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Table Of Contents

GENERAL INFORMATION

1.1

CHAPTER 1

GENERAL INFORMATION

VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

VEHICLE IDENTIFICATION NUMBER (VIN). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . 1.2

VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

PUBLICATION NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

GENERAL: 2009 SPORTSMAN XP 850 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

GENERAL: 2009 SPORTSMAN XP 850 EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

DETAILED: 2009 SPORTSMAN XP 850 / XP 850 EPS. . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7

SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8

METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8

DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8

GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9

Summary of content (309 pages)

PAGE 1
GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION 1 VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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GENERAL INFORMATION VEHICLE IDENTIFICATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification } } } } A 09 ZN 85 AL Emissions & Model Option Year Designation Basic Chassis Designation Engine Designation Engine Designation Number EH085OLE.............................................................Twin Cylinder, 4-Cycle SOHC, Liquid Cooled, Electric Start Vehicle Identification Number (VIN) World Mfg.
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GENERAL INFORMATION VEHICLE INFORMATION 1 Publication Numbers YEAR MODEL MODEL NO. OWNER’S MANUAL PN PARTS MANUAL PN 2009 SPORTSMAN XP 850 A09ZN85AL, AQ, AS, AT, AX, FL 9921854 9921857 2009 SPORTSMAN XP 850 EPS A09ZX85AG, AL, AQ, AR, AS, AX, FS 9921976 9921977 NOTE: Additional 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.
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GENERAL INFORMATION SPECIFICATIONS MODEL: 2009 SPORTSMAN XP 850 MODEL NUMBER:. . . . . . . . . A09ZN85AL, AQ, AS, AT, AX, FL ENGINE MODEL:. . . . . . . . . . EH085OLE Category Dimension Length 83.25 in. / 211.5 cm Width 47.6 in. / 121 cm Height 50.75 in. / 129 cm Wheel Base Ground Clearance Turning Radius 53 in. / 135 cm 11.6 in. / 29.5 cm 84 in. / 213 cm (unloaded) Dry Weight 784 lbs. / 356 kg Front Rack Capacity 120 lbs. / 54 kg Rear Rack Capacity 240 lbs. / 109 kg Max.
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GENERAL INFORMATION 2009 SPORTSMAN XP 850 / XP 850 EPS XP MODELS: A09ZN85AL,AQ,AS,AT,AX,FL XP EPS MODELS: A09ZX85AG,AL,AQ,AR,AS,AX,FS ENGINE MODEL: EH085OLE Engine Platform Domestic Twin Cylinder, 4-Cycle Engine Model Number EH085OLE011 Engine Displacement 850 cc Number of Cylinders 2 Bore & Stroke (mm) 87 x 71.5 mm Compression Ratio 11.0:1 Compression Pressure 210 - 250 psi 1200 ± 50 RPM Engine Idle Speed Cooling System / Cap. Liquid Cooled / 2 qt. (1.
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GENERAL INFORMATION MISC. SPECIFICATIONS AND CHARTS Conversion Table °C to °F: 9/5(°C + 32) = °F 1.
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GENERAL INFORMATION Standard Torque Specifications The following torque specifications are to be used only as a general guideline. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque. 1.
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GENERAL INFORMATION SAE Tap / Drill Sizes Metric Tap / Drill Sizes 1.
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GENERAL INFORMATION Glossary of Terms ABDC: After bottom dead center. ACV: Alternating current voltage. Alternator: Electrical generator producing voltage alternating current. ATDC: After top dead center. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm).
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GENERAL INFORMATION NOTES 1.
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MAINTENANCE CHAPTER 2 MAINTENANCE PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 BREAK-IN PERIOD / MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 MAINTENANCE INTERVALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 GREASE LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 MAINTENANCE QUICK REFERENCE . . .
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MAINTENANCE PERIODIC MAINTENANCE CHART Periodic Maintenance Overview Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Pure Polaris parts available from your Polaris dealer. NOTE: Service and adjustments are critical.
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MAINTENANCE Maintenance Intervals Maintenance Interval (whichever comes first) Item Remarks Hours Calendar Miles (KM) Steering - Pre-Ride - Front Suspension Rear Suspension - Pre-Ride - - Pre-Ride - - Pre-Ride - Brake Fluid Level Brake Lever Travel - Pre-Ride - - Pre-Ride - Brake System - Pre-Ride - Wheels / Fasteners - Pre-Ride - Frame Fasteners - Pre-Ride - - Pre-Ride - - Daily - Inspect;clean often - Daily - Check level daily, change coolant ever
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MAINTENANCE Maintenance Interval (whichever comes first) Item Remarks Hours Calendar Miles (KM) General Lubrication 50 H 3M 500 (800) Lubricate all fittings, pivots, cables, etc.
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MAINTENANCE Grease Lubrication Points There are grease fittings on each upper and lower front and rear A-arms, each rear bearing carrier, and on the front propshaft yoke. Apply a maximum of 3 pumps of grease at each of these areas. Item Recommended Lube Method Frequency Polaris Premium U-Joint Grease Grease fittings (3 pumps maximum) every 500 miles (800 km). Grease before long periods of storage, and after pressure washing or submerging the ATV.
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MAINTENANCE Maintenance Quick Reference III. # 1 Item Engine Oil Lube Rec.
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MAINTENANCE Maintenance Quick Reference, Continued..... III. # Item Lube Rec. Method Frequency* 4 Front Gearcase ADC Reservoir Polaris Premium ADC Front Drive Fluid Maintain fluid level in ADC Reservoir to indicated level Check level every 25 hours; change fluid every two years 5 Front Gearcase Polaris Premium LT Demand Drive Fluid Add fluid until it is visible at the fill hole threads Check level every 25 hours; change fluid yearly or 1000 mi.
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MAINTENANCE LUBRICANTS / SERVICE PRODUCTS Polaris Lubricants,Maintenance and Service Products Part No. Description Engine / Transmission Lubricant Additives / Sealants / Thread Locking Agents / Misc. 2870585 Loctite™ Primer N, Aerosol, 25 g 2871956 Loctite™ Thread Sealant 565 (50 ml.) (6 Count) 2871949 Loctite™ Threadlock 242 (50 ml.) (10 Count) 2870791 Fogging Oil (12 oz. Aerosol) 2871950 2876244 PS-4 PLUS 2W-50 Performance Synthetic 4-Cycle Engine Oil (Quart) Loctite™ Threadlock 242 (6 ml.
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MAINTENANCE GENERAL VEHICLE INSPECTION AND MAINTENANCE FUEL SYSTEM AND AIR INTAKE Fuel System Pre-ride / Daily Inspection WARNING Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance. Gasoline is extremely flammable and explosive under certain conditions. • Tires - check condition and tire pressure • Fuel and oil - fill both to their proper level; do not overfill • Always stop the engine and refuel outdoors or in a well ventilated area.
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MAINTENANCE Fuel Filters There are two fuel filters located within the fuel pump assembly. The fuel pump is non-serviceable. If the internal fuel pump filters require service, the fuel pump and fuel tank must be replaced as an assembly. Electronic Throttle Control Switch (ETC) / Throttle Cable Adjustment NOTE: Sportsman XP requires a new adjustment procedure. 1. Slide the boot back far enough to expose the inline cable adjuster sleeve and loosen the adjuster locknut. 2.
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MAINTENANCE Air Filter / Pre-Filter Service Cleaning: It is advisable to replace the filter when it is dirty. However, in an emergency, it is permissible to clean the main filter if you observe the following practices. 4. Slip the pre-filter screen off of main element. Clean the prefilter with hot soapy water. 5. Rinse and dry thoroughly. 6. Inspect pre-filter screen for tears or damage. 7. Inspect main filter and replace if necessary.
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MAINTENANCE ENGINE Engine Oil and Filter Change Engine Oil Level Always change engine oil and filter at the intervals outlined in the Periodic Maintenance Chart. Always change the oil filter whenever changing the engine oil. Polaris recommends the use of Polaris PS-4 PLUS synthetic engine oil. Always use PS-4 PLUS engine oil. Oil may need to be changed more frequently if Polaris engine oil is not used. CAUTION Mixing brands or using a non-recommended engine oil may cause serious engine damage.
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MAINTENANCE NOTE: The sealing surfaces on the drain plug and crankcase should be clean and free of burrs, nicks or scratches. 9. Reinstall drain plug and torque to 12 ft. lbs. (16 Nm). =T 16. Stop the engine and check for leaks. 17. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick. 18. Dispose of used oil and filter properly. 2 Engine Breather Hose Engine Drain Plug: 12 ft. lbs. (16 Nm) 10.
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MAINTENANCE Valve Clearance Adjustment 1. Remove the seat and both upper side panels. 2. Disconnect the shift linkage from the shift lever. 3. Remove the (2) screws retaining the lower portion of the air box. 4. Remove the hose from the breaker valve located on top of the valve cover. 5. Remove the push rivets retaining the right-hand portion of the rear cab to gain access to the bolts retaining the upper right-hand frame support. 6. Remove the (4) bolts retaining the frame support.
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MAINTENANCE 16. Loosen the jam nut and turn the lash adjuster until the valve lash is correct. 17. Set the intake and exhaust valve lash to specification. = In. / mm. Intake Valve Clearance: .006 in. (.15 mm) 21. Repeat steps 16-18. 22. Clean sealing surfaces of the cylinder head and valve cover. 23. Inspect the condition of the valve cover bolt rubber isolators. If rubber has become hardened or cracked, replace them. 24. Install a new valve cover seal and install the valve cover.
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MAINTENANCE Exhaust Silencer Cleaning 5. 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 exhaust silencer. Wear eye protection. Do not stand behind or in front of the vehicle while purging the carbon from the silencer. Never run the engine in an enclosed area.
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MAINTENANCE TRANSMISSION AND GEARCASES 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 fluid level should be checked and changed in accordance with the maintenance schedule. Transmission Fluid Change Access the drain plug through the rear right-hand wheel well. The plastic skid plate can be removed for better access to the drain plug. 1.
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MAINTENANCE Front Gearcase Lubrication Front Gearcase Fluid Change: 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 drain plug is located on the bottom side of the front gearcase. Access the drain plug through the access hole in the front skid plate. The front gearcase fluid level should be checked and changed in accordance with the maintenance schedule.
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MAINTENANCE Front Gearcase ADC Fluid 5. 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. = 6. The ADC fluid reservoir is located underneath the front rack as shown below. Maintain the fluid level between the “MIN” and “MAX” levels indicated on the reservoir. 1. Disengage the anchors and remove front rack assembly. 2. Check the fluid level of the ADC reservoir.
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MAINTENANCE Rear Gearcase Lubrication Rear Gearcase Fluid Change: 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 drain plug is located on the bottom right-hand side of the rear gearcase. Access the drain plug from the rear right-hand side of the ATV. 1. Remove the fill plug (refer to “Rear Gearcase Fluid Level Check”). 2.
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MAINTENANCE COOLING SYSTEM Cooling System Overview The engine coolant level is controlled, or maintained, by the recovery system. The recovery system components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose. With the engine at operating temperature, the coolant level should be between the MAX and MIN marks on the coolant recovery bottle. If not, perform the following procedure. 1. Position the vehicle on a level surface. 2.
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MAINTENANCE 9. If coolant was required, start engine and check for leaks. Make sure radiator fins are clean to prevent overheating. Coolant Strength / Type Test the strength of the coolant using an antifreeze hydrometer. 10. Add coolant as needed. Maintain the coolant level between the “MIN” and “MAX” marks on the bottle. 11. Reinstall the front rack assembly. Antifreeze Hydrometer Cooling System Hoses 1. Inspect all hoses for cracks, deterioration, abrasion or leaks. Replace if necessary.
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MAINTENANCE PVT / FINAL DRIVE / WHEEL AND TIRE Drive Belt Removal PVT Drying Refer to Chapter 7 “Clutching (PVT)” for more detail. NOTE: If operating the ATV through water, be sure to check the PVT system components for water ingestion. After operating in water, the ATV should be checked immediately. 1. Access the PVT drain plug on the bottom of the PVT cover using a long flat blade screwdriver between the frame and left-hand lower control arm from the rear of the ATV. 2.
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MAINTENANCE Wheel and Hub Torque Table Wheel Installation 1. Verify the transmission is still in PARK and the parking brake is locked. 75 ft. lbs. (102 Nm) 2. Install the wheel hub, washers, and hub nut, if previously removed. Tapered Nut (Short) 45 ft. lbs. (61 Nm) 3. - 80 ft. lbs. (108 Nm) 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. 4.
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MAINTENANCE ELECTRICAL AND IGNITION SYSTEM Tire Pressure Tire Pressure Inspection (PSI - Cold) Front Rear 7 psi (48 kPa) 5 psi (34.5 kPa) Tire Inspection WARNING Operating an ATV with worn tires will increase the possibility of the vehicle skidding and possible loss of control. Battery Maintenance Keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water.
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MAINTENANCE Battery Removal 1. 5. Place the spacers on top of the battery terminals. Be sure they are placed between the battery terminal and cable(s). Remove the seat to access the battery. Positive Cables Negative Cable Spacer Spacer Retaining Screw 6. 2. Disconnect battery negative (-) (black) cable first, followed by the positive (+) (red) cables. CAUTION CAUTION To reduce the chance of sparks: Whenever removing the battery, disconnect the negative (black) cable first. 3.
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MAINTENANCE Spark Plug Inspection / Installation Engine / Chassis Ground 1. Inspect electrodes for wear and carbon buildup. Look for a sharp outer edge with no rounding or erosion of the electrodes. Periodically inspect the electrical ground cable attachments. Cables and connections should be tight and corrosion-free. 2. Clean with electrical contact cleaner or a glass bead spark plug cleaner only. CAUTION: A wire brush or coated abrasive should not be used. 3. Measure gap with a wire gauge.
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MAINTENANCE STEERING Power Steering Unit (EPS Models) Steering Inspection The power steering unit can be accessed through the front left wheel well by removing the mud guard. 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.
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MAINTENANCE Tie Rod End / Steering Inspection 3. To check for play in the tie rod end, grasp the steering tie rod, pull in all directions feeling for movement. Tie a length of string between two stands as shown in the following illustration. Position the stands so the string is flush or parallel with the side of the rear tire. • Repeat inspection for inner tie rod end (on steering post). 2 • Replace any worn steering components.
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MAINTENANCE Toe Alignment Adjustment SUSPENSION If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell you which tie rod needs adjusting. Suspension Inspection NOTE: Be sure handlebars are straight ahead before determining which tie rod(s) need adjustment. CAUTION During tie rod adjustment, it is very important that the following precautions be taken when tightening tie rod end jam nuts.
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MAINTENANCE BRAKE SYSTEM • Check the fluid level of the auxiliary brake master cylinder reservoir. Add fluid to the indicated level. Brake Fluid Inspection The following checks are recommended to keep the brake system in good operating condition. Service life of brake system components depends on operating conditions. Inspect brakes in accordance with the maintenance schedule and before each ride. 2 • Keep fluid level in the hand master cylinder reservoir to the indicated level inside reservoir.
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MAINTENANCE Auxiliary Brake Pedal The hydraulic auxiliary brake system requires no adjustment. Frequently check the brake fluid level for the auxiliary brake system by viewing the level in the master cylinder reservoir located underneath the front rack assembly (see Figure 2-31). Foot Brake • Check the effectiveness of the auxiliary brake by applying approximately 50 lbs. (23 kg) of downward force on the pedal.
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MAINTENANCE MAINTENANCE LOG Service Date Hours / Miles (km) Service Performed / Comments Dealer / Technician 20 Hours / 1 Month (Break-In) 2 100 / 6 Months 2.
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MAINTENANCE NOTES 2.
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ELECTRONIC FUEL INJECTION CHAPTER 3 ELECTRONIC FUEL INJECTION SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 FUEL LINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 EFI SERVICE NOTES . . . . . . . . . . . . . . . . .
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ELECTRONIC FUEL INJECTION SPECIAL TOOLS Fuel Pressure Gauge Kit - PU-43506-A Part Numbers / Descriptions PART NUMBER TOOL DESCRIPTION PU-43506-A Fuel Pressure Gauge Kit PS-48762 Fuel Pressure Gauge Adaptor 2201519 Throttle Position Sensor Tester Kit PU-47063 Digital Wrench™ Diagnostic Software (Includes most recent version of software and a serial number) PU-47471 Digital Wrench™ SmartLink Module Kit (PU-47470, PU-47469, PU-47468) PU-47470 Digital Wrench™ PC Interface Cable PU-47469 Digital Wr
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ELECTRONIC FUEL INJECTION Digital Wrench™ Diagnostic Software PU-47063 Digital Wrench™ - Download Website Located at: www.polaris.diagsys.com This dealer-only software installs on laptop computers equipped with a CD drive and serial port connection, and is designed to replace multiple shop tools often used to test EFI components. It also includes step-by-step diagnostic procedures to aid technician repair and troubleshooting.
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ELECTRONIC FUEL INJECTION FUEL TANK Exploded View PFA Nut Electrical Connector Pressure Regulator Fuel Pump* Float Arm Tank Vent Rollover Valve PFA Gasket Fuel Tank Assembly *NOTE: Fuel Pump is NOT Serviceable Fuel Flow Fuel Rail Fuel Tank Pressure Regulator Fuel Filters 3.
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ELECTRONIC FUEL INJECTION FUEL LINE EFI SERVICE NOTES Quick Connect Removal / Installation For more convenient and accurate testing of EFI components, it is recommended dealers utilize the Digital Wrench™ Diagnostic Software (dealer only), or limited testing may be done manually using the procedures provided. CAUTION Verify fuel system has been depressurized before performing this procedure. 80% of all EFI problems are caused by wiring harness connections.
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ELECTRONIC FUEL INJECTION EFI SYSTEM LAYOUT Exploded View 1. Electronic Control Unit (ECU) 2. Temperature / Manifold Absolute Pressure Sensor (T-MAP) 3. Idle Air Control (IAC) 4. Crankshaft Position Sensor (CPS) 5. Fuel Injectors 6. Fuel Rail 7. Fuel Line (quick connect) 8. Fuel Pump / Regulator / Fuel Gauge Sender (inside fuel tank) 9. Engine Coolant Temperature Sensor (ECT) 10. Throttle Position Sensor (TPS) 11. Throttle Body 12.
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ELECTRONIC FUEL INJECTION EFI COMPONENTS 4. Identification / Location 1. Electronic Control Unit (ECU) - Attached to the air box, located behind the LH side panel. Crankshaft Position Sensor (CPS) - Located in the top portion of the magneto cover on the front of the engine. CPS 3 ECU 5. 2. Temperature and Manifold Absolute Pressure Sensor (T-MAP) - Located in the Integrated Air Fuel Manifold (IAFM). Fuel Injectors - Located in the Integrated Air Fuel Manifold (IAFM).
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ELECTRONIC FUEL INJECTION 8. Fuel Pump / Regulator / Fuel Gauge Sender Assembly - Located behind the right-hand side panel. 10. Throttle Position Sensor (TPS) - Located on the MAG end (front) of the throttle body. TPS Fuel Pump - Located in the fuel tank as an assembly. 11. Throttle Body - Attached between the IAFM and the intake plenum. Throttle Body Fuel Pump Assembly 9.
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ELECTRONIC FUEL INJECTION ELECTRONIC FUEL INJECTION General Information The Electronic Fuel Injection (EFI) system is a complete engine fuel and ignition management design.
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ELECTRONIC FUEL INJECTION ELECTRONIC CONTROL UNIT (ECU) Operation Overview The ECU is the brain or central processing computer of the entire EFI fuel/ignition management system. During operation, sensors continuously gather data which is relayed through the wiring harness to input circuits within the ECU. Signals to the ECU include: ignition (on/off), crankshaft position and speed (RPM), throttle position, engine coolant temperature, intake air temperature, intake manifold air pressure and battery voltage.
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ELECTRONIC FUEL INJECTION ECU Removal / Replacement FUEL PUMP 1. Remove the seat and upper left-hand side panel (see Chapter 9 “Seat and Side Panels”). Operation 2. With the ignition turned off, disconnect the wire harness from the ECU by pulling the black slider out away from the ECU while pulling down on the connector. Once the slider is fully extended, pull the connector from the ECU, using care not to damage the connector or locking mechanism. NOTE: All EFI units utilize quick connect fuel lines.
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ELECTRONIC FUEL INJECTION Fuel Sender Test 2. Locate the fuel pressure valve attached to the fuel rail. 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 fuel pump / sending unit connection and measure the resistance between the Purple and Brown wires. If out of specification, replace the fuel pump / tank assembly.
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ELECTRONIC FUEL INJECTION Fuel Pump / Fuel Tank Removal 8. Remove the vent line from the fitting on top of the fuel tank. IMPORTANT: Syphon as much fuel from the tank as possible before attempting to remove it from the ATV. Vent Fitting WARNING Always wear safety goggles when working with high pressure or flammable fluids. Failure to do so could result in serious injury or complications.
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ELECTRONIC FUEL INJECTION Fuel Pump / Fuel Tank Installation FUEL INJECTORS 1. Reinstall the fuel tank assembly through the right side. Operation Overview 2. Connect the fuel line to the fuel pump outlet and connect the fuel pump electrical harness. 3. Reinstall the vent line to the tank fitting. The fuel injectors mount into the Integrated Air Fuel Manifold (IAFM), and the fuel rail attaches to the top end of them.
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ELECTRONIC FUEL INJECTION Injector leakage is very unlikely, but in rare instances it can be internal (past the tip of the valve needle), or external (weeping around the injector body). The loss of system pressure from the leakage can cause hot restart problems and longer cranking times. Injector problems due to dirt or clogging are unlikely due to the design of the injectors, the high fuel pressure, the use of filters and the detergent additives in the gasoline.
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ELECTRONIC FUEL INJECTION CRANKSHAFT POSITION SENSOR (CPS) 3. Connect an ohmmeter between the pin terminals as shown. A resistance value of 860 Ω ± 10% at room temperature (20° C, 68° F) should be obtained. Operation Overview CPS Connector The engine speed sensor is essential to engine operation, constantly monitoring the rotational speed (RPM) and position of the crankshaft. CPS “Removed” Measure resistance at these two pins 4.
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ELECTRONIC FUEL INJECTION TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP) IDLE AIR CONTROL VALVE (IAC) Operation Overview The Idle Air Control (IAC) is used to stabilize the idle quality of the engine at cold start-up and after warm-up operations. Operation Overview Mounted on the (IAFM), the temperature and manifold absolute pressure sensor (T-MAP) performs two functions in one unit. IAC 3 T-MAP Air passing through the intake is measured by the T-MAP and relayed to the ECU.
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ELECTRONIC FUEL INJECTION IAC Replacement 1. Remove the seat and upper right-hand side panel (see Chapter 9 “Seat and Side Panels”). 2. Disconnect the shift linkage from the shift lever. 3. Remove the spark plug wires. 4. Remove the retaining screw from the lower right-hand side of the airbox. 5. Remove the push rivets retaining the right-hand portion of the rear cab to gain access to the bolts retaining the upper right-hand frame support. 6.
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ELECTRONIC FUEL INJECTION THROTTLE POSITION SENSOR (TPS) TPS Resistance Tests Operation Overview The throttle position sensor (TPS) is a non-serviceable item. If it is faulty, it must be replaced. It can be tested using the following method: The throttle position sensor (TPS) is used to indicate throttle plate angle to the ECU.
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ELECTRONIC FUEL INJECTION Verify TPS Tester Reference Voltage Checking TPS Reading A 5 volt reference voltage signal from the TPS Tester harness is required for the TPS test to be accurate. Refer to the instructions provided with the TPS Tester Kit (2201519) or follow the bullet point steps below to check reference voltage. 1. Remove the seat and upper left-hand side panel (see Chapter 9 “Seat and Side Panels”). 2. Assemble the TPS Tester according to the instructions.
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ELECTRONIC FUEL INJECTION 7. If voltage varies with throttle movement, continue on to the next step. If the sensor did not function correctly, replace it. 8. Allow the throttle lever to rest in the idle position. The voltmeter should read .700 ± .050 volts. 7. If the voltage does not read within the specification, proceed to the “TPS Adjustment” procedure. If the voltage reading is within specification, no adjustment is required. mounting screws and torque to =T TPS Mounting Screws: 17.7 in. lbs.
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ELECTRONIC FUEL INJECTION TPS Replacement NOTE: The correct position of the TPS angle on the throttle body is established and set at the factory. If the TPS is replaced, repositioned or loosened it must be recalibrated. Refer to the “TPS Adjustment” procedure. 1. Remove the seat and upper left-hand side panel (see Chapter 9 “Seat and Side Panels”). 2. Loosen the hose clamp retaining the intake boot to the intake plenum. 3. Remove the (4) bolts retaining the intake plenum and throttle body. 4.
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ELECTRONIC FUEL INJECTION ECT Sensor Replacement IGNITION COIL 1. Drain coolant to level below sensor. Operation Overview 2. Disconnect the ECT sensor from engine harness. Remove the T-MAP sensor to allow access to the ECT sensor. The ignition coil is used to provide high voltage to fire the spark plugs. When the ignition key is on, DC voltage is present in primary side of the ignition coil windings.
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ELECTRONIC FUEL INJECTION Primary Test Ignition Coil and HT Lead Replacement NOTE: The plug caps or coil ends are not removable. The high tension lead (coil wire) must be replaced as an assembly. Measure Between Connector Pins 1 & 2, 2 & 3 0.4 Ω Secondary Test Measure Between End Caps MAG (Short) Wire: 1390 Ω ± 2 % PTO (Long) Wire: 1545 Ω ± 2 % 1. Remove the seat and upper right-hand side panel to access the ignition coil (see Chapter 9 “Seat and Side Panels”). 2.
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ELECTRONIC FUEL INJECTION EFI DIAGNOSTICS Instrument Cluster Trouble Code Display 7. Use the “Diagnostic Trouble Code Table” as a reference. Use the following procedure to display diagnostic trouble codes logged in the ECU if the Check Engine (MIL) icon is illuminated on the instrument cluster. 8. Press and hold the “MODE” button to cycle through all currently active trouble codes. NOTE: In order to view the diagnostic codes on the instrument cluster, the Check Engine (MIL) icon must be illuminated.
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ELECTRONIC FUEL INJECTION DIAGNOSTIC TROUBLE CODE TABLE SPN FMI Suspect Parameter Number Failure Mode Indentifier Driver Circuit Open / Grounded 651 5 Driver Circuit Short to B+ 651 3 Driver Circuit Grounded 651 4 Driver Circuit Open / Grounded 652 5 Driver Circuit Short to B+ 652 3 Driver Circuit Grounded 652 4 Ignition Coil Primary Driver 1 (MAG) Driver Open / Grounded 1268 3 Ignition Coil Primary Driver 2 (PTO) Driver Circuit Short to B+ 1269 3 Driver Circuit Open / Grounded
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ELECTRONIC FUEL INJECTION DIAGNOSTIC TROUBLE CODE TABLE SPN FMI Suspect Parameter Number Failure Mode Indentifier Speed Too High 520211 3 Speed Too Low 520211 4 630 13 Component Condition Idle Speed Calibration Checksum/CRC Error Steering Over Current Shut Down Current Above Normal or Grounded 520221 6 Steering Excessive Current Error Current Above Normal or Grounded 520222 6 Steering Torque or Speed Sensor Partial Failure Condition Exists 520223 31 Steering Torque or Speed Senso
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ELECTRONIC FUEL INJECTION FUEL SYSTEM TROUBLESHOOTING Poor Idle Symptom: Idle Too High (If greater than 1400 RPM when engine is warm) The correct position of the throttle body stop screw is established and set at the factory. DO NOT remove the tamper proof cap to adjust the throttle body stop screw or alter its position in any manner. The stop screw controls the air flow calibration of the throttle body.
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ELECTRONIC FUEL INJECTION EFI SYSTEM BREAK-OUT DIAGRAMS 3 3.
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ELECTRONIC FUEL INJECTION Fuel Injector Circuit (PTO) Fuel Injector Circuit (MAG) 3.
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ELECTRONIC FUEL INJECTION Idle Air Control (IAC) Circuit 3 Crankshaft Position Sensor (CPS) Circuit 3.
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ELECTRONIC FUEL INJECTION Fuel Pump / Fuel Level Sensor Circuit Wire Color Functions Wire Color Function BROWN Ground VT / WHT Fuel Level Sender Signal RED / BLUE EFI Relay Output Battery Voltage 3.
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ELECTRONIC FUEL INJECTION Fuel Pump Circuit 3 Fuel Gauge Circuit 3.
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ELECTRONIC FUEL INJECTION Engine Coolant Temperature Sensor (ECT) Circuit Throttle Position Sensor (TPS) Circuit 3.
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ELECTRONIC FUEL INJECTION Intake Air Temperature / Manifold Absolute Pressure Sensor (T-MAP) Circuit 3 Diagnostic Connector Circuit 3.
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ELECTRONIC FUEL INJECTION Diagnostic Connector Circuit (EPS Models) 3.
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COOLING SYSTEM CHAPTER 4 COOLING SYSTEM SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 COOLING SYSTEM LAYOUT AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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COOLING SYSTEM SPECIAL TOOLS Cooling System Pressure Test 1. PART NUMBER TOOL DESCRIPTION 2870975 Mity Vac™ Pressure Test Tool PA-44995-A Water Pump Mechanical Seal Installer PA-49378 Water Pump Bearing and Coupler Press Tool PA-49316 Water Pump Drive Nut / Flywheel Puller TORQUE SPECIFICATIONS WARNING Never remove radiator cap when engine is warm or hot. The cooling system is under pressure and serious burns may result. Allow the engine and cooling system to cool before servicing. 2.
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COOLING SYSTEM 850cc ENGINE COOLANT FLOW 4 Cooling System Specifications The engine coolant temperature sensor is located in the engine cylinder head below the thermostat housing (see Chapter 3 for further information). ECT Sensor 17 ft. lbs. (23 Nm) Resistance Reading @ Idle Approx.
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COOLING SYSTEM Cooling System Bleeding Procedure RADIATOR 1. Radiator Cleaning Place the vehicle in PARK. CAUTION 1. Check radiator air passages for restrictions or damage. 2. Carefully straighten any bent radiator fins. 3. Remove any obstructions with compressed air or low pressure water. Be sure the engine has cooled and there is no pressure built up in the cooling system before removing the radiator cap. The coolant may be hot and could cause severe injury or burns. 2.
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COOLING SYSTEM 4. Drain the coolant from the radiator by removing the coolant hose from the lower right-hand portion of the radiator. Drain Here 5. Carefully pull rearward on the lower portion of the recovery bottle to disengage the lower tab. Then lift up on the bottle and remove it from the radiator fan shroud. 6. Remove the (2) screws retaining the fuse/relay box to the frame to allow enough room for the radiator to tilt back during removal. 4 5.
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COOLING SYSTEM WATER PUMP SERVICE 6. Remove the coolant by-pass hose from the water pump cover fitting. 7. Remove the (10) cover screws (A) and pump cover (B). Water Pump Impeller Removal NOTE: The water pump impeller, mechanical seal, drive coupler, pump shaft, and pump shaft bearing can be serviced without removing the engine. 1. Remove the fuel tank (see Chapter 3). 2. Remove the (4) screws retaining the engine skid plate and remove the plate from the vehicle. 3.
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COOLING SYSTEM Water Pump Mechanical Seal Replacement 5. Perform the “Water Pump Impeller Removal” procedure. 1. Disconnect the stator and CPS wire harnesses. Support the stator cover by the stator mounting boss, using an aluminum or PVC pipe section or other suitable support block (C) positioned inside the stator housing as shown. Do not attempt to press water pump shaft out of stator housing without first supporting the cover by the stator boss, or cover may be damaged. Stator CPS 4 C 2.
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COOLING SYSTEM Water Pump Mechanical Seal Replacement (Cont.) 8. Protect water pump cover gasket surface and turn cover over. Drive mechanical seal out from stator side of cover. 11. Turn cover over and drive new mechanical seal squarely into housing using seal installer. PA-44995-A 12. Install impeller. Torque bolt to 10 lb-ft. (13.5 Nm) 9. Clean housing thoroughly. 13. Rotate impeller and check for smooth rotation. Water Pump Shaft & Bearing Replacement 1.
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COOLING SYSTEM CAUTION 3. 7. Rotate impeller and check for smooth rotation. 8. Refer to the following pages for water pump assembly and torque information. Be sure bearing is fully seated in cover after Step 2, or severe crankshaft damage will result. Stator Cover Installation Install new coupler hub (A) from kit onto shaft. 1. Orientate the pump shaft tab to line up with the stator mounting bolt closest to the CPS sensor. 4 A 4. Press coupler squarely onto shaft until fully seated. 2.
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COOLING SYSTEM Water Pump Assembly / Torque Specifications 89 in. lbs. (10 Nm) 89 in. lbs. (10 Nm) Stator wire routing 10 ft. lbs. (13.5 Nm) See procedure 89 in. lbs. (10 Nm) See procedure TORQUE SEQUENCE 4.
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COOLING SYSTEM Stator Cover Assembly Torque Specifications 89 in. lbs. (10 Nm) Crankshaft Position Sensor (CPS) Lubricate New O-Rings Coolant Pipe 4 1/8 NPTF Coolant Fitting 89 in. lbs. (10 Nm) TORQUE SEQUENCE A B Use weather strip or contact cement to hold damper rubber (A) on water pump coupler nut (B) during stator cover installation. 4.
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COOLING SYSTEM THERMOSTAT TROUBLESHOOTING Removal (Engine Installed) Cooling System 1. Drain coolant so the coolant level is below the thermostat housing (see “Coolant Drain / Radiator Removal”). 2. Remove the (2) screws from the rear portion of the air box. • Low coolant level 3. Locate the thermostat housing on the left side of the valve cover next to the fuel rail. • Air in cooling system Shown with air box removed for clarity.
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ENGINE CHAPTER 5 ENGINE GENERAL INFORMATION - ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3 OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.
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ENGINE CRANKSHAFT / CAM CHAIN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.46 CAM CHAIN / SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.46 CRANKCASE INSPECTION (LOWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.46 CRANKSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.46 CONNECTING ROD INSPECTION . . . . . . . . . . . . . . . . . . . . . .
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ENGINE GENERAL INFORMATION - ENGINE Special Tools Tool Description Part Number CRANKSHAFT HOLDING TOOL PA-49318 CRANKSHAFT SEAL INSTALLER PA-49320 FLYWHEEL / WATER PUMP DRIVE NUT PULLER PA-49316 FUEL PRESSURE TEST ADAPTOR PS-48762 MITY VAC‘ PRESSURE TEST TOOL 2870975 OIL FILTER WRENCH PV-43527 (2 1/2 in.
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ENGINE Oil Flow Diagram Holes in rocker arm shafts feed rocker arms and rollers Carrier bolt passages feed Center and PTO camshaft main journals Mag end cylinder head bolt passage (exhaust side) Balance Shaft Bearings Balance Shaft Bearings PTO End MAG End Upper Crankcase Main Oil Gallery Connecting Tube (lower crankcase to upper crankcase) Cam chain tensioner Upper crankcase Oil Pressure Regulator (+ 85 PSI) Passage in lower crankcase Oil Filter Oil Pump Pickup Screen Oil Sump Gravity & Splash
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ENGINE Engine Specifications - EH085OLE-011 CYLINDER HEAD (IN. / MM) Cam Lobe Height - Intake (Standard) 0.897" (22.795 mm) Cam Lobe Height - Exhaust (Standard) 0.908" (23.067 mm) Camshaft Journal Outer Diameter - (All) .8632" ± 0.0004" (21.925 ± 0.01 mm) Camshaft Journal Bore Inner Diameter - (All) .8661" ± 0.0004" (22.000 ± 0.01 mm) Camshaft Oil Clearance 0.0034" ± 0.0008" (0.086 ± 0.02 mm) Camshaft End Play 0.008" ± 0.004" (0.20 ± 0.10 mm) Rocker Shaft O.D. (Intake and Exhaust) 0.
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ENGINE CYLINDER / PISTON (IN. / MM) Cylinder Piston Piston Pin Cylinder - Surface warp limit (mating with cylinder head) 0.004" (0.10 mm) Cylinder Bore - Standard 3.4252" ± .0005 (87 mm ± .01mm) Cylinder Out of Round Limit 0.0003" (0.0075 mm) Cylinder to Piston Clearance .0021" ± .0013" (.053 ± .03mm) Piston - Standard O.D. - Measured 90 degrees to pin, 1.3 in. (33.0 mm) down from piston crown. 3.4231" ± .0008" (86.947 ± .02 mm) Piston Pin Bore I.D. (Standard) 0.7877" ± .0002" (20.007 ± .
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ENGINE ENGINE ASSEMBLY VIEWS AND TORQUE VALUES Torque & Torque Sequence - Main Engine Components 4 4 2 5 1 2 6 1 3 6 3 5 89 lb-in. (10 Nm) 13 lb-ft. (18 Nm) 89 lb-in. (10 Nm) 26 lb-ft. (35 Nm) + 90° (see procedure) VALVE COVER CYLINDER HEAD 5 10 9 6 5 10 2 4 1 3 9 8 6 7 1 7 8 3 4 2 13 lb-ft. (18 Nm) 9 lb-ft. (12 Nm) CAMSHAFT CARRIER OIL PUMP COVER 5 89 lb-in. (10 Nm) WATER PUMP COVER 12 16 8 10 14 18 20 7 4 6 1 5 3 4 2 6 1 5 2 8 3 19 89 lb-in.
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ENGINE Valve Cover / Breather Valve 89 lb-in (10 Nm) = Apply All Purpose Grease Torque Pattern 4 5 2 6 1 3 89 lb-in (10 Nm) 44 lb-in (5 Nm) 5.
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ENGINE Camshaft Carrier / Camshaft / Rocker Arm Torque Pattern 9 Slots must be vertical and face OUT 10 6 2 1 7 5 4 3 8 26 mm +/- 1 mm 1. Crankshaft at TDC MAG cylinder 2. Camshaft pin at 10:00 position 3. Snug all bolts 4. Torque to 13 lb-ft. (18 Nm) following torque pattern 5 89.0 lb-in (10 Nm) 89.0 lb-in (10 Nm) 5.
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ENGINE Cylinder Head / Valve / IAFM 89 lb-in. (10 Nm) Thermostat Step 3 - 18 lb-in. (2 Nm) Step 6 - 89 lb-in. (10 Nm) 18 ± 1.5 lb-ft. (25 ± 2 Nm) IAFM Torque Sequence Step 2 - 18 lb-in. (2 Nm) Step 5 - 89 lb-in. (10 Nm) 5.10 Step 4 - 18 lb-in. (2 Nm) Step 7 - 89 lb-in.
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ENGINE Valve & Spring Height Detail Top Bottom 1.861 in. (47.26 mm) 5 Free Length Combustion chamber top Combustion chamber top 5.
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ENGINE Piston / Connecting Rod Arrow to MAG end (toward cam chain) Place circlip gap at top or bottom Paint tolerance mark (see text) Match stamp on rod and cap. Rod stamp can face front or rear of engine (Rod has no offset) Install NEW rod bolts if disassembled 1. Torque bolts to 24 lb-ft (33 Nm) 2. Tighten bolts an additional 60° 5.
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ENGINE Crankshaft Main Journal O.D. 54.98 mm ± .01 (2.1646" ± .0004) Runout Limit .001" (.025 mm) 5 Connecting Rod Journal O.D. 45.015 mm ± .01 (1.7722" ± .0004) Refer to bearing selection procedure and chart on page 5.48. 5.
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ENGINE Crankcase M6 x 20 89 lb-in. (10 Nm) M6 x 35 89 lb-in. (10 Nm) ** Apply light film of engine oil to flange and threads of all M9 crankcase bolts M9 x 160** 26 lb-ft. (35 Nm) M9 x 115** 26 lb-ft. (35 Nm) Torque Pattern 5.
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ENGINE Crankcase - Upper 5 89 lb-in. (10 Nm) Detail - balance shaft end cap and bearing Use tool PA-49320 See procedure See removal procedure. Piston must be removed / installed through top of cylinder as an assembly, with connecting rod attached. 5.
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ENGINE Balance Shaft / Balance Shaft Timing Pin Washer (Install before pin) Split Gear Springs Drive Gear Bearing - Press on inner race only Replace if removed Balance Shaft Timing at TDC on MAG Cylinder 5.
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ENGINE Crankcase (Lower) With Oil Pump See “Crankcase (Lower) / Oil Pump Disassembly” on page 5.41 89 lb-in. (10 Nm) 89 lb-in. (10 Nm) M6x20 106 lb-in. (12 Nm) M3 end cap screws 6-8 lb-in. (.69-.89 Nm) M6x16 (all outer screws) 106 lb-in. (12 Nm) 21 lb-ft. (28 Nm) Install new gasket. Ensure tab is visible to verify assembly. Torque Pattern Oil Pump Cover 5 12 lb-ft. (16 Nm) 21 lb-ft. (28 Nm) Fill 5.
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ENGINE Water Pump Coupler M6 x 16 89 lb-in. (10 Nm) Crankshaft Position Sensor (CPS) Key 74 lb-ft. (100 Nm) Coolant Pipe 1/8 NPTF Coolant Fitting O-Ring 89 lb-in. (10 Nm) 35 lb-in. (4 Nm) Sealant bead should face the cover. A B 5.18 Use weather strip or contact cement to hold damper rubber (A) on water pump coupler nut (B) during stator cover installation. M6 x 20 89 lb-in.
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ENGINE Water Pump / Water Pump Coupler / Stator / Flywheel 89 lb-in. (10 Nm) 89 lb-in. (10 Nm) Stator wire routing See procedure 10 lb-ft. (13.5 Nm) 5 89 lb-in. (10 Nm) See procedure Torque Sequence 10 9 8 6 1 7 4 3 2 5 5.
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ENGINE Drive Coupler (Rear) / Starter Gear 14 lb-ft. (19 Nm) Torque Sequence 5.
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ENGINE ENGINE SERVICE Engine Removal Accessible Engine Components IMPORTANT: Some engine repair procedures can be performed without removing the engine from the vehicle. Refer to “Accessible Engine Components” for further information.
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ENGINE 8. Remove the high tension leads from the engine and remove the (2) nuts from each exhaust flange at the engine. 12. Disconnect the ECU from the main harness. Pull down on the connector while pulling the connector tab out. 9. Remove the exhaust springs retaining the exhaust pipe to the silencer and remove the pipe from the vehicle. Insert a clean shop towel into the engine exhaust ports. 13. Disconnect the harness and ground wire from the ignition coil located on the right side of the air box.
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ENGINE 16. Remove the (4) screws retaining the engine skid plate and remove the plate from the vehicle. 17. Place a drain pan under the front portion of the engine. 18. Slide the clamp back and remove the coolant inlet hose from the water pump housing. 21. Use the Roll Pin Removal Tool (PN 2872608), to drive out the roll pin from the front propshaft.
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ENGINE 24. Remove the (2) through-bolt fasteners retaining the LH engine isolator mount to the engine and remove the lower nut from the mount. Pry up between the frame and isolator mount and remove the mount assembly from the frame. Torque bolts to: 18 ft. lbs. (24 Nm) 27. Remove the (2) screws retaining the IAC mount plate to the frame at the front of the engine. 28. Disconnect the wire harness from the IAC and TPS located on the throttle body.
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ENGINE 33. Pull the engine toward the front of the vehicle to disengage the engine/transmission coupler. Engine Installation Notes After the engine is installed in the frame, review this checklist and perform all steps that apply: General Items 1. Repeat steps in reverse order in the “Engine Removal” section above to reinstall the engine. 2. Install previously removed components using new gaskets, seals, and fasteners where applicable. 3.
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ENGINE ENGINE DISASSEMBLY AND INSPECTION Rocker Carrier / Camshaft Removal 1. Valve Cover / Breather Valve 1. Remove (2) breather housing bolts (A). Inspect bellows (B) for cracks (not required for valve cover removal). 2. Remove (6) rocker cover bolts (C) and isolators (D). 3. Replace isolators and gasket (E) if oil leaks are evident. Rotate engine in direction of rotation until pin (A) is facing UP. Rotate cam another 60° to the 10:00 position to relieve valve spring pressure from camshaft lobes.
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ENGINE Rocker Arm / Rocker Arm Shaft Inspection 1. Mark or tag rocker arms and shafts to keep them in their respective locations for assembly. 2. Slide rocker arm shafts from carrier. 4. Measure I.D. of rocker arms and O.D. of rocker arm shafts. Measure shaft bore in cam carrier. Compare to specifications (See “Engine Specifications - EH085OLE011” on page 5.5). 5 3. Inspect each rocker arm roller. Roller surface should be smooth and radial movement should be minimal.
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ENGINE Camshaft / Camshaft Bore Inspection Cylinder Head Removal 1. 1. 2. After camshaft carrier is removed, lift camshaft from cylinder head. Inspect all main journals and cam lobes as described below and compare to specifications (See “Engine Specifications - EH085OLE-011” on page 5.5). Replace if worn beyond service limit or if any surface is pitted or damaged. Measure all cam lobe heights from base circle to highest point on lobe.
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ENGINE Cylinder Head Warp Inspection 1. Cylinder Head Disassembly Lay a straight edge (A) across surface of cylinder head at several different points and measure warp by inserting a feeler gauge between the straight edge and the cylinder head surface. If warp exceeds the service limit, replace the cylinder head. A WARNING Wear eye protection when removing and installing valve springs. NOTE: Keep mated parts together for assembly. It is important to put cylinder head parts back in the same location.
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ENGINE Valve Inspection 1. Remove all carbon from valves with a soft wire wheel or brush. 2. Check valve face for runout, pitting, and burnt spots. To check for bent valve stems, mount valve in a drill or use “V” blocks and a dial indicator. 5. Measure diameter of valve stem with a micrometer in three places, then rotate 90 degrees and measure again (six measurements total). Compare to specifications. Measure valve stem in several places. Rotate the valve 90 degrees and measure for wear. = In. / mm.
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ENGINE Combustion Chamber 1. 4. Clean all accumulated carbon deposits from combustion chamber and valve seat area. Drive or press new guides from camshaft side of head to proper installed height. Note difference between intake and exhaust guide height below. Intake Valve Guide Height: 8.93 - 9.43 mm NOTE: Carbon Clean Fuel Treatment (2871326) can be used to help remove carbon deposits. IMPORTANT: Do not use a metal scraper, a coarse wire brush, or abrasive cleaners to clean the cylinder head.
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ENGINE Valve Seat Reconditioning Valve seat reconditioning should be performed by a technician proficient in cylinder head reconditioning techniques. Reconditioning techniques vary, so follow the instructions provided by the valve reconditioning equipment manufacturer. Do not grind seats more than necessary to provide proper seat surface, width, and contact point on valve face.
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ENGINE NOTE: When using an interference angle, the seat contact point on the valve will be very narrow, and is a normal condition. Look for an even and continuous contact point all the way around the valve face (A). B 8. Clean all filings from the area with hot soapy water. Rinse and dry with compressed air. 9. Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the valve.
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ENGINE Cylinder Head Assembly Valve Sealing Test NOTE: Assemble valves one at a time to maintain proper order. 1. Clean and dry the combustion chamber area (A). 2. Pour a small amount of clean solvent into each intake port (B) and check for leakage around the valves. The valve seats should hold fluid with no seepage. 3. Repeat for exhaust valves by pouring fluid into each exhaust port (C). 1. Apply engine oil to valve guides and seats. 2. Coat valve stem with Premium Starter Grease (2871460).
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ENGINE Cylinder Head Installation 1. Prepare cylinder head gasket sealing surfaces by cleaning thoroughly to remove all residue. The head gasket must be installed clean and dry, free from oil or grease. 6. Thread cam chain through a new head gasket and install gasket, locating it on the alignment pins. 7. Set cylinder head in place on alignment pins. Apply engine oil to threads and flange of the (6) main cylinder head bolts. 8.
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ENGINE Camshaft / Carrier Assembly Camshaft / Camshaft Carrier Installation 1. 1. Loosen all valve adjuster lock nuts. 2. Turn adjuster screws out (counterclockwise) until they lightly seat against rocker arm. Lubricate all camshaft lobes and bearing journal surfaces with Premium Starter Grease (PN 2871460). NOTE: DO NOT force screws against rocker arm. The adjuster pivot ball may be damaged if forced. 3.
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ENGINE Camshaft Timing 5. Align two sprocket marks with valve cover gasket surface. Also refer to Camshaft Timing Quick Reference (page 5.39). 6. Slide sprocket onto camshaft, aligning slot in sprocket with pin. 7. Screw in the sprocket bolt finger tight. Sprocket bolt must be tightened fully after cam chain tensioner is installed. 1. Rotate camshaft clockwise until pin (A) is facing UP (use a wrench across the flats on the sprocket end). A 5 2.
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ENGINE Cam Chain Tensioner Installation 1. 3. Push tensioner plunger in and hold. 4. Rotate plate and gasket into position and start the inner bolt. 5. Slowly draw bolts evenly until snug. Lubricate tensioner plunger and install in tensioner bore with check valve end of plunger (B) facing OUT (toward cap plate). B 2. Torque: 89 lb-in. (10 Nm) Start outer tensioner bolt through cap plate and new gasket. Start bolt about 5 threads into outer hole. NOTE: “Top” mark on tensioner cap plate faces UP.
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ENGINE Camshaft Timing - Quick Reference View With Stator Cover Removed Crankcase Parting Line View Through Timing Plug TDC Mark Flywheel Pin facing UP IMPORTANT! Valve and / or piston damage can occur if engine is rotated with camshaft incorrectly timed. Sprocket marks aligned with surface of head Crankshaft / Camshaft Center line Tensioner Installed Flywheel key UP (in line with crankshaft / camshaft centerline) or if flywheel is installed use TDC mark. Crankshaft at TDC, MAG Cylinder 5.
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ENGINE Crankcase Disassembly 4. Remove water pump drive coupler damper (D). CAUTION The rotor contains powerful magnets. Use caution when removing and installing the stator cover. DO NOT place fingers between cover and crankcase at any time during the removal / installation process or injury could result.
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ENGINE 7. 8. Fully install Flywheel Puller PA-49316 on threads of flywheel (left hand thread - turn flywheel puller COUNTERCLOCKWISE to install on flywheel). Crankcase (Lower) / Oil Pump Disassembly 1. Remove oil pump cover plate screws. Note location of two longer (M6x20) screws for assembly. These screws secure the pump. 2. Remove three baffle plate screws (A) and plate. Hold puller body (A) and tighten center bolt (B) to remove flywheel. A 90 lb-in. (10 Nm) M6x16 (all outer screws) 96 lb-in.
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ENGINE 6. Measure pump rotor clearance to pump cover plate with a feeler gauge through the pump outlet window and compare to specification. 7. Measure shaft axial (end) free play and compare to specification. 8. Inspect inner rotor drive pin for wear or damage. OIL PUMP DETAIL 9. Remove oil pressure relief from crankcase. Replace if debris has entered, or if oil pressure was outside of specified range. =T 20 ± 2 ft. lbs. (27 ± 3 Nm) M3 end cap screws 6-8 lb-in. (.69-.
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ENGINE Crankcase Disassembly (Upper) Piston / Connecting Rod Removal 1. 1. Remove the oil passage connecting tube (F) with O-rings. Note orientation of piston with arrow (A) to MAG end of crankshaft. F A 2. Note connecting rod and cap marks so they can be oriented properly and assembled in the same manner as matched sets on proper rod journal (G). New rods can be installed with marks to front or rear. Rods have no offset. 2.
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ENGINE Counterbalance Shaft Removal / Inspection 1. Note timing marks on balance shaft drive gears and crankshaft drive gear. Shafts must be properly timed upon assembly. 2. Mark each shaft location for assembly (starter side or oil pipe side). 3. Lift both balance shafts from upper crankcase and remove end plugs. 6. Hold main gear (A) and rotate split gear counterclockwise (viewed from gear end) to compress springs. Split gear should rotate and return freely and completely without binding.
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ENGINE 2. Visually inspect thrust washer. Remove pin and replace washer if damaged or worn to less than 1.15 mm (.045 in.). 6. Lay gear assembly on press plate with split gear side UP. 7. Carefully align pin of balance shaft with slot in gear. Press shaft into gear assembly until seated against washer. 8. Lay new bearing (retaining ring side down) on open press plate so both inner and outer races are supported. 9. Press shaft assembly into bearing until seated. 1.15-1.35 mm (.045 - .053 in.) 3.
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ENGINE Crankshaft / Cam Chain Removal Crankshaft Inspection 1. 1. Visually inspect surface of crankshaft main and connecting rod journals. Replace crankshaft if any journal is scratched or pitted. 2. Measure each main journal (A) and rod journal (B) in two locations, 90 degrees apart. Record measurements for bearing selection on page 5.48. Calculate the difference between the two measurements for each journal to determine concentricity (C).
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ENGINE Connecting Rod Inspection 7. 1. Secure connecting rod lightly in a soft jawed vise. 2. Note location of the piston circlip gap (A) at top. Measure small end I.D. in two directions as shown. Record measurements. Difference between measurements is concentricity. Compare to specifications. A Connecting Rod (Small End) Diameter: 0.7886 + 0.0 / - .015" (20.03 + 0.0 / - .015 mm) 3. Remove piston circlip. 4. Push piston pin out of piston.
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ENGINE Connecting Rod Big End Bearing Selection Piston / Piston Ring Inspection 1. 1. Measure piston ring to ring land clearance with a thickness gauge (A) inserted between bottom edge of ring (B) and piston ring land (C). Replace both piston and rings if clearance exceeds service limit. 2. Repeat for 2nd ring. If using NEW connecting rods, install the bearing color that matches the color marked on the connecting rod cap as shown below. A B Paint mark C 2.
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ENGINE Piston Ring Installed Gap Cylinder Inspection 1. Place each piston ring (A) inside the cylinder (B) (from cylinder head side of crankcase). Use the piston to push the ring squarely into cylinder, as shown below. 1. Remove all gasket material from gasket surface. 2. Lay a straight edge across cylinders (upper crankcase). Measure installed gap with a feeler gauge (C) at both the top and bottom of the cylinder. 3. Use a thickness gauge to measure gap between straightedge and gasket surface.
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ENGINE 6. Measure in two directions (front to back and side to side) on three levels and record measurements. If cylinder is tapered or out of round beyond .001", the crankcase must be replaced. 1/2” Down From Top Piston-to-Cylinder Clearance Measure piston outside diameter at a point 33 mm down from piston crown, at a right angle to piston pin bore. Subtract measurement from maximum measurement obtained in Step 6 of Cylinder Inspection. 1.30 in. (33.0 mm) 1/2” Up From Bottom = In. / mm.
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ENGINE ENGINE ASSEMBLY 4. Install second ring with undercut facing bottom of piston. Rotate ring to place end gap generally toward (intake) side of piston as shown below. 5. Install top ring with “0” mark facing up (toward piston crown) and rotate to position the gap generally at the front as shown below. 6. Be sure top and second rings rotate freely in their grooves and do not bind when compressed by hand. Crankcase Preparation - Upper 1. Refer to Oil Flow Diagram (page 5.
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ENGINE Piston / Connecting Rod Assembly Piston / Connecting Rod Installation 1. 1. Apply clean engine oil to piston assembly and cylinder walls of upper crankcase. 2. Be sure ring end gaps are positioned at least 120 degrees apart as shown below. Oil ring rails at least 60 degrees apart. (See “Piston Ring Installation” on page 5.51). 3. Apply engine oil to ring compressor band and install band (A) over piston rings.
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ENGINE Crankshaft Installation Refer to illustration Crankcase Assembly (Upper) page 5.54. 1. Clean the bearing bore surfaces of upper crankcase (main bearings), connecting rods, and connecting rod caps. 2. 11. Install new bolts and tighten evenly until snug. 12. Torque bolts using the following procedure: Install New Match marks Align tab of a new main bearing with the slot in main bearing bore of crankcase. Press bearing insert firmly into place.
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ENGINE Crankcase Assembly - Upper 89 lb-in. (10 Nm) Detail - balance shaft end cap and bearing Use tool PA-49320 See procedure 5.
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ENGINE Balance Shaft Installation 5. Rotate crankshaft until SINGLE dot on crankshaft gear is visible. See “Balance Shaft Timing” on page 5.56. 1. Balance shafts are identical but should be installed in the same location as removed. 6. Align single dot of drive gear between two dots of balance gear. 7. Align bearing locating ring in groove on crankcase and fully seat the shaft. 8. Verify balance shaft timing is correct by comparing to illustration (page 5.56). 9.
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ENGINE Balance Shaft Timing 5.
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ENGINE Crankcase Preparation (Lower) Clean lower crankcase gasket sealing surfaces. Refer to Oil Flow Diagram (page 5.4) and trace the oil path from the through the lower crankcase. Flush all passages with solvent and then warm soapy water. Rinse with clear warm water and dry with compressed air. Be sure passages are clean and dry before assembling the lower crankcase. Assemble parts in order A-J. I H 89 lb-in. (10 Nm) G 89 lb-in. (10 Nm) M6x20 106 lb-in. (12 Nm) 5 M3 end cap screws 6-8 lb-in. (.69-.
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ENGINE Crankcase Sealant and Torque Values M6 x 20 89 lb-in. (10 Nm) M6 x 35 89 lb-in. (10 Nm) M9 x 160** 26 lb-ft. (35 Nm) M9 x 115** 26 lb-ft. (35 Nm) Torque Pattern 5.58 ** Apply a light film of engine oil to flange and threads of M9 crankcase bolts.
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ENGINE Crankcase Assembly WATER PUMP 1. Prepare upper and lower crankcase and install all components as described on page 5.51 through page 5.57. Water Pump Impeller Removal 2. Inspect crankshaft seals to be sure they are aligned flush with ends of crankcase. 3. Be sure balance shaft end plugs are installed with retaining flange fitted in the grooves of crankcase. 4. Be sure oil passage tube is installed with new O-rings (page 5.53). 5.
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ENGINE TROUBLESHOOTING Engine Spark Plug Fouling Engine Idles But Will Not Accelerate • Spark plug fouled / weak spark • Broken throttle cable • Air intake obstructed • Restricted air filter (main or pre-cleaner) or breather system • Improperly assembled air intake system • Restricted engine breather system • Oil contaminated with fuel • Fuel quality poor (old) or octane too high • PVT system calibrated incorrectly/ components worn or mis-adjusted • Restricted exhaust • Spark plug cap loose or faulty • In
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ENGINE Low Compression • No valve clearance • Valve not seating properly (bent valve or carbon / debris accumulated on sealing surface) • Cylinder head gasket leak • Cylinder or piston worn • Piston rings worn, leaking, broken, or sticking • Bent valve or stuck valve • Valve spring broken or weak • Rocker arm sticking Backfiring • Fouled spark plug or incorrect plug or plug gap 5 • Speed limiter system malfunction • Exhaust system air leaks • Ignition system faulty: Spark plug cap cracked / broken Igniti
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ENGINE NOTES 5.
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TRANSMISSION CHAPTER 6 TRANSMISSION TRANSMISSION SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 LUBRICATION SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 SHIFT LINKAGE / GEAR SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.
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TRANSMISSION TRANSMISSION SPECIFICATIONS SHIFT LINKAGE / GEAR SELECTOR Torque Specifications Shift Linkage Inspection ITEM TORQUE VALUE Transmission Fill Plug 10-14 ft. lbs. (14-19 Nm) Transmission Drain Plug 10-14 ft. lbs. (14-19 Nm) Transmission Case Screws 15-20 ft. lbs. (20-27 Nm) Oil Deflector Plate Screws 7-10 ft. lbs. (9-14 Nm) Bell Housing Screws 50-60 ft. lbs. (68-81 Nm) Bellcrank Nut 12-18 ft. lbs. (16-24 Nm) Shift Detent Plug 17-23 ft. lbs.
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TRANSMISSION TRANSMISSION SERVICE 13. Remove the high tension leads from the engine and remove the (2) nuts from each exhaust flange at the engine. Transmission Removal 1. Position the vehicle on a level surface. 2. Remove the seat and side panels (see Chapter 9). 3. Disconnect the negative (-) battery cable (see Chapter 2). 4. Remove the rear cab and footwells (see Chapter 9). 5. Thoroughly clean the engine, transmission and chassis. 6. Drain the transmission fluid (see Chapter 2). 7.
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TRANSMISSION 18. Remove the (4) bolts securing the right-hand frame support and remove the support from the vehicle. 22. Once you have cleared the coupler, carefully lift the transmission assembly out the right side the of vehicle. 19. Remove the (2) through-bolt fasteners that mount the transmission to the isolator mount on the lower LH side. Transmission Disassembly 1. Remove the drive belt, drive clutch and driven clutch (see Chapter 7 “PVT SYSTEM SERVICE - Disassembly”). 2.
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TRANSMISSION 4. Thread the (2) bolts into the transmission case pin holes to hold the coupler. 8. Coupler 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 9. 5. Remove the retaining nut and transmission coupler. 6. Place the transmission in neutral by moving the bellcrank. 7.
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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. 13. Remove the springs, shift shaft rail and park shaft rail. 15. Repeat the previous step to remove the lower shift fork. 16.
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TRANSMISSION 18. Inspect all bearings, gear teeth, engagement dogs and silent chain. 19. Remove the detent plug, snap ring, washer and gear selector switch. Washer Snap Ring 6 Detent Plug 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. 6.
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TRANSMISSION Transmission Shaft Service Rear Output Shaft Use the exploded views within this section when servicing the transmission shafts. Shaft bearings can be serviced using an arbor press. Input Shaft Reverse Shaft Primary Shaft 6.
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TRANSMISSION Cam Shift Shaft Compensator Shaft Bellcrank Shift Shaft 6 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 6.
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TRANSMISSION Transmission Assembly 1. Thoroughly clean the transmission case halves and shafts. 2. Inspect all seals and O-rings for damage. If transmission was disassembled, seal and O-ring replacement is recommended (see exploded view above). 3. 4. If the bellcrank shift shaft was disassembled, install the gear sector with the step facing the O-ring. Step Replace O-Ring If the cam shift shaft was disassembled, install the detent gear with the step facing the O-ring. Step 5.
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TRANSMISSION 6. Align the timing marks on the cam shift shaft and bellcrank shift shaft. 9. Install the retaining nut and torque to specification. =T 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 7. Snap Ring Place the two shafts into the transmission as an assembly. Detent Plug 6 12.
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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: 7-10 ft. lbs. (9-14 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.
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TRANSMISSION 26. Install the transmission coupler and cone washer (dome facing up). 33. 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. 27. Apply Loctite™ 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. 115-125 ft. lbs.
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TRANSMISSION Transmission Installation 1. Remove the rubber coupler and inspect it for signs of excessive wear or damage. Replace as needed. 2. Install the rubber coupler into the engine coupler. Be sure rubber coupler is properly mounted. 6. Line up the engine and transmission couplers as shown. Engine Coupler 7. Transmission Coupler Slide the transmission forward to engage the couplers. NOTE: Be sure the front propshaft is still attached to the transmission shaft before installing the bolts. 8.
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TRANSMISSION 10. Install the (2) through-bolt fasteners on the lower LH side and torque to specification. 13. Install the rear propshaft and torque the retaining bolts to specification. =T Rear Propshaft Bolts: 18 ft. lbs. (24 Nm) 14. Reverse the transmission removal procedure to complete the installation. 15. Clean the drain plug magnetic surface. 16. Reinstall drain plug with a new O-ring and torque to specification. =T 17. Add the recommended amount of lubricant through the fill plug hole.
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TRANSMISSION Transmission Exploded View 115-125 ft. lbs. (156-170 Nm) FOR REASSEMBLY 50-60 ft. lbs. (68-81 Nm) Apply Polaris Crankcase Sealant. Apply LoctiteTM 2760 to the bolt threads. 10-14 ft. lbs. (14-19 Nm) 17-23 ft. lbs. (23-31 Nm) 7-10 ft. lbs. (9-14 Nm) 7-10 ft. lbs. (9-14 Nm) 10-14 ft. lbs. (14-19 Nm) 15-20 ft. lbs. (20-27 Nm) 10-14 ft. lbs. (14-19 Nm) 6.16 15 ft. lbs.
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TRANSMISSION Exploded View, Continued. Ref. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. Qty.
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TRANSMISSION TROUBLESHOOTING Troubleshooting Checklist Check the following items when shifting difficulty is encountered.
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CLUTCHING (PVT) CHAPTER 7 CLUTCHING (PVT) SPECIAL TOOLS AND SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 PVT SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 GENERAL OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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CLUTCHING (PVT) SPECIAL TOOLS AND SUPPLIES TOOL DESCRIPTION PART NUMBER Drive Clutch Puller (Short) PA-48595 Clutch Holding Wrench 9314177 Clutch Holding Fixture 2871358-A Drive Clutch Spider Removal and Installation Tool 2870341 Roller Pin Tool 2870910 Clutch Bushing Replacement Tool Kit 2871226 Piston Pin Puller 2870386 Clutch Compression Tool 8700220 Clutch Bushing Replacement Tool Kit 2871025 SPECIAL SUPPLIES PART NUMBER Loctite™ 609 N/A RTV Silicone Sealer 8560054 TORQUE SPECI
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CLUTCHING (PVT) Shift Weights Maintenance / Inspection 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. Under normal use the PVT system will provide years of trouble free operation.
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CLUTCHING (PVT) 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.
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CLUTCHING (PVT) PVT SYSTEM SERVICE PVT Sealing and Ducting Components Cover Screws Drain Plug Outer Clutch Cover Clamps Outer Seal Air Inlet Duct O-Ring Boot Screws Inner Clutch Cover Boot Outlet Duct Boot Clamps 7.
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CLUTCHING (PVT) Disassembly 6. Mark the drive belt direction of rotation and remove drive belt (see “DRIVE BELT - Belt Removal”, steps 8-10). Some fasteners and procedures will vary. Refer to the appropriate parts manual for proper fastener placement. 7. Loosen the clamps and remove the PVT outlet duct from the inner PVT cover. 8. Rotate and remove the PVT outlet duct from the vehicle to allow for driven clutch removal. 9. Remove the driven clutch retaining bolt and driven clutch. 1.
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CLUTCHING (PVT) 10. Install the Drive Clutch Holder (PN 9314177) onto the drive clutch. 13. Remove the (10) screws that retain the inner PVT cover to the transmission case and remove the cover. Drive Clutch Holder (9314177) 11. Remove the drive clutch retaining bolt by turning the bolt in a clockwise direction. Inner Clutch Cover 14. 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.
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CLUTCHING (PVT) 4. Install the cover and torque the inner PVT cover screws to specification. =T Outer PVT Cover Screws: 45-50 in. lbs. (5-5.6 Nm) 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 shaft. 8. Install the driven clutch, cup washer, lock washer, and retaining bolt. Torque retaining bolt to specification. 15.
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CLUTCHING (PVT) DRIVE BELT 8. Insert the belt removal tool PN 2877408 into the driven clutch as shown (tool included with vehicle’s tool kit). Belt Removal 1. Position the vehicle on a level surface and place the transmission in Park. 2. Elevate and safely support the rear of the vehicle. 3. Remove the left rear wheel from the vehicle. 4. Remove the (4) bolts retaining the lower left-hand frame support and remove it from the frame.
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CLUTCHING (PVT) Belt Inspection 1. 2. 3. 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. 3. Rotate the driven sheave and walk the belt into the driven clutch. 4. Replace the outer PVT cover seal. 5. Reinstall outer PVT cover and secure with screws. Torque screws to specification.
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CLUTCHING (PVT) DRIVE CLUTCH SERVICE Spring Specifications The drive clutch spring has two primary functions: 1. To control clutch engagement RPM. The springs, which have a higher rate when the clutch is in neutral, will increase clutch engagement RPM. 2. To control the rate at which the drive belt moves upward in the drive clutch sheaves. This is referred to as drive clutch upshift.
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CLUTCHING (PVT) Exploded View Bushing Spring Buttons Lock Washer Washers Bolt Bearing One-Way Bearing Roller Cover Bolts Spacer Nut Pin Flat Washer Cover Bearing Spider Limiter Bolt Washers Clutch Disassembly 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. 2.
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CLUTCHING (PVT) 5. Inspect area on shaft where bushing rides for wear, galling, nicks, or scratches. Replace clutch assembly if worn or damaged. 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. Inspect Shaft 6. Remove and inspect the clutch spring. See “Drive Clutch Spring Specifications” for spring inspection. Spider Removal 1. Remove the limiter spacer from the shaft.
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CLUTCHING (PVT) Roller, Pin, and Thrust Washer Inspection Button To Tower Clearance Inspection 1. 1. Inspect all rollers, bushings and roller pins by pulling a flat metal rod across the roller. Turn roller with your finger. If you notice resistance, galling, or flat spots, replace rollers, pins and thrust washers in sets of three. Also inspect to see if roller and bushing are separating. Bushing must fit tightly in roller. Use the Roller Pin Tool (PN 2870910) to replace rollers and pins.
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CLUTCHING (PVT) 2. 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 pivot bolts for wear or galling. If weights or bolts are worn or broken, replace in sets of three with new bolts. 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”.
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CLUTCHING (PVT) 5. 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. Moveable Sheave Bushing Inspection Inspect the Teflon™ coating (arrow) on the moveable sheave bushing. Inspect both sheaves for signs of wear, grooving or cracking. De-glaze sheave surfaces with a 3M™ Scotch-Brite Pad if needed. = In. / mm. Shaft Diameter: Standard: 1.3745 - 1.375 ( Service Limit: 1.3730” 6.
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CLUTCHING (PVT) Bushing Service CAUTION IMPORTANT: Special Tools Required EBS Clutch Bushing Tool Kit - 2201379 Item A, B C D Qty. 1 1 1 Part # 5132027 5132501 5132029 1 Part Description EBS Puller Tool EBS Puller Nut EBS Main Adapter EBS Bushing Removal Tool E -- 1 Instructions 9915111 Clutch components will be hot! In order to avoid serious burns, wear insulated gloves during the removal process. Moveable Sheave - Bushing Removal 1. Remove clutch as outlined previously in this chapter. 2.
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CLUTCHING (PVT) NOTE: Use Bushing Tool PA-47336. Cover Bushing Removal 8. 1. 9. Install nut (C) onto end of puller rod and hand tighten. Turn puller barrel to increase tension on sheave if needed. Using a hand held propane torch, apply heat around outside of bushing until tiny smoke tailings appear. Install main adapter (Item 8) on puller. Removal Tool (3) Nut (C) Turn sheave counterclockwise on puller rod until it comes free. Lift sheave off puller. 10. Remove nut from puller rod and set aside.
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CLUTCHING (PVT) Clutch Assembly 4. NOTE: It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly. The Teflon bushings are self-lubricating. Torque the spider (counter-clockwise) to specification using the holding fixture and spider tool. Torque with 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 reinstall.
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CLUTCHING (PVT) DRIVEN CLUTCH SERVICE 4. Clutch Disassembly 1. Remove driven clutch from the transmission input shaft. Do not attempt disassembly of the driven clutch from the outside snap ring. The driven clutch must be disassembled from the helix side. Place the clutch into the Clutch Compression Tool PN 8700220. Using Compression Extensions PN PS-45909, press down on top of the spider assembly, compressing the spider onto the shaft. Remove snap ring (A) and slowly release the assembly.
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CLUTCHING (PVT) 6. Remove the inside spider plate (D) and spider dampener (E). Inspect the spider dampener (E) for wear and replace if needed. 9. Press out the spring pins (K) in the inner sheave. K D 10. Pull out the clutch roller pins (L) and rollers (M). E 7. Remove the E-clips (F), washers (G), and the clutch rollers (H). Inspect the rollers for wear; replace if worn. F G M L H K 11. Press the shaft and bearing out of the outer sheave using a press. 8.
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CLUTCHING (PVT) 12. Inspect the bearing for wear. Spin the bearing, if the bearing does not spin smoothly, replace it. To remove the bearing, press the bearing off the shaft. Bushing Service IMPORTANT: Special Tools Required EBS Clutch Bushing Tool Kit - 2201379 Item A, B C D Qty. 1 1 1 Part # 5132027 5132501 5132029 1 Part Description EBS Puller Tool EBS Puller Nut EBS Main Adapter EBS Bushing Removal Tool E -- 1 Instructions 9915111 5132028 Additional Special Tools Inspect Sheave Surface 13.
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CLUTCHING (PVT) Clutch Bushing Removal Clutch Bushing Installation 1. Install main puller adapter (Item 8) onto puller. 1. Install puller adapter (Item 10) onto puller. 2. Install adapter reducer (Item 9). 2. Install adapter (Item 9) onto puller. 3. Using a hand held propane torch, apply heat around outside of bushing until tiny smoke tailings appear. 4. Flip sheave over so bushing faces downward and install onto puller. 5. Install bushing tool (Item 2). 3.
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CLUTCHING (PVT) Clutch Assembly 1. 4. Install a new bearing onto the output shaft using a press. Line up the “X” on the moveable sheave with the “X” on the stationary sheave or use the marks previously used. Put the sheaves together. Align X’s 2. Install the shaft/bearing into the outer sheave. 3. Install the small and large retaining rings into the outer sheave above the bearing. 5. Install the roller (A) onto the roller pin (B) on both sides. A B 7.
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CLUTCHING (PVT) 6. Install the roller pin into the sheave assembly on both sides. The flat side of the roller pin faces downward when the shaft side is laying flat on the bench. 10. Install the spider dampener (G) inside the outer spider and install the inside spider plate (H). Outer Spider D E F G H Flat Side Down 7. Install the spring pins (C) to secure the roller pins. Install until flush with sheave surface. 11.
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CLUTCHING (PVT) 12. Place the clutch into Clutch Compression Tool PN 8700220. Using Compression Extensions PN PS-45909, press down on the top of the spider assembly, pushing the spider onto the shaft. Press down on spider 14. Install the cam (helix) assembly over the shaft. Line up the “X” on the cam, “X” on spider, and “X” on the stationary sheave or use the marks previously made before disassembly. NOTE: If the cam assembly (helix) is difficult to install, be sure the sheaves are aligned.
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CLUTCHING (PVT) Exploded View T25 Screws E-Ring Thrust Washer Roller Spider Dampener Compression Spring Cam (Helix) Retaining Ring Moveable Sheave Outer Spider Roller Pin 7 Spider Insert Clutch Shaft Slotted Spring Pin Retaining Ring Stationary Sheave Ball Bearing 7.
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CLUTCHING (PVT) TROUBLESHOOTING Situation Engine RPM below specified operating range, although engine is properly tuned. Probable Cause -Wrong or broken drive clutch spring. Remedy -Replace with recommended spring. -Drive clutch shift weight too heavy. -Install correct shift weight kit to match engine application. -Driven clutch spring broken or installed in wrong -Replace spring; refer to proper installation location. helix location. -Drive clutch binding. A.
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CLUTCHING (PVT) Troubleshooting, Continued..... Situation Probable Cause -Plugged air intake or outlet. Remedy -Clear obstruction -Belt slippage due to water, oil, grease, etc., rubbing -Inspect system. Clean , repair or replace as necessary. PVT cover on cover. Seal PVT system ducts. overheating (melting) -High vs. low range. -Instruct operator on guidelines for operation in proper driving range for different terrain as outlined in Owner’s Safety and Maintenance Manual.
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CLUTCHING (PVT) NOTES 7.
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FINAL DRIVE CHAPTER 8 FINAL DRIVE GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 TORQUE SPECIFICATIONS / SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.
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FINAL DRIVE GENERAL SPECIFICATIONS CAUTION Torque Specifications Item Aluminum Wheels Steel Wheels Nut Type Specification Tapered Nut 75 ft. lbs. (102 Nm) (Long) Tapered Nut (Short) 45 ft. lbs. (61 Nm) Locking nuts, and bolts with pre-applied locking agent should be replaced if removed. The self-locking properties of the nut or bolt are reduced or destroyed during removal Special Tools Part Number Tool Description 2872608 Roller Pin Removal Tool PU-48951 Axle Boot Clamp Tool WHEELS Removal 1.
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FINAL DRIVE WHEEL HUBS Front Hub Exploded View Sealed Ball Bearing Front Steel Rim Stud Wheel Hub Dust Cover Cone Washers Wheel Nuts Bearing Carrier See Page 8.2 for Torque Value Retaining Ring Front Tire Brake Disc Cotter Pin Hub Cover Front Aluminum Rim Castle Nut Valve 80 ft. lbs. (108 Nm) Rear Hub Exploded View Sealed Ball Bearing Rear Steel Rim Wheel Hub 8 Stud Dust Cover Cone Washers Wheel Nuts Bearing Carrier See Page 8.
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FINAL DRIVE FRONT BEARING CARRIER Inspection / Removal 1. 6. Remove the front wheel hub assembly. 7. Remove the cotter pin from the bottom of the tie rod end. 8. Hold the top of the rod end with a 13 mm open-end wrench and remove the nut from the bottom. Elevate front of vehicle and safely support machine under the frame area. Tie Rod End CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure. Always wear eye protection. 2.
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FINAL DRIVE 13. Rotate bearing by hand and check for smooth rotation. Visually inspect bearing for moisture, dirt, or corrosion. 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. 14.
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FINAL DRIVE Installation 5. 1. Install the drive shaft axle through the backside of the bearing carrier. 2. Install the upper and lower ball joint ends into the bearing carrier. Install the pinch bolts and torque to specification. Install the brake caliper and torque the new mounting bolts to specification. =T Front Caliper Mounting Bolts: 37 ft. lbs. (50 Nm) CAUTION New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly.
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FINAL DRIVE 7. Torque the wheel hub castle nut to specification and install a NEW cotter pin. Tighten nut slightly if necessary to align cotter pin holes. 80 ft. lbs. (108 Nm) FRONT DRIVE SHAFT Removal 1. Elevate front of vehicle and safely support machine under the frame area. CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure. Always wear eye protection. 2.
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FINAL DRIVE 6. Remove the upper ball joint pinch bolt. Installation 7. Using a soft faced hammer, lightly tap on the upper A-arm to remove it from the bearing carrier. 1. Install a new spring ring on the end of the drive shaft and apply an anti-seize compound to the splines. 8. Remove the drive shaft from the front bearing carrier. 9. With a short, sharp jerk, remove drive shaft from the front gearcase. 2.
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FINAL DRIVE FRONT PROPSHAFT PROPSHAFT U-JOINT SERVICE Removal Disassembly 1. Locate the front propshaft roll pin through the right front wheel well. Position the vehicle for roll pin removal. 1. 2. Use the Roll Pin Removal Tool (PN 2872608), to drive out the roll pin from the front propshaft. Remove internal or external snap ring from bearing caps. CAUTION Always wear eye protection. PN 2872608 Roll Pin Roll Pin Removal Tool (PN 2872608) 3.
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FINAL DRIVE 3. Support U-joint in vise as shown and drive inner yoke down to remove remaining bearing caps. 4. Force U-joint cross to one side and lift out of inner yoke. 3. Using a suitable arbor, fully seat the bearing cap in one side. Continually check for free movement of bearing cross as bearing caps are assembled. 4. Install snap ring to contain bearing cap just installed. Repeat procedure for other side. 5.
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FINAL DRIVE FRONT GEARCASE - CENTRALIZED HILLIARD Exploded View 12 7-11 ft. lbs. (9-15 Nm) 19 35 9 7 6 7-11 ft. lbs. (9-15 Nm) 13 20 5 15 in. lbs. (1.7 Nm) 16 1 17 36 23 38 32 29 28 31 34 11 27 7-11 ft. lbs. 15 (9-15 Nm) 33 22 2 4 30 3 10 REF# DESCRIPTION 8-10 ft. lbs.
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FINAL DRIVE AWD Operation Ring Gear The AWD switch may be turned on or off while the vehicle is moving, however, AWD will not enable until the engine RPM drops below 3100. Once the AWD is enabled, it remains enabled until the switch is turned off. 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.
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FINAL DRIVE ADC Operation Engaging the Front Gearcase: Active Descent Control (ADC) is controlled by the ECU and will not enable until the following conditions are met: • Vehicle speed is below 15 mph (24 kph) • Throttle Position Sensor (TPS) is at idle position • The AWD switch is switched to the “ADC” position Once the conditions are met for engagement, ADC remains engaged as long as the conditions are met. With the AWD switch set to “2x4”, the vehicle drives only the rear wheels (2 wheel drive).
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FINAL DRIVE AWD Diagnosis Armature Plate Symptom: AWD Will Not Engage 1. Check the gearcase AWD coil resistance. Measure between the Grey (C) and Brown/White (B) wires. The resistance value should be within specification. Check for Wear Bands 5. Check to make sure the AWD 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.
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FINAL DRIVE Gearcase Removal 1. 7. Remove the cotter pin and nut from each tie rod end at the steering post frog. Stop engine and place gear selector in Park. CAUTION Cotter Pin Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure. Always wear eye protection. 2. Remove both front drive shafts from the front gearcase (see “FRONT DRIVE SHAFT - Removal”). 3.
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FINAL DRIVE 11. Remove the vent line and the (4) bolts securing the front gearcase to frame. 12. Lay the gearcase on its side (vent side up) and rotate it in the frame so the input shaft is facing you. 13. Remove the gearcase from the front LH wheel well area and carefully slide it between the upper and lower A-arms. Gearcase Disassembly / Inspection 1. Drain and properly dispose of used lubricant. Remove any metal particles from the drain plug magnet. 2.
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FINAL DRIVE 4. Remove the cover plate assembly. bearing (A) for wear. Inspect the thrust 6. Remove the armature plate. Inspect the armature plate for distortion or other damage (see “AWD Diagnosis”). Replace as required. NOTE: Thrust bearing (A) located between the two output assemblies is pressed into the clutch pack and is not removable. 7. Remove the ring gear and roll cage from the gearcase as an assembly. A 5. Remove the female output hub assembly.
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FINAL DRIVE 10. Inspect the rollers (B) for nicks, scratches and flat spots. Inspect the roll cage (C) for damage or cracks. The rollers must slide up and down freely within the roll cage surfaces. Inspect the ring gear (D) for consistent wear patterns. Surfaces should be free of nicks or burrs. D 13. Inspect the armature plate for a consistent wear pattern. Uneven wear of the armature plate indicates a warped plate, which may cause intermittent operation (refer to “AWD Diagnosis” for inspection).
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FINAL DRIVE 16. Remove the (3) bolts retaining the input cover. 20. Remove the (4) screws that retain the pump neck assembly to the main gearcase. 17. Remove the cover (H), armature plate (J) and cam (K). 21. Remove the neck and input shaft assembly from the main gearcase. J K H N 18. Inspect the armature plate (J) and cam (K) for excessive wear or damage. If replacement is required, replace the armature plate and cam as an assembly. 19.
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FINAL DRIVE Gearcase Assembly 6. Install the cam, armature plate and input cover assembly with a new O-ring. 7. Torque the input cover screws to specification. NOTE: Refer to the photos used in the “Gearcase Disassembly / Inspection” procedure when needed, while assembling the front gearcase. 1. Thoroughly clean all gearcase components before beginning reassembly. 2. Install new seals and O-rings as shown (included in the Seal Repair Kit). =T Input Cover Screws: 7-11 ft. lbs. (9-15 Nm) 3.
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FINAL DRIVE NOTE: Rotate the ring gear to align the locating pins and holes during installation. 14. Lightly crimp the thrust pad to hold the pad on the cover plate during installation. 11. Install the armature plate. Verify the armature plate tabs align with tab recesses in the roll cage. 15. Place the cover plate assembly on the main gearcase and install the (6) screws. Torque screws to specification. 12. Install the female output hub assembly into the roll cage.
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FINAL DRIVE Setting Ring Gear Backlash 3. NOTE: Ring gear backlash is set at the factory. No adjustment is required, unless the front cover is replaced or the backlash screw has been tampered with. Turn the screw in until it is lightly seated, then turn the screw out 1/4 turn. 4. Set the gearcase upright. Rotate the input shaft at least 4 times. This ensures the ring gear completes one full rotation. 5.
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FINAL DRIVE Gearcase Installation 1. =T Install the gearcase back into the vehicle through the front left wheel well, between the upper and lower A-arms. Front Gearcase Mounting Bolts: 36 ft. lbs. (49 Nm) 5. Connect and route the AWD wire harness along the frame and install a plastic tie strap to attach it to the frame. Tie Strap 2. Route the ADC reservoir and clear hose up through the center of the chassis. Do not allow hose to become pinched. 6.
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FINAL DRIVE 8. Install the (2) bolts securing the lower portion of the steering post to the gearcase and torque to specification. 14. Add the recommended amount of fluid through the fill hole. Maintain the fluid level even with the bottom threads of the fill plug hole. 22 ft. lbs. (30 Nm) Fill Plug 8-10 ft. lbs. (11-14 Nm) Drain Plug =T Steering Post to Gearcase Bolts: 22 ft. lbs. (30 Nm) 9. Gearcase fluid flush with the bottom of thread area. 8-10 ft. lbs.
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FINAL DRIVE ADC System Fluid Bleeding 1. 9. Close the valve when clean (bubble-free) fluid begins to flow from the valve. Position the vehicle on a level surface and allow the vehicle to sit for at least 30 minutes. 10. Repeat steps 7-9 on the remaining bleeder valve. 2. Thoroughly clean the areas around the ADC reservoir and bleeder valves. 11. Torque the bleeder valves to specification and reinstall the protective caps. 3. Remove the reservoir cap and diaphragm assembly. 4.
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FINAL DRIVE REAR BEARING CARRIER 6. Remove the rear wheel hub assembly. 7. Remove the bolts that attach the rear bearing carrier to the upper and lower A-arms. 8. Remove the bearing carrier from the rear drive shaft. 9. Rotate bearing by hand and check for smooth rotation. Visually inspect bearing for moisture, dirt, or corrosion. Inspection / Removal 1. Elevate rear of vehicle and safely support machine under the frame area. CAUTION Serious injury may result if machine tips or falls.
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FINAL DRIVE 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. Bearing Installation 4. Thoroughly clean the rear bearing carrier housing and the outer race on the new bearing.
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FINAL DRIVE Bushing Replacement Installation 1. Check bearing carrier bushings and shafts for excessive wear or damage. 1. Install drive shaft axle through the backside of the bearing carrier. Be sure bushings and pivot tubes are installed. 2. If replacement is required, slide shafts out and remove the bushings with a drift punch. 2. Install the fasteners that attach the rear bearing carrier to the upper and lower A-arms. Torque bolts to specification. 3.
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FINAL DRIVE 5. Install the brake caliper and torque the new mounting bolts to specification. 7. CAUTION Install the rear wheel and (4) wheel nuts. Torque wheel nuts to specification. =T Wheel Nuts: Steel Wheels: 45 ft. lbs. (61 Nm) Aluminum Wheels: 75 ft. lbs. (102 Nm) New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly. 8. Rotate wheel and check for smooth operation.
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FINAL DRIVE REAR DRIVE SHAFT 5. Remove the rear wheel hub assembly. 6. Remove the bolt that attaches the upper A-arm to the rear bearing carrier. 7. Tilt the top portion of the bearing carrier down and pull the rear drive shaft out from the bearing carrier. Removal 1. Elevate rear of vehicle and safely support machine under the frame area. CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure. Always wear eye protection. 2.
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FINAL DRIVE 8. 9. Grasp the rear drive shaft and pull sharply outward on the shaft to disengage it from the rear gearcase. Installation 1. Install a new spring ring on the end of the drive shaft and apply an anti-seize compound to the splines. 2. Align the splines of the drive shaft with the rear gearcase and reinstall the drive shaft. Use a rubber mallet to tap on the outboard end of the drive shaft if necessary. Inspect the axle splines and CV boots for any damage. 10.
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FINAL DRIVE DRIVE SHAFT SERVICE 2. Remove the large end of the boot from the CV joint and slide the boot down the shaft. 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.
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FINAL DRIVE 7. Remove the CV boot from the shaft. CAUTION Complete disassembly of the CV joint is NOT recommended. The internal components are a precision fit and develop their own characteristic wear patterns. Intermixing the internal components could result in looseness, binding, and/or premature failure of the joint. IMPORTANT: If the grease in the joint is obviously contaminated with water and/or dirt, the joint should be replaced. 13.
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FINAL DRIVE 19. Install and tighten the large clamp using the Axle Boot Clamp Tool (PU-48951). Axle Boot Clamp Tool PU-48951 Inner Plunging Joint / Boot Replacement 1. Using a side cutters, cut away and discard the boot clamps. 2. Remove the large end of the boot from the plunging joint and slide the boot down the shaft. 3. Clean the grease from the face of the joint. 4. Place the drive shaft in a soft-jawed vise. 5.
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FINAL DRIVE IMPORTANT: Tap on inner race only! 6. Make sure the circlip is still on the shaft and not left in the joint. 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. Circlip 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.
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FINAL DRIVE 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 joint’s external surfaces and place the excess grease in the boot. Drive Shaft Exploded View FRONT SHAFT Spring Ring 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. Plunging Joint 20.
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FINAL DRIVE REAR PROPSHAFT Removal 1. Locate the rear propshaft through the right rear wheel well. Propshaft NOTE: If needed, remove the right rear wheel to gain better access to the rear propshaft bolts. 2. Remove the (4) bolts retaining the rear propshaft to the rear gearcase input shaft coupler. 8 3. Slide the shaft towards the transmission and pivot the propshaft down. Slide the propshaft off the transmission output shaft and out from the vehicle. Installation 1.
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FINAL DRIVE REAR GEARCASE 9. Gearcase Removal 10. Remove the brake line retainer and left rear brake caliper. 1. Position the vehicle on a level surface and remove the seat. 2. Drain the rear gearcase lubricant (see Chapter 2). 3. Remove the rear cab (see Chapter 9). 4. Remove the left rear wheel, lower left-hand frame support and outer PVT cover (see Chapter 7 “DRIVE BELT - Belt Removal”). 5. Remove the (4) bolts retaining the rear propshaft to the rear gearcase input shaft.
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FINAL DRIVE 12. Remove the left rear suspension and drive shaft from the vehicle as an assembly. 14. Remove the through-bolt fastener retaining the upper Aarm to the bearing carrier. Pivot the wheel hub and bearing carrier down to remove the drive shaft. IMPORTANT: Take care not to stretch the brake line while removing the drive shaft. 13. Remove the right rear wheel. Remove the cotter pin, nut and washers retaining the drive shaft at the wheel hub. 15.
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FINAL DRIVE Gearcase Disassembly and Inspection 5. Inspect the ring gear teeth for chipped, worn, or broken teeth. 6. Inspect the pinion shaft by rotating the assembly in the gearcase housing while checking for any looseness or roughness. Inspect the pinion gear teeth for chipped, worn, or broken teeth. IMPORTANT: Pinion and ring gear shimming information is NOT provided. The components are matched at the factory which requires special OEM tooling in order to properly assemble and shim the gears.
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FINAL DRIVE Gearcase Bearing and Seal Replacement 1. 2. 5. Remove the retaining ring and lift the pinion shaft and bearing from the main gearcase (see Figure 8-27). If the gearcase is completely assembled, perform the “Gearcase Disassembly and Inspection” procedure. 6. Support the pinion shaft and press the bearing off the shaft (see Figure 8-27). Remove the nut and locking washer(s) from the pinion shaft (nut was loosened during “Gearcase Removal”). 7. Thoroughly clean the pinion shaft. 8.
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FINAL DRIVE 13. Install the seals into the case halves using a standard seal installer or other suitable method. Seal depth should be approximately .110 in. (2.79 mm) from the main surface. Gearcase Assembly 1. Grease all seals with Polaris All Season Grease (PN 2871322) upon assembly to prevent from damaging seals. 2. Install the ring gear into the main gearcase. 3. Install the shim previously removed onto the ring gear. Shim 14.
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FINAL DRIVE Gearcase Installation 9. 1. Install the coupler onto the pinion shaft splines. 2. Install the locking washer(s) and retaining nut. 3. Torque the retaining nut to specification. =T Coupler Retaining Nut Torque: 90-110 ft. lbs. (122-149 Nm) 4. 5. Install the rear gearcase by reversing the “Gearcase Removal” procedure at the beginning of this section. Refer to the following steps for torque specifications. Install the gearcase through-bolt mounting fasteners and torque to specification.
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FINAL DRIVE Gearcase Exploded View 15-20 ft. lbs. (20-27 Nm) 3 16 18 13 11 15 8 6 11 20 7 9 19 17 5 14 18 10 4 10-14 ft. lbs. 2 (14-19 Nm) 90-110 ft. lbs. (122-149 Nm) 12 ft. lbs.
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BODY / FRAME CHAPTER 9 BODY / FRAME TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 DECAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 PLASTIC PUSH RIVET REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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BODY / FRAME TORQUE SPECIFICATIONS ITEM TORQUE VALUE ft.lbs. (Nm) Upper RH Frame Support 30 ft. lbs. (41 Nm) Lower LH Frame Support 30 ft. lbs. (41 Nm) DECAL REPLACEMENT WARNING SPECIAL TOOLS Plastic Push Rivet Removal Polaris ATVs use a two piece plastic push rivet to fasten most body components. Using the “Multi-Function Pliers” eases removal and prevents from damaging the push rivets and body components.
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BODY / FRAME SEAT AND SIDE PANELS 5. If removing the right-hand side panel, remove the gear shift selector cap, retaining screw and knob to allow removal. 6. Reverse this procedure to reinstall components. 7. When installing the seat, start the front portion first, then follow by installing the rear portion. Be sure the under-seat fasteners are fully engaged upon installation. Removal / Installation 1. Grasp one side of the seat near the rear edge. 2.
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BODY / FRAME FRONT BUMPER FOOTWELLS Removal / Installation Removal / Installation 1. 1. Remove the seat and upper side panel (see “SEAT AND SIDE PANELS”). 2. Remove the push rivets and screws that retain the footwell. 3. Repeat this procedure to remove the other footwell. 4. Reverse this procedure to reinstall the footwells. Remove the (2) push rivets from each side of the bumper. 2. Remove the (4) bolts retaining the upper front bumper to the frame. 3.
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BODY / FRAME FRONT CAB 10. Using a clean shop rag or towel, cover the fuel fill hose inlet to prevent dirt or debris from entering the fuel tank. Removal 1. Remove the seat and upper side panels (see “SEAT AND SIDE PANELS”). 2. Remove the mud guards (see “MUD GUARDS”). 3. Remove the (4) push rivets retaining the front cab to the footwells on each side. 4. Remove the (2) screws retaining the front cover to the front cab and remove the cover.
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BODY / FRAME REAR RACK Removal / Installation 1. Remove the (8) Torx-headed fasteners as shown below. 2. Remove the rear rack and rack support from the rear cab. 2. Remove the (4) screws retaining the rear cab to the frame (see “REAR CAB”). 3. Lift up on the rear cab and remove the bumper covers by sliding them off the rear bumper. 4. Reverse this procedure to reinstall the covers. REAR CAB Removal / Installation 3. 1.
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BODY / FRAME HEADLIGHT POD Assembly / Installation Disassembly / Removal 1. 1. Remove the (5) Torx-headed screws retaining the upper and lower headlight pods. Reverse the “Disassembly / Removal” procedure. NOTE: Make sure to route all vent lines, wire harness and throttle cable correctly into the lower headlight pod. 2. When installing the headlight into the lower pod, be sure to install the O-rings prior to installing the headlight. 3.
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BODY / FRAME MAIN FRAME Frame Support Exploded View 9.
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BODY / FRAME CHASSIS Body Plastic Removed View 9 9.
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BODY / FRAME NOTES 9.
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STEERING / SUSPENSION CHAPTER 10 STEERING / SUSPENSION GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 REMOVAL / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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STEERING / SUSPENSION GENERAL SPECIFICATIONS HANDLEBAR Torque Specifications Removal / Replacement 1. Remove the upper and lower headlight pods from the handlebar bracket (see Chapter 9). Item Specification Aluminum Wheels 75 ft. lbs. (102 Nm) Steel Wheels 45 ft. lbs. (61 Nm) IMPORTANT: Take note of all vent line, wire harness and throttle cable routing for reassembly purposes. Wheel Hub Retaining Nuts (front and rear) 80 ft. lbs. (108 Nm) 2.
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STEERING / SUSPENSION Installation STEERING 1. Steering Post Removal Locate the the alignment pin on the bottom side of the upper block. The pin should line up with the alignment hole in the lower block and should face the front. 1. Remove the front rack and front cover (see Chapter 9). 2. Remove the upper and lower headlight pods from the handlebar bracket (see Chapter 9). IMPORTANT: Take note of all vent line, wire harness and throttle cable routing for reassembly purposes. 2.
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STEERING / SUSPENSION 6. Remove the (2) bolts retaining the lower steering post bracket to the front gearcase. Steering Post Installation 1. Remove Reverse the “Steering Post Removal” procedure to reinstall the steering post. Refer to the “Steering Exploded View” for torque values. NOTE: Make sure to route all vent lines, wire harness and throttle cable correctly into the lower headlight pod. 7. 2.
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STEERING / SUSPENSION Steering Exploded View 20 ft. lbs. (27 Nm) 22 ft. lbs. (30 Nm) 12 ft. lbs. (16 Nm) 44 ft. lbs. (60 Nm) 12 ft. lbs. (16 Nm) 12 ft. lbs. (16 Nm) 12 ft. lbs. (16 Nm) 44 ft. lbs. (60 Nm) 44 ft. lbs. (60 Nm) REF. DESCRIPTION REF.
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STEERING / SUSPENSION STEERING (EPS MODELS) 6. Remove the (2) fasteners retaining the upper steering post bushing bracket. Upper Steering Post Removal 1. Remove the front rack and front cover (see Chapter 9). 2. Remove the upper and lower headlight pods from the handlebar bracket (see Chapter 9). IMPORTANT: Take note of all vent line, wire harness and throttle cable routing for reassembly purposes. 3. Remove the (4) fasteners retaining the handlebar bracket and block to the steering post. Remove 7.
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STEERING / SUSPENSION NOTE: Make sure to route all vent lines, wire harness and throttle cable correctly into the lower headlight pod. 5. When installing the headlight into the lower pod, be sure to install the O-rings prior to installing the headlight. 6. Place the headlight into the lower pod mounting tabs and press firmly until the headlight snaps into place. 7. Lift the O-ring up and over the headlight mounting tab to secure it. 4.
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STEERING / SUSPENSION 9. Loosen the hose clamp and remove the fuel inlet hose from the fuel tank. Cover the tank inlet and remove the fuel tank assembly out the right side (see Chapter 3). 12. Carefully lift the power steering unit up to disengage the lower steering coupler and remove it from the chassis. 10. Disconnect the (2) electrical harnesses from the power steering unit. Power Steering Unit Installation 1. Position the vehicle so the front wheels are pointing straight forward. 2.
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STEERING / SUSPENSION 5. Install the (4) mounting fasteners and torque fasteners to specification. Refer to “Steering Exploded View (EPS Models)”. 6. Reconnect the (2) electrical harnesses to the power steering unit. 11. Install the fuel tank assembly, fuel line and reconnect the fuel pump harness (see Chapter 3). 12. Reinstall the upper steering post bushing bracket and torque the (2) fasteners to specification.
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STEERING / SUSPENSION Steering Exploded View (EPS Models) 20 ft. lbs. (27 Nm) 15 ft. lbs. (20 Nm) 30 ft. lbs. (41 Nm) 22 ft. lbs. (30 Nm) 44 ft. lbs. (60 Nm) 22 ft. lbs. (30 Nm) 12 ft. lbs. (16 Nm) 44 ft. lbs. (60 Nm) 12 ft. lbs. (16 Nm) 12 ft. lbs. (16 Nm) 12 ft. lbs. (16 Nm) 44 ft. lbs. (60 Nm) 44 ft. lbs. (60 Nm) REF. DESCRIPTION REF.
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STEERING / SUSPENSION STEERING TIE ROD • If replacing just the tie rod end (D), loosen the jam nut (E) and remove the rod end. Tie Rod / Tie Rod End Replacement • Install new rod end and torque jam nuts to specification. Use the following procedure to replace the tie rod assembly or tie rod ends. 5. Install the new tie rod assembly (C). 1. 6. Install the rod ends and fasteners (B) in the proper orientation (see illustration). 7.
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STEERING / SUSPENSION FRONT A-ARMS Exploded View 40 ft. lbs. (54 Nm) 40 ft. lbs. (54 Nm) 21 ft. lbs. (28 Nm) 21 ft. lbs. (28 Nm) REF. DESCRIPTION REF. DESCRIPTION 1 Upper A-arm 8 Bushing 2 Lower A-arm 9 Pivot Shaft 3 Retaining Ring 10 Bolt 4 Ball Joint 11 Nut 5 Nut 12 CV Shield 6 Bolt 13 Screw 7 Grease Fitting 10.
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STEERING / SUSPENSION Removal / Replacement WARNING 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 from the upper A-arm. The locking agent on the existing bolts was destroyed during removal. DO NOT reuse old hardware. Serious injury or death could result if fasteners come loose during operation. 8.
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STEERING / SUSPENSION BALL JOINT SERVICE 4. Removal IMPORTANT: Do not reuse a ball joint if it has been removed for any reason. If removed, it must be replaced. Use this removal procedure only when replacing the ball joint. 1. Use a press and correct size driver to remove the ball joint from the A-arm. Correct Driver Placement The A-arm must be removed to perform this procedure (see “FRONT A-ARMS - Removal / Replacement”). The driver must fit the inside diameter of the A-arm end.
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STEERING / SUSPENSION is properly seated. Press into the A-arm in this direction Place driver HERE to support A-arm Upper A-arm Shown 2. After the new ball joint is installed into the A-arm, install a new retaining ring. 3. Reinstall the A-arm (see “FRONT A-ARMS - Removal / Replacement”). 4. Repeat the ball joint service procedure for any additional A-arm ball joint replacements. 10 10.
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STEERING / SUSPENSION REAR A-ARMS Exploded View 45 ft. lbs. (61 Nm) 40 ft. lbs. (54 Nm) 45 ft. lbs. (61 Nm) REF. DESCRIPTION REF. DESCRIPTION 1 Bolt 7 Bolt 2 Nut 8 Lower A-arm 3 Bushing 9 Bolt 4 Upper A-arm 10 Pivot Shaft, Upper 5 Grease Fitting 11 Pivot Shaft, Lower 6 Pivot Shaft 12 Bushing, Lower 10.
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STEERING / SUSPENSION Removal 10. Remove the fastener retaining the stabilizer linkage to the lower A-arm. The following procedure details upper and lower A-arm removal and replacement on one side of the vehicle. 1. Elevate and safely support the rear of the vehicle and remove the rear wheel. Upper A-arm Removal 2. Remove the through-bolt fastener attaching the upper Aarm to the bearing carrier (see “Exploded View”). 3.
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STEERING / SUSPENSION REAR STABILIZER BAR Exploded View 22 ft. lbs. (30 Nm) 17 ft. lbs. (23 Nm) 37 ft. lbs. (50 Nm) REF. DESCRIPTION REF. DESCRIPTION 1 Bolt 6 Nut 2 Stabilizer Bar Bracket 7 Linkage, Stabilizer Bar 3 Bushing, Stabilizer Bar 8 Bolt 4 Nut 9 Flat Washer 5 Stabilizer Bar 10 Bushing, Linkage 10.
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STEERING / SUSPENSION Linkage Removal / Installation 1. 2. Remove the (2) exhaust springs that retain the exhaust pipe to the silencer. 3. Remove the exhaust silencer from the vehicle through the right rear wheel well. Elevate rear of vehicle and safely support machine under the frame area. CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure. Always wear eye protection. 2. Remove the (4) wheel nuts and remove the rear wheel.
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STEERING / SUSPENSION 5. Remove the upper bushing from the stabilizer linkage on each side of the vehicle. SHOCKS / SPRINGS Exploded View Spring 37 ft. lbs. (50 Nm) Spring Retainer Shock Remove 6. Adjusting Cam Remove the (4) fasteners retaining the stabilizer bar bracket to the frame. 37 ft. lbs. (50 Nm) Remove Shock Removal / Installation Stabilizer Bar 1. Elevate the vehicle off the ground to relieve the suspension load. 2.
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BRAKES CHAPTER 11 BRAKES SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 GENERAL BRAKE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 GENERAL TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 SPECIAL TOOLS / BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.
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BRAKES SPECIFICATIONS General Brake Specifications FRONT BRAKES Item Standard Service Limit Brake Pad Thickness -- .040” / 1 mm Brake Disc Thickness .187” / 4.75 mm .167” / 4.24 mm Brake Disc Thickness Variance Between Measurement -- .002” / .051 mm Brake Disc Runout -- .010” / .254 mm Caliper Piston Diameter 1.186” / 30.12 mm 1.184” / 30.07 mm Caliper Bore Diameter 1.192” / 30.28 mm 1.194” / 30.33 mm Standard Service Limit Brake Pad Thickness -- .
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BRAKES BRAKE SYSTEM SERVICE NOTES Disc brake systems are light weight, low maintenance, and perform well in the conditions this vehicle will routinely encounter. There are a few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function and maximum pad service life. • Do not over-fill the master cylinder fluid reservoir(s). • Make sure the brake lever / pedal returns freely and completely. • Adjust stop pin on calipers after pad service.
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BRAKES HYDRAULIC BRAKE SYSTEM OPERATION The brake system consists of the following components or assemblies: hand brake master cylinder w/lever, foot brake master cylinder w/pedal, brake fluid reservoirs, brake lines, brake calipers, brake pads, and brake discs, which are secured to the drive line. When the brake lever or pedal is applied, it moves the hydraulic piston within the master cylinder.
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BRAKES Brake Caliper Exploded View Apply Polaris DOT 4 Brake Fluid to Component J K 47 in. lbs. (5.3 Nm) E Apply Polaris All Purpose Grease F H C A D A. Caliper Mount B. Brake Pads C. Piston D. Caliper Assy. E. Square O-ring (thick) F. Square O-ring (thin) G. Boot, Pin Bushing H. Boot, Pin Seal J. Bleeder Screw K. Adjustment Set Screw G B Hand Master Cylinder Exploded View 7 in. lbs. Q (0.8 Nm) F A. Lever B. Piston C. Locking Lever D. Primary Cup E. O-ring F. Reservoir Cover G. Pivot Pin H.
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BRAKES BRAKE BLEEDING Polaris DOT 4 Brake Fluid PN: 2872189 Fluid Replacement NOTE: When bleeding the brakes or replacing the fluid, always start with the caliper farthest from the master cylinder. Bleeding Procedure Front Brake System Bleeding CAUTION Always wear safety glasses during these procedures. Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact with finished surfaces. 1.
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BRAKES 9. Repeat the procedure on the two remaining front calipers. 4. 10. Add DOT 4 brake fluid to .25” - .30” (6 - 8 mm) from the top of the reservoir. Using a funnel, add brake fluid to the MAX level mark on the reservoir. 5. Install a box end wrench on the rear caliper bleeder screw. Attach a clean, clear hose to fitting and place the other end in a container. Be sure the hose fits tightly on fitting. 12. Proceed to “Rear Brake System Bleeding” to complete bleeding procedure. 6.
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BRAKES HAND BRAKE MASTER CYLINDER 1. Removal 1. Clean master cylinder and reservoir assembly. Make sure you have a clean work area to disassemble brake components. 2. Place a shop towel or suitable catch container under the master cylinder brake line connection. Remove the banjo bolt fitting that connects the brake line to the master cylinder. Discard the sealing washers. Install master cylinder on handlebars.
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BRAKES FOOT BRAKE MASTER CYLINDER 3. Remove the (2) through-bolts retaining the master cylinder to the mount bracket. Replace components as needed. Operation Overview 4. Reverse this procedure when reinstalling and torque mounting fasteners to specification. When the brake pedal is applied it contacts the piston of the foot brake master cylinder. As the pressure within the system is increased, the pistons located in the rear brake calipers move outward and apply equal pressure to the brake pads.
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BRAKES BRAKE PADS Pad Inspection Pad Removal 1. 1. Loosen the (4) wheel nuts. 2. Elevate and support the side of the ATV in which the caliper brake pads are being serviced. Measure the thickness of the pad material. Replace pads if worn beyond the service limit. CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. 3. Remove the wheel nuts and wheel. 4. Remove the (2) brake caliper mounting bolts and caliper. = In. / mm.
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BRAKES 3. Install the caliper and torque new mounting bolts to specification. CALIPER SERVICE Caliper Removal CAUTION New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly. 1. Loosen the (4) wheel nuts. 2. Elevate and support the side of the ATV in which the caliper is being serviced. CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls.
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BRAKES 2. Remove mounting bracket, pin assembly and dust boot. Caliper Inspection 1. 3. 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. Using a hammer and a small punch, remove the piston from the caliper body, then remove the square O-rings (see “BRAKE CALIPER - Exploded View”). = In. / mm. Front Calipers: Caliper Bore I.D. Std: 1.192” (30.28 mm) Service Limit: 1.194” (30.
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BRAKES = In. / mm. Front Calipers: Caliper Piston O.D. Std: 1.186” (30.12 mm) Service Limit: 1.184” (30.07 mm) Rear Calipers: Caliper Piston O.D. Std: 1.250” (31.75 mm) Service Limit: 1.246” (31.65 mm) 4. Compress the mounting bracket and make sure the dust seals are fully seated. 5. Install the brake pads. 6. Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt, oil or grease. Caliper Installation 1. CAUTION Caliper Reassembly 1.
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BRAKES BRAKE DISC SERVICE Disc Inspection 1. Visually inspect the brake disc for scoring, scratches, or gouges. Replace the disc if any deep gouges are evident. Measure the disc thickness at 8 different points around the pad contact surface using a 0–1” micrometer. Replace disc if worn beyond service limit. Image shown is for reference only. Disc Removal / Replacement 1. Loosen the (4) wheel nuts. 2. Elevate and support the side of the ATV in which the brake disc is being serviced. = In. / mm.
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BRAKES 5. Remove the two brake caliper mounting bolts. CAUTION: Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. 10. Install wheel hub assembly, cone washers, and hand tighten the castle nut. Install washers with domed side out. Cone Washers Rear Caliper Shown Wheel Hub Remove Out 11. Install the brake caliper and torque the new mounting bolts to specification. CAUTION 6. Remove the wheel hub assembly from the bearing carrier. 7.
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BRAKES 12. Torque wheel hub nut to specification and install a new cotter pin. Tighten nut slightly if necessary to align cotter pin holes. TROUBLESHOOTING Brake Squeal • Dirty/contaminated friction pads 80 ft. lbs.
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WIRE DIAGRAM 2009 SPORTSMAN XP 850 (PAGE 1 OF 2) WD-1
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WIRE DIAGRAM 2009 SPORTSMAN XP 850 (PAGE 2 OF 2) WD-2
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WIRE DIAGRAM 2009 SPORTSMAN XP 850 (AWD / ADC) WD-5
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WIRE DIAGRAM 2009 SPORTSMAN XP 850 (BATTERY CHARGING) WD-7
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WIRE DIAGRAM 2009 SPORTSMAN XP 850 (BATTERY PLUS) WD-9
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WIRE DIAGRAM 2009 SPORTSMAN XP 850 (BRAKE LAMPS-START) WD-11
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WIRE DIAGRAM 2009 SPORTSMAN XP 850 (CHASSIS POWER) WD-13
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WIRE DIAGRAM 2009 SPORTSMAN XP 850 (COOLING FAN) WD-15
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WIRE DIAGRAM 2009 SPORTSMAN XP 850 (ECM WAKE-UP) WD-17
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WIRE DIAGRAM 2009 SPORTSMAN XP 850 (EFI) WD-19
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WIRE DIAGRAM 2009 SPORTSMAN XP 850 (ENGINE CRANK) WD-21
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WIRE DIAGRAM 2009 SPORTSMAN XP 850 (EPS) WD-23
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WIRE DIAGRAM 2009 SPORTSMAN XP 850 (FUEL PUMP & LEVEL) WD-25
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WIRE DIAGRAM 2009 SPORTSMAN XP 850 (GEAR SENSOR) WD-27
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WIRE DIAGRAM 2009 SPORTSMAN XP 850 (GROUND SPEED SENSOR) WD-29
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WIRE DIAGRAM 2009 SPORTSMAN XP 850 (KEY ON POWER) WD-31
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WIRE DIAGRAM 2009 SPORTSMAN XP 850 (HEADLAMPS) WD-33