to specification. 5. Attach upper A-arm to bearing carrier. Torque new fastener to specification. 6. Reinstall the lower portion of the shock and stabilizer linkage to the upper A-arm. Torque shock / linkage fastener to specification.

=T Upper/Lower A-arm Retainer Bolt: 30 ft-lbs (41 Nm) Upper/Lower Bearing Carrier Bolt: 30 ft-lbs (41 Nm) Lower Shock/Linkage Mount Bolt: 30 ft-lbs (41 Nm) 7. Install wheel and torque wheel nuts to specification. ITEM

NUT TYPE

SPECIFICATION

Aluminum Wheels

Lug Nut

30 ft-lbs (41 Nm) plus 90° (1/4 turn)

Flange Nut

35 ft-lbs (47 Nm)

Steel Wheels

8. Upon A-arm installation completion, test vehicle at low speeds before putting into service.

5.31

BODY / STEERING / SUSPENSION Exploded View

30 ft-lbs (41 Nm)

Spring

30 ft-lbs (41 Nm) Shaft

Nuts

Bushings Shock

Bushings

Upper A-arm

Shaft

30 ft-lbs (41 Nm)

Bushings

30 ft-lbs (41 Nm)

Shaft Shaft

CV Shield

Bearing Carrier 30 ft-lbs (41 Nm) 30 ft-lbs (41 Nm)

Bushings Screws Bushings

Bearing

Lower A-arm

5.32

Snap Ring

30 ft-lbs (41 Nm)

Shaft

Bushings Shaft

BODY / STEERING / SUSPENSION REAR STABILIZER BAR / LINKAGE

6. Inspect the rubber bushings on the stabilizer linkage rod (E) and replace if needed. If replacing the stabilizer linkage, remove the lower shock bolt from the upper A-arm.

Removal / Installation 1. Elevate and safely support vehicle with weight removed from the rear wheels.

7. Reverse this procedure for installation. 8. Torque the stabilizer retaining bolts / nuts (B) and upper rubber bushing nuts (A) to specification.

2. Remove the retaining nut (A) from the upper portion of the stabilizer bar linkage bushing on each side of the vehicle.

9. If the stabilizer linkage was removed, torque the lower shock retaining bolt to specification.

3. Remove the two fasteners (B) that secure the stabilizer bar to the main frame on each side.

4. Remove the stabilizer bar (C) from the frame and inspect the stabilizer bar for straightness.

Upper Linkage Retaining Nut: 30 ft-lbs (41 Nm) Stabilizer Retaining Nuts: 17 ft-lbs (23 Nm) Lower Shock/Linkage Bolt: 30 ft-lbs (41 Nm)

5. Inspect the stabilizer bar bushings (D) and replace if needed.

Exploded View A 30 ft-lbs (41 Nm)

5 C

B 17 ft-lbs (23 Nm)

30 ft-lbs (41 Nm)

5.33

BODY / STEERING / SUSPENSION SHOCKS / SPRINGS

Shock Replacement

Exploded View

1. Using a spring compressor, compress the shock spring far enough to remove the spring retainer. 30 ft-lbs (41 Nm)

Spring

Shock Spring Compressor Tool 2870623

Spring Retainer

Shock

Adjusting Cam

2. Remove the spring and adjusting cam from the existing shock and install components onto the new shock.

30 ft-lbs (41 Nm)

3. Compress the shock spring and install the spring retainer. 4. Reinstall the shock onto the vehicle and torque new fasteners to specification.

Shock Removal / Installation 1. Elevate the vehicle off the ground to relieve the suspension load. 2. Remove the upper and lower fasteners retaining the shock and remove the shock from the vehicle. 3. Reverse the procedure to reinstall the shock. Torque new fasteners to specification.

=T Upper/Lower Shock Bolt: 30 ft-lbs (41 Nm)

5.34

CLUTCH (PVT) SYSTEM

CHAPTER 6 CLUTCH (PVT) SYSTEM SPECIAL TOOLS AND SUPPLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 2871358-A FIXTURE MODIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 SPECIAL SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2

TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 PVT SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 GENERAL OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 DRIVE CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 SHIFT WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 DRIVEN CLUTCH OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 PVT BREAK-IN (DRIVE BELT / CLUTCHES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 MAINTENANCE / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4 OVERHEATING / DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5

PVT SYSTEM SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6 PVT SEALING AND DUCTING COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6 PVT DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7 PVT ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8

DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10 PVT BREAK-IN (DRIVE BELT / CLUTCHES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10

2011 DRIVE CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11 2011 DRIVE CLUTCH EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11 CLUTCH DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11 DRIVE CLUTCH SPRING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12 BUTTON TO TOWER CLEARANCE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13 SHIFT WEIGHT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13 SPIDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14 STATIONARY SHEAVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15 MOVEABLE SHEAVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15 CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15

2012-2013 DRIVE CLUTCH SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17 2012-2013 DRIVE CLUTCH EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17 CLUTCH DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17 DRIVE CLUTCH SPRING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18 NEEDLE BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19 BUTTON TO TOWER CLEARANCE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19 SPIDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19 SHIFT WEIGHT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20 CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21 MOVEABLE SHEAVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22 DRIVE CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22

DRIVEN CLUTCH SERVICE (2011 - 2013) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.24 EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.24 CLUTCH DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.24 CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.26

CLUTCH OFFSET PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.27 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.28

6.1

CLUTCH (PVT) SYSTEM SPECIAL TOOLS AND SUPPLIES

TORQUE SPECIFICATIONS

Special Tools

PVT System Fastener Torques

PART NUMBER

TOOL DESCRIPTION

PA-48595

Drive Clutch Puller

2871358-B

Clutch Holding Fixture

2870341 PU-50518

ITEM Drive Clutch Spider

265 ft-lbs (360 Nm)

Drive Clutch Retaining Bolt

47 ft-lbs (64 Nm) Left-Hand Thread

Driven Clutch Retaining Bolt

13 ft-lbs (18 Nm)

Drive Clutch Spider Tool Universal Clutch Compressor Tool

TORQUE VALUE

Drive Clutch Cover Bolts

110 in-lbs (12.4 Nm)

Inner PVT Cover Screws

7 ft-lbs (9.5 Nm)

2871358-A Fixture Modification

Outer PVT Cover Screws

48 in-lbs (5.4 Nm)

Converts existing 2871358-A to 2871358-B for diesel clutches

Drive Clutch Weight Pins

45 in-lbs (5 Nm)

SPX Corp: 1-800-328-6657 or http://polaris.spx.com

• Thread hole locations of tool 2871358-A to accept (3) M12 socket head cap screws using a 12mm x 1.75 tap as shown:

(3) M12 Socket Head Cap Screws 12mm x 1.75 Tap

2871358-A to 2871358-B Modification

(Socket Head Cap Screws Fastenal® P/N 0163647)

Special Supplies PART NUMBER N/A 8560054

6.2

SPECIAL SUPPLIES Loctite™ 609 RTV Silicone Sealer

CLUTCH (PVT) SYSTEM PVT SYSTEM OVERVIEW

Shift Weights

General Operation

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.

WARNING All PVT maintenance or repairs should be performed 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: • Drive Clutch • Driven Clutch • 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 the drive clutch sheaves.

Driven Clutch Operation Driven clutches primarily sense torque, opening and closing according to the forces applied to it from the drive belt and the transmission input shaft. If the torque resistance at the transmission input shaft is greater than the load from the drive belt, the drive belt is kept at the outer diameter of the driven clutch sheaves. As engine RPM and horsepower increase, the load from the drive belt increases, resulting in the belt rotating up toward the outer diameter of the drive clutch sheaves and downward into the sheaves of the driven clutch. This action, which increases the driven clutch speed, is called upshifting. Should the throttle setting remain the same and the vehicle is subjected to a heavier load, the drive belt rotates back up toward the outer diameter of the driven clutch and downward into the sheaves of the drive clutch. This action, which decreases the driven clutch speed, is called backshifting. In situations where loads vary (such as uphill and downhill) and throttle settings are constant, the drive and driven clutches are continually shifting to maintain optimum engine RPM. At full throttle a perfectly matched PVT system should hold engine RPM at the peak of the power curve. This RPM should be maintained during clutch upshift and backshift. In this respect, the PVT system is similar to a power governor. Rather than vary throttle position, as a conventional governor does, the PVT system changes engine load requirements by either upshifting or backshifting.

PVT Break-In (Drive Belt / Clutches) A proper break-in of the clutches and drive belt will ensure a longer life and better performance. Break in the clutches and drive belt by operating at slower speeds during the 10 hour break-in period as recommended (see Chapter 5 “Engine Break-In Period” for break-in example). Pull only light loads. Avoid aggressive acceleration and high speed operation during the break-in period.

6.3

CLUTCH (PVT) SYSTEM Maintenance / Inspection Under normal use the PVT system will provide years of trouble free operation. Periodic inspection and maintenance is required to keep the system operating at peak performance. The following list of items should be inspected and maintained to ensure maximum performance and service life of PVT components. Refer to the troubleshooting checklist at the end of this chapter for more information. • Belt Inspection • 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 • Sheave Faces (clean and inspect for wear) • PVT System Sealing. Refer to appropriate illustrations on the following pages. The PVT system is air cooled by fins on the drive clutch stationary sheave. The fins create a low pressure area in the crankcase casting, drawing air into the system through an intake duct. The opening for this intake duct is located at a high point on the vehicle (location varies by model). The intake duct draws fresh air through a vented cover. All connecting air ducts (as well as the PVT cover) 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.

6.4

CLUTCH (PVT) SYSTEM Overheating / Diagnosis During routine maintenance, or whenever PVT system overheating is evident, it’s important to check the inlet and outlet ducting for obstructions. Obstructions to air flow through the ducts will significantly increase PVT system operating temperatures. The vehicle should be operated in Low when plowing or pulling heavy loads, or if extended low speed operation is anticipated. CLUTCH DRIVE BELT & COVER RELATED ISSUES: DIAGNOSIS Vehicle Usage

What To Do

Loading the vehicle into a truck or tall Shift transmission to Low during loading of the vehicle to prevent belt trailer when in high range. burning. 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. Warm engine at least 5 min., then with transmission in neutral, advance Insufficient engine warm-up when throttle to approx. 1/8 throttle in short bursts, 5 to 7 times. The belt will exposed to low ambient temperatures. become more flexible and prevent belt burning. Slow and easy clutch engagement.

Fast, effective use of the throttle for efficient engagement.

Towing/Pushing at low RPM/low ground Use Low only. speed. Plowing snow, dirt, etc./utility use.

Use Low only.

Stuck in mud or snow.

Shift the transmission to Low, carefully use fast, aggressive throttle application to engage clutch. WARNING: Excessive throttle may cause loss of control and vehicle overturn.

Shift the transmission to Low, carefully use fast, aggressive, brief throttle 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, the throttle should not be held at the full position for more than 10 seconds. ingestion into the PVT system. Clutch seals should be inspected for damage if repeated leaking occurs. Clutch malfunction.

For inspection of clutch components, please contact your Polaris dealer. Shift transmission to Low during loading of the vehicle to prevent belt  burning.

Poor engine performance.

Fouled plugs, foreign material in gas tank, fuel lines, or carburetor. Contact you dealer for further service information.

RANGE OPERATION GUIDELINES:

Low: Heavy pulling, basic operational speeds less than 7 MPH, riding through rough terrain (swamps, mountains, ect.), low ground speeds. High: High ground speeds, speeds above 7 MPH.

IMPORTANT: Using High Gear when pulling heavy loads, operating on hilly terrain, or in wet, muddy conditions will increase the chance of drive belt damage.

6.5

CLUTCH (PVT) SYSTEM PVT SYSTEM SERVICE PVT Sealing and Ducting Components

Air Inlet Housing

Drain Plug

Cover Screws Outer PVT Cover

O-Ring Outer Seal

Filter

Clamp Screws Inner PVT Cover

Clamp

Outlet Duct

6.6

Inlet Duct

CLUTCH (PVT) SYSTEM PVT Disassembly Some fasteners and procedures will vary. Refer to the appropriate parts manual for proper fastener placement. 1. Remove ALL items in the dumb / cargo box.

7. Insert Drive Clutch Puller (PA-48595) into the drive clutch and use it to remove the clutch from the shaft. TIP: Lubricate the threads and end of special tool with grease to eliminate binding during the removal process.

2. Lift the dump / cargo box. 3. Remove dump / cargo box damper clips/pins and remove damper. Tilt dump / cargo box all the way back. 4. Remove the outer PVT cover and drive belt. Refer to “Belt Removal”. 5. Remove the driven clutch retaining bolt and driven clutch.

PA-48595

Drive Clutch Puller: PA-48595 8. If removing the inner PVT cover, continue to step #9. 9. Loosen the clamp and remove the PVT outlet duct from the inner PVT cover. 10. Remove the screws that retain the inner PVT cover to the transmission case and remove the cover.

6. Remove the drive clutch retaining bolt by turning the bolt in a clockwise direction.

Reverse Threads

Inner PVT Cover

NOTE: The drive clutch retaining bolt has left-hand threads. Turn the bolt clockwise to remove it.

11. Remove the old silicone material from the inner PVT cover and transmission case using a wire brush. Clean both surfaces thoroughly in preparation for assembly.

6.7

CLUTCH (PVT) SYSTEM PVT Assembly 1. Inspect the inner PVT cover. Replace if cracked or damaged. The mating surface must be clean to ensure adhesion of new silicone sealant. 2. Be sure to “flame treat” the inner PVT cover prior to applying silicone to ensure good adhesion. Pass the flame of a propane torch back and forth quickly over the area where the silicone is to be applied (2-3 inches from the flame tip is recommended). Do not hold the torch too close to the surface. Keep the torch moving to prevent damage. 3. Apply RTV silicone sealant to the outside edge of the inner PVT cover to ensure a water tight fit between the cover and the transmission. Inner PVT over

9. Clean end of taper on crankshaft and the taper bore inside drive clutch using a tapered reamer. 10. Install the drive clutch, bushing, washer, lock washer, and the left-hand threaded retaining bolt. Torque retaining bolt to specification. 11. Install drive belt noting direction of rotation if the belt is being reused. Refer to “Belt Installation”, steps 1-3. 12. Install the PVT outlet duct. 13. Replace the outer PVT cover seal. 14. Reinstall outer PVT cover and secure with screws. Torque screws to specification. 15. Install the seat, start the engine and test operation PVT.

=T Inner PVT Cover Screws: 7 ft-lbs (9.5 Nm) Driven Clutch Retaining Bolt: 13 ft-lbs (18 Nm) Drive Clutch Retaining Bolt: 47 ft-lbs (64 Nm) Outer PVT Cover Screws: 48 in-lbs (5.4 Nm)

Apply Bead of TV Silicone 4. Install the cover and torque the inner PVT cover screws to specification. 5. Wipe away any excess silicone sealant. 6. Clean the splines inside the driven clutch and on the transmission input shaft. 7. Apply a light film of grease to the splines on the shafts. 8. Install the driven clutch, cup washer, lock washer, and retaining bolt. Torque retaining bolt to specification.

6.8

CLUTCH (PVT) SYSTEM DRIVE BELT

6. Walk the belt out of the driven clutch while rotating the driven clutch clockwise as shown below.

Belt Removal 1. Position the vehicle on a level surface and place the transmission in Neutral. Engage the parking brake. 2. Tilt the dump box up and remove the dump box shock / box actuator asm. Secure the dump box in the up position. 3. Remove the screws retaining the outer PVT cover and remove the cover, Remove through LH wheel well

PVT Outlt

7. Release the belt from the driven clutch sheaves by pressing the belt down where indicated (C).

Outer VT cover

C Inner VT Cover

4. Mark the drive belt direction of rotation so that it can be installed correctly. 5. Firmly grasp the belt, then pull it out and over the edge of the inner clutch cover as shown below (A). Be sure the driven clutch sheaves have spread as shown below (B). B

8. Remove belt from the drive clutch and remove the belt from vehicle. 9. Inspect belt for wear and damage. Replace if necessary.

Belt Inspection 1. Inspect belt for hour glassing (extreme circular wear in at least one spot and on both sides of the belt). Hour glassing occurs when the drive train does not move and the drive clutch engages the belt. 2. Inspect belt for loose cords, missing cogs, cracks, abrasions, thin spots, or excessive wear. Compare belt measurements with a new drive belt. Replace if necessary.

3. Belts with thin spots, burn marks, etc., should be replaced to eliminate noise, vibration, or erratic PVT operation. See the Troubleshooting Chart at the end of this chapter for possible causes.

6.9

CLUTCH (PVT) SYSTEM Belt Installation 1. With the clutches installed, install the belt around the drive clutch and driven clutch as shown below. NOTE: Be sure to install the drive belt in the same rotational direction as indicated in the belt removal procedure.

4. With the belt fully installed, rotate the driven clutch ten rotations clockwise and counter-clockwise to properly seat the belt on the driven clutch sheaves. 5. Reinstall the outer PVT cover with a new cover seal and secure with screws. Torque screws to specification.

=T Outer PVT Cover Screws: 48 in-lbs (5.4 Nm) 6. Tilt the dump box down and install the dump box shock / box actuator asm. 7. Install the seat, start the engine and test the operation of the PVT system.

PVT Break-In (Drive Belt / Clutches) 2. Rotate the drive and driven clutch clockwise to ‘walk’ belt onto driven clutch. 3. Press downward on the drive belt in location (A) while rotating the drive clutch clockwise to further spread the driven clutch sheaves and install the belt.

A proper break-in of the clutches and drive belt will ensure a longer life and better performance. Break in the clutches and drive belt by operating at slower speeds during the 10 hour break-in period as recommended (see Chapter 5 “Engine Break-In Period” for break-in example). Pull only light loads. Avoid aggressive acceleration and high speed operation during the break-in period.

6.10

CLUTCH (PVT) SYSTEM 2011 DRIVE CLUTCH SERVICE 2011 Drive Clutch Exploded View Stationary Sheave

Moveable Sheave

Shim

Buttons Spring

Cover Cover Bolts

Nut

Weight Pin Shift Weight

Clutch Disassembly and Inspection 1. Using a permanent marker, mark the cover, spider, and moveable and stationary sheaves for reference, as the cast in X's may not have been in alignment before disassembly.

Spider

2. Mark the stationary sheave and clutch shaft to verify the shaft has not turned in the sheave after tightening the spider during clutch assembly.

3. Remove cover bolts evenly in a cross pattern and remove cover plate.

6.11

CLUTCH (PVT) SYSTEM 4. Inspect cover bushing (A). The outer cover bushing is manufactured with a Teflon coating. Wear is determined by the amount of Teflon remaining on the bushing.

Drive Clutch Spring Inspection CAUTION Never shim a drive clutch spring to increase its compression rate. This may result in complete stacking of the spring coils and subsequent clutch cover failure. 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.

Cover Bushing Inspection: Replace the cover if more brass than Teflon is visible on the bushing.

With the spring resting on a flat surface, measure its free length from the outer coil surfaces. Also check to see that spring coils are parallel to one another. Distortion of the spring indicates stress fatigue, requiring replacement.

5. Inspect area on shaft where the cover bushing rides for wear, galling, nicks, or scratches. Replace clutch assembly if worn or damaged. Inspect Shaft

2011 Drive Clutch Spring Specifications

6.12

Color

Black and Silver

Free Length

3.05” (77.47 mm)

CLUTCH (PVT) SYSTEM Button To Tower Clearance Inspection

Shift Weight Inspection

1. Inspect for any clearance between spider button to tower. If excess clearance exists, replace drive clutch.

1. Remove shift weight bolts and weights. Inspect the contact surface of the weight. The surface should be smooth and free of dents or gall marks. Inspect the weight pivot bore and bolts for wear or galling. If weights or bolts are worn or broken, replace in sets of three with new bolts and nuts. Inspect for excessive wear

Inspect .005” Limit

Nut

Shift Weight

Inspect for excessive wear Bolt

Inspect for excessive wear .001” Limit

WARNING The clutch assembly is a precisely balanced unit. Never replace parts with used parts from another clutch assembly.

= In. / mm.

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”.

Button to Tower Clearance: .000 - .005 in (.000 - .127 mm)

6.13

CLUTCH (PVT) SYSTEM Spider Removal 1. Install clutch in holding fixture PN 2871358-B. Wedge the clutch ribs against the hex screws. NOTE: 2871358-B holding fixture is required to fit diesel drive clutches due to a thick rib design. REFER TO PAGE 6.2 for modification of existing tool 2871358-A.

NOTE: It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly. Be sure to note the number and thickness of these washers. To maintain proper clutch balance and belt-to-sheave clearance, be sure to reinstall original quantity and thickness washers.

3. Inspect roller surfaces. Replace the drive clutch assembly if worn, damaged or cracked. 2871358-B

2870341

Button Button

4. Inspect the buttons. Replace the drive clutch assembly if worn, damaged or cracked.

2871358-B

2. Loosen the spider clockwise using Clutch Spider Tool PN 2870341. Remove the spacers from the shaft and set aside for reassembly. IMPORTANT: The clutch shaft has left-hand threads. Be sure to turn the Spider Removal Tool in a clockwise direction to remove.

6.14

Roller Roller

CLUTCH (PVT) SYSTEM Stationary Sheave Inspection

Moveable Sheave Inspection

NOTE: Remove cover, spring, and spider following instructions for drive clutch removal, then proceed as follows:

Inspect the Teflon coating on the moveable sheave bushing. Inspect sheave for signs of wear, grooving or cracking. De-glaze sheave surfaces with a 3M ScotchBrite Pad if needed.

1. Remove the moveable sheave. 2. Measure the stationary sheave shaft thickness and compare to specification. Replace if worn or damaged. 3. Inspect surface of shaft for pitting, grooves, or damage. Measure the outside diameter for out-ofround or taper. Replace the drive clutch assembly if shaft is worn or damaged.  Inspect sheave for signs of wear, grooving or cracking. De-glaze sheave surfaces with a 3M Scotch-Brite Pad if needed.

Inspect

Moveable Sheave Bushing Inspection: Replace the clutch if more brass than Teflon is visible on the bushing.

Clutch Assembly NOTE: It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly.

CAUTION

= In. / mm. Shaft Diameter: 1.370 - 1.375 in (34.798 - 34.925 mm)

Do not apply oil or grease to the bushings. The Teflon bushings are self-lubricating. Reassemble the drive clutch in the sequence provided. Verify the marks that were made earlier are aligned during each phase of assembly.

1. Install moveable sheave onto the fixed sheave. Install the shims that were previously removed onto the clutch shaft.

6.15

CLUTCH (PVT) SYSTEM 2. If removed, install shift weights using new lock nuts on the weight pins. Torque to specification.

IMPORTANT: If the marks are not in alignment upon assembly, the clutch will not be in balance and the drive clutch assembly must be replaced. 7. Install the drive clutch spring.

Use new lock nuts 3. Apply Loctite® 263™ to the spider threads. 4. Install spider onto the moveable sheave. Verify the marks that were made earlier are aligned during each phase of assembly.

8. Install the drive clutch cover. Be sure all alignment marts are in alignment.

5. Turn the moveable sheave and spider counterclockwise on the shaft and torque to specification using the holding fixture and spider tool. Torque with a smooth motion to avoid damage to the stationary sheave. IMPORTANT: The clutch shaft has left-hand threads. Be sure to turn the Spider Removal Tool in a counterclockwise direction to install.

CAUTION Be sure the spider spacer washers are fully seated on the spider. Any misalignment will alter clutch balance. 6. After the spider has been torqued, remove the clutch assembly from the holding fixture and inspect the alignment marks made during disassembly.

9. Install cover bolts and torque in a cross pattern evenly to specification.

=T Drive Clutch Weight Pins: 45 in-lbs (5Nm) Spider Torque: 265 ft-lbs (350 Nm) Drive Clutch Cover Bolts: 100 in-lbs (12 Nm)

6.16

CLUTCH (PVT) SYSTEM 2012-2013 DRIVE CLUTCH SERVICE 2012-2013 Drive Clutch Exploded View Stationary Sheave Moveable Sheave Thrust Washer Cover Bolts 110 in-lbs (12.4 Nm)

Shim (1) Buttons Spring

Nut 45 in-lbs (5 Nm)

Cover

Shift Weight

Weight Pin Non-braking Needle Bearing

Spider 265 ft-lbs (350 Nm)

2. Mark the stationary sheave and clutch shaft to verify the shaft has not turned in the sheave after tightening the spider during clutch assembly.

3. Remove cover bolts evenly in a cross pattern and remove cover plate.

6.17

CLUTCH (PVT) SYSTEM 4. Inspect cover bushing (A). The outer cover bushing is manufactured with a Teflon coating. Wear is determined by the amount of Teflon remaining on the bushing.

Cover Bushing Inspection: Replace the cover if more brass than Teflon is visible on the bushing.

5. Inspect area on shaft where the cover bushing rides for wear, galling, nicks, or scratches. Replace clutch assembly if worn or damaged. Inspect Shaft

2012-2013 Drive Clutch Spring Specifications

6.18

Color

Black / Red

Free Length

3.05” (77.47 mm)

CLUTCH (PVT) SYSTEM Needle Bearing Inspection

Spider Removal

1. Rotate the clutch bearing in both clockwise and counter-clockwise directions. The non-braking needle bearing should rotate in both directions on the shaft with only a slight amount of drag.

1. Install clutch in holding fixture PN 2871358-B. Wedge the clutch ribs against the hex screws.

2. Verify there is no binding or rough spots. If problems are noted continue with disassembly.

NOTE: NOTE: 2871358-B holding fixture is required to fit diesel drive clutches due to a thick rib design. REFER TO PAGE 6.2 for modification of existing tool 2871358-A.

2871358-B

Button To Tower Clearance Inspection 1. Inspect for any clearance between spider button to tower. If excess clearance exists, replace drive clutch.

Inspect .005” Limit 2870341

2871358-B

= In. / mm. Button to Tower Clearance: .000 - .005 in (.000 - .127 mm)

6.19

CLUTCH (PVT) SYSTEM NOTE: It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly. Be sure to note the number and thickness of these washers. To maintain proper clutch balance and belt-to-sheave clearance, be sure to reinstall original quantity and thickness washers.

Shift Weight Inspection 1. Remove shift weight bolts and weights. Inspect the contact surface of the weight. The surface should be smooth and free of dents or gall marks. Inspect the weight pivot bore and bolts for wear or galling. If weights or bolts are worn or broken, replace in sets of three with new bolts and nuts. Inspect for excessive wear

Nut

3. Inspect roller surfaces. Replace the drive clutch assembly if worn, damaged or cracked.

Shift Weight

Inspect for excessive wear Bolt

Inspect for excessive wear

Button

WARNING Roller

4. Inspect the buttons. Replace the drive clutch assembly if worn, damaged or cracked.

The clutch assembly is a precisely balanced unit. Never replace parts with used parts from another clutch assembly. NOTE: A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly. See “Roller, Pin and Thrust Washer Inspection”.

6.20

CLUTCH (PVT) SYSTEM Clutch Inspection NOTE: Remove cover, spring and spider following the instructions for drive clutch disassembly, then proceed as follows:

4. Inspect surface of shaft for pitting, grooves or damage. Measure the outside diameter and compare to specifications. Replace the drive clutch assembly if shaft is worn or damaged.

1. Remove and inspect the moveable sheave spacer (A). Visually inspect the spacer for damage and replace if necessary. Measure thickness of the moveable sheave spacer and compare to specification. A

= In. / mm. Shaft Diameter: 1.370 - 1.375 in (34.798 - 34.925 mm) 5. Visually inspect the thrust washers for damage. Measure the thickness and compare to specification. Replace if worn or damaged.

= In. / mm. Moveable Sheave Spacer Thickness: .156 +/- .010 in (3.9624 +/- .254mm)

= In. / mm.

2. Remove the moveable clutch sheave. 3. Lift the bearing and (2) thrust washers off the shaft. Replace as an assembly if worn, damaged, or if operational problems were noted prior to disassembly. Non-braking Needle Bearing

Thrust Washer Thickness: Standard: .030 in (.76 mm) Service Limit: .025 in (.64 mm)

4 Thrust Washers

6.21

CLUTCH (PVT) SYSTEM Moveable Sheave Inspection Inspect the Teflon coating on the moveable sheave bushing. Inspect sheave for signs of wear, grooving or cracking. De-glaze sheave surfaces with a 3M ScotchBrite Pad if needed.

1. Install the shift weights, bolts and new nuts onto the moveable sheave. Torque shift weight bolts to specification. 2. Install the non-braking needle bearing, the (2) thrust washers and the spacer onto the stationary sheave. Washers

Spacer Inspect

Non-braking Needle Bearing

Stationary Sheave Moveable Sheave Bushing Inspection: Replace the clutch if more brass than Teflon is visible on the bushing.

3. Install moveable sheave onto stationary sheave shaft. Be sure the moveable sheave slides freely on non breaking needle bearing surface. 4. Apply Loctite® 263™ to the spider threads.

Drive Clutch Assembly

5. Install the spider assembly onto the shaft threads. Be sure all of the alignment marks are in alignment.

CAUTION Do not apply oil or grease to the bushings. The Teflon bushings are self-lubricating. Reassemble the drive clutch in the following sequence. Be sure marks that were made during disassembly are aligned during each phase of assembly.

6. Install clutch onto holding fixture (PN 2871358-B) and secure in a bench vice. Tighten the spider using Clutch Spider Tool (PN 2870341). Torque spider to specification.

2870341

2871358-B

6.22

CLUTCH (PVT) SYSTEM 7. After the spider has been torqued, remove the clutch assembly from the holding fixture and inspect the alignment marks made during disassembly.

9. Install the drive clutch cover. Be sure all alignment marks are in alignment.

IMPORTANT: If the marks are not in alignment upon assembly, the clutch will not be in balance and the drive clutch assembly must be replaced.

10. Install cover bolts and torque in a cross pattern evenly to specification.

=T 8. Install the drive clutch spring. Drive Clutch Weight Pins: 45 in-lbs (5 Nm) Spider Torque: 265 ft-lbs (350 Nm) Drive Clutch Cover Bolts: 100 in-lbs (12 Nm)

6.23

CLUTCH (PVT) SYSTEM DRIVEN CLUTCH SERVICE (2011 - 2013) Exploded View

Compression Spring

Outer Spring Retainer Secondary Stationary Sheave

Inner Spring Retainer

Retaining Ring

Moveable Inner Sheave

Clutch Disassembly / Inspection CAUTION

3. Place the clutch into the Universal Clutch Compressor Tool PN PU-50518. Apply and hold downward pressure on the outer spring retainer. Carefully remove the snap ring.

Wear eye protection when removing snap ring to prevent serious personal injury. Snap ring pressure is loaded by the compression spring.

PU-50518

1. Remove driven clutch from the transmission input shaft. 2. Mark the position of the clutch sheaves before disassembly or use the Xâ&#x20AC;&#x2122;s on the sheaves for reference. This aids in reassembly and maintains clutch balance after reassembly.

NOTE: Spring is compression only and has no torsional wind.

6.24

CLUTCH (PVT) SYSTEM 4. With the snap ring (A) removed and spring pressure relieved, remove the outer spring retainer (B), compression spring (C), and inner spring retainer (D).

7. Remove the inner spring retainer from the inner sheave. Inspect for wear and replace as needed.

C D Inspect for abnormal wear

8. Check the rollers in the stationary sheave for wear. If rollers are worn, a new driven clutch assembly may be needed.

B A D C

5. Separate the two clutch sheaves.

Check rollers for wear 9. Inspect the bushings inside the moveable sheave. Inspect bushings for wear

6. Inspect the helix on the moveable sheave. Inspect for abnormal wear

Moveable Sheave Bushing Inspection: Replace the bushing if more brass than Teflonâ&#x201E;˘ is visible.

6.25

CLUTCH (PVT) SYSTEM 10. Inspect the Teflon™ coating on the moveable sheave bushings. 11. Inspect driven clutch sheave faces for wear or damage. 12. Clean and inspect splines on helix and transmission input shaft. 13. Lube splines with a light film of grease.

CAUTION Assemble Sheaves

Do not apply oil or grease to the bushings. The Teflon bushings are self-lubricating.

Clutch Assembly

3. Install spring into inner retainer.

1. Install the inner spring retainer if removed.

4. Install outer retainer on top of spring.

CAUTION Do not apply oil or grease to the bushings. The Teflon bushings are self-lubricating.

5. Place the clutch into Universal Clutch Compressor Tool PN 50518. Apply and hold downward pressure on the outer spring retainer.

PU-50518

2. Align the “X” marks on each of the sheaves during reassembly.

6.26

CLUTCH (PVT) SYSTEM 6. Compress the outer retainer and install the snap ring. Snap Ring

3. Add or remove offset washers behind the driven clutch accordingly to avoid belt contact with either drive clutch sheave.

Offset Washers

CLUTCH OFFSET PROCEDURE Clutch Offset Adjustment If the vehicle exhibits drive clutch drag or hard shifting while at idle speed, a clutch offset adjustment may be required. Washers located behind the driven clutch on the transmission input shaft may need to be added or removed in order to obtain the proper offset. Refer to the “Clutch Offset Procedure” provided below. 1. Follow steps procedure.

1-4

the

“PVT

Disassembly”

2. Inspect / measure the drive clutch belt to sheave clearance with a feeler gauge. There should be a minimum of .010” of clearance between the belt and sheave on both sides of the belt. If the belt is contacting either sheave or there is less than .010” of belt to sheave clearance remove the drive belt and driven clutch. Sheave

Belt

Sheave

.030” offset washer - PN 7556454 .060” offset washer - PN 755 4. Reinstall the driven clutch and drive belt. Torque the driven clutch retaining bolt to specification. Be sure to rotate the driven clutch counterclockwise several times to ensure the belt is tight and riding at the proper height in the clutch. 5. Inspect the belt to sheave clearance again. If the belt rests evenly between the sheaves, the offset is correct and the vehicle can be reassembled. If the belt is still contacting either sheave, remove the drive belt and driven clutch. Add or remove offset washers behind the driven clutch accordingly. 6. To reinstall driven clutch and belt, see step 4. 7. Inspect the outer clutch cover gasket and replace if necessary. 8. Install the outer clutch cover and torque cover screws to specification. 9. Reinstall dump / cargo box damper pins and clips and lower dump / cargo box into the locked position.

Measure both sides with a feeler gauge

10. Sit in the drivers seat, apply the foot brake and start the engine. Place the gear selector in high range and test the vehicle for drive clutch drag or hard shifting while at idle speed.

=T Driven Clutch Retaining Bolt: 13 ft-lbs (18 Nm) Outer PVT Cover Screws: 48 in-lbs (5.4 Nm)

6.27

CLUTCH (PVT) SYSTEM TROUBLESHOOTING PVT Troubleshooting Issue

Probable Cause

Correction

-Wrong or broken drive clutch spring.  -Drive clutch shift weight too heavy.  -Driven clutch spring broken or installed in wrong helix location.

-Replace with recommended spring.  -Install correct shift weight kit to match engine application.  -Replace spring; refer to proper installation location.

-Drive clutch binding.  -Belt worn unevenly - thin / burnt spots.  -Driven clutch malfunction.  -Sheave face grooved.

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.  -Replace belt.  A. Replace ramp buttons. B. Inspect movable sheave for excessive bushing clearance.  -Replace the clutch.

Engine RPM above specified operating range.

-Incorrect drive clutch spring (too high spring rate).  -Drive clutch shift weights incorrect for application (too light).  -Drive clutch binding.  -Driven clutch binding.  -Converter sheaves greasy; belt slipage.

-Install correct recommended spring.  -Install correct recommended shift weights.  -Disassemble and clean clutch, inspecting shift weights and rollers. Reassemble without the spring and move sheaves through entire range to further determine probable cause.  -Disassemble, clean, and inspect driven clutch, noting worn sheave bushing and ramp buttons and helix spring location.  -Clean sheaves with denatured alcohol or brake cleaner, install new belt.

Harsh drive clutch engagement.

-Drive belt worn too narrow.  -Excessive belt / sheave clearance with new belt.

-Replace belt.  -Perform belt / sheave clearance adjustment with shim washers beneath spider.

Drive belt turns over

-Wrong belt for application.  -Clutch alignment out of spec.  -Engine mount broken or loose.

-Replace with correct belt.  -Adjust clutch alignment.  -Inspect / adjust or replace.

Engine RPM below specified operating range, although engine is properly tuned.

Erratic engine operating RPM during acceleration or load variations.

6.28

CLUTCH (PVT) SYSTEM PVT Troubleshooting, Continued..... Issue

Belt burnt, thin spots

PVT cover overheating (melting)

Water ingestion

Belt slippage

Probable Cause -Abuse (continued throttle application when vehicle is stationary, excess load)  -Dragging brake  -Slow, easy clutch engagement

-Plugged air intake or outlet.  -Belt slippage due to water, oil, grease, etc., rubbing on cover. -Clutches or weight being applied to cover while in operation.  -High vs. low range.

Engagement erratic or stabby

-Caution operator to operate machine within guidelines.  -Vehicle operated with park brake on. Inspect brake system.  -Fast, effective use of throttle for efficient engagement. -Clear obstruction  -Inspect system. Clean, repair or replace as necessary.  Seal PVT system ducts. -Remove weight. Inform operator.  -Instruct operator on guidelines for operation in proper driving range for different terrain as outlined in Owner’s Safety and Maintenance Manual.

-Cover seals or ducts leaking  -Operator error

-Find leak and repair as necessary.  -Instruct operator on guidelines for operation in wet terrain as outlined in Owner’s Safety and Maintenance Manual.

-Belt worn out  -Water ingestion  -Belt contaminated with oil or grease

-Replace belt.  -Inspect and seal PVT system.  -Inspect and clean.

-Belt worn or separated, thin spots, loose belt PVT noise

Correction

-Broken or worn clutch components, cover hitting clutches -Thin spots on belt, worn belt -Drive clutch bushings stick

-Replace belt.  -Inspect and repair as necessary. -Replace belt. Refer to belt burnt troubleshooting and instruct operator. -Inspect and repair clutches.

6.29

CLUTCH (PVT) SYSTEM

NOTES

6.30

FINAL DRIVE

CHAPTER 7 FINAL DRIVE SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 FRONT BEARING CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 BEARING CARRIER INSPECTION / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 BEARING CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6 DRIVE SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6 DRIVE SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6

FRONT PROPSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7 REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7 SUPPORT BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8

PROPSHAFT U-JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9 ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10

FRONT GEARCASE - CENTRALIZED HILLIARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11 CENTRALIZED HILLIARD EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12 AWD DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12 GEARCASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13 GEARCASE DISASSEMBLY / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14 GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17 GEARCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19

REAR BEARING CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21 ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22

REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24

DRIVE SHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25 DRIVE SHAFT / CV JOINT HANDLING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25 OUTER CV JOINT / BOOT REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25 INNER PLUNGING JOINT / BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27 DRIVE SHAFT EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30

REAR PROPSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.31

REAR GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.31 GENERAL OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.31 GEARCASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.33 GEARCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.33 REAR GEARCASE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.36 REAR GEARCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.39 REAR GEARCASE EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.40

7.1

FINAL DRIVE SPECIAL TOOLS

FRONT BEARING CARRIER

Special Tools

Bearing Carrier Inspection / Removal

PART NUMBER

TOOL DESCRIPTION

2872608

Roll Pin Removal Tool

8700226 or PU-48951

Axle Boot Clamp Tool

SPX Corp: 1-800-328-6657 or http://polaris.spx.com

TORQUE SPECIFICATIONS Wheel and Hub Torque Table ITEM

NUT TYPE

SPECIFICATION

Aluminum Wheels (Cast)

Lug Nut

30 ft-lbs + 1/4 Turn (41 Nm + 1/4 Turn)

Steel Wheels (Black / Camo)

Flange Nut

35 ft-lbs (47 Nm)

Front Hub

Castle Nut

80 ft-lbs (108 Nm)

Rear Hub

Castle Nut

110 ft-lbs (150 Nm)

1. Elevate front of vehicle and safely support machine under the frame area.

CAUTION Use care when supporting vehicle so that it does not tip or fall. Serious injury may occur if vehicle tips or falls. 2. Check bearings for side play by grasping the top and bottom of the tire firmly and checking for movement. The tire should rotate smoothly without binding or rough spots.

3. Remove the (4) wheel nuts and remove the front wheel. 4. Remove the cotter pin and loosen the front wheel hub castle nut. Remove the nut, and (2) cone washers from the front wheel hub assembly. Castle Nut

Cone Washers

Cotter Pin

7.2

FINAL DRIVE 5. Remove the two brake caliper mounting bolts.

9. Remove the upper and lower ball joint pinch bolts.

Pinch Bolts

CAUTION Do not hang the caliper by the brake line.

10. Using a soft faced hammer, lightly tap on the bearing carrier while removing the upper and lower ball joint ends.

6. Remove the front wheel hub assembly.

11. Remove the bearing carrier from the front drive shaft.

7. Remove the steering tie rod end fastener from the front bearing carrier.

12. Rotate bearing by hand and check for smooth rotation. Visually inspect bearings for moisture, dirt, or corrosion.

Steering Tie Rod End

NOTE: Due to extremely close tolerances and minimal wear, the bearing 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. 13. Replace bearing if moisture or corrosion is evident.

Bearing Replacement 8. Remove the lower shock mounting fastener attached to the upper A-arm and remove the shock from the Aarm.

Bearing Removal 1. Remove outer snap ring.

Snap Ring

7.3

FINAL DRIVE 2. From the back side of the bearing carrier, tap on the outer bearing race with a drift punch in the reliefs as shown.

8. Wipe the housing clean of any excess compound and install the snap ring.

Bearing Carrier Installation 1. Install the end of the drive shaft through the backside of the bearing carrier. 2. Install the upper and lower ball joint ends into the front bearing carrier. 3. Install pinch bolts and torque to specification

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.

23 ft-lbs (31 Nm)

4. Inspect the bearing carrier housing for scratches, wear or damage. Replace front bearing carrier if damaged. Bearing Installation

5. Thoroughly clean the front bearing carrier housing and the outer race on the new bearing. Be sure that all oil residue has been removed from each surface.

Pinch Bolts: 23 ft-lbs (31 Nm)

6. Support the bottom of the bearing carrier housing. 4. Install shock to A-arm and torque fastener to specification.

CAUTION Use an arbor and press only on the outer race, otherwise bearing damage may occur.

30 ft-lbs (41 Nm)

7. Apply Loctite® 603™ retaining compound to the outer circumference of the new bearing race and carefully press the new bearing into the bearing carrier housing. NOTE: Use care to not allow any of the Loctite® compound to get in the bearing.

Apply Loctite® 603™

=T Snap Ring

Shock Mounting Bolts: 30 ft-lbs (41 Nm) 5. Apply grease to the drive shaft splines.

Bearing

7.4

FINAL DRIVE 6. Install front wheel hub assembly, cone washers, and hand tighten the castle nut. Install washers with domed side out.

=T Front Caliper Mounting Bolts: 30 ft-lbs (41 Nm)

Cone Washers

CAUTION

Wheel Hub

Fastener has a pre-applied locking agent which is destroyed upon removal. Always use new fastener upon assembly.

Out 7. Install the steering tie rod end onto the front bearing carrier and torque fastener to specification.

9. Torque wheel hub nut to specification and install a NEW cotter pin. Tighten nut slightly if necessary to align cotter pin holes. 80 ft-lbs (108 Nm)

40 ft-lbs 54 (Nm)

NEW Cotter Pin

=T Tie Rod End Fastener: 40 ft-lbs (54 Nm)

Front Hub Castle Nut: 80 ft-lbs (108 Nm)

8. Install the front brake caliper. Install new mounting bolts and torque to specification.

10. Install wheel and (4) wheel nuts. Torque wheel nuts to specification.

30 ft-lbs (41 Nm)

Wheel Nut: Steel Wheels: 35 ft-lbs (47 Nm) Aluminum Wheels: 30 ft-lbs + 1/4 Turn (41 Nm + 1/4 Turn) 11. Rotate wheel and check for smooth operation. Bend both ends of cotter pin around the end of the shaft.

7.5

FINAL DRIVE FRONT DRIVE SHAFT

Drive Shaft Installation

Drive Shaft Removal

1. Install new spring ring on the end of the drive shaft. Apply an anti-seize compound to splines.

1. Perform the “Bearing Carrier Inspection / Removal” procedure listed under the “FRONT BEARING CARRIER” section within this chapter.

Apply Anti-Seize

NOTE: Perform all removal steps with the exception of removing the steering tie rod end. It will not be necessary to remove the tie rod end from the front bearing carrier when removing the front drive shaft.

CAUTION Use care when supporting vehicle so that it does not tip or fall. Serious injury may occur if vehicle tips or falls.

New Spring Ring

2. Remove the drive shaft from the front bearing carrier. 3. With a short, sharp jerk, remove drive shaft from the front gearcase.

2. Align splines of drive shaft with front gearcase and reinstall the drive shaft. Use a rubber mallet to tap on the outboard end of the drive shaft if necessary.

4. Refer to the “DRIVE SHAFT SERVICE” procedure if repairing the drive shaft. 3. Install drive shaft into the front bearing carrier. 4. Perform the “Bearing Carrier Installation” procedure listed under the “FRONT BEARING CARRIER” section within this chapter.

7.6

FINAL DRIVE FRONT PROPSHAFT

5. Remove the (2) nuts and bolts retaining the bearing support

Removal / Installation 1. Elevate and safely support vehicle under the frame. The use of a vehicle hoist is recommended for this procedure.

CAUTION Use care when supporting vehicle so that it does not tip or fall. Serious injury may occur if vehicle tips or falls.

Remove

2. Access the front propshaft roll pin through the skid plate hole beneath vehicle. 3. Use the Roll Pin Removal Tool (PN 2872608), to drive out the roll pin from prop shaft from beneath the front skid plate.

6. Slide the rear portion of the shaft rearward to separate it from the front portion. Remove the front portion of the prop shaft from the vehicle through the floor panel.

Roll Pin Removal Tool: PN 2872608

7. Slide the front portion of the prop shaft slightly back and from front gearcase to remove the shaft from the front gearcase splines.

4. Remove the rear floor panel to access the support bearing. The bearing is located just in front of the engine, under the floor.

Support Bearing

8. Using care, pull the rear portion of the propshaft forward to disengage the transmission output splines and gently slide it forward out of the removed floor area. 9. Reverse removal for properly installing prop shafts. 10. Be sure to lubricate the rear and mid splines with all purpose grease and the front gearcase splines with anti-seize. 11. Torque bearing support fasteners to specification.

=T Bracket

Bearing Support Fasteners: 33 ft-lbs (45 Nm) 12. Use a NEW roll pin upon installation.

7.7

FINAL DRIVE Support Bearing Replacement 1. Follow steps 4-6 of the “Front Propshaft Removal / Installation” procedure.

9. Apply Loctite 242 or equivalent to the bearing set screws. Tighten the (2) bearing set screws to specification. Next, tighten the bearing support fasteners.

2. Remove the bearing support (upper and lower half) and the (2) set screws retaining the bearing to the shaft.

=T Bearing Set Screws: 33 in-lbs (3.7 Nm) Apply Loctite 242 Bearing Support Fasteners: 33 ft-lbs (45 Nm)

3. Remove the bearing retaining ring. Remove

10. Reinstall the large storage container, floor panel and front seat base.

Remove Remove

4. Slide the bearing off the end of the shaft.

5. Clean the surface of the shaft and install the new bearing. 6. Align the front and rear portions of the propshaft and slide them together. 7. Install the upper and lower halves of the bearing support along with the (2) fasteners. Finger tighten only. Be sure rubber isolator ring is installed. Install bearing retaining ring. 8. Slide the rear portion of the propshaft forward or backward to obtain the proper spline engagement.

7.8

FINAL DRIVE PROPSHAFT U-JOINT SERVICE

3. Support U-joint in vise as shown and drive inner yoke down to remove remaining bearing caps.

Disassembly 1. Remove internal or external snap ring from all bearing caps.

CAUTION Always wear eye protection.

4. Force U-joint cross to one side and lift out of inner yoke.

NOTE: If yoke or bearing is removed, cross bearing must be replaced. Note orientation of grease fitting and mark inner and outer yoke for correct repositioning during installation. 2. Support inner yoke as shown and drive outer yoke down (bearing cap out) with a soft face hammer.

7.9

FINAL DRIVE Assembly 1. Install new bearing caps in yoke by hand. Carefully install U-joint cross with grease fitting properly positioned inward toward center of shaft. Take care not to dislodge needle bearings upon installation of cross joint. Tighten vise to force bearing caps in.

5. Install outer yoke, aligning marks made before disassembly.

6. Repeat Steps 1-4 to install bearing caps on outer yoke. 7. Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown. 2. Using a suitable arbor, fully seat bearing cap in one side. 3. Continually check for free movement of bearing cross as bearing caps are assembled.

8. 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. 4. Install snap ring to contain bearing cap just installed. Repeat procedure for other side.

7.10

FINAL DRIVE FRONT GEARCASE - CENTRALIZED HILLIARD Centralized Hilliard Exploded View 9 ft-lbs (12 Nm)

9 ft-lbs (12 Nm)

REF #

DESCRIPTION

QTY

REF #

DESCRIPTION

QTY

O-Ring

Hub Sub-Assembly (Female)

O-Ring

Hub Sub-Assembly (Male)

Dowel Pin

Rollers

Vent Hose Fitting

Torsion Spring

Ball Bearing

Spring, Wireform

Ball Bearing (Double Row)

H-Clip Spring

Bushing

Nylon Spacer

Bushing

Torsion Spring Retainer

Oil Seal

Backlash Spacer

Oil Seal

Ring Gear Spacer

Retaining Ring, Internal

Pinion Gear

Cover Screws, M6 (T30 Torx)

Armature Plate

Cover Plate Assembly

AWD Coil

Gearcase Housing

Fill Plug

Clutch Housing (Ring Gear)

Drain Plug, Magnetic

Roll Cage

Retaining Ring, External

Hub / Race Assembly

7.11

FINAL DRIVE Operation The AWD switch may be turned on or off while the vehicle is moving, however, AWD will not enable until the vehicle speed drops below an indicated 8 MPH. Once the AWD is enabled, it remains enabled until the switch is turned off.

Ring Gear Roll Cage

Engage the AWD switch before getting into conditions where the front wheel drive may be needed. If the rear wheels are spinning, release the throttle before switching to AWD.

CAUTION

Rollers

Switching to AWD while the rear wheels are spinning or slipping may cause severe drive shaft and gearcase damage. Always switch to AWD while the rear wheels have traction or are at rest. With the AWD switch off, the vehicle drives through the rear wheels only (2 wheel drive). When the AWD is enabled, the front drive acts as an on-demand AWD system. This means, the front drive will engage once the rear wheels have lost traction, and will remain engaged until the torque requirement goes away (i.e. rear wheels regain traction). Roll Cage

Output Hubs and Centers Roll Cage Rollers in Ring Gear

Armature Plate Output Hub

CAUTION Switching to AWD while the rear wheels are spinning or slipping may cause severe drive shaft and gearcase damage. Always switch to AWD while the rear wheels have traction or are at rest. AWD Disengagement: Once the rear wheels regain traction, the front wheels will return to the “over-running” condition. The vehicle is now back to rear wheel drive until the next loss of rear wheel traction occurs.

AWD Diagnosis Symptom: AWD Will Not Engage 1. Check the gearcase coil resistance. To test the coil resistance, measure between the Grey and Brown/ White wires. The measurement should be within specification.

Roll Cage & Rollers Armature Plate Ring Gear

Ring Gear

Torsion Spring Magnetic Coil

AWD Engagement: When the AWD switch is activated, the AWD coil is powered by a 12 Vdc input which creates a magnetic field. This magnetic field attracts an armature plate that is keyed to the roll cage. When the ring gear and roll cage are spinning (vehicle is moving), the energized coil and armature plate will apply drag to the roll cage that indexes the rollers inside the ring gear to an engagement position. While in the engagement position, the front drive will be in an “over-running” condition (not engaged), until the rear wheels lose traction. Once the rear wheels begin to lose traction, the front drive will engage by coupling the output hubs to the ring gear via the rollers. The front drive will remain engaged until the torque requirement goes away (i.e. rear wheels regain traction).

7.12

Front Gearcase Coil Resistance: 21.6 - 26.4 Ohms

FINAL DRIVE 2. Turn the ignition switch and AWD switch on and place gear selector in High or Low gear. Check for minimum battery voltage at the Gray and Brown/White chassis wires that power the coil. A minimum of 11 Vdc should be present.

6. Inspect the rollers for nicks and scratches. The rollers must slide up, down, in and out freely within the roll cage sliding surfaces and H-springs.

Rollers 3. If electrical tests are within specification, remove gearcase (see “Gearcase Removal”) and inspect components. 4. Inspect the armature plate for a consistent wear pattern. There should be two distinct wear bands (one band inside the other). If only one band of wear is present (or if there is wear between the two bands), inspect the coil area as indicated in Step 5. A wear band with an interrupted wear mark may indicate a warped plate, which may cause intermittent operation.

Roll Cage Assembly

Armature Plate 7. Inspect the roll cage assembly for cracks or excessive wear. If damaged, replace the roll cage assembly.

Gearcase Removal 1. Stop engine, place machine in gear and set parking brake. 2. Elevate front of vehicle and safely support machine under the frame area.

CAUTION

Check for Wear Bands 5. Check to make sure the coil is seated in the U-shaped insert that is pressed into the gearcase cover. The top of the coil should be seated below the U-shaped insert. The U-shaped insert controls the pole gap. If the top of the coil is above the surface of the U-shaped insert it raises the armature plate, thereby increasing pole gap. If the pole gap increases, the coil will not be strong enough to engage the AWD system. If this is found, replace the cover plate assembly. Gearcase Cover Plate Asm.

Coil

Use care when supporting vehicle so that it does not tip or fall. Serious injury may occur if vehicle tips or falls. 3. Remove both front drive shafts from the front gearcase (see “FRONT DRIVE SHAFT - Removal”). 4. Remove the front propshaft from the front gearcase (see “FRONT PROPSHAFT - Removal”). 5. Remove the LH wheel well panel and disconnect the AWD wire harness. Cut the plastic tie strap to free the connector end from the main harness to allow gearcase removal.

U-shaped insert Side cutaway view of Centralized Hilliard cover

7.13

FINAL DRIVE 6. Remove the (4) bolts securing the bottom of the gearcase to the skid plate frame.

Disconnect AWD ire harness

Vent line Clamp

Gearcase Disassembly / Inspection 1. Drain and properly dispose of gearcase fluid. Remove any metal particles from the drain plug magnet. 2. Remove the (7) cover screws and remove the cover plate assembly.

Remove bolts from skid plate fame

7. Remove the vent line from the gearcase. 8. Remove the gearcase from the front left-hand wheel well area and pull it out between the upper and lower A-arms.

7.14

FINAL DRIVE 3. Remove the LH output hub assembly from the clutch housing or outer cover plate assembly.

5. Remove the torsion spring retainer and torsion spring from the top of the ring gear. Spring Retainer

LH Output Hub

Non-serviceable DO NOT Remove

Torsion Spring

LH Output Hub

NOTE: Nylon spacer is non-serviceable and should not be removed. 4. Remove and inspect the armature plate. Refer to “AWD Diagnosis” for detailed inspection process.

6. Remove the clutch housing / ring gear and roll cage assembly from the gearcase housing. Remove as an assembly

Armature Plate

7.15

FINAL DRIVE 7. Remove the RH output hub assembly from the gearcase housing.

10. Inspect the AWD coil located in the outer cover plate assembly. Refer to “AWD Diagnosis” for detailed inspection process. Replace the cover plate seal and O-ring. Inspect Coil

Replace O-Ring & Seal 8. Remove pinion seal, internal retaining ring and pinion gear assembly from the gearcase housing. Inspect and clean the gearcase housing and replace all oil seals and O-rings. Pinion Shaft

External Snap Ring

Replace Seal

11. Remove the roll cage assembly and rollers from the clutch housing. Use a shop towel to cover the housing in order to retain all the rollers. NOTE: Rollers are spring loaded. Take care not to allow them to fall out or lose them upon removal of the roll cage. 12. Thoroughly clean all parts and inspect the rollers (A) for nicks and scratches. The rollers must slide up and down and in and out freely within the roll cage (B) sliding surfaces and H-springs. C

Bearing Internal Snap Ring

9. Inspect the pinion gear for chipped, broken or missing teeth. Inspect the pinion bearing for signs of wear and the pinion shaft seal surface for pitting. A

IMPORTANT: Refer to the “Electronic Parts Catalog” for individual part availability. Most parts are to be replaced as an assembly or as a complete kit.

Inspect

7.16

13. Inspect clutch housing ring gear (C) for a consistent wear pattern. Inspect the ring gear for chipped, broken, or missing teeth.

FINAL DRIVE 14. Inspect the roll cage assembly (B) sliding surfaces and H-springs. The sliding surfaces must be clean and free of nicks, burrs or scratches. If damaged, replace the roll cage assembly.

3. Install a new pinion shaft seal into the pinion gear housing. Using a universal seal installer, press the new seal into the housing until the seal is just below the housing chamfer. Press in oil seal just past chamfer

H-Spring

15. Inspect both output hub assemblies. Inspect the bearings and replace if needed.

4. Install the RH output hub into the gearcase housing. RH Output Hub

Thrust Bearing Bearing

Spacer

Roller Surface

16. Clean and inspect all remaining front gearcase components. Check each for excessive wear or damage.

7 5. Carefully install the rollers into the roll cage assembly while installing the assembly into the clutch housing. NOTE: Install the roll cage so that the ring gear grooves line up with the roll cage slots (see below).

Gearcase Assembly 1. As mentioned during gearcase disassembly section, replace all O-rings, seals and worn components. 2. Install pinion shaft assembly and install internal snap ring. NOTE: If bearing replacement was required, press new bearing onto the pinion shaft and install a new external snap ring.

Align during installation

7.17

FINAL DRIVE 6. Install the torsion spring by wrapping each leg of the spring around the dowel pin on the ring gear.

9. Be sure the armature plate tabs are fully engaged into the roll cage assembly and are resting on the cutgrooves of the ring gear.

Engage Tabs

7. Align the spring retainer dowel pin with the ring gear dowel pin and install the retainer on top of the torsion spring.

NOTE: Verify armature plate tabs are in the slots on the roll cage and are resting in the ring gear grooves. 10. Carefully install the ring gear and roll cage assembly into the gearcase housing.

Align during installation

8. Check the action of the torsion spring by rotating in both directions to ensure the spring and retainer are installed properly. 11. Install a new O-ring on the cover plate assembly. NOTE: Be sure the square O-ring is placed flat on the cover surface. If the O-ring is twisted fluid leakage may occur.

7.18

FINAL DRIVE 12. Carefully install the LH output hub assembly into the cover plate. Take care not to damage the new cover plate seal while installing the output hub.

Gearcase Installation 1. Install the gearcase through the front left-hand wheel well area between the upper and lower A-arms.

LH Hub

13. Install the output cover assembly onto the gearcase housing. Install the (7) cover plate screws and torque to specification.

2. Install the vent line to the gearcase and ensure it’s routed properly up top under the hood. 3. Install propshaft onto the front gearcase.

Torque Screws

4. Install new mounting bolts and torque to specification.

7 =T Cover Plate Screws: 9 ft-lbs (12 Nm)

=T Gearcase Mounting Bolts: 30 ft-lbs (40 Nm) 5. Drive a new roll pin into the front propshaft (see “FRONT PROPSHAFT - Installation”). 6. Install the drive shafts into the front gearcase (see “FRONT DRIVE SHAFT - Installation”). 7. Connect the AWD harness and tie the harness to the main harness using a plastic tie strap. 8. Reinstall the LH wheel well panel.

7.19

FINAL DRIVE 9. Add the proper lubricant to the front gearcase. Check drain plug for proper torque. Refer to Chapter 2 for fluid fill and change information.

REAR BEARING CARRIER Inspection 1. Support the machine securely with rear wheels elevated.

CAUTION Use care when supporting vehicle so that it does not tip or fall. Serious injury may occur if vehicle tips or falls. 2. Check the bearings for side play. Grasp the top and bottom of the wheel or wheel hub and check for movement. 3. If movement is detected, inspect wheel hub, castle nut torque and bearing condition. The tire should rotate smoothly without binding or rough spots. Correct as necessary.

Removal 1. Elevate the rear end of the vehicle and safely support the vehicle under the main frame area. 2. Remove wheel nuts, washers and wheel. 3. Remove the cotter pin, castle nut and washers.

Castle Nut

Washers Cotter Pin

7.20

FINAL DRIVE 4. Remove the two brake caliper mounting bolts and remove the caliper from the bearing carrier.

Disassembly 1. Remove the retaining ring from the bearing carrier.

2. From the back side, tap on the outer bearing race with a drift punch in the reliefs as shown.

CAUTION Do not hang the caliper by the brake line. 5. Slide the wheel hub out from the bearing carrier and drive shaft.

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.

6. Remove the upper and lower A-arm fasteners from the bearing carrier.

7 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. 7. Remove the bearing carrier. Inspect the bearing again for smoothness and side to side movement, replace as needed.

4. Inspect bearing housing for scratches, wear or damage. Replace housing if damaged. 5. Replace the bearing carrier bushings if worn or damaged.

7.21

FINAL DRIVE Assembly 1. Thoroughly clean the bearing carrier housing and prepare the components for assembly.

4. Install a new retaining ring into the bearing carrier groove.

Installation 1. Place the bearing carrier over the drive shaft. 2. Align the bottom of the bearing carrier with the lower A-arm. If previously removed, install new lower A-arm bushings. Install the lower bearing carrier fastener. 3. With the drive shaft placed in the bearing carrier, align the top of the bearing carrier with the upper A-arm. If previously removed, install new upper A-arm bushings. Install the upper bearing carrier fastener.

2. Support the bottom of the bearing carrier housing. Start the bearing (A) in the bearing carrier housing (B). Use an arbor press to install the bearing.

A B

NOTE: The lower shock bolt may need to be removed to allow the upper A-arm to move freely. 4. Torque the upper and lower bearing carrier fasteners to specification. 3. Press the bearing into place until the outer bearing race bottoms in housing.

CAUTION

=T Bearing Carrier Fasteners: 30 ft-lbs (41 Nm)

Use an arbor and press only on the outer race, as bearing damage may occur.

5. Install the wheel hub assembly onto the drive shaft. 6. Install the washers (domed side out) and the wheel hub castle nut hand tight.

7.22

FINAL DRIVE 7. Install the wheel, washers and wheel nuts. Torque wheel nuts to specification.

REAR DRIVE SHAFT Removal

1. Perform the “REAR BEARING CARRIER - Removal” procedure, steps 1-5.

Wheel Nut: Steel Wheels: 35 ft-lbs (47 Nm) Aluminum Wheels: 30 ft-lbs + 1/4 Turn (41 Nm + 1/4 Turn) 8. Carefully lower the vehicle. Torque the wheel hub castle nut to specification. Install a new cotter key.

2. Remove the lower shock fastener to free the upper Aarm.

Remove

=T Rear Hub Castle Nut: 110 ft-lbs (150 Nm)

3. Remove the upper bearing carrier fastener and separate the bearing carrier from the upper A-arm.

7.23

FINAL DRIVE 4. Carefully slide the drive shaft out by pulling the bearing carrier outward and tipping it down to remove the shaft.

5. Remove the drive shaft using short, sharp jerks to free the circlip.

Installation 1. Install a new circlip on the end of the drive shaft output shaft. Apply an anti-seize compound to the splines.

2. Align the splines of the drive shaft with the transmission and reinstall the drive shaft. Use a rubber mallet to tap on the outboard end of the drive shaft if necessary. 3. Install the drive shaft into the bearing carrier. 4. Perform the “REAR BEARING CARRIER Installation” procedure to properly reassemble the vehicle.

6. Refer to the “DRIVE SHAFT SERVICE” section if repairing the drive shaft.

7.24

FINAL DRIVE DRIVE SHAFT SERVICE

2. Remove the large end of the boot from the CV joint and slide the boot down the shaft.

Drive Shaft / CV Joint Handling Tips Care should be exercised during drive shaft removal or when servicing CV joints. Drive shaft components are precision parts. Cleanliness and following these instructions is very important to ensure proper shaft function and a normal service life. • The complete drive shaft and joint should be handled by getting hold of the interconnecting shaft to avoid disassembly or potential damage to the drive shaft joints. • Over-angling of joints beyond their capacity could result in boot or joint damage. • Make sure surface-ground areas and splines of shaft are protected during handling to avoid damage. • Do not allow boots to come into contact with sharp edges or hot engine and exhaust components. • The drive shaft is not to be used as a lever arm to position other suspension components.

3. Clean the grease from the face of the joint. 4. Place the drive shaft in a soft-jawed vise. 5. Using a soft-faced hammer, or brass drift, strike the inner race of the joint to drive the joint off the drive shaft. Be sure to tap evenly around the joint to avoid binding. Brass Drift Shown

• Never use a hammer or sharp tools to remove or to install boot clamps. • Be sure joints are thoroughly clean and that the proper amount and type of grease is used to refill when joint boots are replaced and when joints are cleaned. Refer to text for grease capacity of CV joints and CV joint boots.

Outer CV Joint / Boot Replacement 1. Using a side cutters, cut away and discard the boot clamps. IMPORTANT: Tap on inner race only!

7.25

FINAL DRIVE 6. Make sure the circlip is on the shaft and not left in the joint. Circlip

NOTE: Shiny areas in ball tracks and on the cage spheres are normal. Do not replace CV joints because parts have polished surfaces. Replace CV joint only if components are cracked, broken, worn or otherwise unserviceable. 10. Clean the splines on the end of the shaft and apply a light coat of grease prior to reassembly. 11. Slide the small boot clamp and boot (small end first) onto the drive shaft and position the boot in it’s groove machined in the shaft. 12. Install a NEW circlip on the end of the shaft.

7. Remove the CV boot from the shaft.

13. Grease the joint with the special CV joint grease provided in the boot replacement kit. Fill the cavity behind the balls and the splined hole in the joint’s inner race. Pack the ball tracks and outer face flush with grease. Place any remaining grease into the boot.

CAUTION

Complete disassembly of the CV joint is NOT recommended. The internal components are precision fit and develop their own characteristic wear patterns. Intermixing the internal components could result in looseness, binding, and/or premature failure of the joint. IMPORTANT: If the grease in the joint is obviously contaminated with water and/or dirt, the joint should be replaced.

8. Thoroughly clean the joint with an appropriate solvent and dry the joint to prevent any residual solvent from being left in the joint upon reassembly. 9. Visually inspect the joint by tilting the inner race to one side to expose each ball. Severe pitting, galling, play between the ball and its cage window, any cracking or damage to the cage, pitting or galling or chips in raceways call for joint replacement.

7.26

The grease provided in the replacement kit is specially formulated for wear resistance and durability. DO NOT use substitutes or mix with other lubricants. NOTE: The amount of grease provided is premeasured. Use the entire package contents. 14. Slide the joint onto the drive shaft splines and align the circlip with the lead-in chamfer on the inner race of the joint.

15. Use a soft-faced hammer to tap the joint onto the drive shaft until it locks into place. 16. Pull on the joint to make sure it is securely locked in place. 17. Remove excess grease from the CV joint's external surfaces and place the excess grease in the boot.

FINAL DRIVE 18. Pull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft. Make sure the boot is not dimpled or collapsed.

Inner Plunging Joint / Boot Replacement 1. Using a side cutters, cut away and discard the boot clamps.

19. Install and tighten the large clamp using the Axle Boot Clamp Tool (PU-48951).

2. Remove the large end of the boot from the plunging joint and slide the boot down the shaft. Axle Boot Clamp Tool: 8700226 or PU-48951 20. While pulling out on the CV shaft, fully extend the CV joint and slide a straight O-ring pick or a small slotted screw driver between the small end of the boot and the shaft. This will allow the air pressure to equalize in the CV boot in the position that the joint will spend most of its life. Before you remove your instrument, be sure the small end of the boot is in its correct location on the shaft.

21. Install and tighten the small clamp on the boot using the Axle Boot Clamp Tool (PU-48951). 3. Clean the grease from the face of the joint. 4. Place the drive shaft in a soft-jawed vise.

7.27

FINAL DRIVE 5. Using a soft-faced hammer, or brass drift, strike the inner race of the joint to drive the joint off the drive shaft. Be sure to tap evenly around the joint to avoid binding.

8. Thoroughly clean the joint with an appropriate solvent and dry the joint to prevent any residual solvent from being left in the joint upon reassembly.

Brass Drift Shown

IMPORTANT: Tap on inner race only!

9. Visually inspect the joint for damage. Replace if needed.

6. Make sure the circlip is still on the shaft and not left in the joint.

10. Clean the splines on the end of the shaft and apply a light coat of grease prior to reassembly.

Circlip

11. Slide the small boot clamp and boot (small end first) onto the drive shaft and position the boot in its groove machined in the shaft. 12. Install a NEW circlip on the end of the shaft. 13. Grease the joint with the special CV joint grease provided in the boot replacement kit. Fill the cavity behind the balls and the splined hole in the jointâ&#x20AC;&#x2122;s inner race. Pack the ball tracks and outer face flush with grease. Place any remaining grease into the boot.

CAUTION 7. Remove the boot from the shaft.

The grease provided in the replacement kit is specially formulated for wear resistance and durability. DO NOT use substitutes or mix with other lubricants.

CAUTION Complete disassembly of the plunging joint is NOT recommended. The internal components are precision fit and develop their own characteristic wear patterns. Intermixing the internal components could result in looseness, binding, and/or premature failure of the joint.

NOTE: The amount of grease provided is premeasured. Use the entire package contents. 14. Fully compress the joint and push the drive shaft firmly into the inner race.

IMPORTANT: If the grease in the joint is obviously contaminated with water and/or dirt, the joint should be replaced.

7.28

FINAL DRIVE 15. Align the circlip with the lead-in chamfer.

21. Pull out on the drive shaft to center the joint in the housing. Slide a straight O-ring pick or a small slotted screw driver between the large end of the boot and the joint housing and lift up to equalize the air pressure in the boot. 22. Position the boot lip in its groove. Install and tighten the large clamp using the Axle Boot Clamp Tool (8700226 or PU-48951).

16. Use a soft-faced hammer to tap the joint onto the drive shaft until you reach the end of the splines and the joint locks in place. 17. Pull on the joint to test that the circlip is seated and that the joint is securely fastened to the shaft. 18. Remove excess grease from the plunging jointâ&#x20AC;&#x2122;s external surfaces and place the excess grease in the boot. 19. Pull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft. Make sure the boot is not dimpled or collapsed. 20. Install and tighten the small clamp using the Axle Boot Clamp Tool (8700226 or PU-48951).

Axle Boot Clamp Tool: 8700226 or PU-48951

7.29

FINAL DRIVE REAR PROPSHAFT

Drive Shaft Exploded View

Removal

FRONT SHAFT Spring Ring

1. Drive the roll pin from the rear propshaft yoke located at the transmission.

Plunging Joint

Gear Side Boot Kit

Wheel Side Boot Kit

Roll Pin Removal Tool: PN 2872608

CV Joint

REAR SHAFT

2. Remove the parking brake caliper assembly from the caliper mount bracket to allow the rear propshaft to slide back on the rear gearcase input shaft.

Rear 4x4 Shown Spring Ring Plunging Joint

Remove

Gear Side Boot Kit

Wheel Side Boot Kit

3. Slide the rear propshaft back on the rear gearcase input shaft, remove the propshaft from the transmission and remove the propshaft from the vehicle.

CV Joint

7.30

FINAL DRIVE Installation

REAR GEARCASE

1. Install the rear propshaft onto the rear gearcase input shaft and slide back fully to allow yoke installation on the transmission output shaft.

General Operation

2. Slide the rear propshaft forward onto the transmission output shaft. 3. Align the rear propshaft pin hole with the pin hole on the transmission rear output shaft. Drive a NEW roll pin into the propshaft yoke. 4. Install the parking brake caliper assembly. Tighten the two mounting bolts in increments and torque to specification.

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. NOTE: ‘Turf’ or ‘Differential Unlock’ mode disabled above 10 MPH indicated ground speed.

18 ft-lbs (24 Nm)

=T Parking Brake Caliper - Mounting Bolts: 18 ft-lbs (24 Nm)

When “Differential-Unlock” is selected on the switch, the rear differential becomes unlocked for tighter turns. An electrical solenoid mounted in the rear gearcase housing actuates the shift yoke. The solenoid plunger extends out to move the shift yoke and slides the clutch gear away from the engagement dogs that are attached to the differential gear assembly. This unlocks the rear differential.

When switch position is set to “Unlock”, the solenoid is powered and the plunger extends to disengage the clutch gear and unlock the differential.

7.31

FINAL DRIVE When the clutch gear is unlocked the rear drive shafts are dependent on the differential allowing tighter turns. When it’s locked it becomes a solid rear axle increasing traction.

Differential - Unlock Clutch Gear

Differential Shift Yoke

Clutch Gear When “Differential-Lock” is selected on the switch, power is removed from the electrical solenoid allowing the solenoid plunger to retract. Spring tension moves the shift yoke back into place and engages the clutch gear into the engagement dogs that are attached to the differential gear assembly, locking the rear differential as a solid rear axle.

Locked Mode Clutch Gear

When switch position is set to “Lock”, power is removed from the solenoid and the plunger retracts to engage the clutch gear and lock the differential.

Locked Axle Shaft

Axle Shaft

Unlocked Mode Differential - Lock IRS Axle Clutch Gear

Unlocked Shift Yoke

7.32

Clutch Gear

Axle Shaft

FINAL DRIVE Gearcase Removal

Gearcase Disassembly

1. Follow the “REAR DRIVE SHAFT - Removal” procedure to remove the rear drive shafts from each side of the rear gearcase.

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.

2. Disconnect the differential solenoid 2-wire harness. 3. Completely drain the lubricant from the rear gearcase.

1. Remove the differential solenoid from the gearcase cover if servicing the solenoid, shift lever, shift lever spring, or shift yoke. If none of these items are being serviced, the solenoid can remain installed in the gearcase cover.

Drain Plug 4. Remove the (4) bolts that secure the rear gearcase to the frame.

2. Remove the bolts that secure the cover to the housing. Remove Cover Bolts

Remove the (2) fasteners from each side. 5. Remove the (3) fasteners retaining the parking brake caliper bracket to the rear gearcase and carefully pull the rear gear case assembly from the frame. Allow the rear propshaft to slide off of the rear gearcase shaft.

Bracket

(3) Propshaft

7.33

FINAL DRIVE 3. Remove the differential assembly from the housing.

4. Inspect the bevel gear teeth for chipped, worn, or broken teeth. Inspect Teeth

5. Remove the small bearing from the differential assembly. Inspect the bearing for smoothness and wear.

7.34

6. Remove the shims from the differential assembly. Be sure to keep the shims together for reassembly.

7. Remove the large bearing from the differential assembly. Inspect the bearing for smoothness and wear.

8. Remove the shims from the differential assembly. Be sure to keep the shims together for reassembly.

FINAL DRIVE 9. If the solenoid was removed for servicing, inspect the tip of the solenoid for wear. If the tip of the solenoid is flattened the solenoid must be replaced.

12. Loosen the lock assembly pin.

13. Remove the pin from the gearcase cover. 10. Remove the clutch gear from the gearcase cover.

11. Inspect the shift lever (A), shift lever spring (B), shift return springs (C), and shift yoke (D) for excessive wear or damage. If disassembly is required proceed to the next step. If no disassembly is required proceed to “Rear Gearcase Assembly.”

14. Carefully remove the shift yoke assembly from the gearcase cover.

7.35

FINAL DRIVE 15. Inspect the shift lever (A), shift lever spring (B), shift return springs (C), shift yoke (D), and lock pin bushing (E). Inspect the components for excessive wear or damage and replace as needed.

C A

Do Not Disassemble. Replace as an assembly if damaged or worn.

C E

Rear Gearcase Assembly NOTE: Grease all seals and O-rings with Polaris All Season Grease (PN 2871322) upon assembly.

2. Replace the drive shaft oil seals located in the main gearcase and gearcase cover

1. Remove the pinion shaft oil seal using a seal puller and replace with a new seal.

NOTE: The pinion gear assembly is NOT intended to be disassembled from the case, as it requires special OEM tooling in order to properly reassemble. If there is any damage to the pinion gear, bearings or case, the assembly must be replaced.

3. Replace all worn components.

7.36

FINAL DRIVE 4. Install the original shims (A) onto the differential assembly (B) on both sides. Install the bearings (C), replace with new bearings if needed.

6. If previously removed; assembly the shift lever (A), shift lever spring (B), shift return springs (C), shift yoke (D), and lock pin bushing (E).

D C C E

7. Carefully install the shift yoke assembly into the gearcase cover.

B A

5. Install the differential assembly into the carrier housing.

7 8. Install the lock assembly pin and tighten.

7.37

FINAL DRIVE 9. Install the new lightly greased O-ring onto the carrier cover.

11. If previously removed, install the differential solenoid into the carrier cover. Torque solenoid to specification.

O-Ring

38 ft-lbs (52 Nm)

10. Assemble the gearcase halves and install the (7) bolts that secure the cover to the housing. Torque the bolts in a criss cross pattern to specification. 30 ft-lbs (41 Nm)

7.38

=T Gearcase Cover Bolts: 30 ft-lbs (41 Nm) Differential Solenoid: 38 ft-lbs (52 Nm)

FINAL DRIVE Rear Gearcase Installation 1. Place the rear gearcase assembly into the frame. Slide the rear propshaft onto the rear gearcase input shaft. 2. Install the (4) gearcase mounting fasteners and torque the fasteners to specification. 3. Install the parking brake caliper bracket fasteners and torque the fasteners to specification.

Fill Plug 25 ft-lbs (34 Nm)

Bracket

17 ft-lbs (23 Nm)

Propshaft 40 ft-lbs (54 Nm)

4. Connect the differential solenoid 2-wire harness. Drain Plug 38 in-lbs (4 Nm)

5. Follow the “REAR DRIVE SHAFT - Installation” procedure to reinstall the rear drive shafts. 6. Torque drain plug to specification. 7. Add Polaris ATV Angle Drive Fluid (PN 2876160) to rear carrier. Refer to maintenance information in Chapter 2 for more details.

= Rear Gearcase Lubricant / Capacity: ATV Angle Drive Fluid / 22 fl. oz. (650 ml)

8. Torque fill plug to specification.

=T Gearcase Mounting Fasteners: 40 ft-lbs (54 Nm) Park Brake Bracket Fasteners: 17 ft-lbs (23 Nm) Gearcase Drain Plug: 38 in-lbs (4 Nm) Gearcase Fill Plug: 25 ft-lbs (34 Nm) NOTE: The rear gearcase lubricant must be checked and filled when the gearcase is properly mounted in the vehicle and the vehicle resting on level ground.

7.39

FINAL DRIVE Rear Gearcase Exploded View 38 in-lbs (4 Nm) 80 ft-lbs (108 Nm)

288 ft-lbs (390 Nm)

25 ft-lbs (34 Nm)

30 ft-lbs (41 Nm) 38 ft-lbs (52 Nm) REF

DESCRIPTION

QTY

Hypoid Gear Assembly

Bearing Cone - Diff

Pinion Nut

Carrier Housing Half

Bearing Cup - Diff

Oil Seal - Pinion

Carrier Cover Half

Bearing - Roller

Pinion Thrust-

Diff Case Half

Bearing - Cup

Lock Pin Bushing

Diff Case Cover Half

Hex Head Plug

Shift Return Spring

Diff Side Gear

Clutch Gear

Drain Plug

Diff Pinion Mate Gear

O-Ring - Housing Halves

Oil Seal - Shaft

Pinion Mate Thrust-

Lock Assembly Pin

Fill Plug

Diff Cross Pin

Vent Tube

Shift Yoke

Diff Roll Pin

Flanged Hex Bolt - Housing

Shift Lever

Hex Bolt - Ring Gear

Diff Solenoid

Shift Lever Spring

Diff Case Thrust-Washer

Spacer - Kit

Pinion Spacer

Side Gear Thrust-Washer

Bearing Cup - Pinion

Diff Case Thrust-Washer

Bearing Cone - Pinion

7.40

QTY REF

DESCRIPTION

QTY REF

TRANSMISSION

CHAPTER 8 TRANSMISSION SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 TRANSMISSION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 LUBRICATION SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2

SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2

SHIFT CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3 TRANSMISSION SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4 TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4 TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 TRANSMISSION SHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8 COMPENSATOR SHAFT PRELOAD CHECK AND ADJUSTMENT PROCEDURE . . . 8.10 TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13 TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16 TROUBLESHOOTING CHECKLIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19 TRANSMISSION EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20

8.1

TRANSMISSION SPECIAL TOOLS

SHIFT LEVER

Special Tools

Removal

SPX Corp: 1-800-328-6657 or http://polaris.spx.com

1. Remove the (2) push rivets retaining the dash panel and remove the panel from the dash to access the shift lever.

TRANSMISSION SPECIFICATIONS

2. Remove the shift knob cover, retaining screw and shift knob from the shift lever.

Torque Specifications ITEM

TORQUE VALUE

Transmission Fill Plug

12 ft-lbs (16 Nm)

Transmission Drain Plug

12 ft-lbs (16 Nm)

Transmission Case Screws

18 ft-lbs (24 Nm)

Oil Deflector Plate Screws

9 ft-lbs (12 Nm)

Bell Housing Screws

55 ft-lbs (75 Nm)

Bellcrank Nut

15 ft-lbs (20 Nm)

Shift Detent Plug

20 ft-lbs (27 Nm)

Transmission Coupler Nut

120 ft-lbs (163 Nm)

Lubrication Specifications TRANSMISSION

CAPACITY

Synthetic AGL plus Transmission Fluid (PN 2878068) (Quart)

32 oz. (946 ml)

3. Remove the grommet around the shift lever from the dash. 4. Remove the clip and washer retaining the shift cable to the shift lever and disconnect the cable end from the lever. 5. Remove the retaining ring, outer washer, and both bushings from the shift lever. 6. Slide the shift lever off the mounting bracket and out from the frame.

Installation 1. Repeat the steps in reverse order to install the gear shift lever.

8.2

TRANSMISSION SHIFT CABLE

2. Locate the shift cable adjustment point located on the RH side of the frame, by the air filter housing.

Inspection Shift cable adjustment is necessary when symptoms include:

3. With two open-end wrenches, loosen the outside jam nut counterclockwise. Turn the outside jam nut 1 1/2 turns.

• Noise on deceleration • Inability to engage a gear

Inside Jam Nut

• Excessive gear clash (noise) • Gear selector is moving out of desired range Inspect shift cable, clevis pins, and pivot bushings and replace if worn or damaged. 1. Place gear selector in neutral. Make sure the transmission bell crank is engaged in the neutral position detents. Bell Crank in Neutral Position

Outside Jam Nut

4. 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. 5. Repeat Step 3 and Step 4 until the proper adjustment is made to the shift cable. 6. Use this procedure to loosen or tighten the shift linkage cable as needed.

Adjustment Point

8.3

TRANSMISSION TRANSMISSION SERVICE

11. Remove the crankshaft sensor.

Transmission Removal 1. Position the vehicle on a level surface. 2. Thoroughly clean the engine, transmission and chassis. 3. Tilt the cargo box. 4. Remove the seat base and seat back (see Chapter 5). Remove

5. Disconnect the negative (-) battery cable ď&#x20AC; (see Chapter 2). 6. Drain the transmission fluid (see Chapter 2).

12. Disconnect the speed sensor located on the lower right-hand side of the transmission.

7. Remove the outer PVT cover:

13. Disconnect the gear position switch from the top of the transmission. 14. Disconnect the shift cable from the gear selector on the transmission.

Remove

8. Remove the drive and driven clutch assemblies (refer to Chapter 6). 9. Remove the PVT intake and outlet ducts from the transmission.

15. Remove the shift cable bracket. This creates the room necessary for transmission removal. 16. Remove the parking brake to prepare for propshaft removal (refer to Chapter 9).

10. Remove the inner PVT cover (see Chapter 6).

8.4

TRANSMISSION 17. Remove the rear propshaft from the transmission output shaft. Refer to Chapter 7.

21. While pushing on the forward end of the engine to create separation, grab the clutch shaft and carefully work the transmission away from the engine. Allow the front propshaft to slide off the front transmission shaft.

18. Remove the transmission vent lines. 22. Once you have cleared the engine coupler, lift the transmission assembly out of vehicle with the aid of an assistant or hoist.

Transmission Disassembly 1. Remove the drive belt, drive clutch and driven clutch (see Chapter 7 “PVT SYSTEM SERVICE Disassembly”). 2. If attached, remove the screws that secure the inner PVT cover to the transmission case and remove the cover. 19. Remove the 13mm and (2) 15mm bolts retaining the transmission to the engine (shown).

15mm

20. From under the vehicle, remove the fasteners that retain the transmission mounts to the frame on each side.

3. Remove (2) retaining bolts from the transmission cover (see Step 7). These are thread forming bolts that can be used to hold the coupler during removal and installation.

8.5

TRANSMISSION 4. Thread the (2) bolts into the transmission case pin holes to hold the coupler. Coupler

8. Carefully lift up on the cover. Use a soft-faced hammer to tap on the input shaft and rear output shaft to ease cover removal. Output Shaft

Thread bolts in pin holes. Primary Shaft

Input Shaft

9. Lift up on the rear output shaft assembly and remove the front output shaft assembly. 5. Remove the retaining nut and transmission coupler. 6. Place the transmission in neutral by moving the bellcrank. 7. Lay the transmission down with the cover facing up and remove the bolts retaining the transmission cover.

Front Output Shaft

Rear Output Shaft

10. Remove the (2) screws retaining the oil deflector plate.

8.6

TRANSMISSION 11. Lift up on the rear output shaft assembly enough to remove the compensator assembly.

14. Lift up on each end of the shift fork and rotate the fork out of the shift shaft cam.

Compensator Assembly Rear Output Shaft

12. Remove the rear output shaft assembly and silent chain from the transmission.

15. Repeat the previous step to remove the lower shift fork.

13. Remove the springs, shift shaft rail and park shaft rail.

16. Remove the input shaft assembly and reverse shaft assembly together from the transmission.

8 Park Shaft Rail Shift Shaft Rail

17. If servicing either shaft assembly, remove the reverse silent chain and separate the shaft assemblies.

8.7

TRANSMISSION 18. Inspect all bearings, gear teeth, engagement dogs and silent chain.

Transmission Shaft Service Use the exploded views within this section when servicing the transmission shafts. Shaft bearings can be serviced using an arbor press. Input Shaft

19. Remove the detent plug, snap ring, washer and gear selector switch. Washer

Snap Ring

Detent Plug

Primary Shaft

20. Remove the retaining ring and washer from the cam shift shaft. Remove the nut, bellcrank and washer from the bellcrank shift shaft. Washer

Bellcrank Washer

Retaining Ring

21. Remove both shift shafts from the transmission as an assembly. Lightly tap on each shaft to ease removal.

8.8

TRANSMISSION Rear Output Shaft

Compensator Shaft

Reverse Shaft

NOTE: Stack the belleville washers and place them into the belleville cup upon assembly as shown. The “UP” stamping on each washer should face out when assembling the washer stack. “UP” Marking

Belleville Washers

Cup

8.9

TRANSMISSION Cam Shift Shaft

Compensator Shaft Preload Check and Adjustment Procedure NOTE: The compensator shaft preload must be checked and/or adjusted for proper transmission operation. 1. Place the transmission compensator shaft assembly on a suitable work bench with the retaining ring facing up. 2. By hand, press down on the belleville cup to remove the slight spring tension from the preload shims and retaining ring. Remove retaining ring and spacers. Make note of the order and positioning of the shim(s) as they are removed. Press Belleville Cup Down

Remove Retaining Ring and Spacers

Bellcrank Shift Shaft

3. Remove the belleville cup. 4. Remove the belleville cup preload coil spring from the center of the belleville washers. Remove Spring

5. Reinstall the belleville cup onto the compensator shaft. Be sure the belleville washer stack is installed in the proper order/position if they were removed.

8.10

TRANSMISSION 6. Reinstall the retaining ring onto the compensator shaft using the proper retaining ring pliers. Install Retaining Ring

VALUE A

Be sure these are not installed at this time

7. Hold the compensator shaft and rotate the belleville cup as much as possible clockwise and counter clockwise to properly position belleville washers and seat the retaining ring. Repeat this step 2-3 times. 8. Position the compensator cam lobes centered into the flats as shown below.

10. Add 0.020 in. (0.508 mm) to “VALUE A” and record this number below as “VALUE B”.  VALUE B: _________ (VALUE A + 0.020 in. / 0.508 mm) 11. Use the thickest preload shims available out of Shim Kit 2204264 or use the existing shims to equal or be within ±.005 in. (0.127 mm) of the measurement recorded as “VALUE B”. 12. Check the thickness of the preload shim(s) with a caliper to be sure they are equal to or within ± 0.005 in. (0.127 mm) of “VALUE B” from steps 10-11.

Cam Lobe Centered in Flat / Low Spot

9. Using an appropriate feeler gauge, measure and record the distance between the top of the belleville cup and the bottom of the retaining ring.  Record this measurement as “VALUE A”.  VALUE A: __________ 13. Remove the retaining ring from the compensator shaft using a proper retaining ring pliers. 14. Remove the belleville cup from the compensator shaft. 15. Install the belleville cup preload coil spring. Be sure it is seated properly and did not catch on a belleville washer. 16. Install the belleville cup.

8.11

TRANSMISSION 17. Install and center the preload shims selected from step 11. Be sure the THICKEST of the preload shims is installed last so it will be resting against the retaining ring. THICKEST Preload Shim on Top

18. By hand, press the belleville cup down and install the retaining ring using a proper retaining ring pliers. Be sure the retaining ring is seated properly in the compensator shaft slot. 19. The compensator shaft preload has now been properly set, proceed with transmission assembly / service. Compensator Preload Shims (Included in Shim Kit 2204264) .015” (.381 mm) Qty. 1 .020” (.508 mm) Qty. 2 .025” (.635 mm) Qty. 1 .031” (.787 mm) Qty. 1 .050” (1.27 mm) Qty. 2

8.12

TRANSMISSION Transmission Assembly

1. Thoroughly clean the transmission case halves and shafts.

4. If the bellcrank shift shaft was disassembled, install the gear sector with the step facing the O-ring.

2. Inspect all seals and O-rings for damage. If transmission was disassembled, seal and O-ring replacement is recommended (see exploded view above).

Step

Replace O-Ring

3. If the cam shift shaft was disassembled, install the detent gear with the step facing the O-ring.

Step

5. Install new O-rings on both shift shafts and lubricate prior to installation. Replace O-Ring

NOTE: Both shift shafts have skip-tooth keyed splines for assembly purposes.

8.13

TRANSMISSION 6. Align the timing marks on the cam shift shaft and bellcrank shift shaft.

9. Install the retaining nut and torque to specification.

Align Marks

Bellcrank Retaining Nut: 15 ft-lbs (20 Nm) 10. Install the washer and a new retaining ring onto the cam shift shaft. The retaining ring should be tight on the shaft. 11. Install the transmission switch, washer and snap ring. Washer

Snap Ring

7. Place the two shafts into the transmission as an assembly.

Detent Plug

12. Install the detent plug and torque to specification.

IMPORTANT: Gently rock or twist the shift shafts upon installation to prevent from damaging the new O-rings. Forcing the shift shafts straight into the transmission housing may cut the O-rings.

Detent Plug: 20 ft-lbs (27 Nm) 13. Assemble the input shaft and reverse shaft with the lower shift fork and park pawl installed.

8. Install the washer over the bellcrank shift shaft and install the bellcrank by aligning the skip-tooth splines. Shift Fork Skip-Tooth Splines

Bellcrank

Park Pawl

14. Place the assembly into the transmission housing making sure to move the park pawl arm behind the shift shaft cam during installation.

8.14

TRANSMISSION 15. Lift up on the lower shift fork and rotate the end into the cam.

18. Install the oil deflector plate and install new retaining screws. Torque screws to specification.

=T Deflector Plate Retaining Screws: 9 ft-lbs (12 Nm) 19. Install the rear output shaft assembly and silent chain. 20. Lubricate all seal lips to prevent damage upon assembly. 21. Lift up slightly on the rear output shaft and install the compensator shaft and front output shaft assemblies. 16. Install the upper shift fork and rotate the end into the cam.

22. If primary shaft was serviced, reinstall shaft assembly into the transmission case. Apply grease to the primary shaft shim(s) and place them into the transmission cover. 23. Carefully install the transmission cover onto the transmission. Apply even pressure to cover while setting into place. A soft-faced hammer can be used once the cover is started and aligned. IMPORTANT: Take care not to damage seals during cover installation. 24. Install the retaining bolts and torque to specification. Leave (2) bolts out to use later when tightening the coupler.

=T 17. Install both rails and springs. Transmission Cover Bolts: 18 ft-lbs (24 Nm) 25. Install a new O-ring onto the compensator shaft prior to installing the transmission coupler. Park Shaft Rail Shift Shaft Rail

NOTE: Make sure the spring is flush with the top of the shift shaft rail. If not flush, the rail may not be fully seated.

O-Ring

8.15

TRANSMISSION IMPORTANT: Be sure to install the O-ring all the way down onto the shaft, past the groove. 26. Install the transmission coupler and cone washer (dome facing up). 27. Apply Loctiteâ&#x201E;˘ 2760 to the shaft threads and install the coupler retaining nut. 28. Hold the transmission coupler using the (2) transmission cover bolts that were left out. Thread the bolts into the transmission case and torque the coupler nut to specification.

Transmission Installation 1. Position the vehicle on a level surface. 2. Thoroughly clean the engine, transmission and chassis. 3. Install the rubber coupler into the engine coupler. Be sure rubber coupler is properly mounted. Lubricate the rubber with a soap/water solution to aid installation.

120 ft-lbs (163 Nm)

4. Install a new gasket onto the engine mounting plate. 5. With the aid of an assistant or hoist, carefully place the transmission assembly into the chassis.

=T Transmission Coupler Retaining Nut: 120 ft-lbs (163 Nm)

6. Slide the front propshaft onto the front transmission shaft.

29. Remove the (2) bolts holding the coupler and install them in the transmission cover. Torque the bolts to specification (see Step 24).

7. While pushing on the forward end of the engine, grab the clutch shaft of the transmission and carefully work the transmission to the engine. Verify the front propshaft stays installed on the front transmission shaft.

8.16

TRANSMISSION 8. Align the engine and transmission coupler as shown. Engine Coupler

12. Install the transmission vent lines.

Transmission Coupler

13. Install the rear propshaft to the transmission output shaft. (Refer to Chapter 7). Install a NEW roll pin. NOTE: Verify the front propshaft is properly attached to the transmission shaft before installing the bolts. 9. Install the 13mm and (2) 15mm bolts that retain the transmission to the engine.

15mm

14. Install the parking brake assembly and tighten fasteners to specification (Refer to Chapter 9).

10. Torque the transmission-to-engine bolts in two steps to the specified torque value using a cross pattern.

=T Transmission-to-Engine Retaining Bolts: 18 ft-lbs (24 Nm) 11. Align the (2) transmission mount fasteners on each side of the frame and torque to specification.

=T Transmission Mount Fasteners: 18 ft-lbs (24 Nm)

8.17

TRANSMISSION 15. Install the shift cable bracket. Torque the fasteners to specification.

20. Install the PVT intake and outlet ducts from the transmission.

Install

16. Install the shift cable to the gear selector on the transmission. 21. Refer to Chapter 6 for PVT system installation. 22. Add the recommended amount of lubricant through the fill plug hole. Maintain the lubricant level at the bottom of the fill plug hole when filling the transmission. Do not overfill.

Install

Fill Plug 12 ft-lbs (16 Nm)

17. Install the gear position switch connector at the top of the transmission. 18. Install the speed sensor connector located on the lower right-hand side of the transmission. 19. Install the crankshaft sensor. Torque the fastener to specification. Gearcase lubricant flush with the bottom of thread area.

Install

Transmission Lubricant: Synthetic AGL Plus (PN 2878068) (Quart) Capacity: 32 oz. (946 ml)

8.18

TRANSMISSION 23. Reinstall fill plug with a new O-ring and torque to specification.

=T Drain/Fill Plug: 12 ft-lbs (16 Nm)

Troubleshooting Checklist Check the following items when shifting difficulty is encountered. • Engine idle speed is above specification • Transmission fluid type/quality • Loose or worn linkage • Worn linkage at the transmission bellcrank • Bent bellcrank • Worn, broken or damaged internal transmission components • Mis-aligned clutches NOTE: To determine if shifting difficulty is caused by an internal transmission problem, isolate the transmission by disconnecting linkage 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), or damage. Inspect all bearings, circlips, thrust washers and shafts for wear.

8.19

TRANSMISSION Transmission Exploded View 120 ft-lbs (163 Nm)

FOR REASSEMBLY 15 ft-lbs (20 Nm)

Apply Polaris Crankcase Sealant. Apply LoctiteTM 2760 to the bolt threads.

55 ft-lbs (75 Nm)

12 ft-lbs (16 Nm)

9 ft-lbs (12 Nm)

20 ft-lbs (27 Nm)

12 ft-lbs (16 Nm) 9 ft-lbs (12 Nm)

18 ft-lbs (24 Nm)

8.20

12 ft-lbs (16 Nm)

TRANSMISSION Exploded View, Continued REF #

DESCRIPTION

QTY

REF #

DESCRIPTION

QTY

Plug, Hex

Cup, Belleville

Plug, Hex

Thrust Spacer

Plug, Hex, Magnetic

Sprocket, 47 T

Screw

Reverse Shaft, 53T

Screw

Input Shaft, 25T

Screw

Compensator Cam

Nut

Helical Gear, 42T

Nut

Compensator Gear, 54T

Thrust Washer

Output Shaft

Thrust Washer

Bellcrank

Belleville Washer

Vent Tube

Dowel Pin

Gear, 67 T

Dowel Pin

Sprocket, 48 T

Snap Ring

Shift Shaft

Retaining Ring

Shift Rail

Retaining Ring

Detent Plug

Retaining Ring

Engagement Dog

Retaining Ring

Engagement Dog

Retaining Ring

Compensator Shaft

Retaining Ring

Shift Fork

Retaining Ring

Dowel

Thrust Washer

Shift Fork

Thrust Washer

Engagement Dog

Shim

Sprocket, 19T

Shim

Output Asm.

Thrust Washer

Primary Shaft Asm.

Belleville Washer

Compensator Shim Pack

Thrust Washer

Primary Shim pack

Collar

Switch Shaft

Ball Bearing

Oil Deflector

Ball Bearing

Bearing Cover Asm.

Ball Bearing

Silent Chain

Ball Bearing

Silent Chain

Needle Bearing

Gear Switch

Ball Bearing

O-Ring

Needle Bearing

O-Ring

8.21

TRANSMISSION 37

Needle Bearing

O-Ring

Ball Bearing

Seal, Triple Lip

Flanged Bearing

O-Ring

Compression Spring

O-Ring

Wave Spring

Seal

Compression Spring

Seal, Triple Lip

Compression Spring

Transmission Coupler

Gearcase Cover

Speed Sensor

Gearcase, Main

Ball Bearing

Bell Housing

100

Collar

Sector Gear, 38T

Detent Bullet

8.22

BRAKES

CHAPTER 9 BRAKES GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 BRAKE SYSTEM GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3 BRAKE SYSTEM SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3 BRAKE NOISE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3 HYDRAULIC BRAKE SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4 BRAKE SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5

MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6

FOOT BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6 PEDAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6 PEDAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6

BRAKE BLEEDING / FLUID CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7 FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8 FRONT CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10 CALIPER EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10 CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10 CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11 CALIPER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12 CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12 CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13

REAR BRAKE PADS (NON CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14 REAR CALIPER SERVICE (NON CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16 REAR CALIPER EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16 CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16 CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17 CALIPER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17 CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17 CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18

REAR CALIPER SERVICE (CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19 REAR CALIPER EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19 CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19 CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20 CALIPER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21 CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21 CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22

FRONT BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23 REAR BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26 EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27 CABLE TENSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27

PARKING BRAKE CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28 EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28 CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28 CALIPER DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29 NEW BRAKE PAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29 CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.30

PARKING BRAKE DISC SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.30 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.31

9.1

BRAKES GENERAL SPECIFICATIONS Specifications and Service Limits 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

.188" ( 4.78 mm)

.170" (4.32 mm)

Front Brake Disc Runout

.010" (.254 mm)

REAR BRAKE SYSTEM Item

Standard

Service Limit

Rear Brake Pad Thickness

.298 ± .007"/ 7.56 ± .178 mm

.180" (4.6 mm)

Rear Brake Disc Thickness

.188" (4.78 mm)

.170" (4.32 mm)

Rear Brake Disc Runout

.010" (.254 mm)

PARK BRAKE SYSTEM Item

Standard

Service Limit

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

0.161” - 0.177” (4.09 - 4.50 mm)

.150" (3.81 mm)

TORQUE SPECIFICATIONS

SPECIAL TOOLS

Torque Specifications

Special Tools Torque ft-lbs

Torque Nm

Front Caliper Mounting Bolts

Rear Caliper Mounting Bolts

Park Brake Caliper to Mount Bracket Bolts

Park Brake Lever Mount Bolts

Brake Line Flare Fittings

Brake Line Banjo Bolts (All)

Front Brake Disc to Hub Bolts

Rear Brake Disc to Hub Bolts

Park Brake Disc Mounting Bolt

Brake Switch

Master Cylinder Mount Bolts

Item

9.2

PART NUMBER

DESCRIPTION

2870975

Mity Vac™ Pressure Test Tool

SPX Corp: 1-800-328-6657 or http://polaris.spx.com

BRAKES BRAKE SYSTEM GENERAL INFORMATION Brake System Service Notes Disc brake systems are light weight, low maintenance, and perform well in the conditions this vehicle will routinely encounter. There are a few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function and maximum pad service life. • Optional pads are available to suit conditions in your area. Select a pad to fit riding style and environment. • Do not over-fill the master cylinder fluid reservoir. • Make sure the brake pedal returns freely and completely. • Adjust stop pin on front caliper after pad service. • Check and adjust master cylinder reservoir fluid level after pad service. • Make sure atmospheric vent on reservoir is unobstructed. • Test for brake drag after any brake system service and investigate cause if brake drag is evident. • Make sure caliper moves freely on guide pins (where applicable). • Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely. • Perform a brake burnishing procedure after installing new pads to maximize service life. • DO NOT lubricate or clean the brake components with aerosol or petroleum products. Use only approved brake cleaning products.

Brake Noise Troubleshooting Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise (squeal caused by vibration). If cleaning does not reduce the occurrence of brake noise, Permatex™ Disc Brake Quiet can be applied to the back of the pads. Follow directions on the package. This will keep pads in contact with caliper piston(s) to reduce the chance of squeaks caused by dirt or dust. Brake Noise Troubleshooting Possible Cause

Remedy

Dirt, dust, or imbedded material on pads or disc

Spray disc and pads with CRC Brakleen™ or an equivalent non-flammable aerosol brake cleaner. Remove pads and/or disc hub to clean imbedded material from disc or pads.

Pad(s) dragging on disc (noise or premature pad wear) because of improper adjustment Master cylinder reservoir overfilled Master cylinder compensating port restricted Master cylinder piston not returning completely Caliper piston(s) not returning Operator error (riding the brake)

Adjust pad stop (front calipers)  Set to proper level Clean compensating port Inspect. Repair as necessary Clean piston(s) seal  Educate operator

Loose wheel hub or bearings

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 The Polaris brake system consists of the following components or assemblies: brake pedal, master cylinder, hydraulic brake lines, brake calipers, brake pads, and brake discs, which are secured to the drive line. When the foot activated brake lever is applied it applies pressure on the piston within the master cylinder. As the master cylinder piston moves inward it closes a small opening (compensating port) within the cylinder and starts to build pressure within the brake system. As the pressure within the system is increased, the pistons located in the brake calipers move outward and apply pressure to the moveable brake pads. These pads contact the brake discs and move the calipers in their floating bracket, pulling the stationary side pads into the brake discs. The resulting friction reduces brake disc and vehicle speed. The friction applied to the brake pads will cause the pads to wear. As these pads wear, the piston within the caliper moves further outward and becomes self adjusting. Fluid from the reservoir fills the additional area created when the caliper piston moves outward. Brake fluid level is critical to proper system operation. Too little fluid will allow air to enter the system and cause the brakes to feel spongy. Too much fluid could cause brakes to drag due to fluid expansion. Located within the master cylinder is the compensating port which is opened and closed by the master cylinder piston assembly. As the temperature within the hydraulic system changes, this port compensates for fluid expansion or contraction. Due to the high temperatures created within the system during heavy braking, it is very important that the master cylinder reservoir have adequate space to allow for fluid expansion. Never overfill the reservoir! Do not fill the reservoir beyond the MAX LEVEL line! When servicing Polaris brake systems use only Polaris DOT 4 Brake Fluid (PN 2872189). WARNING: Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws. Do not store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture. This causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of serious injury.

9.4

BRAKES Brake System Exploded View NON CREW

LH Front Caliper 2

Brake 3 Switch (2011)

LH Rear Line

LH Rear Caliper

LH Front Brake Line

Master Cylinder Top View

2 1

RH Front Caliper

MC Rear Brake Line

2 1

RH Front Brake Line

1 Brake Switch (2012-2013)

RH Rear Caliper

Caliper Banjo Style Fittings: 15 ft-lbs (20 Nm). All Caliper Bleed Screws:

RH Rear Line

CREW

Brake Switch 3 (2011)

All Flare Style Fittings:

3 14 ft-lbs (19 Nm)

LH Front Brake Line

LH Front Caliper

Master Cylinder Top View

3 2

LH Rear Line

LH Rear Caliper 1

Master Cylinder Side View

2 47 in-lbs (5.3 Nm)

MC Rear Brake Line

RH Front Caliper

RH Front Brake Line

1 Brake Switch (2012-2013)

RH Rear Caliper

Master Cylinder Side View

Caliper Banjo Style Fittings: 15 ft-lbs (20 Nm). All Caliper Bleed Screws:

RH Rear Line

1 1

2 47 in-lbs (5.3 Nm)

All Flare Style Fittings:

3 14 ft-lbs (19 Nm)

9.5

BRAKES MASTER CYLINDER

FOOT BRAKE PEDAL

Removal

Pedal Removal

1. Remove the retaining clip (A) from the clevis pin (B) that attaches the master cylinder to the brake pedal lever.

1. Remove the E-clip from the end of the brake pedal mount bracket. Master Cylinder

2. Remove LH wheel well panel to access master cylinder.

Brake Pedal Mount Bracket

Clevis Pin

C Clip

15 ft-lbs (20 Nm)

Bushing E-Clip

Bushing

Brake Pedal

2. Remove the retaining clip and clevis pin from the master cylinder to free it from the brake pedal. E D

15 ft-lbs (20 Nm) (x2 2011)

15 ft-lbs (20 Nm) (2012-2013)

3. Remove the two mounting bolts (C) that secure the master cylinder to the frame.

3. Slide the brake pedal and bushings off the mount bracket.

Pedal Installation 1. Reverse Steps 1-3 for foot brake installation. 2. Use a new E-clip upon installation.

4. Remove master cylinder and place a fluid catch container under the master cylinder brake line banjo bolt (D) and pressure switch (E).

CAUTION Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact with finished surfaces. 5. Loosen the brake line banjo bolt (D) and pressure switch (E), allow the fluid to drain. NOTE: Make note of front and rear brake line orientation on the master cylinder. 6. Dispose of brake fluid properly and do not re-use.

Installation 1. Reverse Steps 1-5 for master cylinder installation. Refer to the torque specifications in the illustration.

9.6

BRAKES BRAKE BLEEDING / FLUID CHANGE Brake Bleeding Procedure NOTE: When bleeding the brakes or replacing the fluid always start with the furthest caliper from the master cylinder.

Bleeder Screw

CAUTION Always wear safety glasses.

CAUTION Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact with finished surfaces.

8. Place a small amount of fresh brake fluid into a small, clear container and place the other end of bleeder hose into the container.

1. Locate master cylinder reservoir in the front LH wheel well area (Figure 1-6). Clean reservoir cover thoroughly.

9. Have an assistant slowly pump the brake pedal until pressure builds and then hold.

2. Remove cover from reservoir.

10. Quickly open and close the bleed screw while holding pressure on the brake pedal.

3. If changing fluid, remove old fluid from reservoir with a Mity Vac™ pump or similar tool.

NOTE: Do not release brake pedal before bleeder screw is tight or air may be drawn into master cylinder.

Mity Vac™: PN 2870975

11. Release brake pedal pressure. Check level of fluid in reservoir and add if necessary (Figure 1-6).

4. Add brake fluid to the indicated MAX level of reservoir (Figure 1-6).

12. Repeat Steps 9, 10, and 11 until brake pedal is firm and no air can be seen moving through the clear hose. Add fluid as necessary to maintain level in reservoir.

Add Fluid HERE

Master Cylinder Fluid Level Between the MIN and MAX line. IMPORTANT: Maintain at least 1/2” (1.27 cm) of brake fluid in the reservoir to prevent air from entering the master cylinder. 13. Tighten bleeder screw and remove bleeder hose. Torque bleeder screw to specification.

Figure 1-6

Level Indicator

14. Repeat Steps 9 - 13 for the remaining brake calipers. 15. Install master cylinder reservoir cover.

Polaris DOT 4 Brake Fluid: P/N 2872189 5. Begin bleeding procedure with caliper furthest from master cylinder.

16. 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). 17. Check brake system for fluid leaks.

6. Install a box-end wrench on caliper bleeder screw. 7. Attach a tight-fitting, clear hose to the bleeder fitting.

Brake Bleeder Screw: 47 in-lbs (5.3 Nm)

9.7

BRAKES FRONT BRAKE PADS

5. Push the mounting bracket inward and the slip outer brake pad out between the bracket and caliper body.

Pad Removal 1. Elevate and support front of vehicle.

CAUTION Use care when supporting vehicle so that it does not tip or fall. Serious injury may occur if vehicle tips or falls. 2. Remove the wheel nuts, washers and front wheel. Loosen pad adjuster screw.

6. Remove the inner pad from the bracket and caliper.

Pad Inspection Pad Adjuster

1. Measure the thickness of the pad material. Replace pads if worn beyond the service limit.

3. Remove the upper and lower caliper mounting bolts and remove the caliper from the front hub. NOTE: When removing caliper, use care not to damage brake line. Support caliper so to avoid kinking or bending brake line. 4. Push caliper piston into caliper bore slowly using a C-clamp or locking pliers with pads installed.

Measure Thickness in. / ft.

= 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.

9.8

mm / cm

1 1

Front Brake Pad Thickness: New: .298 ± .007” (7.56 ± .178 mm) Service Limit: .180” (4.6 mm)

BRAKES Pad Assembly / Installation 1. Lubricate mounting bracket pins with a light film of disc brake caliper lube, and install rubber dust boots.

5. Install the pad adjuster set screw and turn clockwise until stationary pad contacts disc, then back off 1/2 turn (counterclockwise). 1/2 Turn

Apply disc brake caliper lube

Pad Adjuster

2. Compress mounting bracket and make sure dust boots are fully seated. Install pads with friction material facing each other.

WARNING If brake pads are contaminated with grease, oil, or liquid soaked do not use the pads. Use only new, clean pads. 3. Install caliper onto front hub and torque mounting bolts.

6. Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap. Master Cylinder Fluid Up to MAX line inside reservoir 7. Install wheel and torque wheel nuts to specification (see “Chapter 2 - Maintenance”).

Brake Burnishing Procedure It is required that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise. Start machine and slowly increase speed to 30 mph. Gradually apply brakes to stop machine. Allow pads and disc to cool sufficiently during the procedure. Do not allow pads or disc to become hot or warping may result. Repeat this procedure 10 times.

30 ft-lbs (41 Nm)

=T Front Caliper Mounting Bolts: 30 ft-lbs (41 Nm) 4. Slowly pump the brake pedal until pressure has been built up. Maintain at least 1/2, (12.7 mm) of brake fluid in the reservoir to prevent air from entering the brake system.

9.9

BRAKES FRONT CALIPER SERVICE Caliper Exploded View Apply Polaris DOT 4 Brake Fluid to Components

C B

Apply disc brake caliper lube

47 in-lbs (5.3 Nm) A

D E

F G A. Socket Set Screw  B. Bleeder Screw  C. Caliper Assy.  D. Boots  E. Square O-rings F. Pistons  G. Caliper Mount  H. Brake Pads I. Brake Scraper J. Bolts

H I

Caliper Removal 1. Elevate and safely support the front of the vehicle.

5. Loosen brake pad adjustment set screw to allow brake pad removal after the caliper is removed.

2. Remove the (4) wheel nuts and the front wheel.

CAUTION Use care when supporting vehicle so that it does not tip or fall. Serious injury may occur if vehicle tips or falls. 3. Clean caliper area before removal. 4. Place a container below the caliper to catch brake fluid when removing the line. Remove brake line from caliper.

Remove Brake Line

9.10

Pad Adjuster

BRAKES 6. Remove the two caliper mounting bolts and the caliper.

IMPORTANT: Do not remove the caliper pistons with a standard pliers. The piston sealing surfaces will become damaged if a standard pliers is used. 4. Once the pistons are removed, use a pick to carefully remove the square O-rings from the caliper. O-rings should be replaced during caliper service.

Remove

Caliper Disassembly 1. Remove both brake pads from the caliper (see “FRONT BRAKE PADS - Pad Removal”). 2. Remove the mount bracket assembly and the dust boots from caliper. Thoroughly clean the caliper before disassembly and prepare a clean work area for disassembly.

5. Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol.

Clean Components

3. Use a commercially available caliper piston pliers to extract the pistons from the caliper.

IMPORTANT: Be sure to clean the seal grooves in caliper body.

9.11

BRAKES Caliper Inspection

Caliper Assembly

1. Inspect caliper body for nicks, scratches, pitting or wear. Measure bore size and compare to specifications. Replace if damaged or worn beyond service limit.

1. Install new O-rings in the caliper body. Be sure the grooves are clean and free of residue or brakes may drag upon assembly.

Seal Grooves

New O-Rings

in. / ft.

mm / cm

1 1

Caliper Piston Bore ID: Std: 1.373” (34.87 mm) Service Limit: 1.375” (34.93 mm) 2. Inspect piston for nicks, scratches, pitting or wear. Measure piston diameter and replace if damaged or worn beyond service limit.

2. Coat pistons with clean Polaris DOT 4 Brake Fluid. Install pistons with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance. 3. Lubricate the mounting bracket pins with disc brake caliper lube, and install the rubber dust seal boots. Apply disc brake caliper lube

4. Compress the mounting bracket and make sure the dust seal boots are fully seated. Install the brake pads. Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt, oil or grease. in. / ft.

mm / cm

1 1

Caliper Piston OD: Std: 1.370” (34.80 mm) Service Limit: 1.368” (34.75 mm) 3. Inspect the brake disc and pads as outlined in this chapter.

9.12

BRAKES Caliper Installation 1. Install caliper specification.

and

torque

mounting

bolts

3. Install the pad adjustment screw and turn until stationary pad contacts disc, then back off 1/2 turn. 1/2 Turn

IMPORTANT: If brake disc scraper was removed, be sure to reinstall it upon caliper installation. Disc Scraper

Pad Adjuster

30 ft-lbs (41 Nm) 4. Perform brake bleeding procedure as outlined earlier in this chapter. 5. Install wheel and torque wheel nuts to specification (see Chapter 2).

=T Front Caliper Mounting Bolts: 30 ft-lbs (41 Nm) 2. Install brake line and torque the banjo bolt to the proper torque specification.

6. 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. NOTE: If new brake pads are installed, brake burnishing is required (see “FRONT BRAKE PADS Brake Burnishing Procedure”).

15 ft-lbs (20 Nm)

Banjo Bolt: 15 ft-lbs (20 Nm)

9.13

BRAKES REAR BRAKE PADS (NON CREW)

6. Remove the brake pads.

Pad Removal 1. Elevate and support rear of machine.

CAUTION Use care when supporting vehicle so that it does not tip or fall. Serious injury may occur if vehicle tips or falls. 2. Remove the rear wheel. Loosen pad adjuster screw 2-3 turns.

Pad Inspection 1. Clean the caliper with brake cleaner or alcohol. 2. Measure the thickness of the pad material. Replace pads if worn beyond the service limit.

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.

Measure Thickness

in. / ft.

mm / cm

1 1

Rear Brake Pad Thickness: New: .298 + .007” (7.56 + .178 mm) Service Limit: .180” (4.6 mm)

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.

9.14

BRAKES Pad Installation

Brake Burnishing Procedure

1. Install new pads in caliper body.

It is required that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise. Start machine and slowly increase speed to 30 mph. Gradually apply brakes to stop machine. Allow pads and disc to cool sufficiently during the procedure. Do not allow pads or disc to become hot or warping may result. Repeat this procedure 10 times.

2. Install caliper specification.

and

torque

mounting

bolts

30 ft-lbs (41 Nm)

=T Rear Brake Caliper Mounting Bolts: 30 ft-lbs (41 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 1/2â&#x20AC;? (12.7 mm) of brake fluid in the reservoir to prevent air from entering the master cylinder.

9.15

BRAKES REAR CALIPER SERVICE (NON CREW) Rear Caliper Exploded View Apply Polaris DOT 4 Brake Fluid to Component

Apply disc brake caliper lube

A. Socket Set Screw  B. Bleeder Screw  C. Caliper Assy.  D. Boot  E. Square O-rings F. Piston  G. Caliper Mount  H. Brake Pads

47 in-lbs (5.3 Nm)

Caliper Removal 1. Safely support the rear of the machine.

3. After the fluid has drained into the container, remove the two caliper mounting bolts and remove caliper.

CAUTION Use care when supporting vehicle so that it does not tip or fall. Serious injury may occur if vehicle tips or falls. 2.

Place a container under brake line to catch brake fluid draining from brake lines. Use a wrench to remove the brake line.

4. Clean disc, caliper body, and pistons with brake cleaner or alcohol.

9.16

BRAKES Caliper Disassembly

Caliper Inspection

1. Remove brake pad adjuster screw (A).

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.

2. Push upper pad retainer pin inward and slip brake pads past edge, if pads are still installed. 3. Remove mounting bracket (B) and dust boot (C). B

Pads

C F

E A in. / ft.

4. Remove piston (D) and square O-rings (E) from the caliper body (F).

mm / cm

1 1

Caliper Piston Bore ID: Std: 1.505” (38.23 mm) Service Limit: 1.507” (38.28 mm) 2. Inspect piston for nicks, scratches, wear or damage. Measure diameter and replace if damaged or worn beyond service limit.

5. Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol. NOTE: Be sure to clean seal grooves in caliper body.

in. / ft.

mm / cm

1 1

Caliper Piston OD: Std: 1.500” (38.10 mm) Service Limit: 1.498” (38.05 mm) 3. Inspect the brake disc and pads as outlined for brake pad replacement in this chapter.

9.17

BRAKES Caliper Assembly

Caliper Installation

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.

1. Install the rear caliper onto the mounting bolts. Torque mounting bolts to specification.

2. Install brake line banjo bolt. Torque banjo bolt to specification. 30 ft-lbs (41 Nm)

Lubricate With B Brake Fluid

2. Coat the piston with clean DOT 4 Brake Fluid (PN 2872189). Install piston (B) with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance. 3. Lubricate the mounting bracket pins with disc brake caliper lube, and install the rubber dust seal boots.

15 ft-lbs (21 Nm)

=T Brake Caliper Mounting Bolts: 30 ft-lbs (41 Nm) Brake Line Banjo Bolt: 15 ft-lbs (21 Nm) 3. Install the rear wheel and wheel nuts. Carefully lower the vehicle. 4. 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. NOTE: If new brake pads are installed, brake burnishing is required (see “REAR BRAKE PADS Brake Burnishing Procedure”).

4. Compress the mounting bracket and make sure the dust seals are fully seated. Install the brake pads. Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt, oil or grease.

9.18

BRAKES REAR CALIPER SERVICE (CREW) Rear Caliper Exploded View 47 in-lbs B (5.3 Nm)

Apply Polaris DOT 4 Brake Fluid to Component

E Apply Silicone Grease

F C

G H D

I A. Socket Set Screw  B. Bleeder Screw  C. Caliper Assy.  D. Boot  E. Square O-rings (large) F. Square O-rings (small) G. Piston  H. Caliper Mount  I. Brake Pads

Caliper Removal 1. Elevate and safely support the rear of the vehicle.

4. Place a container below the caliper to catch brake fluid when removing the line. Remove brake line from caliper.

CAUTION Use care when supporting vehicle so that it does not tip or fall. Serious injury may occur if vehicle tips or falls. 2. Remove the (4) wheel nuts, (4) washers and rear wheel. Remove Brake Line

3. Clean caliper area before removal.

9.19

BRAKES 5. Loosen brake pad adjustment set screw to allow brake pad removal after the caliper is removed.

3. Use a commercially available caliper piston pliers to extract the pistons from the caliper.

Pad Adjuster

6. Remove the two caliper mounting bolts and the caliper.

Remove

Caliper Disassembly 1. Remove both brake pads from the caliper. 2. Remove the mount bracket assembly and the dust boots from caliper. Thoroughly clean the caliper before disassembly and prepare a clean work area for disassembly.

5. Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol.

Clean Components

IMPORTANT: Be sure to clean the seal grooves in caliper body.

9.20

BRAKES Caliper Inspection

Caliper Assembly

1. Inspect caliper body for nicks, scratches, pitting or wear. Measure bore size and compare to specifications. Replace if damaged or worn beyond service limit.

1. Install new O-rings in the caliper body. Be sure the grooves are clean and free of residue or brakes may drag upon assembly.

Seal Grooves

New O-Rings

in. / ft.

mm / cm

1 1

Caliper Piston Bore ID: Std: 1.192” (30.28 mm) Service Limit: 1.194” (34.33 mm) 2. Inspect piston for nicks, scratches, pitting or wear. Measure piston diameter and replace if damaged or worn beyond service limit.

2. Coat pistons with clean Polaris DOT 4 Brake Fluid. Install pistons with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance. 3. Lubricate the mounting bracket pins with silicone grease and install the rubber dust seal boots. Apply Grease to Each Bracket Pin

mm / cm

1 1

Caliper Piston OD: Std: 1.186” (30.12 mm) Service Limit: 1.184” (30.07 mm) 3. Inspect the brake disc and pads as outlined in this chapter.

9.21

BRAKES Caliper Installation 1. Install caliper specification.

and

torque

mounting

bolts

4. Perform brake bleeding procedure as outlined earlier in this chapter. 5. Install wheel and torque wheel nuts to specification.

=T Wheel Nuts: Steel Wheels: 35 ft-lbs (47 Nm) Aluminum Wheels: 30 ft-lbs + 90° (1/4 turn) 30 ft-lbs (41 Nm)

=T Rear Caliper Mount Bolt: 30 ft-lbs (41 Nm) 2. Install brake line and torque the banjo bolt to the proper torque specification.

15 ft-lbs (20 Nm)

3. Install the pad adjustment screw and turn until stationary pad contacts disc, then back off 1/2 turn.

1/2 Turn

Pad Adjuster

9.22

BRAKES FRONT BRAKE DISC

Disc Inspection

Disc Runout

1. Visually inspect disc for scoring, scratches, or gouges. Replace the disc if any deep scratches are evident.

1. Mount dial indicator as shown to measure disc runout. Slowly rotate the disc and read total runout on the dial indicator. Replace the disc if runout exceeds specification.

2. Use a 0-1” micrometer and measure the disc thickness at eight different points around the pad contact surface. Replace disc if worn beyond service limit. Measure Thickness

Front Disc

in. / ft.

mm / cm

1 1

Brake Disc Thickness: New: .188” (4.78 mm) Service Limit: .170” (4.32 mm) in. / ft.

mm / cm

1 1

Brake Disc Runout: Service Limit: .010” (.254 mm)

Brake Disc Thickness Variance: Service Limit: .002” (.051 mm) difference between measurements

Disc Removal / Replacement 1. Remove front brake caliper (see “Front Caliper Service”). 2. Remove cotter pin, castle nut and washers. 3. Remove the wheel hub assembly from the vehicle and remove the (4) bolts retaining the disc to the hub. (4) Bolts

Washers Nut Cotter Pin

9.23

BRAKES 4. Clean the wheel hub mating surface and install new disc on wheel hub. Torque new bolts to specification.

REAR BRAKE DISC Disc Runout

18 ft-lbs (24 Nm)

1. Mount a dial indicator and measure disc runout. Slowly rotate the disc and read total runout on the dial indicator. Replace the disc if runout exceeds specification.

80 ft-lbs (108 Nm)

=T Brake Disc Retaining Bolts: 18 ft-lbs (24 Nm)

CAUTION Fastener has a pre-applied locking agent which is destroyed upon removal. Always use new fastener upon assembly. 5. Install wheel hub assembly, washers, and castle nut. Torque castle nut to specification and install a new cotter pin.

in. / ft.

Brake Disc Runout: Service Limit: .010” (.254 mm)

=T Wheel Hub Castle Nut: 80 ft-lbs (108 Nm) 6. Install front brake caliper (see “Front Caliper Service”). Follow bleeding procedure outlined earlier in this chapter. 7. Field test unit for proper braking action before putting into service. Inspect for fluid leaks and firm brakes. Make sure the brake is not dragging when pedal is released. If the brake drags, re-check assembly and installation.

9.24

mm / cm

1 1

BRAKES Disc Inspection 1. Visually inspect disc for scoring, scratches, or gouges. Replace the disc if any deep scratches are evident.

4. Clean the wheel hub mating surface and install new disc on wheel hub. 5. Install new bolts and torque to specification. 28 ft-lbs (38 Nm)

2. Use a 0-1” micrometer and measure disc thickness at 8 different points around perimeter of disc. Replace disc if worn beyond service limit.

Rear Disc 110 ft-lbs (150 Nm) Measure Thickness in. / ft.

mm / cm

1 1

Brake Disc Thickness New: .188” (4.78 mm) Service Limit: .170” (4.32 mm) Brake Disc Thickness Variance Service Limit: .002” (.051 mm) difference between measurements

Disc Removal / Replacement 1. Remove rear brake caliper (see “Rear Caliper Service”). 2. Remove cotter pin, castle nut and washers. 3. Remove the wheel hub assembly from the vehicle and remove the (4) bolts retaining the disc to the hub. (4) Bolts

CAUTION Fastener has a pre-applied locking agent which is destroyed upon removal. Always use new fastener upon assembly. 6. Install wheel hub assembly, washers, and castle nut. Torque castle nut to specification and install a new cotter pin.

=T Brake Disc Retaining Bolts: 28 ft-lbs (38 Nm) Wheel Hub Castle Nut: 110 ft-lbs (150 Nm) 7. Install rear brake caliper (see “REAR CALIPER SERVICE”). Follow the bleeding procedure outlined earlier in this chapter. 8. Field test unit for proper braking action before putting into service. Inspect for fluid leaks and firm brakes. Make sure the brake is not dragging when pedal is released. If the brake drags, re-check assembly and installation.

Washers Nut Cotter Pin

9.25

BRAKES PARKING BRAKE Exploded View

Parking Brake Lever

Bolts 14 ft-lbs (19 Nm) Clevis Pin Nuts

Clevis Pin

13 ft-lbs (18 Nm)

Parking Brake Caliper

Screw

Nut

18 ft-lbs (24 Nm)

Clip

Clip Washer

Bolt Mount Bracket Cable

Nut

Rear Propshaft w/Parking Brake Disc

Bolts

Rear Gearcase

9.26

18 ft-lbs (24 Nm)

BRAKES Inspection

Adjustment Procedure

1. Inspect the parking brake cable and brake pads on the caliper assembly. Refer to the appropriate “Parking Brake Caliper Service” procedure for brake pad replacement information.

1. Place the vehicle in neutral on a flat level surface.

Outboard Pad

Inboard Pad

2. Carefully lift the rear of the vehicle off the ground and stabilize on jack stands. 3. Locate the parking brake cable adjustment area where the cable attaches to the caliper mount bracket.

Parking Brake Cable Adjustment Propshaft

Cable Tension Adjustment When the parking brake is fully engaged and the parking brake indicator is illuminated, engine speed is limited to 1300 RPM in all gears, including neutral. If throttle is applied, this limiting feature prevents operation, which protects the parking brake pads from excessive wear. NOTE: Inspect the parking brake cable tension after the first 25 hours of operation and every 100 hours of operation afterwards to ensure proper cable tension. Loss of tension in the parking brake cable will cause illumination of the parking brake light and activation of the limiting feature. If this occurs, inspect and adjust parking brake cable tension. If performing this service is difficult due to conditions or location, open the hood and temporarily disconnect the parking brake connector. Reconnect the parking brake connector as soon as it is practical and adjust the parking brake cable to proper tension.

4. Use two open-end wrenches and loosen the outer jam nut (D). Back out the outer jam nut (D) 1 1/2 turns. 5. Now hold the outer jam nut (D) and turn in the inner jam nut (C) clockwise, until the jam nut is tight against the bracket. 6. Repeat Step 4 and Step 5 until the proper adjustment is obtained for the parking brake. NOTE: See Chapter 10 for more information on the parking brake switch.

1. Pull back on the parking brake lever (located in the dash). 2. After 3-5 clicks the “(P)” brake light should illuminate on the instrument cluster and the wheels of the vehicle should not rotate when turning by hand. After 8 full clicks of lever travel, the vehicle should not roll while parked.

9.27

BRAKES PARKING BRAKE CALIPER SERVICE Exploded View

Hex Nut Pad & Holder Pad & Holder 18 ft-lbs (24 Nm)

Hex Head Mount Bolt

Plain Washer

Sleeve

Thrust Washer

Shim Pack (4 Shims)

Nut

Lever Asm. Bolt 35 ft-lbs (34 Nm)

Stationary Actuator Spring Pin Compression Spring

Caliper Removal NOTE: Do not get oil, grease, or fluid on the parking brake pads. Damage to or contamination of the pads may cause the pads to function improperly.

Steel Balls (3) 2. If replacing the brake pads, slightly loosen the caliper assembly bolts before removing the complete caliper assembly. This will ease the caliper disassembly procedure later.

1. Remove the clip pin and pin (A) from the parking brake cable.

NOTE: Be sure the parking brake is not engaged.

9.28

BRAKES 3. Loosen the two brake caliper mounting bolts (B) in equal increments.

6. Measure the thickness of the rear caliper parking brake pads. Replace assembly or pads as needed. See illustration below for proper readings.

Inboard Pad New .304” (7.72 mm) Limit: 0.24” (6.1 mm) Inboard Pad

Outboard Pad

Outboard Pad New 0.360” (9.14 mm) Limit: 0.31” (7.87 mm)

4. Remove the mounting bolts from the mount bracket and lift the parking brake caliper assembly out of the vehicle.

Caliper Disassembly / Inspection

Installed Disc to Park Brake 0.375” (0.953 cm) New Rotor Disc Thickness 0.169 +/- .008” (4.29 +/- .20mm) Replace at .150” (3.81mm) or less

NOTE: Refer to the “Electronic Parts Catalog” for parking brake caliper replacement information. 1. Remove the two caliper assembly nuts (C) that were previously loosened during Step 2 of “Caliper Removal”.

New Brake Pad Installation NOTE: Parking Brake Pads can be replaced by ordering one of the following kits: PN 2203148 - Brake Pad and Shim Kit PN 2203147 - Brake Pad Kit There may be more parts in the service kit than your brake requires. Check the parts list included with the kit for the exact quantities.

1. Using the stationary actuator, assemble the caliper components as shown below. Do not install the springs or shims yet. Measure the gap for the brake disc. Disassemble and add shims between thrust washer and the inside brake pad as needed to close the gap to .203” - .193” (5.16 - 4.90 mm). 2. Slide the brake pads and springs from the assembly. NOTE: Retain the lever and ball bearings for reassembly.

Add shims until gap measures .203” - .193” (5.16 - 4.90 mm)

3. Inspect brake pads for excessive wear. Replace as needed. 4. Check the three steel balls for any signs of cracking. Replace as needed. 5. Check ball seats in lever and stationary actuator. If excessively worn, replace parts as needed.

9.29

BRAKES 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 specification.

=T Parking Brake Caliper - Assembly Bolts: 25 ft-lbs (34 Nm)

PARKING BRAKE DISC SERVICE Disc Inspection / Removal 1. Measure the brake disc with a micrometer. If the thickness of the disc is less than specified, replace the rear propshaft assembly. 2. Follow the rear prop shaft removal procedure listed in Chapter 7 to remove the rear propshaft assembly. Remove Bolts

3. Ensure the parking brake assembly functions properly by actuating the lever before reinstallation.

in. / ft.

= Caliper Installation 1. Install the parking brake assembly into place. Tighten the two mounting bolts in increments for proper installation.

1 1

Parking Brake Disc: New: .161” - .177” (4.09-4.50 mm) Service Limit: .150” (3.81 mm) 3. Refer to Chapter 7 to reinstall the rear propshaft assembly.

18 ft-lbs (24 Nm)

2. Torque the two mounting bolts to specification.

=T Parking Brake Caliper - Mounting Bolts: 18 ft-lbs (24 Nm) 3. Install the cable, pin, and clip pin. Test the park brake for proper function.

9.30

mm / cm

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

9.31

BRAKES

NOTES

9.32

ELECTRICAL

CHAPTER 10 ELECTRICAL GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 BATTERY CONDUCTANCE ANALYZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 COMPONENTS UNDER SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 COMPONENTS BEHIND DASH PANEL / UNDER HOOD . . . . . . . . . . . . . . . . . . . . . . 10.3

SWITCHES / CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 HEADLIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 AWD / 2WD / TURF SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 DIFFERENTIAL SOLENOID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 BRAKE LIGHT SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 PARKING BRAKE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5

INSTRUMENT CLUSTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 RIDER INFORMATION DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 STANDARD DISPLAY MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 DIAGNOSTIC DISPLAY MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 INSTRUMENT CLUSTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 INSTRUMENT CLUSTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10

INSTRUMENT CLUSTER TROUBLESHOOTING TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11 ALL WHEEL DRIVE (AWD) COIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15 GEAR POSITION INDICATOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15 HEADLIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16 TAIL LIGHT / BRAKE LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21 COOLING SYSTEM BREAK-OUT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21 FAN CONTROL CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22 FAN CONTROL CIRCUIT BYPASS TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22 COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22 COOLING FAN ON/OFF & HOT LIGHT ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22

FUEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23 RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23 FUSES / CIRCUIT BREAKER / RESISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27 VEHICLE CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28 FUEL SOLENOID WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29 CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30 CHARGING SYSTEM RATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30 CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30 CHARGING SYSTEM “BREAK EVEN” TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30 CHARGING SYSTEM ALTERNATOR WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . 10.31

BATTERY SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32 BATTERY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32 BATTERY REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33 CONVENTIONAL BATTERY TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34 BATTERY CONDUCTANCE ANALYZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34 CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35 OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35

STARTER SYSTEM AND WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36 VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36

10.1

ELECTRICAL GENERAL INFORMATION

Battery Conductance Analyzer

Special Tools

Conductance describes the ability of a battery to conduct current. A conductance tester functions by sending a low frequency AC signal through the battery and a portion of the current response is captured, from this output a conductance measurement is calculated. Conductance testing is more accurate than voltage, specific gravity, or load testing.

Part Number

Tool Description

PV-43568

Fluke™ 77 Digital Multimeter

PV-43526

Connector Test Kit

2870630

Timing Light

2870836

Battery Hydrometer

2460761

Hall Sensor Probe Harness

2871745

Static Timing Light Harness

MDX-610P

Battery / Conductance Tester

Authorized Polaris dealers/distributors are required to use the conductance analyzer when testing 12V Polaris batteries.

SPX Corp: 1-800-328-6657 or http://polaris.spx.com

Electrical Service Notes Keep the following notes in mind when diagnosing an electrical problem: • Refer to wiring diagram for stator and electrical component resistance specifications. • When measuring resistance of a component that has a resistance value under 10 Ohms, remember to subtract meter lead resistance from the reading. Connect the leads together and record the resistance. The resistance of the component is equal to tested value minus the lead resistance. • Become familiar with the operation of your meter. Be sure leads are in the proper jack for the test being performed (i.e. 10A jack for current readings). Refer to the Owner’s Manual included with your meter for more information.

Polaris MDX-610P - PN: PU-50296

• Voltage, amperage, and resistance values included in this manual are obtained with a Fluke™ 77 Digital Multimeter (PV-43568). This meter is used when diagnosing electrical problems. Readings obtained with other meters may differ. • Pay attention to the prefix on the multimeter reading (K, M, etc.) and the position of the decimal point. • For resistance readings, isolate the component to be tested. Disconnect it from the wiring harness or power supply.

10.2

ELECTRICAL Components Under Seat

SWITCHES / CONTROLS

The following components can be accessed under the seat:

Headlight Switch 1. Remove the dash panel from the dash (see Chapter 5).

• Alternator • Battery

2. Disconnect the headlight switch harness by depressing the connector lock and pulling on the connector. Do not pull on the wiring.

• Battery Cables • Terminal Block • Starter

3. Inspect the switch connections and test the switch for continuity.

• Glow Plugs

• When the headlight switch is turned to ‘low beam’, there should be continuity between terminals 5 and 3.

• Fuel Solenoid • Fuel Pump • Fuel Sender

Components Behind Dash Panel / Under Hood

• When the headlight switch is turned to ‘high beam’, there should be continuity between terminals 5 and 6.

The following components can be accessed with the dash panel removed (see Chapter 5 for removal) or under the hood: • Speedometer • Speedometer Mode Switch • AWD/2WD/TURF Switch • Headlight Switch • 12 VDC Accessory Power Points • Ignition Switch • Parking Brake Switch • Relays • Fuses • VCM

10.3

ELECTRICAL AWD / 2WD / TURF Switch

Differential Solenoid

1. Remove the dash panel from the dash (see Chapter 5).

The differential solenoid is located on the left side of the rear gear case. The solenoid actuates an engagement dog, which locks and unlocks the rear differential. Refer to Chapter 7 for more information on the rear differential mechanical operation.

2. Disconnect the switch harness by depressing the connector lock and pulling on the connector. Do not pull on the wiring. 3. Inspect the switch connections and test the switch for continuity. • When the switch is in position #1 (AWD), there should be continuity between terminals 2 and 3. • When the switch is in position #3 (TURF), there should be continuity between terminals 2 and 1. • Refer to the AWD/TURF Diagram in this chapter for more information.

Differential Solenoid Circuit Operation The Rear Diff Solenoid Relay is located on the frame under the rear cargo box. When the switch is pushed to activate “TURF” mode, a power signal is provided to the VCM from the AWD / 2WD / TURF Switch. Depending on engine speed, gear position criteria and parking brake input, the VCM energizes the Rear Diff Solenoid Relay, allowing it to enable the differential solenoid. The Rear Diff Solenoid Relay will not engage at speeds above 8 MPH. The differential will return to 2wd anytime the parking brake is applied. NOTE: The rear differential will not unlock if the parking brake is set. If the rear differential fails to switch from operational modes: • Check the solenoid and relay connectors. Look for loose wires or bad connections. • Check the AWD / 2WD / TURF Switch wires for loose connections. • Remove solenoid from rear differential and ensure the solenoid plunger is actuating. • Check for a signal from the VCM to ensure the solenoid has power to be activated. • If all other components are verified, try a known working VCM.

10.4

ELECTRICAL Brake Light Switch

Parking Brake Switch

2011 - The brake light switch is located on the rear portion of the frame below the drive. The brake pressure switch is installed into a junction block.

The parking brake switch is located within the parking brake lever. Follow the parking brake lever under the dash to locate the internally mounted switch.

2012-2013 - The brake light switch is located on the front brake line banjo bolt of the master cylinder. The brake switch can be accessed through the RH or LH wheel well opening with the wheel well panel removed. 1. Disconnect the wire harness from the brake switch. 2011 Brake Switch

20122013

The switch remains in the “open” position when the park brake lever is not applied. When the parking brake lever is applied, the switch makes contact and sends a signal to the VCM on Pin #15, which disables ‘TURF’ mode and to the park relay, which activates and illuminates the “Park Brake Indicator - (P)” light near the top-center of the instrument cluster.

Brake Switch

2. Connect an ohmmeter across switch contacts. Reading should be infinite (OL). 3. 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 retest. Replace switch if necessary.

NOTE: No feature exists to prevent drive-away with the parking brake applied. An alarm will sound when the transmission is shifted into gear with the parking brake applied.

10.5

ELECTRICAL Testing The Parking Brake Switch

INSTRUMENT CLUSTER

1. Disconnect the harness connector at the parking brake switch (Orange/Red and Red/White wires).

Overview

2. Place the ohmmeter leads onto the switch terminals. The reading should be infinite (OL).

The RANGER Diesel instrument cluster senses vehicle speed from the transmission and RPM from the flywheel. The instrument cluster measures distance in miles as well as and hours of operation. Park Brake Indicator

Speedometer

Speedometer Needle

3. Apply the parking brake. Continuity should now exist between the switch terminals. If no continuity exists when the parking brake is applied, try to clean the switch terminals and re-test. Replace switch if necessary. 4. If the switch functions properly, check the Park Relay and VCM for proper function. Rider Information Display

NOTE: In addition to showing vehicle speed, the speedometer needle flashes when a low fuel condition exists. NOTE: Use the “Mode Button” shown below to toggle between Instrument Cluster display screens.

Key Switch

10.6

Mode Button

Instrument Cluster

ELECTRICAL Rider Information Display

Standard Display Modes

The rider information display is located in the instrument cluster. All segments will light up for 2.5 seconds at startup.

Use the yellow mode button located under the speedometer to toggle through the mode options.

NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. 3

7 8

Odometer Mode The odometer records the miles traveled by the vehicle. Trip Meter Mode The trip meter records the miles or kilometers traveled by the vehicle on each trip if it's reset before each trip. To reset the trip meter, select the trip meter mode. Press and hold the mode button until the display reads 0. NOTE: In the Rider Information Display, the trip meter display contains a decimal point, but the odometer displays without a decimal point.

Hour Meter Mode This mode logs the total hours the engine has been in operation.

1 1. Gear Indicator - This indicator displays gear shifter position. H = High Gear L = Low Gear N = Neutral R = Reverse Gear 2. AWD Indicator - This indicator illuminates when the AWD switch is in the AWD position. 3. Engine Hour Display Indicator 4. Service Interval / Diagnostic Mode Indicator 5. Low Battery and Over Voltage - This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged. It may also occur when the engine is at idle and high electrical load (lights, cooling fan, accessories) is applied. Drive at a higher RPM or recharge the battery to clear the warning. 6. Odometer / Tachometer / Tripmeter / Hour Meter 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.

Tachometer Mode The engine RPM is displayed digitally. NOTE: Small fluctuations in the RPM from day to day may be normal because of changes in humidity, temperature and elevation.

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.

8. Check Engine Warning Indicator - The word HOT displays if the engine overheats. Do not operate the vehicle if this warning appears. Serious engine damage could result. It will also display if there is an electrical fault with a sensor or system.

10.7

ELECTRICAL Battery Voltage Screen

Gear Circuit Diagnostic Screen

View this screen to check battery voltage level.

This screen displays the resistance value (in ohms) being read at the gear switch input of the gauge.

Tachometer Screen View the tachometer to check engine speed.

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.

10.8

ELECTRICAL Programmable Service Interval

Miles / Kilometers Toggle

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.

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.

NOTE: The service interval is programmed to 50 hours at the factory. To enable or disable the service interval: 1. Enter the diagnostic mode. 2. Toggle to the service interval screen. 3. Press and hold the mode button for about seven (7) seconds, until either ON or OFF appears in the Rider Information Display, depending on your preference.

To reset the service interval: 1. Enter the diagnostic mode. 2. Toggle to the service interval screen. 3. Press and hold the mode button for 2-3 seconds, until the wrench icon flashes. Release the button. 4. Press and release the mode button once to advance the setting by one hour. Press and hold the mode button to advance the hours quickly. NOTE: If you scroll past the intended number, press and hold the button until the hours cycle back to zero. 5. When the desired setting is displayed, wait until the wrench icon stops flashing. The new service interval is now programmed.

10.9

ELECTRICAL Instrument Cluster Removal

Instrument Cluster Installation

NOTE: Do not allow alcohol or petroleum products to come in contact with the instrument cluster lens.

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.

1. Remove the dash panel from the dash (see Chapter 5). 2. Disconnect the wire connectors from the back side of the instrument cluster.

4. Be sure the rubber mount inside the dash panel is fully installed and that the indexing key on the rubber mount is lined up with the keyway in the dash panel. 3. Push the instrument cluster out from the back side of the dash panel, while securely holding the panel and rubber mount.

10.10

5. 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. Apply pressure on the bezel while pressing down on the instrument cluster.

ELECTRICAL INSTRUMENT CLUSTER TROUBLESHOOTING TESTS Test 1 - No All Wheel Drive

* *Diesel: AWD disabled above 8 MPH ground speed

10.11

ELECTRICAL TEST 2 - No Display

TEST 3 - Speed Sensors (MPH & RPM)

10.12

ELECTRICAL TEST 4 - No AWD Hub Safety Limiter

10.13

ELECTRICAL TEST 5 - Fuel Gauge Display Not Working

TEST 6 - Shift Indicator Not Working (Transmission Switch)

10.14

ELECTRICAL ALL WHEEL DRIVE (AWD) COIL

GEAR POSITION INDICATOR SWITCH

Operation Overview

Test Diagram

• When the AWD switch is “ON”, 12 VDC power is present at the hub coil. • If the criteria is met, the instrument cluster provides a ground path at pin #16 (Brown/White wire). When this occurs the AWD icon should display in the instrument cluster.

NOTE: Also see “INSTRUMENT CLUSTER TROUBLESHOOTING” TRANSMISSION SWITCH High / Low / Neutral / Reverse

• The AWD system must be grounded to operate.

Diagnosing System Failures • Verify the AWD switch is functional and that a minimum of 11 volts is present at the hub coil. • Verify the AWD hub coil is functional. Test the AWD hub coil using an ohm meter. See specifications below:

High Range Low Range Neutral Reverse

Green/White Violet

Brown/Red

White/Blue Blue/Red

AWD Hub Coil Resistance: 24  ± 5% • Verify the wiring harness, wiring, connectors, connector pins and grounds are undamaged, clean and connected properly. • Verify continuity of wire connections with a volt/ ohm meter. IMPORTANT: Verify all wires and wiring connections have been tested properly with a known good volt/ ohm meter before suspecting a component failure. 80% of all electrical issues are caused by bad/failed connections and grounds.

10.15

ELECTRICAL HEADLIGHTS

6. Once the beam is set to the position, tighten the adjustment screw. Repeat the procedure to adjust the other headlight.

Headlight Adjustment The RANGER headlights are adjustable. 1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall.

25 ft. (7.6 m) X1

WARNING Due to the nature of light utility vehicles and where they are operated, headlight lenses become dirty. Frequent washing is necessary to maintain lighting quality. Riding with poor lighting can result in severe injury or death.

8 in. (20 cm)

Headlight Bulb Replacement 1. Open the hood. 2. Locate the bulb on the back side of headlight.

2. Measure the distance from the floor to the center of the headlight (X1) and make a mark on the wall at the same height (X2).

Bulb

3. With the machine in Neutral and parking brake applied, start the engine and turn the headlight switch on. 4. The most intense part of the headlight beam should be aimed 8 in. (20 cm) below the mark placed on the wall in Step 2. NOTE: Rider weight must be included in the seat while performing this procedure. 5. Locate the T25 Torx-head adjustment screw through the wheel well (see illustration). Adjust the beam to the desired position by loosening the adjustment screw and moving the lamp to the appropriate height.

3. Turn the bulb counterclockwise to remove it.

4. Unplug the headlight bulb from the wiring harness. Be sure to pull on the connector, not on the wiring. 5. Install the wire harness into the new headlight bulb. 6. Install the bulb into the housing and rotate it clockwise 90Â° to lock it in place. NOTE: Make sure the tab on the bulb locates properly in the housing.

10.16

ELECTRICAL Headlight Housing Removal

5. Remove the O-rings (A) from each side of the headlight housing. Remove the adjustment screw (B) and pull the headlight from the brackets.

1. Open the hood. 2. Remove the front facia to access the headlight housing.

3. Carefully pull the fascia out far enough to access the headlight housing. Headlight Housing

4. Remove the bulb from the headlight housing (see “Headlight Bulb Replacement”).

10.17

ELECTRICAL Headlight Housing Installation 1. Install the headlight housing by pressing the headlight tabs back into the brackets. 2. Secure the headlight housing with the rubber O-rings on each side (A). Install the adjustment screw (B). NOTE: Be sure to twist the O-rings upon installation as shown below.

3. Reinstall the bulb into the housing and rotate it clockwise 90° to lock it in place. 4. Reinstall the front fascia and securely tighten all fasteners.

Install

5. Adjust headlights using the “Headlight Adjustment” procedure.

10.18

ELECTRICAL RANGER Diesel Lighting System Diagram (simplified)

Ranger Diesel Lighting System

10.19

ELECTRICAL TAIL LIGHT / BRAKE LIGHT LED Lamp Replacement 1. From the rear of the LED lamp, remove the (2) T20 Torx-head screws retaining the lamp assembly.

T20 Screws

2. Remove the lamp from the cargo box and disconnect the tail light / brake light wire harness. NOTE: Before replacing the LED lamp assembly, use a digital multi-meter to test the harness to ensure the lamp is receiving 12 volts and that a ground path is present. 3. If the LED still does not work, replace the LED lamp assembly with the recommended lamp. 4. Reinstall the assembly by reversing this procedure. 5. Test the tail light / brake light after installation to verify proper function.

10.20

ELECTRICAL COOLING SYSTEM Cooling System Break-Out Diagram

Park Brake Relay

10.21

ELECTRICAL Fan Control Circuit Operation

Coolant Temperature Sensor

Power is supplied to the fan via the Orange/Black wire when the relay is energized. The Brown wire provides the ground path for the fan motor. Refer to “RELAYS” later in this chapter for more information on fan functions.

The coolant temperature sensor can be tested using an ohmmeter or voltmeter.

CAUTION Keep hands away from fan blades during operation. Serious personal injury could result. NOTE: The fan may not function or operation may be delayed if coolant level is low or if air is trapped in the cooling system. Be sure cooling system is full and purged of air. Refer to Chapter 2 “Maintenance” for cooling system filling information.

Fan Control Circuit Bypass Test 1. Disconnect harness from coolant temperature sensor on engine. 2. With the parking brake applied, turn the ignition key “ON”. The fan should start running. 3. If the fan runs with the sensor harness disconnected, but will not turn on when the engine is hot, check the coolant temperature sensor and connector terminals. If the fan does not run or runs slowly, check the fan motor wiring, ground, motor condition and mechanical relay for proper operation. Repair or replace as necessary.

10.22

1. With the engine and temperature sensor at room temperature (77°F = 25°C), disconnect the harness connector. 2. With the meter in the ohms mode, place the meter leads onto the sensor contacts. 3. Use the following table to determine if the sensor needs to be replaced. Temperature ° F (° C)

Resistance

77 ° F (25 ° C)

29.9 k  ± 2%

176 ° F (80 ° C)

3.93 k  ± 2%

248 ° F (120 ° C)

1.22 k  ± 2%

NOTE: If the coolant temperature sensor or circuit malfunctions the radiator fan will default “ON”.

Cooling Fan on/off & HOT Light on/off The fan on/off and hot lamp on/off are both controlled by the VCM via the coolant temp sensor. Fan

HOT Light

ON 194 ° F (90 ° C)

ON 221° F (105° C)

OFF 179 ° F (82 ° C)

OFF 212° F (100° C)

NOTE: If the coolant temperature sensor or circuit malfunctions the radiator fan will default “ON”.

ELECTRICAL FUEL SENDER

RELAYS

Testing

NOTE: Refer to the “Electronic Power Steering (EPS)” section in this chapter for information on EPS relays.

1. Drain the fuel tank and remove it from the chassis. 2. Set the fuel tank on a flat surface.

The relays assist with items such as fan, chassis, park light, glow plugs and rear differential operation.

3. Attach an ohm meter to the fuel sender harness Violet/ White wire (B) and Brown wire (C).

Fan Relay

4. Allow the sender float to sit in the empty position and compare to specification.

The Fan Relay, controlled by the VCM and Engine Coolant Temp Sensor, operates the fan motor.

Fuel Sender - Empty: 5  ± 5% 5. Slowly tilt the tank so that gravity moves the sender float to the full position and compare to specification.

Fuel Sender

Empty: 5 ± 5%  Half 57 ± 5%  Full 90  ± 5%

Fuel Sender - Full: 90± 5% 6. If the readings are not to specification, or if the reading is erratic or LCD display “sticks”, check the following before replacing the fuel pump assembly. • Loose float • Float contact with tank • Bent Float Rod If none of the conditions exists, the sender assembly is faulty. Fuel sender assembly replacement is required.

Color

Function

Orange B1

VCM controlled input at pin #4

Orange B2

Key-On 12V power supply, provides power to operate the relay.

Red / White B3

15 Amp circuit breaker protected, 12V relay power supply.

Relay switched 12V power to the fan Orange / Black motor. 20 amp circuit breaker B5 protected.

10.23

ELECTRICAL Chassis Relay

Start Relay

The Chassis Relay, controlled by the VCM and key switch, powers the Chassis components.

The Start Relay, located in the fuse block, is controlled by the brake switch and key switch, and powers the relay for starter operation.

Color

Function

Brown D1

Relay ground.

Orange D2

Key-On 12V power supply, provides power to operate the relay.

Red D3 White D5

12V relay power supply, B+. Output connects relay 12V power to the fuse box buss.

Color White / Red D1

Key-On Ground

Red / White C1

Power From 20A In-line Circuit Breaker

Orange C3 White / Red D3

10.24

Function

Input from the brake switch to energize the solenoid. Relay switched power to the starter solenoid.

ELECTRICAL Park Relay

Glow Plug Relay

The Park Relay, controlled by the park brake switch and VCM, operates the park brake lamp and disables turf mode to 2-wheel drive.

The Glow Plug Relay, controlled by the VCM, operates the glow plug duration based on coolant temperature.

Color

Function

Orange A1

Key-On 12V power supply, provides the relay power supply and voltage to operate the relay.

Orange A3

Key-On 12V power supply, provides the relay power supply and voltage to operate the relay.

Ground input via the park brake switch Orange / Red B1 to energize the solenoid. Also signals VCM Pin #15 for Turf Mode to 2wd.

Color

Function

Yellow / Violet E1 Ground controlled by VCM Pin #1. Orange E2 Red E3 Black / Red E5

Key-On 12V power. 12V power 30 amp fuse-protected for glow plugs. Relay switched power to the glow plugs.

Relay switched power to illuminate the Orange / Red B3 park lamp on Pin #10 of the Instrument Cluster.

10.25

ELECTRICAL Fuel Pull-In Coil Relay The Fuel Pull-In Coil Relay, controlled by the VCM at pin #12, operates the engine fuel pull in coil capability.

Color

Function

Green A1

VCM controlled relay ground at Pin #12

Orange A2

Key-On 12V power.

Red A3

12V power 30 amp fuse-protected for pull-in coil operation.

Orange / Black A5

Relay switched power to the pull-in coil.

10.26

ELECTRICAL FUSES / CIRCUIT BREAKER / RESISTOR Operation The fuses, located in the fuse boxes under the hood, provide current protection for components such as the VCM, main harness, lights, accessories and power steering (If equipped - EPS Models Only). A 20 Amp circuit breaker, located under the hood near the relay/fuse box, protects the fan motor circuit.

10.27

ELECTRICAL VEHICLE CONTROL MODULE Operation The Vehicle Control Module (VCM) controls or monitors the following functions on the RANGER Diesel: Fan operation via the coolant sensor, Turf mode operation, Park Relay, High-Temp Indicator, Ground Speed, Wait to Start lamp and glow plug operation. See complete wiring diagram for more detail.

10.28

ELECTRICAL FUEL SOLENOID WIRING DIAGRAM

10.29

ELECTRICAL CHARGING SYSTEM

Charging System “Break Even” Test

Charging System Rating The RANGER Diesel alternator is rated 12v, 55A, 742 watts (at 13.5v nominal voltage).

Current Draw - Key Off CAUTION Do not connect or disconnect the battery cable or ammeter with the engine running. Damage will occur to electrical components. Connect an ammeter in series with the negative battery cable. Check for current draw with the key off. If the draw is excessive, loads should be disconnected from the system one by one until the draw is eliminated. Check component wiring as well as the component for partial shorts to ground to eliminate the draw. Current Draw Inspection Key Off

CAUTION Do not allow the battery cables to become disconnected while the engine is running. Follow the steps below as outlined to reduce the chance of damage to electrical components. The “break even” point of the charging system is the point at which the alternator overcomes all system loads (lights, etc.) and begins to charge the battery. Depending on battery condition and system load, the break even point may vary slightly. The battery should be fully charged before performing this test.

WARNING Never start the engine with an ammeter connected in series. Damage to the meter or meter fuse will result. Do not run test for extended period of time. Do not run test with high amperage accessories. 1. Using an inductive amperage metering device, (set to DC amps) connect to the negative battery cable. 2. With engine off, and the key switch and lights in the ON position, the ammeter should read negative amps (battery discharge). Reverse meter lead if a positive reading is indicated. 3. Shift transmission into neutral with the parking brake applied and start the engine. With the engine running at idle, observe meter readings.

30 Amp

4. Increase engine RPM while observing ammeter and tachometer. 5. Note RPM at which the battery starts to charge (ammeter indication is positive). Current Draw - Key Off: Maximum of .01 DCA (10 mA)

6. With lights and other electrical loads off, the “break even” point should occur at approximately just above idle RPM. 7. With the engine running, turn the lights on and engage brake to keep the brake lights on. 8. Repeat test, observing ammeter and tachometer. With lights on, ‘break even’ charging should occur below 2000 RPM.

10.30

ELECTRICAL Charging System Alternator Wiring Diagram Refer to Chapter 11 - Yanmar Engine Service, for alternator repair procedures.

10.31

ELECTRICAL BATTERY SERVICE

Low Maintenance Battery Inspection

Battery Information

The low maintenance battery is located under the seat.

Polaris Diesel RANGERs are equipped with a LowMaintenance Battery. Diesel Battery Specs: 575 CCA @ 0 degrees F. 10HR @ 40 AH

Battery

WARNING Battery electrolyte is poisonous. It contains acid! Serious burns can result from contact with the skin, eyes, or clothing. ANTIDOTE External: Flush with water.  Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call a physician immediately.  Eyes: Flush with water for 15 minutes and get prompt medical attention.

• Inspect the battery case for obvious damage such as cracks or leaks. Look for discoloration, warping or raised top, which may indicate the battery has overheated or been overcharged. • Make sure the battery top is clean and dry. A dirty battery actually discharges across the grime on top of the case. Use a soft brush and a baking soda solution.

WARNING The gases given off by a battery are explosive. Any spark or open flame near a battery can cause an explosion which will spray battery acid on anyone close to it. Should there be contact with battery acid, wash the affected area with large quantities of cool water and seek immediate medical attention.

WARNING

• Inspect the battery terminals, screws and cables for breakage, corrosion or loose connections. Clean the terminals and cable ends with a wire brush and coat terminals with Nyogel™. IMPORTANT: Don’t add acid, or distilled water to a low maintenance battery!

CALIFORNIA PROPOSITION 65 WARNING: Batteries, battery posts, terminals and related accessories contain lead and lead compounds, and other chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. WASH HANDS AFTER HANDLING.

10.32

ELECTRICAL Battery Terminal Blocks

Battery Terminals / Bolts

A terminal block is located under the seat next to the battery. Another terminal block under the hood provides easy hookup for accessories.

Use Polaris corrosion resistant Nyogel™ grease (PN 2871329) on battery terminals.

Under Hood Terminal Block

Under Seat Terminal Block

=T Battery Terminal Pinch Bolt: 13 ft-lbs (18 Nm)

Battery Removal / Installation See Chapter 2 “Maintenance” for battery service procedures.

=T Terminal Block Nuts: 23 in-lbs (2.6 Nm)

10.33

ELECTRICAL Conventional Battery Testing

OCV - Open Circuit Voltage Test

Whenever a service complaint is related to either the starting or charging systems, the battery should be checked first.

Battery voltage should be checked with a digital multimeter. Readings of 12.6 volts or less require further battery testing and charging. See the following chart.

Following are three tests which can easily be made on a battery to determine its condition: OCV Test, Specific Gravity Test and Load Test.

Battery Conductance Analyzer Conductance describes the ability of a battery to conduct current. A conductance tester functions by sending a low frequency AC signal through the battery and a portion of the current response is captured, from this output a conductance measurement is calculated. Conductance testing is more accurate than voltage, specific gravity, or load testing. Authorized Polaris dealers/distributors are required to use the conductance analyzer when testing 12V Polaris batteries.

NOTE: Lead-acid batteries should be kept at or as near a full charge as possible. Electrolyte level should be kept between the low and full marks. If the battery is stored or used in a partially charged condition, or with low electrolyte levels, hard crystal sulfation will form on the plates, reducing the efficiency and service life of the battery. OPEN CIRCUIT VOLTAGE State of Charge

YuMicronâ&#x201E;˘ Type

100% Charged

12.70 V

75% Charged

12.50 V

50% Charged

12.20 V

25% Charged

12.0 V

0% Charged

11.9 V or less

Load Test Polaris MDX-610P: PN: PU-50296

A battery may indicate a full charge condition in the OCV test and the specific gravity test, but still may not have the storage capacity necessary to properly function in the electrical system. For this reason, a battery capacity or load test should be conducted whenever poor battery performance is encountered. This is the best test of battery condition under starting load. Use a load testing device that has an adjustable load. Apply a load of three times the ampere-hour rating. At 14 seconds into the test, check battery voltage. A good 12V battery will have at least 10.5 Volts. If the reading is low, charge the battery and retest.

10.34

ELECTRICAL Charging Procedure 1. Remove the battery to prevent damage from leaking or spilled acid during charging. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater. 3. Install battery in vehicle. Coat threads of battery bolt with a corrosion resistant dielectric grease. Dielectric Grease: PN 2871329 4. Connect battery cables.

WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. 5. After connecting the battery cables, install the cover on the battery and attach the hold down strap. 6. Install clear battery vent tube from vehicle to battery vent. Vent tube must be free from obstructions and kinks and securely installed. If not, battery gases could accumulate and cause an explosion. Vent should be routed away from frame and body to prevent contact with electrolyte. Avoid skin contact with electrolyte, as severe burns could result. If electrolyte contacts the vehicle frame, corrosion will occur.

Off Season Storage See Chapter 2 “Maintenance” for battery service procedures.

10.35

ELECTRICAL STARTER SYSTEM AND WIRING DIAGRAM Refer to Chapter 11 - Yanmar Engine Service, for starter repair procedures. NOTE: Only torque starter B+ cable nut to 5-8 ft-lbs.

5-8 ft-lbs

Voltage Drop Test The Voltage Drop Test is used to test for bad connections. When performing the test, you are testing the amount of voltage drop through the connection. A poor or corroded connection will appear as a high voltage reading. Voltage shown on the meter when testing connections should not exceed .1 VDC per connection or component. To perform the test, place the meter on DC volts and place the meter leads across the connection to be tested. Refer to the voltage drop tests in the “Starter System Testing Flow Chart”. Voltage should not exceed .1 DC volts per connection

Troubleshooting Starter Motor Does Not Run • Battery discharged - Low specific gravity • Loose or faulty battery cables or corroded connections (see Voltage Drop Tests) • Related wiring loose, disconnected, or corroded • Poor ground connections at battery cable, starter motor or starter solenoid (see Voltage Drop Tests) • Faulty key switch • Faulty starter solenoid or starter motor • Engine problem - seized or binding (can engine be rotated easily) Starter Motor Turns Over Slowly • Battery discharged - low specific gravity • Excessive circuit resistance - poor connections (see Voltage Drop Test) • Engine problem - seized or binding (can engine be rotated easily) • Faulty or worn brushes in starter motor Starter Motor Turns - Engine Does Not Rotate • Faulty starter drive • Faulty starter drive gears or starter motor gear • Faulty flywheel gear or loose flywheel

10.36

ELECTRICAL Starter Motor Wiring Diagram

10.37

ELECTRICAL

NOTES

10.38

2011 - 2012 RANGER DIESEL PAGE 1 OF 2

2011-2012 RANGER DIESEL PAGE 2 OF 2

2012 RANGER DIESEL CREW PAGE 1 OF 2

2012 RANGER DIESEL CREW PAGE 2 OF 2

2011-2012 RANGER DIESEL / DIESEL CREW (CARGO BOX) PAGE 1 OF 1

2013 RANGER DIESEL

2013 RANGER DIESEL CREW

2013 RANGER DIESEL / DIESEL CREW (CARGO BOX)