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2008 RANGER RZR

SERVICE MANUAL

FOREWORD

This service manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly

equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from

the operator's perspective when seated in a normal riding position.

Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop

procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with

service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper

tools as specified.

Comments or suggestions about this manual may be directed to: Service Publications Dept. @ Polaris Sales Inc.

2100 Hwy 55 Medina Minnesota 55340.

2008 Service Manual PN 9921278

improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this

publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any

reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

Summary of content (320 pages)

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2008 RANGER RZR SERVICE MANUAL FOREWORD This service manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position.
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UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS Throughout this manual, important information is brought to your attention by the following symbols: WARNING SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle. CAUTION SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.
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GENERAL INFORMATION 1 MAINTENANCE 2 ENGINE 3 FUEL INJECTION 4 BODY / STEERING / SUSPENSION 5 CLUTCHING 6 FINAL DRIVE 7 TRANSMISSION 8 BRAKES 9 ELECTRICAL 10
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GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION 1 MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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GENERAL INFORMATION MODEL INFORMATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Model Year Designation } } } } Machine Model Number Identification R 08 VH 76 AD Emissions & Model Option Basic Chassis Designation Engine Designation Engine Designation Number EH076OLE021 ..................................................... Twin Cylinder, Liquid Cooled, OHV 4 Stroke, Electric Start VIN Identification World Mfg.
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GENERAL INFORMATION Unit Serial Number (VIN) Location The machine model number and serial number (VIN) are important for vehicle identification. The VIN number (A) is stamped on a portion of the LH frame rail close to the front wheel. The model and VIN numbers are also located on a sticker under the hood (B) or on the lower frame rail in front of the LH rear tire (C). A A B C 1.
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GENERAL INFORMATION GENERAL SPECIFICATIONS MODEL: 2008 RANGER RZR MODEL NUMBER: R08VH76AD, AG ENGINE MODEL: EH076OLE021 Category Length Width Height Wheel Base Ground Clearance Dry Weight Gross Vehicle Weight Front Storage Capacity Cargo Box Dimension Cargo Box Capacity Maximum Weight Capacity (Payload) Hitch Towing Capacity Hitch Tongue Capacity FRONT Dimension / Capacity 102 in. / 259 cm 50 in. / 127 cm 68.5 in. / 174 cm 77 in. / 196 cm 10 in. / 25.4 cm 945 lbs. / 429 kg 1727 lbs. / 783 kg 25 lbs. / 11.
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GENERAL INFORMATION MODEL: 2008 RANGER RZR Drivetrain MODEL NUMBER: R08VH76AD, AG ENGINE MODEL: EH076OLE021 Transmission Type Polaris Automatic PVT Platform Polaris Domestic Twin Cylinder, Liquid Cooled, 4-Stroke Gear Ratio: Front / Rear High Low Rev 3.14:1 8.71:1 5.94:1 Engine Model Number EH076OLE021 Drive Ratio - Front 3.82:1 Engine Displacement 760cc Drive Ratio - Final 3.70:1 Number of Cylinders 2 Shift Type In Line Shift - H / L / N / R / P Bore & Stroke (mm) 80 x 76.
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GENERAL INFORMATION VEHICLE INFORMATION Publication Numbers Model Model No. Owner’s Manual PN Parts Manual PN 2008 RANGER RZR, Red R08VH76AD 9921181 9921207 2008 RANGER RZR, Green R08VH76AG 9921181 9921207 NOTE: When ordering service parts be sure to use the correct parts manual. NOTE: Polaris factory publications can be found at www.polarisindustries.com or purchased from www.purepolaris.com.
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GENERAL INFORMATION MISC. SPECIFICATIONS AND CHARTS 1 Conversion Table °C to °F: 9/5(°C + 32) = °F °F to °C: 5/9(°F - 32) = °C 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 Decimal Equivalents 1 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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MAINTENANCE CHAPTER 2 MAINTENANCE PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 PERIODIC MAINTENANCE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.
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MAINTENANCE ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 BATTERY OFF SEASON STORAGE . . .
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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 Pre-Ride - 25 Hour Maintenance Interval Item Steering Front Suspension Rear Suspension Maintenance Interval (whichever comes first) Miles Hours Calendar (KM) Pre-Ride - Remarks - Pre-Ride - - Pre-Ride - - Pre-Ride - Brake Fluid Level Brake Pedal Travel - Pre-Ride - - Pre-Ride - Brake Systems Wheels / Fasteners Frame Fasteners - Pre-Ride Pre-Ride Pre-Ride - Engine Oil Level - Pre-Ride - Air Filter / Pre-Filter - Pre-Ride - Coolant Level - Daily -
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MAINTENANCE 50 - 300 Hour Maintenance Interval Item Throttle Cable / Throttle E Pedal Throttle Body Air Intake E Ducts / Flange General Lubrication Shift Linkage Maintenance Interval (whichever comes first) Miles Hours Calendar (KM) Remarks 2 50 H 6M 300 (500) Inspect; adjust; lubricate; replace if necessary 50 H 6M 300 (500) Inspect ducts for proper sealing / air leaks 50 H 50 H 3M 6M 500 (800) 500 (800) Lubricate all fittings, pivots, cables, etc.
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MAINTENANCE COMPONENT INSPECTION / SERVICE LOCATIONS Front and Rear View 2.
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MAINTENANCE RH and LH Side Views 2 2.
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MAINTENANCE LUBRICANTS / SERVICE PRODUCTS Polaris Lubricants, Maintenance and Service Products NOTE: Each item can be purchased separately at your local Polaris dealer. Part No. Description Additives / Sealants / Thread Locking Agents / Misc. Part No. Description Engine Lubricant 2870585 Loctite™ Primer N, Aerosol, 25 g 2871956 Loctite™ Thread Sealant 565 (50 ml.) (6 Count) 2870791 Fogging Oil (12 oz.
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MAINTENANCE MAINTENANCE REFERENCES Item Ref. Rec. Lube / Fluid Method Frequency* Change after 25 hrs, and then 6 months or 100 hours thereafter; Change more often in extremely dirty conditions, or short trip cold weather operation. Engine Oil Page 2.7 Premium 4-Cycle Synthetic 0W-40 (PN 2871281) Add oil to proper level on dipstick. Engine Coolant Page 2.6 Polaris Antifreeze 60/40 (PN 2871534) Fill recovery bottle between Fill as required. Change MAX and MIN lines. coolant every 2 years.
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MAINTENANCE GENERAL VEHICLE INSPECTION AND MAINTENANCE Shift Cable Inspection / Adjustment Shift cable adjustment may be necessary if symptoms include: • No AWD or gear position display on instrument cluster Pre-Ride / Daily Inspection • Ratcheting noise on deceleration Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.
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MAINTENANCE 6. 7. Once the proper adjustment is obtained, place the shift cable and upper jam nut into the mount. Tighten the lower jam nut against the mount. Start engine and shift through all gears to ensure the shift cable is properly adjusted. If transmission still ratchets after cable adjustment, the transmission will require service. 2. Be sure fuel line is routed properly. IMPORTANT: Make sure line is not kinked or pinched. 3. Replace fuel line every two years.
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MAINTENANCE Throttle Pedal Inspection 3. Squeeze the end of the rubber boot and slide it far enough to expose the end of the inline cable adjuster. If the throttle pedal has excessive play due to cable stretch or cable misadjustment, it will cause a delay in throttle speed. Also, the throttle may not open fully. If the throttle pedal has no play, the throttle may be hard to control, and the idle speed may be erratic. Boot Lock Nut 4. 5.
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MAINTENANCE 3. 4. Remove air filter assembly and remove the pre-filter sleeve. Inspect the main air filter element and replace if necessary. Do not clean the main filter, the filter should be replaced. NOTE: If the filter has been soaked with fuel or oil it must be replaced. 5. Wash pre-filter in warm soapy water and allow it to air dry. NOTE: If unable to clean the pre-filter, replace it. Seal Installation 1. 2. 3. Clean the air box thoroughly.
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MAINTENANCE ENGINE Lever Lock Engine Oil Level The twin cylinder engine is a wet-sump engine, meaning the oil is contained in the bottom of the crankcase. To check the oil level follow the procedure listed below. Dipstick SAFE Dipstick 6. ADD 8 OZ Reinstall the dipstick completely, but do not lock it. NOTE: Make certain the dipstick is inserted all the way into the filler tube to keep the angle and depth of dipstick consistent. 1. Position vehicle on a level surface. 2.
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MAINTENANCE Engine Oil and Filter Service 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. WARNING NOTE: The sealing surface on the drain plug should be clean and free of burrs, nicks or scratches. 8. Reinstall drain plug and torque to 16 ft. lbs. (22 Nm). 9. Remove both seats and rear service panel. 10. Place shop towels beneath oil filter.
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MAINTENANCE Engine Breather Hose Inspection The engine is equipped with a breather hose. Inspect the breather hose for possible kinks or wear. The hose is form fitted for a proper fit. Follow the breather hose from the side of the airbox to the engine valve cover. A smooth idle generally indicates good compression. Low engine compression is rarely a factor in running condition problems above idle speed. A cylinder leakdown test is the best indication of engine condition.
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MAINTENANCE TRANSMISSION AND GEARCASES Transmission / Gearcase Specification Chart DRAIN / LEVEL CHECK PLUG TORQUE GEARCASE LUBRICANT CAPACITY Transmission (Main Gearcase) AGL - Synthetic ATV Gearcase Lubricant 24 oz. (710 ml) 40-50 ft. lbs. (54-68 Nm) 30-45 in. lbs. (3-5 Nm) Transmission (Transfer Case) AGL - Synthetic ATV Gearcase Lubricant 14 oz. (414 ml) 40-50 ft. lbs. (54-68 Nm) 30-45 in. lbs. (3-5 Nm) Front Gearcase Premium Demand Drive Fluid LT 6.75 oz. (200 ml) 8-10 ft. lbs.
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MAINTENANCE Main Gearcase - Lubricant Level Check: The fill plug is located on the side of the gearcase just below the shift lever bell crank. Maintain the fluid level even with the bottom of the fill plug hole. 1. Position vehicle on a level surface. 2. Remove the fill plug. 3. Check the fluid level. Transfer Case Drain Plug Main Gearcase Drain Plug Transfer Case Lubricant Change: 1. Remove the fill plug and the level check plug (refer to “Transfer Case - Lubricant Level Check”). 2.
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MAINTENANCE Front Gearcase Lubrication 1. Position vehicle on a level surface. The front gearcase lubricant level should be checked and changed in accordance with the maintenance schedule. 2. Remove the fill plug and check the fluid level. 3. Add the recommended fluid as needed. • Be sure vehicle is positioned on a level surface when checking or changing fluid. 4. Reinstall the fill plug and torque to 8-10 ft. lbs. (11-14 Nm). • Check vent hose to be sure it is routed properly and unobstructed.
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MAINTENANCE Rear Gearcase Lubrication Rear Gearcase Specifications Lubricant Change: The drain plug is located on the bottom right side of the rear gearcase. Specified Lubricant: ATV Angle Drive Fluid (PN 2871653) Capacity: 18 oz. (532 ml) Fill Plug Fill Plug Torque: 40-50 ft. lbs. (54-68 Nm) Drain Plug Torque: 30-45 in. lbs. (3-5 Nm) Lubricant Level Check: The fill plug is located on the right side of the rear gearcase. Maintain the fluid level even with the bottom of the threads of the fill plug hole.
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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. 4. NOTE: If overheating is evident, allow system to cool completely and check coolant level in the radiator and inspect for signs of trapped air in system.
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MAINTENANCE Cooling System Pressure Test 2. Carefully straighten any bent radiator fins. Refer to Chapter 3 for cooling system pressure test procedure. 3. Remove any obstructions with compressed air or low pressure water. Cooling System Hoses 1. Inspect all hoses for cracks, deterioration, abrasion or leaks. Replace if necessary. CAUTION Washing the vehicle with a high-pressure washer could damage the radiator fins and impair the radiators effectiveness.
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MAINTENANCE FINAL DRIVE / WHEEL AND TIRE Radiator Removal 1. Remove the front bumper (see Chapter 5). 2. Remove the upper engine outlet hose and recovery hose from the top of the radiator. 3. Wheel, Hub, and Spindle Torque Table Item Nut Type Specification Aluminum Wheels (Cast) Lug Nut #1 90 ft. lbs. (122 Nm) Steel Wheels (Black / Camo) Flange Nut #2 27 ft. lbs. (37 Nm) Hub Retaining Nuts (Front & Rear) - 80 ft. lbs.
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MAINTENANCE 5. Carefully lower the vehicle to the ground. 6. Torque the wheel nuts and/or hub nut to the proper torque specification listed in the torque table at the beginning of this section. 7. If hub nut was removed, install a new cotter pin after the hub nut has been tightened. WARNING Operating a RANGER with worn tires will increase the possibility of the vehicle skidding easily with possible loss of control. Worn tires can cause an accident.
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MAINTENANCE ELECTRICAL AND IGNITION SYSTEM Battery Removal Battery Maintenance 1. Keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly. Remove the driver’s seat to access the battery.
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MAINTENANCE Battery Off Season Storage Spark Plug Service Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge. 1. Remove both driver and passenger seats. 2. Remove the rear service panel.
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MAINTENANCE 9. Measure gap with a wire gauge. Refer to specifications in the following illustration for proper spark plug type and gap. Adjust gap if necessary by carefully bending the side electrode. STEERING AND SUSPENSION Steering Inspection The steering components should be checked periodically for loose fasteners, worn tie rod ends, ball joints, 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 Steering Inspection / Tie Rod Ends and Hubs • To check for play in the tie rod end, grasp the steering tie rod and pull in all directions feeling for movement. Toe Alignment Inspection 1. Place machine on a smooth level surface. 2. Set steering wheel in a straight ahead position and secure the steering wheel in this position. 3. Place a chalk mark on the center line of the front tires approximately 10” (25.4 cm) from the floor or as close to the hub/axle center line as possible.
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MAINTENANCE Toe Adjustment Suspension Spring Adjustment If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell you which tie rod needs adjusting. 1. Position the vehicle on a level surface. 2. Stop the engine. NOTE: Be sure steering wheel is straight ahead before determining which tie rod(s) need adjustment. 3. Raise and safely support the front or rear of the vehicle off the ground to allow the suspension to fully extend.
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MAINTENANCE BRAKE SYSTEM Brake Pad / Disc Inspection Brake Fluid Inspection 1. Check the brake pads for wear, damage, or looseness. Always check the brake pedal travel and inspect the brake fluid reservoir level before each operation. If the fluid level is low, add DOT 4 brake fluid only. 2. Inspect the brake pad wear surface for excessive wear. 3. Pads should be changed when the friction material is worn to .040” (1 mm). Brake fluid should be changed every two years.
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ENGINE CHAPTER 3 ENGINE ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 CRANKCASE EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 ENGINE FASTENER TORQUE PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.
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ENGINE ENGINE SPECIFICATIONS Crankcase Exploded Views 3.
PAGE 46
ENGINE Oil Pump / Water Pump / Engine Cover Exploded View 3 3.
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ENGINE Stator Cover / Starter / Water Pump Oil Filter / Pressure Relief / Exploded View 3.
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ENGINE Cylinder / Cylinder Head / Piston Exploded View 3 3.
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ENGINE Engine EFI Sensors / Valve Cover / General Component Exploded View NOTE: See Chapter 4 for more information on the EFI System 3.
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ENGINE Engine Fastener Torque Patterns Crankcase Bolt Tighten Sequence 3 22 ± 2 ft. lbs. (30 ± 3 Nm) Cylinder Head Bolt Tighten Sequence Lubricate threads and between washer and underside of bolt with engine oil. Torque in sequence to spec provided, allow the gasket to set for 1 minute, then tighten in sequence 90° (1/4 turn). 35 ± 4 ft. lbs. (47.5 ± 5.5 Nm) + 90° (1/4 turn) 3.
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ENGINE Torque Specifications Engine Torque Specifications Fastener Size in. lbs. (Nm) ft. lbs. (Nm) Camshaft Gear 8 mm 22 ± 2 (30 ± 3) Camshaft Thrust Plate 6 mm 115 ± 12 (13 ± 1.35) 9.5 ± 1 (13 ± 1.35) Throttle Body Adaptor Bolts 8 mm 216 ± 24 (24.5-± 2.7) 18 ± 2 (24.5 ± 2.7) Counterbalance Gear 8 mm 22 ± 2 (30 ± 3) Crankcase Bolts 8 mm * 22 ± 2 (30 ± 3) Crankcase Breather 5 mm Cylinder Head Bolts 11 mm Exhaust Manifold 8 mm Flywheel 14 mm Injector Rail 8 mm 216 ± 24 (24.
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ENGINE 800 EFI Engine Service Specifications Cylinder Head - Engine Specifications Main Component: Cylinder Head Camshaft Counter Balance EH076OLE021 Cam Lobe Height - Intake / Exhaust 1.3334" (33.8674 mm) Camshaft Journal Outer Diameter - Mag 1.654" ± 0.00039" (42 ± 0.010 mm) Camshaft Journal Outer Diameter - Center 1.634"± 0.00039" (41.50 ± 0.010 mm) Camshaft Journal Outer Diameter - PTO 1.614" ± 0.00039" (41 ± 0.010 mm) Camshaft Journal Bore Inner Diameter - Mag 1.656" ± 0.00039" (42.07 ± 0.
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ENGINE Cylinder / Piston - Engine Specifications Main Components: Cylinder / Piston / Connecting Rod Cylinder Lifter Piston Piston Pin EH076OLE021 Cylinder - Surface warp limit (mating with cylinder head) 0.004" (0.10 mm) Cylinder Bore - Standard 3.1495" (80 mm) Cylinder Taper Limit 0.00031" (0.008 mm) Cylinder Out of Round Limit 0.00030" (0.0075 mm) Cylinder to Piston Clearance .0015" ± .00059" (.040 ± .015mm) Lifter Outer Diameter Standard 0.84245" ± 0.00025" (21.39 8 ± 0.
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ENGINE Special Tools Part Number Tool Description PV-43527 OIL FILTER WRENCH 2200634 VALVE SEAT RECONDITIONING KIT PU-45257 VALVE SPRING COMPRESSOR PU-45652 VALVE PRESSURE HOSE 2871043 FLYWHEEL PULLER 2870390 PISTON SUPPORT BLOCK PU-45497-1 CAM GEAR SPRING INSTALLATION KIT PU-45497-2 CAM GEAR TOOTH ALIGNMENT TOOL PU-45498 CAM SPANNER WRENCH PU-45838 GEAR HOLDER 3 PA-44995 WATER PUMP MECHANICAL SEAL INSTALLER PU-45543 UNIVERSAL DRIVER HANDLE PA-45483 MAIN SEAL INSTALLER PU-45658
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ENGINE ENGINE COOLING SYSTEM 3. Cooling System Specifications Condition Thermostat Open Thermostat Full Open Lift Thermostat Closed System Capacity Specification The system must maintain 10 psi for five minutes or longer. If pressure loss is evident within five minutes, check the radiator, hoses, clamps and water pump seals for leakage. Pressure Cap Test WARNING 180° F (82° C) 6 mm at 203° F (95° C) Never remove pressure cap when engine is warm or hot.
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ENGINE Cooling System Exploded View Engine Outlet Hose (Thermostat Housing) Radiator Inlet Hose 3 Engine Inlet Hose (Water Pump Cover) Fan Motor Pressure Cap Shroud To Bottle Filler Neck Recovery Bottle Radiator Outlet Hose If Built After 4/16/2007 Radiator To Filler Neck Coolant Flow Diagram Filler Neck Engine Water Pump Engine Thermostat Housing Recovery Bottle Radiator 3.
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ENGINE Cooling System Bleeding Procedure WARNING 3. Remove pressure cap and top off coolant. 4. Remove recovery bottle cap and fill bottle to the full line. Recovery Bottle Always wear safety glasses and proper shop clothing when performing the procedures in this manual. Failing to do so may lead to possible injury or death. Pressure Cap CAUTION Use caution when performing these procedures. Coolant may be hot and may cause severe injury or burns.
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ENGINE 10. Add Polaris Premium Antifreeze to the radiator filler neck if the level goes down. If no bubbles are seen at the filler neck, the system should be purged of air GENERAL ENGINE SERVICE Engine Lubrication Specifications WARNING = Be sure to install the pressure cap before shutting off the engine. Coolant may spit out of the radiator. 11. Stop the engine and let cool, top off the radiator filler neck with coolant.
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ENGINE Oil Flow Chart This chart describes the flow of oil through the 800 EFI engine. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through the oil filter. If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element. At this point, the oil is supplied to the main oil galley through a crankcase passage.
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ENGINE Engine Removal 8. Remove the (2) push rivets from the rear of the center console. Because of its design configuration, Polaris recommends removing the engine, transmission, and rear gearcase as one assembly. Use the following procedure when engine removal is required. IMPORTANT: Some engine repair procedures can be performed without removing the RZR engine assembly from the vehicle. Refer to “Accessible Engine Components” on Page 3.15 for further information.
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ENGINE 12. Elevate the rear of the vehicle off the ground using a suitable ATV lift and remove both rear wheels. 13. Remove all exhaust components from vehicle and engine. 14. Loosen the hose clamp attaching the outlet duct to the PVT cover. Leave the duct attached to the upper frame support. 18. Remove the (6) fasteners retaining the upper bolt-in frame brace and remove it from the vehicle with the ignition coil and PVT duct attached. Frame Brace Ignition Coil PVT Duct Outlet Duct PVT Cover 19.
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ENGINE 22. Loosen the hose clamp between the throttle body and intake adaptor. Loosen Clamp 25. Remove the airbox and throttle body from the vehicle as an assembly. Take care in not allowing the throttle cable to bend excessively or kink. Carefully place the assembly on the floor next to the vehicle. Insert a shop towel into the engine intake adaptor to prevent dirt from entering the engine. NOTE: Ensure throttle cable is not being excessively bent or kinked while removed from the vehicle. 26.
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ENGINE 29. Mark the upper jam nut and loosen the lower jam nut. Pull the shift cable out of the mount. 32. Disconnect the stator / alternator harness. Stator Connector Mark Upper Jam Nut Lower Jam Nut 33. Disconnect the transmission speed sensor harness. NOTE: If the upper jam nut is moved, shift cable adjustment will be required during engine installation (see Chapter 2 “Shift Cable Inspection / Adjustment”). Speed Sensor Connector 30. Disconnect the transmission gear indicator switch harness.
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ENGINE 35. Remove the through-bolt that attaches the upper A-arm to the rear hub on both sides of the vehicle. 38. Disconnect the engine coolant temperature (ECT) sensor harness. ECT Connector 3 36. Pivot the A-arms upward and rear hub carriers downward and remove the drive shafts from the hub carriers. 39. Loosen the hose clamp and remove the lower coolant hose from the water pump cover inlet and drain coolant into a suitable container. Hub Carrier 37.
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ENGINE 44. Remove RH engine mount fastener. 47. Using an engine hoist, hook a chain between the engine / transmission mounting plate and the transmission / rear gearcase mounting plate. 45. Remove the (2) lower bolts that retain the LH transmission mount to the frame. Engine/Transmission Mount Plate Transmission/Gearcase Mount Plate Remove (2) Lower Bolts 46. Remove the (2) rear gearcase mount bracket fasteners and mount bolt and remove bracket from vehicle.
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ENGINE 49. Remove propshaft from the transmission output shaft. 3. Remove only the (4) outer fasteners retaining the engine to the transmission bracket. 50. Then move assembly towards the front of the vehicle while lifting it out to allow the rear gearcase to clear the rear portion of the frame. 51. Then lift assembly high enough to clear vehicle frame and completely remove it from the vehicle to a work bench.
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ENGINE ENGINE DISASSEMBLY AND INSPECTION Cylinder Head Assembly Exploded View Rocker Arms Retainer Locks (keepers) Push Rods Spring Retainers Springs Valve Seals Valve Spring Seats Cylinder Head Hydraulic Lifters Valves 3.
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ENGINE Rocker Arms 5. 1. Remove the valve cover. 2. Mark or tag rocker arms in order of disassembly to keep them in order for reassembly. If the push rod (A) is visibly bent, it should be replaced. A 3 Cylinder Head Removal 3. Inspect the wear pad at the valve end of the rocker arm for indications of scuffing or abnormal wear. If the pad is grooved, replace the rocker arm. NOTE: Do not attempt to true this surface by grinding. 4.
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ENGINE Cylinder Head Inspection Valve Seal / Spring Service (On Engine) Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon. NOTE: The following procedure is only for servicing the top end of the valve train when replacing valve springs or replacing valve seals. CAUTION Use care not to damage sealing surface. In some cases the valve train can be serviced while the cylinder head is still on the engine.
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ENGINE Cylinder Head Disassembly 4. 1. IMPORTANT: It is recommended to replace seals whenever the cylinder head is disassembled. Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup. Carefully remove the cylinder components. 5. Remove valve guide seals. Mark the valves with a white pen. Remove the valves from the cylinder head. This will ensure that the valves are properly placed during engine reassembly. 3 Mark the Valves 2.
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ENGINE Valve Inspection 1. 2. Remove all carbon from valves with a soft wire wheel or brush. Check valve face for runout, pitting, and burnt spots. To check for bent valve stems, mount valve in a drill or use “V” blocks and a dial indicator. = In. / mm. Valve Stem Diameter: Intake: 0.2356" + 0.00039" (5.985 + 0.01 mm) Exhaust: 0.2351" + 0.00039" (5.972 + 0.01 mm) 6. Measure valve guide (C) inside diameter at the top middle and end of the guide using a small hole gauge and a micrometer.
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ENGINE Combustion Chamber 1. Clean all accumulated carbon deposits from combustion chamber and valve seat area with carbon cleaner and a soft plastic scraper. IMPORTANT: Do not use a wire brush, metal scraper, or abrasive cleaners to clean the bottom of the cylinder head. Extensive damage to the cylinder head may result. Wear safety glasses during cleaning. Combustion Area NOTE: Valve seat width and point of contact on the valve face is very important for proper sealing.
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ENGINE 4. Inspect the cut area of the seat: * If the contact area is less than 75% of the circumference of the seat, rotate the pilot 180° and make another light cut. NOTE: When using an interference angle, the seat contact point on the valve will be very narrow, and is a normal condition. Look for an even and continuous contact point all the way around the valve face (A). * If the cutter now contacts the uncut portion of the seat, check the pilot. Look for burrs, nicks, or runout.
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ENGINE 8. Clean all filings from the area with hot soapy water. Rinse and dry with compressed air. 9. Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the valve. Cylinder Head Reassembly NOTE: Assemble the valves one at a time to maintain proper order. 1. Apply engine oil to valve guides and seats. NOTE: Lapping is not required with an interference angle valve job. 2.
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ENGINE Valve Sealing Test Valve Lifter Removal / Inspection 1. 1. Remove the valve lifters by reaching into the crankcase and pushing the lifter up through the lifter bore by hand. 2. Thoroughly clean the lifters in cleaning solvent and wipe them with a clean, lint-free cloth. 3. Mark the lifters with a white pen if using the lifters for reassembly. This will ensure that the lifters are properly placed during engine reassembly. Clean and dry the combustion chamber area (A).
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ENGINE Piston Removal 1. Remove circlip (A). Mark the piston with a white pen to ensure proper orientation (if reused) during assembly. The oil control ring is a three piece design consisting of a top and bottom steel rail and a center expander section. The top rail has a locating tab on the end which fits into a notch (B) in the upper oil ring land of the piston. To Remove: A) Remove the top rail first followed by the bottom rail. B) Remove the expander.
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ENGINE Cylinder Inspection 1. Remove all gasket material from the cylinder sealing surfaces. 2. Inspect the top of the cylinder (B) for warp using a straight edge (A) and feeler gauge (C). Refer to Ill. 1 and Ill. 2. 3. Inspect cylinder for wear, scratches, or damage. 4. Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge.
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ENGINE Standard Bore Size (Both Cylinders): 3.1496" (80 mm) If cylinder wear or damage is excessive, it will be necessary to replace the cylinder. The cylinders are lined with a nicasil coating and are not repairable. Hone only enough to de-glaze the outer layer of the cylinder bore. Cylinder Hone Selection and Honing Procedure Cylinders may be wet or dry honed depending upon the hone manufacturer’s recommendations. Wet honing removes more material faster and leaves a more distinct pattern in the bore.
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ENGINE Piston-to-Cylinder Clearance 2. Measure piston pin O.D. Replace piston and/or piston pin if out of tolerance. Measure piston outside diameter at a point 5 mm up from the bottom of the piston at a right angle to the direction of the piston pin. Subtract this measurement from the maximum cylinder measurement obtained in Step 5. 5 mm Piston Pin Measurement Locations Piston Piston Pin Piston to Cylinder Clearance: See “800 EFI Engine Service Specifications” on page 3.9 Piston Pin O.D.
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ENGINE 4. Measure piston ring to groove clearance by placing the ring in the ring land and measuring with a thickness gauge. Replace piston and rings if ring-to-groove clearance exceeds service limits. 3. If the bottom installed gap measurement exceeds the service limit, replace the rings. If ring gap is smaller than the specified limit, file ring ends until gap is within specified range. NOTE: Always check piston ring installed gap after re-boring a cylinder or when installing new rings.
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ENGINE 6. Inspect gear teeth on starter drive (A). Replace starter drive if gear teeth are cracked, worn, or broken. 7. Inspect the bendix bushing (C) in the mag cover for wear. Replace as needed. C 2871043 4. A Use caution when removing the wire holddown (B) and the stator assembly (D). Do not tap or bump the gear /stator housing cover or the stator. This could cause the seal around the gear/stator housing cover and the crankcase to break, causing a leak. Flywheel / Stator Removal / Inspection 1.
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ENGINE 2. Remove the nylok nut (C), washer (D), and water pump impeller (E). Remove part of the water pump seal behind the impeller. 5. Remove the starter bendix (G), wire holddown plate (H), and the woodruff key (I) from the crankshaft. The stator does not have to be removed at this point. I E 3 G D C H 6. 3. Remove flywheel nut and washer. 4. Install Flywheel Puller (PN 2871043) and remove flywheel (F).
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ENGINE 8. Use a white pen to accent the timing marks on the following gears: camshaft gear (K), crankshaft gear (M), or counterbalance gear (N) This will ensure proper gear alignment and timing during reassembly of the gears. K Water Pump Gear Timing Marks CAUTION Wear safety glasses at all times. Use caution when working with the top gear. The springs could cause injury or become lost should they pop out. 12. Remove all three springs using one of the tapered pins from the Tapered Pins (PU-45497-1).
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ENGINE 14. Inspect the gear teeth and the three tabs on the gears for wear. Inspect Teeth & Tabs To Assemble: • Hold the spring with one finger. • Start the pointed end of the tapered pin into the cam gear hole. Slowly push the dowel through the hole until the end of the dowel is almost flush with the spring. • Perform this procedure with all three tapered pins. • Do not push the pins too far through or the springs will pop out. NOTE: Do not remove the tapered pins at this time. 17.
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ENGINE 19. Once the gears are pressed together, firmly hold the gears together with one hand. Carefully remove the Tapered Pins (PU-45497-1) by pulling them out one at a time with the other hand. 21. To remove the balance shaft gear, the flat side of the camshaft (P) must face the balance shaft gear. To rotate the camshaft, use the Cam Spanner Wrench (PU-45498) to rotate the camshaft so the flat side of the camshaft faces the balance shaft gear. PU-45498 P 20.
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ENGINE 23. Inspect the crankshaft gear (Q) for broken or worn teeth. If the crankshaft gear does not need to be replaced, it does not need to be removed. If the crankshaft gear is damaged, remove the crankshaft gear with the Flywheel Puller (PN 2871043). 26. Rotate the water/oil pump gear (S), so that all four bolts are visible though the gear. Remove the four bolts with a hex wrench. Pull out the pump. S Q 24. Install the two puller bolts (R).
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ENGINE 29. Remove the oil pressure relief. The oil pressure relief consists of a bolt, washer, spring, and valve (dowel). Inspect the valve (dowel) for signs of possible obstructions. Use compressed air to blow out any debris. 31. Carefully press the gear off the assembly while supporting the housing assembly. Press Off Gear CAUTION 30. Reinstall the valve (dowel chamfered end first). Install the spring, washer, and bolt. Torque to specification . 22 ± 2 ft. lbs. (30 ± 3 Nm).
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ENGINE 34. Press shaft into the new bearing.. 37. Remove thrust plate (U). U Press On Bearing 3 35. Press the bearing/shaft assembly using the bearing's outer race. Do not use the shaft to press the assembly into the housing, as bearing damage may result. Install retaining ring. Press Bearing / Shaft Assembly using outer race only 36. Press gear onto shaft while supporting the housing. 38. Remove PTO end engine mount. Remove crankcase bolts. Tap on the reinforced areas on the cases using soft hammer.
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ENGINE 39. Remove and clean oil pick up (V) and oil baffle weldment (W). Camshaft Inspection 1. 2. 3. W Thoroughly clean the cam shaft. Visually inspect each cam lobe for wear, chafing or damage. Measure height of each cam lobe using a micrometer. Compare to specification. V 40. Remove balance shaft and crankshaft. Cam Lobe Height = In. / mm. Cam Lobe Height (Intake & Exhaust): Std: 1.3334" (33.8674 mm) 4. Measure camshaft journal outside diameters (O.D.). 41.
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ENGINE 5. Measure ID of camshaft journal bores. = In. / mm. ENGINE REASSEMBLY Crankcase Reassembly CAUTION Camshaft Journal Bore I.D.: (Mag): 1.656" ± 0.00039" (42.07± 0.010 mm) (Ctr.) 1.637" ± 0.00039" (41.58 ± 0.010 mm) (PTO) 1.617" ± 0.00039" (41.07 ± 0.010 mm) 6. Calculate oil clearance by subtracting journal O.D.s from journal bore I.D.s. Compare to specification. = In. / mm. Calculated Camshaft Oil Clearance: Std: 0.0027" (.070mm) Limit: .0039" (.
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ENGINE NOTE: Always install new balance shaft bearings. 4. 7. Apply assembly lube to cam journals and balance shaft bearing surfaces of the MAG case halve. Install camshaft and balance shaft. Assemble the crankcase halves. Apply LocTite™ 242 (PN 2871949) to the threads and pipe sealant to the bolt flanges. Torque bolts to specification following torque pattern at beginning of this chapter. =T Crankcase Bolt Torque: 22 + 2 ft. lbs. (30 + 3 Nm) Torque in sequence 8.
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ENGINE 10. Lubricate connecting rods with 0W-40 engine oil. 13. Install piston assemblies into cylinder aligning the piston pin holes, to ensure proper alignment of the pistons to the connecting rods upon assembly. Partially install the piston pins into the pistons. 3 11. Install new cylinder gasket on crankcase. Align gasket on the dowel pins for proper gasket alignment.
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ENGINE NOTE: While installing in piston circlips, cover all engine passages. The clip could fall into the engine during installation. 17. Assemble rotors as marked when disassembled. Use a cleaner to remove the marks previously made on the rotors. Line Up Marks 18. Apply assembly lube or oil to the rotors on the oil pump shaft. 16. Install camshaft thrust plate (G) with new bolts. Torque bolts to specification. NOTE: New bolts have patch lock on the threads and do not require Loctite™.
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ENGINE 20. Install oil pump housing bolts (H). The new bolts contain patch lock, so Loctite™ is not needed on the new bolts. Torque bolts to specification and follow the torque sequence at beginning of the chapter. 22. Before installing the crankshaft gear (I), heat the crankshaft gear to 250° F (121° C) on a hot plate (J). J I H 3 NOTE: Occasionally spin the oil pump when installing bolts to check for binding of the rotors. =T Oil Pump Bolt Torque: 84 ± 8 in.lbs. (9.50 ± 0.
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ENGINE 25. Install counter balance shaft gear (J) with new key, aligning timing marks with crankshaft gear (I). Install washer and bolt. Use the Gear Holder (PU-45838). Torque to specification. NOTE: Cam Spanner Wrench (PU-45498) is only needed to rotate the camshaft when the entire valve train is assembled. J PU-45498 I PU-45838 =T Balance Shaft Gear Bolt Torque: 22 ± 2 ft. lbs. (30 ± 3 Nm) 27. Reinstall the camshaft gear; so the timing marks are properly aligned. Install the washer and bolt.
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ENGINE 28. Before installing the gear / stator housing, replace the seals in the cover. Install a new water pump seal (N) into the gear / stator housing. Use the Water Pump Mechanical Seal Installer (PA-44995) to properly install the seal to the correct depth in the cover. NOTE: Install the crankshaft seal (P) with the seal lip facing out (towards the crankcase). P PA-44995 O PA 99 -4 4 3 5 N Seal lip goes towards the crankcase. 30.
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ENGINE 32. Before installing the gear/stator housing cover, install the Water Pump Seal Saver (PA-45401) onto the water pump shaft. PA-45401 35. Install the gear/stator housing gasket onto he crankcase. Gear / Stator Housing Gasket 33. Install a NEW gasket to the gear/stator housing cover and crankcase. With the tools installed, carefully place the gear/stator housing cover over the protection tools. 36. Secure the gear / stator housing cover to the crankcase with the cover bolts.
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ENGINE NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2870585) to remove any debris. This will ensure proper sealing when installing bolts. 39. Install water pump cover (R) with new O-ring seal. Torque bolts to specification in proper sequence (see Page 3.4). Install the O-ring dry, no lubricants 37. Install shaft seal with ceramic surface facing inward. R 3 96 ± 3 in. lbs. (10.85 ± 1.35 Nm) =T 38. Install water pump impeller (P).
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ENGINE Flywheel / Stator Installation =T NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2870585) to remove any debris. This will ensure proper sealing when installing bolts. 1. Install stator assembly (S) and bolts. Torque bolts to specification. 2. Install the wire hold down bracket (T). Install two new wire hold down bolts. New bolts contain patch-lock. Torque bolts to specification, following the proper bolt torque sequence.
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ENGINE 3. Lubricate threads and top of washers underside of bolt head with engine oil. Install head bolts (C) and torque to specification. 5. Lubricate rockers (E) with engine oil. E C 3 6. Verify pushrods are engaged in lifters. 7. Install rockers. Be sure that tab of fulcrum (F) is seated in head stand-off. Torque bolts to specification. =T F Cylinder Head Bolt Torque: Initial setting: 35± 4 ft. lbs. (47.5 ± 5.
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ENGINE 8. Install breather reed (G) into rocker cover (H). Lightly apply black RTV sealant to the outer edges of the breather reed. The reed has a tab and will assemble one-way only. Torque the breather bolts to specification. 11. Install thermostat (J), new O-ring, and thermostat housing. Torque to specification. K 20 ± 5 in.lbs. (2.5 ± .55 Nm) 17 ± 2 ft. lbs. (23 ± 3 Nm) H J I G 84 ± 8 in. lbs. (9.5 ± 0.9 Nm) =T =T Breather Bolt Toque: 20 ± 5 in. lbs. (2.5± 0.
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ENGINE 1. After the engine is completely assembled and ready for installation, the engine must be properly primed with Polaris 0W-40 Synthetic Oil (PN 2871281). Fill the oil filter three-quarters full with Polaris 0W-40 Synthetic Oil (PN 2871281). Let the oil soak into the filter for 8-10 minutes. Install the filter onto the engine. ENGINE INSTALLATION Engine Assembly and Installation Use the following procedure to reinstall the engine assembly.
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ENGINE 2. 3. Lightly tighten all fasteners evenly to eliminate any gaps that may be present in the mounting areas. Torque fasteners to specification using a 2 part sequence. • Install engine / transmission / rear gearcase mounting hardware and torque to specification. • Torque fasteners to half of the specified torque value • Then torque fasteners to the full specified torque value 30 ft. lbs. (41 Nm) 40 ft. lbs. (54 Nm) 17 ft. lbs. (23 Nm) 28 ft. lbs. (38 Nm) 17 ft. lbs.
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ENGINE Engine Break-In Period The break-in period consists of the first 25 hours of operation, or the time it takes to use 14 gallons (53 liters) of fuel. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components. CAUTION 3 Use only Polaris Premium 0-40W All Season synthetic oil or equivalent. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result.
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ENGINE TROUBLESHOOTING Engine Spark Plug Fouling • Spark plug cap loose or faulty • Incorrect spark plug heat range or gap • PVT system calibrated incorrectly/ components worn or mis-adjusted Engine Idles But Will Not Accelerate • Spark plug fouled/weak spark • Broken throttle cable • Obstruction in air intake • Air box removed (reinstall all intake components) • Incorrect ignition timing • Restricted exhaust system • Cam worn excessively • Fuel quality poor (old) or octane too high • Low compression Eng
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ENGINE Excessive Smoke and Carbon Buildup • Excessive piston-to-cylinder clearance • Wet sumping due to over-full crankcase • Worn rings, piston, or cylinder • Worn valve guides or seals • Restricted breather • Air filter dirty or contaminated Low Compression Cooling System Overheating • Low coolant level • Air in cooling system • Wrong type/mix of coolant • Faulty pressure cap or system leaks • Restricted system (mud or debris in radiator fins causing restriction to air flow, passages blocked in radiator
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ELECTRONIC FUEL INJECTION CHAPTER 4 ELECTRONIC FUEL INJECTION GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 SERVICE NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 EFI SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . .
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ELECTRONIC FUEL INJECTION GENERAL INFORMATION WARNING * Gasoline is extremely flammable and explosive under certain conditions. * EFI components are under high pressure. Verify system pressure has been relieved before disassembly. * Never drain the fuel system when the engine is hot. Severe burns may result . * Do not overfill the tank. The tank is at full capacity when the fuel reaches the bottom of the filler neck. Leave room for expansion of fuel.
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ELECTRONIC FUEL INJECTION TPS Tester Regulator - 4010264 Fuel Pressure Gauge Kit - PU-43506-A This tester regulator regulates the 9 volt battery voltage to a 5 volt input, required when using the TPS harness PU-47082. IMPORTANT: The EFI fuel system remains under high pressure, even when the engine is not running. Before attempting to service any part of the fuel system, the pressure must be relieved. The pressure adapter has an integrated relief valve. Connect to the test valve and release the pressure.
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ELECTRONIC FUEL INJECTION Digital Wrench™ Diagnostic Software - PU-47063 Digital Wrench™ - Download Website 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. Located at: www.polaris.diagsys.
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ELECTRONIC FUEL INJECTION Service Notes • For more convenient and accurate testing of EFI components, it is recommended dealers utilize the Digital Wrench™ Diagnostic Software (dealer only), or testing may be done manually using the procedures provided. • 80% of all EFI problems are caused by wiring harness connections.
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ELECTRONIC FUEL INJECTION EFI System Exploded View 1. Electronic Control Unit (ECU) 2. Intake Air Temperature / Manifold Air Pressure Sensor (T-BAP) 3. Crankshaft Position Sensor (CPS) 4. Fuel Injectors 5. Fuel Filter 6. Fuel Pump / Regulator / Gauge Sender Asm. (Located in tank as an assembly) 7. Fuel Rail 8. Engine Coolant Sensor (ECT) 9. Throttle Position Sensor (TPS) 10. Throttle Body 11. Ignition Coil 12. Spark Plugs 1 11 6 5 8 7 4 10 12 9 2 3 4.
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ELECTRONIC FUEL INJECTION EFI System Component Locations 1. 4. Electronic Control Unit (ECU) - Located behind the driver’s seat next to the seat belt assembly and just above the voltage regulator. Fuel Injectors / Fuel Rail - Attached to the fuel rail located in the intake track of the cylinder head. Fuel Injectors ECU 4 Fuel Rail 5. 2. Temperature and Barometric Air Pressure Sensor (T-BAP) - Located in the rubber intake boot between the air box and throttle body.
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ELECTRONIC FUEL INJECTION 6. Throttle Body - Located between the rubber air box boot and the rubber cylinder head adaptor. 9. Ignition Coil - Located behind the driver’s seat and rear service panel just above the PVT cover. Ignition Coil Throttle Body 7. Throttle Position Sensor (TPS) - Located on the right-hand side of the throttle body. TPS 8. Engine Coolant Temperature Sensor (ECT) - Located in the cylinder head next to the thermostat housing.
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ELECTRONIC FUEL INJECTION FUEL TANK Exploded View Screw Screw Rear Tank Bracket Front Tank Bracket Hi-Temp Flex Conduit Quick Connect Fuel Line 4 Fuel Pump Asm Pad Pad Cap Gasket Fuel Tank Fuel Flow Fuel Rail Fuel Injectors Fuel Tank Pressure Regulator Fuel Filters Fuel Pump Assembly Quick Connect Fuel Line 4.
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ELECTRONIC FUEL INJECTION Fuel Lines - Quick Connect ELECTRONIC FUEL INJECTION RANGER EFI models use quick connect fuel lines. Refer to the steps below for fuel line removal. Principal Components 1. The Electronic Fuel Injection (EFI) system is a complete engine fuel and ignition management design. This system includes the following principal components: Place a shop towel around the fuel line to catch any dripping fuel. Squeeze the connector tabs together and push the locking slide back.
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ELECTRONIC FUEL INJECTION The ECU controls the amount of fuel being injected and the ignition timing by monitoring the primary sensor signals for air temperature, barometric air pressure, engine temperature, speed (RPM), and throttle position (load). These primary signals are compared to the programming in the ECU computer chip, and the ECU adjusts the fuel delivery and ignition timing to match the values.
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ELECTRONIC FUEL INJECTION RANGER RZR 800 EFI RPM Limit: Hard Limit - Injector suppression occurs • High: 6500 TEMPERATURE AND BAROMETRIC AIR PRESSURE SENSOR (T-BAP) Operation Overview • Low: 6500 Mounted in the throttle body intake boot, the T-BAP sensor performs two functions in one unit. • Neutral: 6500 • Reverse: 6500 • Park: 6500 Soft Limit - Timing suppression occurs • High: 6375 • Low: 6375 • Neutral: 6375 • Reverse: 6375 • Park: 6375 ECU Service Never attempt to disassemble the ECU.
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ELECTRONIC FUEL INJECTION 3. Install new sensor using a light coating of oil on the o-ring to aid installation. Bolt T-BAP Intake Boot The two-tooth gap creates an “interrupt” input signal, corresponding to specific crankshaft position for PTO cylinder. This signal serves as a reference for the control of ignition timing by the ECU. Synchronization of the CPS and crankshaft position takes place during the first two revolutions each time the engine is started.
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ELECTRONIC FUEL INJECTION 3. 4. If the resistance is correct. - Test the main harness circuit between the sensor connector terminals and the corresponding pin terminals at the ECU (see wiring diagram). - Check the sensor mounting, air gap, flywheel ring gear for damage or runout, and flywheel key. Follow the “CPS Replacement” procedure to inspect CPS and flywheel ring gear for damage. 4. Remove the (3) bolts retaining the front portion of the mounting bracket to the transmission.
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ELECTRONIC FUEL INJECTION 8. Lift the mounting bracket straight up and out from the vehicle. Remove Bracket Installation IMPORTANT: When reinstalling the transmission to rear gearcase mount bracket, it is extremely important to torque all (7) fasteners to specification. Refer to the following procedure. NOTE: Special tool (PA-48873) will be required to torque the mounting bracket fasteners when the transmission and rear gearcase are installed in the vehicle. Special Tool PA-48873 4 9.
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ELECTRONIC FUEL INJECTION 4. Using special tool (PA-48873), torque the (3) bolts that retain the front portion of the mounting bracket to the transmission. 5. Remove the special tool and attach an extension to the torque wrench. Torque the bottom bolt that attaches the bracket to the rear gearcase through the hole in the frame support. Upper Transmission Bolt Bottom Rear Gearcase Bolt NOTE: Special Tool is not required for this torque. Torque with an extension Middle Transmission Bolt 6.
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ELECTRONIC FUEL INJECTION Upper Rear Gearcase Bolt 7. 4 Torque the remaining bolt that attaches the bracket to the front side of the rear gearcase. Front Rear Gearcase Bolt NOTE: A multi-directional torque wrench is required in this application because of the limited access to this bolt. Check with the manufacturer of your torque wrench to see if it can be used to tighten lefthand threaded bolts. 4.
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ELECTRONIC FUEL INJECTION FUEL INJECTORS Operation Overview NOTE: All EFI units utilize quick connect fuel lines. The fuel injectors mount into the cylinder head, and the fuel rail attaches to them at the top end. Replaceable O-rings on both ends of the injector prevent external fuel leaks and also insulate it from heat and vibration. Fuel Injectors • When temperatures prohibit touching, listen for a buzzing or clicking sound with a screwdriver or mechanic's stethoscope.
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ELECTRONIC FUEL INJECTION Fuel Injector Test Fuel Injector Replacement NOTE: The Bosch harness connector and locking spring is bonded to the fuel injectors with an epoxy mix. DO NOT attempt to disconnect the Bosch connector from the fuel injectors. Damage will occur to the injector and/or harness if attempting to separate at that location. Separate the fuel injector from the vehicle by disconnecting at the end of the harness as shown in this procedure. 1. Be sure the engine has cooled enough to work on.
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ELECTRONIC FUEL INJECTION 6. Disconnect the harness for the fuel injector(s) located next to the ignition coil. Cut the plastic tie strap and push the harness for the fuel injector(s) up over the air box to allow fuel injector removal. 8. Fuel Injector Harnesses Using a 6mm hex wrench, loosen the fuel rail mounting screw from the cylinder head. Carefully pull the rail away from the injectors and remove the injector(s) from the cylinder head along with the harness.
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ELECTRONIC FUEL INJECTION FUEL PUMP • If the engine is stopped with the key switch "on" (as in the case of an accident). Operation Overview NOTE: All EFI units utilize quick connect lines. An electric fuel pump assembly is used to transfer fuel to the EFI system from inside the fuel tank. This assembly includes the fuel pump, fuel filters, regulator and fuel gauge sender. The pump is rated for a minimum output of 25 liters per hour at 39 psi and has two non-serviceable fuel filters.
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ELECTRONIC FUEL INJECTION 1. Remove the cap from the fuel test valve. 4. If the pump did not activate (Step 3), disconnect the harness connector from the fuel pump. Connect a DC voltmeter across terminals “A” and “C” in the plug on the vehicle harness side. Turn on the key switch and observe voltage to ensure a minimum of 7 volts is present. Disconnect and Test Here Test Valve 2. Pin “C” Brown Connect the pressure hose of the Polaris pressure tester (PU-43506-A) to the test valve on the fuel rail.
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ELECTRONIC FUEL INJECTION Fuel Tank / Fuel Pump Replacement 5. IMPORTANT: Syphon as much fuel from the tank as possible before attempting to remove it from the vehicle. Disconnect the fuel pump electrical harness. Disconnect Here WARNING Always wear safety goggles when working with high pressure or flammable fluids. Failure to do so could result in serious injury or complications. NOTE: The fuel pump assembly may be a serviceable item on some vehicles.
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ELECTRONIC FUEL INJECTION 8. Remove the (2) fasteners from the rear seat base and remove the assembly from the vehicle. 11. Remove the (3) Torx fasteners from the rear RH fender well and remove the fender well from the vehicle. 9. Remove the (11) push rivets and (4) Torx screws retaining the RH rocker panel and remove panel from the vehicle. NOTE: Lift fender well up over the fuel tank filler neck and out from the vehicle.
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ELECTRONIC FUEL INJECTION Fuel Pump Removal / Installation Fuel Tank Installation 1. 1. Carefully reinstall the fuel tank assembly. 2. Reinstall the (2) tank brackets and fasteners. 3. Reinstall the rear RH fender well and secure with fasteners. 4. Reinstall the seat belt mechanism and secure the lower bolt. 5. Reinstall the RH rocker panel and all (15) fasteners. 6. Reinstall the rear seat base and secure with the (2) fasteners. 7.
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ELECTRONIC FUEL INJECTION THROTTLE POSITION SENSOR (TPS) Operation Overview Set up the TPS Tester (PU-47082), according to the instructions that accompanied the tester. Make sure that the 9 volt battery is new. 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 4. A 5 volt reference voltage from the harness is required for the TPS test to be accurate. Refer to the instructions provided with the TPS Test Adapter Harness (PU-47082) or follow the bullet point steps to check reference voltage. Move the throttle open and closed slowly while reading the display. The voltage should increase and decrease smoothly with no “jumps” when the throttle is applied.
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ELECTRONIC FUEL INJECTION TPS Initialization 6. NOTE: The correct TPS position is established and set at the factory. Use this procedure only if the TPS was repositioned, replaced or loosened. Back out air flow screw until it no longer is in contact with throttle plate cam. The throttle plate should seal off throttle bore completely. Back Air Flow Screw Out Until No Contact is Made STEP 1 Establishing zero offset voltage: This step is crucial as it sets the TPS position using a fixed physical stop.
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ELECTRONIC FUEL INJECTION 12. If it does not read .528 ± .01 volts, loosen the screw holding the TPS to the throttle body. Rotate TPS until voltmeter reads .528 ± .01 volts. 13. Retighten TPS mounting screw, and verify the voltage did not change. If changed, repeat the previous steps. STEP 2 Establishing correct flow: Now that the zero offset voltage has been set, you can now set the throttle body to the correct air flow value. 1.
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ELECTRONIC FUEL INJECTION ENGINE COOLANT TEMPERATURE SENSOR (ECT) ECT Sensor Test Operation Overview Mounted on the cylinder head, the engine temperature sensor measures coolant temperature. The engine temperature sensor is a Negative Temperature Coefficient (NTC) type sensor, as the temperature increases the resistance decreases. ECT Engine Temperature Sensor To quickly rule out other components and wiring related to the ETS, disconnect the harness from the ETS.
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ELECTRONIC FUEL INJECTION IGNITION COIL Primary Test Operation Overview Measure Between Connector Pins 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. During engine rotation, an AC pulse is created within the crankshaft position sensor for each passing tooth on the flywheel.
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ELECTRONIC FUEL INJECTION GENERAL TROUBLESHOOTING 3. Any “blink codes” stored in the ECU will display a numerical “blink code”, one at a time, in numerical order, on the instrument cluster display. 4. The word “End” and/or the number “61” will display after all of the codes have been displayed or if no codes are present. Diagnostic “Blink Codes” NOTE: The EFI diagnostic mode is intended to quickly view the cause of the “Check Engine” light. To recall blink codes (fail codes) from the ECU: 1.
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ELECTRONIC FUEL INJECTION EFI Troubleshooting Poor Idle Fuel Starvation / Lean Mixture Symptom: Idle Too High (If greater than 1300 RPM when engine is warm) Symptoms: Hard start or no start, bog, backfire, popping through intake / exhaust, hesitation, detonation, low power, spark plug erosion, engine runs hot, surging, high idle, idle speed erratic.
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ELECTRONIC FUEL INJECTION EFI SYSTEM BREAKOUT DIAGRAMS Diagnostic Connector Circuit Malfunction Indicator Lamp (MIL) Circuit 4.
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ELECTRONIC FUEL INJECTION Fuel Injector (PTO) Circuit 4 Fuel Injector (MAG) Circuit 4.
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ELECTRONIC FUEL INJECTION Engine Coolant Temperature Sensor (ECT) Circuit Engine Overheat Lamp Driver Circuit 4.
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ELECTRONIC FUEL INJECTION Crankshaft Position Sensor (CPS) Circuit 4 Air Temperature and Barometric Air Pressure Sensor (T-BAP) Circuit 4.
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ELECTRONIC FUEL INJECTION Throttle Position Sensor (TPS) Circuit Fuel Pump Circuit 4.
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BODY / STEERING / SUSPENSION CHAPTER 5 BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 MULTI-FUNCTION PLIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2 CAB FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS ITEM TORQUE VALUE ft.lbs. (Nm) Front LH / RH Upper A-Arm Bolt 37 ft. lbs. (50 Nm) Front LH / RH Lower A-Arm Bolt 37 ft. lbs. (50 Nm) Rear LH / RH Upper Control Arm Bolt 37 ft. lbs. (50 Nm) Rear LH / RH Lower Control Arm Bolts 37 ft. lbs. (50 Nm) Lower LH / RH Rear Bearing Carrier 37 ft. lbs. (50 Nm) Upper LH / RH Rear Bearing Carrier 37 ft. lbs. (50 Nm) Outer Tie Rod to Bearing Housing 42.5 ft. lbs.
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BODY / STEERING / SUSPENSION CAB FRAME Assembly / Removal NOTE: Finger tighten all components until cab frame is completely assembled on vehicle, then tighten to specifications listed. 1. Assemble the rear cab frame and the front cab frame at the coupler joints and secure with four (3/8-16 x 1 1/4) screws and (3/8-16 Nyloc) nuts. Tighten screws to 25-28 ft. lbs. (34-38 Nm). 2. Place the assembled cab frame onto the vehicle and align the rear mount holes.
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BODY / STEERING / SUSPENSION BODY EXPLODED VIEWS Dash Instruments / Controls A. Instrument Cluster (Speedo) B. Headlight Switch C. 2WD/AWD Switch D. 12 Volt Accessory Receptacle E. Speedometer “Mode” Button F. Key Switch G. Work Light Switch A E G D C B F 5.
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BODY / STEERING / SUSPENSION Front Bumper T30 Screws Front Bumper Support Front Bumper Torx Screw Radiator Screen Washer O-Ring T25 Screw T27 Screw T27 Screw 5 Headlight Winch Pocket Cover T25 Screws Rear Bumper LH Tail/Work Light T27 Screw RH Tail/Work Light Speed Nuts T25 Screws Rear Bumper T27 Screws 5.
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BODY / STEERING / SUSPENSION Hood / Front Body Work Center Hood Panel Push Rivets Front LH Fender Flair Pin Grommet Grommet Push Rivets Hood / Dash T27 Screws Push Rivets Push Rivets Front RH Fender Flair Reflector Front Bumper Winch Pocket Cover 5.
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BODY / STEERING / SUSPENSION Seat Assembly Seat Back Seat Hoop Tube 48 in. lbs. (5.4 Nm) Seat Bottom Latch Body Nuts Lever 5 Seat Base Asm. Spring Plate Cap 41-57 in. lbs. (4.6-6.4 Nm) 41-57 in. lbs. (4.6-6.4 Nm) Grommets Seat Belts / Mounting Driver Seat Passenger Seat 3 Point Seat Belt 35 ft. lbs. (47 Nm) 35 ft. lbs. (47 Nm) 3 Point Seat Belt 3 Point Seat Belt 35 ft. lbs. (47 Nm) Latch Plunger 35 ft. lbs. (47 Nm) 35 ft. lbs. (47 Nm) Rear Seat Base 5.
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BODY / STEERING / SUSPENSION Floor / Rocker Panels Self-Tapping Screw Plastic Dart LH Rocker Rear Support Bracket Push Rivets Console Cover Self-Tapping Screws Rear Support Bracket Self-Tapping Screw Cup Holder Front Support Bracket Plastic Dart T27 Screw Self-Tapping Screw U-Type Nuts Push Rivets Torx Screws Front Support Bracket Plastic Dart T27 Screw RH Rocker Self-Tapping Screws 5.
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BODY / STEERING / SUSPENSION Rear Cargo Box / Fenders Tie Down Bracket Rear LH Fender Flair Push Rivets Rear LH Fender Tie Down Bracket Torx Screw & Nut Rear Cargo Box Torx Screw & Nut T25 Screws Torx Screws T27 Screws 5 Rear LH Panel Divider Rear RH Fender Rear RH Fender Flair Pin Grommet Push Rivets T25 Screws Rear Main Service Panel Bolts Rear RH Panel Divider Sound Foam Heat Shield T27 Screws Cargo Box Supports 5.
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BODY / STEERING / SUSPENSION Chassis / Main Frame 15 ft. lbs. (20 Nm) Bolt-In Brace Rear Bumper Support Main Frame 15 ft. lbs. (20 Nm) 17 ft. lbs. (23 Nm) Hitch 30 ft. lbs. (41 Nm) Skid Plate 6-8 ft. lbs. (8-11 Nm) 5.
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BODY / STEERING / SUSPENSION BODY COMPONENT REMOVAL Front Bumper Seats 1. 1. Remove the (4) push rivets from the sides of the front bumper. To remove the driver or passenger seat, lift upward on the latch lever located behind the seat bottom. Latch Lever Push Rivets 2. Lift upward and forward on the seat while lifting up on the latch lever and remove the seat from the vehicle. Torx Screws 2. Remove the (6) Torx screws retaining the upper, middle and lower portion of the bumper. 3.
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BODY / STEERING / SUSPENSION Hood and Front Body Work 4. Remove the (8) push rivets that attach the dash assembly to the rocker panels on each side. 5. Remove the (2) Torx screws and (2) push rivets that retain the front and rear portions of the dash assembly and remove the dash assembly from the vehicle. Hood Removal 1. To remove the hood, lift up on the rear portion of the hood to disengage the pins from the grommets. Lift Up HERE Push Rivets 2.
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BODY / STEERING / SUSPENSION Rocker Panels, Console and Floor Rear Fender, Flair and Tie Down Removal Rocker Panel Removal 1. Remove the rear bumper (see “BODY COMPONENT REMOVAL - Rear Bumper”). 2. Remove the (8) push rivets that retain the rear portion of the rocker panels to the rear fenders. 3. Remove the (3) push rivets and remove the fender flair from the rear fender. 4. Remove the (3) Torx screws from the bottom side of the fender and the upper push rivet from the top side.
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BODY / STEERING / SUSPENSION STEERING ASSEMBLY Exploded View Cap Steering Wheel 15-19 ft. lbs. (20-26 Nm) 25-31 ft. lbs. (34-42 Nm) Wave Washers Upper Steering Shaft 23 ft. lbs. (31 Nm) Bushing Lower Steering Shaft Pivot Tube 42.5 ft. lbs. (58 Nm) Bushing Bushing 7 ft. lbs. (10 Nm) Bushing 27-33 ft. lbs. (37-45 Nm) 12 ft. lbs. (16 Nm) 23 ft. lbs. (31 Nm) Bushing LH Boot Gear Box Asm. Oil Locking Shock Asm. 12-14 ft. lbs. (16-19 Nm) RH Boot 42.5 ft. lbs. (58 Nm) Boot 17 ft. lbs.
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BODY / STEERING / SUSPENSION WHEEL HUBS Front Hub Exploded View Sealed Ball Bearing Stud Bolts Wheel Hub Cone Washers Cotter Pin Bearing Carrier Castle Nut Retaining Ring 80 ft. lbs. (108 Nm) Brake Disc Front Rim 5 Front Tire Flanged Nuts 27 ft. lbs. (37 Nm) Valve Rear Hub Exploded View Stud Sealed Ball Bearing Bolts Wheel Hub Cotter Pin Cone Washers Bearing Carrier Castle Nut 80 ft. lbs. (108 Nm) Retaining Ring Brake Disc Front Rim Front Tire Flanged Nuts 27 ft. lbs. (37 Nm) Valve 5.
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BODY / STEERING / SUSPENSION FRONT A-ARMS Removal / Replacement The following procedure details upper and lower A-arm removal and replacement on one side of the vehicle. 1. 2. 3. 4. Elevate and safely support the front of the vehicle and remove the front wheel. Remove the lower shock fastener (A) from the upper Aarm. Remove the upper ball joint pinch bolt (B) from the front bearing carrier.
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BODY / STEERING / SUSPENSION BALL JOINT SERVICE Exploded View 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. 37 ft. lbs. (50 Nm) Pivot Tube Upper A-arm 1. The A-arm must be removed to perform this procedure (see “FRONT A-ARMS - Removal / Replacement”). Ball Joint Ball Joint Grease Zerk Bushings 37 ft. lbs.
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BODY / STEERING / SUSPENSION 4. Use a press and correct size driver to remove the ball joint from the A-arm. Installation 1. Correct Driver Placement Place the A-arm in the correct position for ball joint installation. Face the A-arm end flat on top of the driver. Carefully drive the ball joint into place until the ball joint is properly seated. Press into the A-arm in this direction The driver must fit the inside diameter of the A-arm end.
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BODY / STEERING / SUSPENSION FRONT STABILIZER BAR 4. Remove the (2) upper radiator retaining bolts. 5. Remove the (4) bolts retaining the lower radiator mount bracket and remove the bracket from the frame. Sway Bar Linkage Removal 1. Elevate and safely support the front of the vehicle off the ground. 2. Remove the lower shock mounting fasteners and spacers from both upper A-arms on each side of the vehicle (see “Exploded View” on page 5.20). 3.
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BODY / STEERING / SUSPENSION 8. Remove the (4) bolts retaining the upper radiator mount bracket and remove the bracket from the frame. Exploded View Main Frame T30 Screws Grease Zerk Clamp Stabilizer Bar Clamp Mount Bracket Bushings Nuts 9. Lift up on the stabilizer bar and remove it from the vehicle. Spacer 10. Inspect the stabilizer bar for straightness. Inspect the bushings and replace if needed. 11. Reverse the procedure for installation. Torque the linkage fasteners to 27-33 ft. lbs.
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BODY / STEERING / SUSPENSION REAR A-ARMS WARNING Removal 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. The following procedure details upper and lower A-arm removal and replacement on one side of the vehicle. Repeat the following steps to remove the A-arm(s) from the opposite side. NOTE: Use the exploded view in this section as a reference during the procedure (see page 5.
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BODY / STEERING / SUSPENSION 11. Remove the (2) fasteners (E) attaching the lower A-arm to the frame and remove the lower A-arm from the vehicle (see previous illustration). Exploded View 12. Examine A-arm and bearing carrier bushings and pivot tubes (see “Exploded View”). Replace if worn. Discard hardware. 13. If not replacing the A-arm, thoroughly clean the a-arm and pivot tubes. 37 ft. lbs. (50 Nm) Pivot Tube Upper A-arm 14. Insert new A-arm bushings and pivot tubes into the new A-arm.
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BODY / STEERING / SUSPENSION REAR STABILIZER BAR 4. Remove the stabilizer bar and bracket from the frame as an assembly. Removal / Installation 1. Remove the exhaust pipe and exhaust silencer from the vehicle. Bushings Remove Fasteners NOTE: The exhaust silencer can be removed through the side of the vehicle after the exhaust pipe is detached from the header pipe. 2. Remove the retaining nut from the upper portion of the stabilizer bar linkage bushing on each side of the vehicle. 5.
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BODY / STEERING / SUSPENSION SHOCKS / SPRINGS DECAL REPLACEMENT Exploded View WARNING Spring 27-33 ft. lbs. (37-45 Nm) The following procedure involves the use of an open flame. Perform this procedure in a well ventilated area, away from gasoline or other flammable materials. Be sure the area to be flame treated is clean and free of gasoline or flammable residue. Spring Retainer WARNING Shock Do not flame treat components that are installed on the vehicle.
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CLUTCHING CHAPTER 6 CLUTCHING SPECIAL TOOLS AND SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 PVT SYSTEM FASTENER TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 PVT SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 GENERAL OPERATION.
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CLUTCHING SPECIAL TOOLS AND SUPPLIES PVT SYSTEM OVERVIEW General Operation TOOL DESCRIPTION PART NUMBER Drive Clutch Puller (Short) PA-48595 Clutch Holding Wrench 9314177 Clutch Holding Fixture 2871358 Spider Nut Socket 2870338 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 L
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CLUTCHING Driven Clutch Operation Maintenance / Inspection Driven clutches primarily sense torque, opening and closing according to the forces applied to it from the drive belt and the transmission input shaft. If the torque resistance at the transmission input shaft is greater than the load from the drive belt, the drive belt is kept at the outer diameter of the driven clutch sheaves. Under normal use the PVT system will provide years of trouble free operation.
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CLUTCHING Overheating / Diagnosis During routine maintenance, or whenever PVT system overheating is evident, it’s important to check the inlet and outlet ducting for obstructions. Obstructions to air flow through the ducts will significantly increase PVT system operating temperatures. The vehicle should be operated in Low when plowing or pulling heavy loads, or if extended low speed operation is anticipated.
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CLUTCHING PVT SYSTEM SERVICE PVT Sealing and Ducting Components Clutch Outlet Duct Clutch Inlet Duct Inner Clutch Cover Push Rivets Boot Clamps Boot Clamps Bolt/Washer Cover Screws Retainer Screws Outer Cover Seal Disassembly Outer Clutch Cover 6. Some fasteners and procedures will vary. Refer to the appropriate parts manual for proper fasteners and fastener placement. 1. Remove driver and passenger seats (see Chapter 5). 2.
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CLUTCHING 8. Remove driven clutch offset spacers from the transmission input shaft. Assembly 1. Inspect inner clutch cover-to-engine seal. Replace if cracked or damaged. 2. Place a new foam seal on transmission input shaft. 3. Apply RTV silicone sealant to outside edge of inner clutch cover-to-engine seal, to ensure a water tight fit between the seal and the cover. Surfaces must be clean to ensure adhesion of silicone sealant. Keep Spacers In Order (Note Thickness) Retaining Bolt 9.
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CLUTCHING 8. Clean splines inside driven clutch and on the transmission input shaft. 9. Apply a light film of grease to the splines on the shaft. DRIVE BELT Belt Removal 1. Remove outer clutch cover as described in PVT Disassembly. 2. Mark the drive belt direction of rotation so that it can be installed in the same direction. 10. Install the driven clutch, washer, lock washer, and retaining bolt. Torque to specification. 11. Clean end of taper on crankshaft and the taper bore inside drive clutch.
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CLUTCHING Belt Inspection Belt Installation NOTE: Be sure to position belt in the same position as when removed or so part number is easily read. 1. Loop belt over the drive clutch and over top of the driven sheave. 2. While pushing down on top of belt, turn the back, or moveable driven sheave, clockwise. 3. The belt then should be able to be pushed down into and between the sheaves. Projected Belt Width Belt Width New: 1.188” (3.02 cm) Wear Limit: 1.157 (2.94 cm) 1.
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CLUTCHING DRIVE CLUTCH SERVICE Spring Specifications The drive clutch spring has two primary functions: 1. 2. To control clutch engagement RPM. The springs which have a higher rate when the clutch is in neutral will increase clutch engagement RPM. To control the rate at which the drive belt moves upward in the drive clutch sheaves. This is referred to as drive clutch upshift. There are other components which control upshift, but the spring is one of the primary components in insuring optimum performance.
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CLUTCHING Shift Weights Shown below are the shift weights which have been designed for the PVT system. These shift weights have many factors designed into them for controlling engagement RPM and shifting patterns. Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to sheave clearance, clutch balance and shifting pattern. 6.
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CLUTCHING Exploded View Bushing Lock Washer Spring Limiter Spider Cover Bearing Bolt Bearing Non-Braking Bearing Spacer Button Roller Button Cover Screws Flat Washer Pin Washers Nut Bolt Washers 6 Shift Weight 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. 3. Inspect cover bushing (A).
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CLUTCHING 4. 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 5. Remove and inspect the clutch spring. See “Drive Clutch Spring Specifications” for spring inspection.
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CLUTCHING 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 2. Remove shift weight bolts and weights. Inspect as shown. The contact surface of the weight should be smooth and free of dents or gall marks. Inspect the weight pivot bore and pivot bolts for wear or galling. If weights or bolts are worn or broken, replace in sets of three with new bolts. Clutch Inspection NOTE: Remove cover, spring, and spider following instructions for drive clutch removal, then proceed as follows: 1. Remove the moveable sheave spacer sleeve (1) and the thrust washer (2).
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CLUTCHING 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 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 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. 11.
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CLUTCHING 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 spider to specification using the holding fixture and spider tool. Torque with smooth motion to avoid damage to the stationary sheave. =T Spider Torque: 200 ft. lbs. (271 Nm) CAUTION Do not apply oil or grease to the bushings. CAUTION Reassemble the drive clutch in the following sequence.
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CLUTCHING 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. Do not disassemble from this side 2. It is important to mark the position of the shaft, cam cover, and sheave before disassembly or use the X’s on the components for reference.
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CLUTCHING 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 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 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 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. 6 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 6.
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CLUTCHING 6. 7. 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. 9. Install the spring over the shaft. Flat Side Down 10. Install the clutch rollers (D) onto each side of the outside spider. Install the washers (E) and E-clips (F) to secure the rollers. The rollers should spin freely. Install the spring pins (C) to secure the roller pins. Install until flush with sheave surface. 11.
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CLUTCHING 13. 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 A 15. 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 Exploded View T25 Screws E-Ring Thrust Washer Roller Spider Dampener Compression Spring Cam (Helix) Retaining Ring Thrust Washer Outer Spider Moveable Sheave Roller Pin Spider Insert Clutch Shaft Slotted Spring Pin Retaining Ring Stationary Sheave 6.
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CLUTCHING TROUBLESHOOTING Situation Engine RPM below specified operating range, although engine is properly tuned. Probable Cause -Wrong or broken drive clutch spring. Remedy -Replace with recommended spring. -Drive clutch shift weight too heavy. -Install correct shift weight kit to match engine application. -Driven clutch spring broken or installed in wrong -Replace spring; refer to proper installation location. helix location. -Drive clutch binding. A.
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CLUTCHING Troubleshooting, Continued..... Situation Probable Cause -Plugged air intake or outlet. Remedy -Clear obstruction -Belt slippage due to water, oil, grease, etc., rubbing -Inspect system. Clean , repair or replace as necessary. Seal PVT system ducts. on cover. PVT cover -Clutches or weight being applied to cover while in -Remove weight. Inform operator. overheating (melting) operation. -High vs. low range.
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FINAL DRIVE CHAPTER 7 FINAL DRIVE SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 FRONT BEARING CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.
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FINAL DRIVE SPECIAL TOOLS PART NUMBER TOOL DESCRIPTION 2872608 Roller Pin Removal Tool 8700226 CV Boot Clamp Pliers (earless type) 2. Check bearings for side play by grasping the top and bottom of the tire firmly and checking for movement. The tire should rotate smoothly without binding or rough spots. 3. Remove the (4) wheel nuts and remove the front wheel. 4. Remove the cotter pin and loosen the front wheel hub castle nut. Remove the nut, and (2) cone washers from the front wheel hub assembly.
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FINAL DRIVE 6. 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. Remove 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.
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FINAL DRIVE Bearing Installation 3. 5. Thoroughly clean the front bearing carrier housing and the outer race on the new bearing. Be sure that all oil residue has been removed from each surface. 6. Support the bottom of the bearing carrier housing. CAUTION 17 ft. lbs. 23 (Nm) Use an arbor and press only on the outer race, otherwise bearing damage may occur. 7. Install pinch bolts and torque to 17 ft. lbs. (23 Nm).
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FINAL DRIVE =T Torque wheel hub nut to 80 ft. lbs. (108 Nm) and install a NEW cotter pin. Tighten nut slightly if necessary to align cotter pin holes. Front Caliper Mounting Bolt Torque: 30 ft. lbs. (40 Nm) 80 ft. lbs. (108 Nm) CAUTION New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly. 7. Install the steering tie rod end onto the front bearing carrier and torque fastener to 42.5 ft. lbs. (58 Nm). NEW Cotter Pin 42.
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FINAL DRIVE FRONT DRIVE SHAFT 6. Drive Shaft Removal 1. Remove the upper ball joint pinch bolt. Pinch Bolt Elevate front of vehicle and safely support machine under the frame area. CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure. Wear eye protection when removing bearings and seals. 2. Remove the (4) wheel nuts and remove the front wheel. 3. Remove the cotter pin and loosen the front wheel hub castle nut.
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FINAL DRIVE Drive Shaft / CV Joint Handling Tips 4. Care should be exercised during drive shaft removal or when servicing CV joints. Drive shaft components are precision parts. It may be necessary to tap the CV joint assembly outward with a soft faced hammer. Retaining Ring Cleanliness and following these instructions is very important to ensure proper shaft function and a normal service life.
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FINAL DRIVE 9. Add grease through large end of boot. 10. Position large end of boot on CV joint, purge excess air by partially compressing axle into CV bell. Lift one edge of boot to let out excess air. Secure the CV boot with clamp. Drive Shaft Installation 1. Install new spring ring on drive shaft. Apply an anti-seize compound to splines. NEW Spring Ring FRONT DRIVE SHAFT Joint Capacity** 45 Grams Plunging Joint Apply Anti-Seize 2.
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FINAL DRIVE 5. Install the upper pinch bolt and torque to 17 ft. lbs. (23 Nm). =T 17 ft. lbs. (23 Nm) Wheel Hub Castle Nut Torque: 80 ft. lbs. (108 Nm) Install brake caliper mounting bolts and torque to 30 ft. lbs. (40 Nm). 30 ft. lbs. (40 Nm) =T Pinch Bolt Torque: 17 ft. lbs. (23 Nm) 6. Apply grease to drive shaft axle splines. 7. Install front wheel hub assembly, cone washers, and hand tighten the castle nut. Install washers with domed side out.
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FINAL DRIVE PROPSHAFT SERVICE 6. Remove the fasteners retaining the plastic skid plate and remove the skid plate from the vehicle. Removal / Installation 1. Locate the propshaft roll pin and use the Roll Pin Removal Tool (PN 2872608), to remove the roll pin. NOTE: Front wheel can be removed to gain better access to the propshaft roll pin. Cupped Washers Screws Roll Pin Removal Tool (PN 2872608) 7. Remove the propshaft from the vehicle. 8. Reverse removal steps to reinstall propshaft.
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FINAL DRIVE 2. Support inner yoke as shown and drive outer yoke down (bearing cap out) with a soft face hammer. 3. Support U-joint in vise as shown and drive inner yoke down to remove remaining bearing caps. 2. Tighten vise to force bearing caps in. 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. 7 4. Force U-joint cross to one side and lift out of inner yoke. 4.
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FINAL DRIVE FRONT GEARCASE / CENTRALIZED HILLIARD Centralized Hilliard Exploded View 9 5 7 5 2 8 6 4 3 10 1 7-11 ft. lbs. (10-15 Nm) REF# DESCRIPTION QTY REF# DESCRIPTION QTY 1 Cover Screws 6 6 Roll Cage Assembly with H-Springs 1 2 Cover Plate Assembly 1 7 Rollers 20 3 Thrust Plate 1 8 Clutch Housing / Ring Gear 1 4 Armature Plate 1 9 Gearcase Housing 1 5 Output Hub Assembly 2 10 Wire Harness Retainer 1 7.
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FINAL DRIVE All Wheel Drive Operation Front Gearcase Engagement: The AWD switch may be turned on or off while the vehicle is moving. Initially, the vehicle’s electronic system will not enable the AWD until the engine RPM is below 3100. Once enabled, AWD will remain engaged until the rear wheels regain traction and the propshaft speed matches the front axle speed . 4x4 Engagement: When the AWD switch is turned on, a 12 Vdc current charges the hub coil and creates a magnetic field.
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FINAL DRIVE AWD Diagnosis 5. Symptom: AWD Will Not Engage 1. Check the gearcase coil resistance. To test the coil resistance, measure between the Grey and Brown/White wires. The measurement should be within specification. Check to make sure the coil is seated in the U-shaped insert that is pressed into the gearcase cover. The top of the coil should be seated below the U-shaped insert. The U-shaped insert controls the pole gap.
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FINAL DRIVE Gearcase Removal 7. 1. Stop engine and place gear selector in Park. 2. Refer to “FRONT DRIVE SHAFT - Drive Shaft Removal” and remove both front drive shafts from the front gearcase. 3. Remove the propshaft (see “PROPSHAFT SERVICE”). 4. Disconnect the wire harness above the front gearcase and remove the harness from the retaining dart. Remove the gearcase from the front LH wheel well area and slide it between the upper and lower A-arm. AWD Harness Gearcase Disassembly / Inspection 1.
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FINAL DRIVE NOTE: The backlash for the centralized hilliard is set at the factory. No adjustment is required unless the cover plate assembly is replaced, or the backlash adjustment screw is removed. See the "Backlash Adjustment” procedure later in this chapter for details on backlash setting. 5. 8. Remove the (4) screws retaining the pinion shaft assembly and remove the assembly from the gearcase housing. Inspect and clean the gearcase housing and replace the seal.
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FINAL DRIVE 12. Remove the roll cage assembly and rollers from the clutch housing. Use a shop towel to cover the housing in order to retain all the rollers. 16. Inspect both output hub assemblies. Inspect the bearings and replace if needed. Thrust Bearing NOTE: Rollers are spring loaded. Take care not to allow them to fall out or lose them upon removal of the roll cage. Bearing 13. Thoroughly clean all parts and inspect the rollers (A) for nicks and scratches.
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FINAL DRIVE 5. Carefully install the rollers into the roll cage assembly while installing the assembly into the clutch housing. 9. Install the RH output hub into the clutch housing assembly. RH Hub Clutch Housing IMPORTANT: To ensure gearcase is assembled properly, assemble the gearcase components starting with the cover plate and build upward. 6. 10. While holding the hub in the clutch housing, flip the clutch housing over and install the armature plate.
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FINAL DRIVE 12. Line up the gearcase housing with the cover plate assembly. Set the gearcase housing on top of the assembled cover plate. Take care not to damage the new seal when installing the gearcase housing. NOTE: Rotate the input shaft while setting the gearcase housing in place. Backlash Thrust Plate Adjustment NOTE: Ring gear backlash is set from the factory. No adjustment is required unless the cover plate, ring gear/clutch housing, or pinion gear assembly is replaced.
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FINAL DRIVE 4. Set the gearcase upright. 5. Back the adjustment screw out while rotating the pinion shaft. The pinion shaft should rotate freely during four complete rotations. The four pinion shaft rotations ensures that the ring gear completes one full rotation. 4. Install the vent line. Install Vent Line Connect Harness 30 ft. lbs. (41 Nm) =T 6. If a tight spot is felt during rotation, loosen the backlash adjustment screw further and repeat pinion shaft rotation.
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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. Bearing Carrier 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. Be sure machine is secure before beginning this service procedure. Wear eye protection when removing bearings and seals. 2.
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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 5. Thoroughly clean the rear bearing carrier housing and the outer race on the new bearing.
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FINAL DRIVE Bearing Carrier Installation 1. 5. Install brake caliper mounting bolts and torque to 18 ft. lbs. (24 Nm). Install drive shaft axle through the backside of the bearing carrier. Be sure bushings and pivot tubes are installed. 18 ft. lbs. 24 (Nm) =T 2. Install the fasteners that attach the rear bearing carrier to the upper and lower A-arms. Torque bolts to 37 ft. lbs. (50 Nm). Rear Caliper Mounting Bolt Torque: 18 ft. lbs.
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FINAL DRIVE 7. Install wheel and (4) wheel nuts. Torque wheel nuts to specification. 4. Remove the two brake caliper attaching bolts. CAUTION: Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. =T Wheel Nut Torque: Steel Wheels: 27 ft. lbs. (37 Nm) Aluminum Wheels: 90 ft. lbs. (122 Nm) 8. Remove Rotate wheel and check for smooth operation. Bend both ends of cotter pin around end of spindle in different directions. REAR DRIVE SHAFT Removal 1.
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FINAL DRIVE 7. Slide the rear drive shaft out of the bearing carrier by pulling the bearing carrier assembly outward and tipping it down to remove the shaft. Outer CV Joint / Boot Replacement 1. Place the drive shaft in a soft-jawed vise. 2. Using side cutters, cut away and discard the boot clamps. 3. Slide the boot down the shaft and wipe the grease away from the face of the joint to access the snap ring located in the recess of CV joint. Snap Ring 8.
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FINAL DRIVE 6. Remove 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. 7. 8.
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FINAL DRIVE 14. Slide the joint onto the shaft splines while holding the snap ring in the face of the inner race open. Push or tap the joint onto the drive shaft until it “clicks” into place. Pull on the joint to make sure it is securely locked in place. Tap joint onto shaft Inner Plunging Joint / Boot Replacement 1. Place the drive shaft in a soft-jawed vise. 2. Using a side cutters, cut away and discard the boot clamps. 3.
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FINAL DRIVE IMPORTANT: If the grease in the joint is obviously contaminated with water and/or dirt, the joint should be replaced. 7. Thoroughly clean the joint with an appropriate solvent and dry the joint to prevent any residual solvent from being left in the joint upon reassembly. 8. Visually inspect the joint for damage. Replace if needed. 9. Slide the boot clamp and boot (small end first) onto the drive shaft and position the boot in its groove machined in the shaft. 12.
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FINAL DRIVE 16. Add any remaining grease to the boot. Installation 17. 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. 1. Install new spring ring on drive shaft. Apply anti-seize compound to splines. NEW Spring Ring 18. Tighten the small clamp using an appropriate clamp pliers. 19. Pull out on the drive shaft to center the joint in the housing.
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FINAL DRIVE 4. Lift bearing carrier into place and install the bolt attaching the bearing carrier to the upper A-arm. Torque fastener to 37 ft. lbs. (50 Nm). =T Rear Caliper Mounting Bolt Torque: 18 ft. lbs. (24 Nm) CAUTION 37 ft. lbs. 50 (Nm) New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly. 8. Torque wheel hub nut to 80 ft. lbs. (108 Nm) and install a NEW cotter pin.
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FINAL DRIVE REAR GEARCASE 5. Remove the fasteners and bracket that secure the rear gearcase to the transmission. 6. Remove the (4) fasteners and remove the rear mount from the rear gearcase. Gearcase Removal 1. Drain the fluid from the rear gearcase. 2. Remove the rear drive shafts from each side of the rear gearcase. See “REAR DRIVE SHAFT” on page 7.24 3. Remove the exhaust pipe and exhaust silencer to allow for gearcase removal. Silencer Remove Remove Elbow Pipe Header Pipe Remove 7 4.
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FINAL DRIVE Gearcase Disassembly IMPORTANT: Due to the manufacturing process, the pinion and ring gear assembly are NOT intended to be disassembled and replaced. Pinion and ring gear shimming information is NOT provided. The components are matched at the factory which requires special OEM tooling in order to properly assemble and shim the gears. In the event damage to the gears or housing requires replacement, the entire assembly must be replaced. 1. Drain and properly dispose of used gearcase fluid. 2.
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FINAL DRIVE 5. Inspect the ring gear teeth for chipped, worn, or broken teeth. If damaged, replace the ring gear and pinion gear as a set. 7. Remove the input shaft seal using a seal puller or other suitable method. 8. Inspect the input 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. If damaged, replace the ring gear and pinion gear as a set.
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FINAL DRIVE Gearcase Assembly 1. Install a new input shaft seal using a standard seal installer or other suitable method. 2. Install new seals on each side of the gearcase housing using a standard seal installer or other suitable method. Install a new o-ring in the gearcase cover. 3. If removed, install each axle spool bearing race using standard bearing installation tools and a shop press. WARNING Wear the appropriate safety equipment while installing bearing races to reduce the risk of injury. 7.
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FINAL DRIVE 4. Install the shim(s) previously removed onto the appropriate sides of the axle spool. Install the bearings. The bearings are a slip-fit and will slide onto the axle spool. Gearcase Installation 1. Install the rear gearcase by reversing the procedure listed under “REAR GEARCASE - Gearcase Removal” at the beginning of this section. IMPORTANT: When reinstalling the transmission to rear gearcase mount bracket, it is extremely important to torque all (7) fasteners to specification.
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FINAL DRIVE Gearcase Exploded View 14 6 13 9 16 10 4 12 6 5 3 9 7 1 17 10 8 18 23-27 ft. lbs. (31-37 Nm) 70-80 ft. lbs. (95-108 Nm) 15 7 7 2 23-27 ft. lbs. (31-37 Nm) 23-27 ft. lbs. (31-37 Nm) 16 21 40 ft. lbs. (54 Nm) 20 30-45 in. lbs.
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FINAL DRIVE WHEEL HUBS Front Hub Exploded View Sealed Ball Bearing Stud Bolts Wheel Hub Cone Washers Cotter Pin Bearing Carrier Castle Nut Retaining Ring 80 ft. lbs. (108 Nm) Brake Disc Front Rim Front Tire Flanged Nuts See Page 7.2 for Torque Value Valve 7 Rear Hub Exploded View Stud Sealed Ball Bearing Bolts Wheel Hub Cotter Pin Cone Washers Bearing Carrier Castle Nut 80 ft. lbs. (108 Nm) Retaining Ring Brake Disc Front Rim Front Tire Flanged Nuts See Page 7.
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TRANSMISSION CHAPTER 8 TRANSMISSION TORQUES / SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TRANSMISSION TORQUES / SPECIFICATIONS SHIFT LEVER Maintain and check/change these items in accordance with the maintenance schedule in Chapter 2 or during service repairs. Removal ITEM TORQUE VALUE Transmission Fill Plugs 40-50 ft. lbs.(54-67 Nm) Transmission Drain / Level Plugs 30-45 in. lbs.(0.2-0.3 Nm) Transmission Case Screws 23-27 ft. lbs. (31-36 Nm) Shift Lever Screw 15-20 ft. lbs. (20-27 Nm) Detent Sleeve Screw 40-45 ft. lbs.(54-61 Nm) Detent Adjustment Screw 23-27 ft. lbs.
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TRANSMISSION Shift Cable Inspection / Adjustment 4. Adjust the shift cable so there is the same amount of cable travel when shifting slightly past the detents of HIGH (H) gear and PARK (P). 5. Thread the upper or lower jam nut as required to obtain proper cable adjustment. Shift cable adjustment may be necessary if symptoms include: • No AWD or gear position display on instrument cluster • Ratcheting noise on deceleration • Inability to engage a gear 1.
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TRANSMISSION TRANSMISSION SERVICE 3. Remove the (7) bolts retaining the transmission support bracket. Transmission Removal / Service Notes x7 The engine, transmission and rear differential are bolted together as a unit. Removal of the transmission is not possible without removing the engine and differential. The shift housing cannot be removed without first disassembling the transfer case. NOTE: Refer to the “Engine Removal” section in Chapter 3 to remove the engine and drivetrain.
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TRANSMISSION 8. After removing the cover, remove the intermediate shaft bearing cup and shims from the cover. Bearing cup is a slip-fit. Note and record the number and thickness of shims and set aside. Also note the two alignment dowels (circle) in the cover for installation. 10. Remove the intermediate pinion shaft assembly from the housing. Check bearings and gear teeth for wear or damage and replace as needed. The shaft can be disassembled as shown using a press and standard bearing removal tools.
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TRANSMISSION 13. Remove the front output pinion shaft assembly. The shaft can be disassembled as shown using a press and standard bearing removal tools. 15. Remove the lower snap ring from under the gear. 16. Remove the intermediate shaft seal using a seal puller or other suitable method. 14. Remove the upper snap ring from the top side of the 21T main pinion gear and remove the gear. 8.
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TRANSMISSION Transfer Case Reassembly 1. 2. 3. Install the shims, bearing cup and alignment dowels into the retaining bracket. 4. Install a new output shaft seal flush with the case. Install the output pinion shaft assembly and bearing cup/bracket assembly as shown. Verify the alignment dowels are seated. Torque the bracket screws evenly to specification. Install the intermediate shaft seal (circled) flush or slightly below the case.
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TRANSMISSION 5. Reinstall the intermediate pinion shaft assembly and bearing cup. 7. Install the transfer case cover. Align the dowels (#1 & #7) and insert the cover screws (note position of the longest screw #4). Torque the screws evenly to specification in sequence as shown. 1 4 8 6 3 2 6. Assemble the transfer case cover using new components as required. Press in new bearings and a seal using standard installation tools.
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TRANSMISSION Transmission Shift Housing Disassembly 2. IMPORTANT: Shift housing repairs are not possible without performing transfer case disassembly. Read and understand all instructions before beginning disassembly. 1. Place the transmission shift housing onto a flat surface as shown. Lift the transmission case half straight up and remove. Verify transmission is in neutral. Remove the (7) shift housing case screws from the front of the transmission and (2) from the backside as shown.
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TRANSMISSION 4. Remove the (5) screws retaining the park flange. Inspect the park flange dogs for wear or damage. Replace as required. 7. Remove the input shaft seal and clutch intermediate shaft seal using a seal puller or punch. 5. Inspect the shaft bearing. Use a standard bearing puller to remove the shaft bearing if required. 8. Remove the (2) screws that attach the shift switch to the shift housing. Inspect the O-ring, switch poles and spring pins for wear or damage. Replace parts as required.
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TRANSMISSION 9. Remove the plate, pins, springs, drum gear and thrust washer from the shift housing. Replace any worn or damaged components. 10. Remove the inner shift detent screws, springs, and balls from each side of the shift housing. 11. Remove the park flange sleeve from the clutch shaft. 12. Pull back fully on gear selector arm to bring shift collar up and disengage the shift collar from the clutch yoke. Lifting on the clutch shaft may aid in shift collar removal.
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TRANSMISSION 14. Remove the sliding shoes from the clutch yoke. 17. From the back side of the high gear assembly, separate the high and low gear assemblies by tapping the gear retaining plate from the roll pins using a brass punch. Note the order of disassembly on the entire gear assembly (plate, thrust washer, bearing, thrust washer). Inspect all parts for wear or damage and replace as required. High Gear Low Gear 15. Remove the clutch shaft from the housing.
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TRANSMISSION 20. Remove the clutch yoke from the gear selector shaft and spring. 21. Remove the transmission input shaft from the housing. Inspect the shaft bearing and replace if required using a shop press. Inspect the gears for damage and/or wear. Replace the shaft if required. 22. Remove the screw from the end of the gear selector shaft assembly and remove the assembly from the housing. Note the clips, spring and plate orientation. 23.
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TRANSMISSION Transmission Shift Housing Reassembly 1. 3. Install the input shaft assembly. 4. Install clutch yoke into the gear selector shaft and spring. Align the pivot pin holes and install clutch yoke pivot pin. 5. Apply sealant to the clutch yoke set screw threads and install flush with the case. Do not torque. Install a new shift lever seal flush with the case. Apply lubricant to the seal lip. Press new bearings (if required) into the housing.
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TRANSMISSION 6. 7. Assemble the high and low gear assemblies as shown. Complete the assembly by aligning the roll pin holes and tapping the roll pins through the retaining plate and into the high gear using a brass punch. 8. Install the clutch shaft into the housing. Note that the forward gear assembly is loose in the housing and that alignment of the shaft, gear assembly, thrust washer and bearing is necessary for shaft installation. 9. Install the sliding shoes onto the clutch yoke.
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TRANSMISSION 11. Install the outer sleeve screws and inner shift detent screws, springs, and balls from each side of the shift housing. Use new o-rings anytime these screws are removed. Torque the outer sleeve screws to specification. TURN INNER DETENT SCREWS ONLY UNTIL LIGHT SHIFTING RESISTANCE IS FELT AT THIS TIME. PLACE THE TRANSMISSION IN NEUTRAL.
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TRANSMISSION 13. Install the reverse idler lower washer, needle bearing, gear, upper washer and snap ring onto the idler shaft of the transmission case half. 16. Install the reverse clutch/gear assembly onto the park flange. Note the orientation of the (2) thrust washers (top / bottom of gear assembly), and needle bearing. Complete the assembly by aligning the roll pin holes and tapping the roll pins through the retaining plate and into the reverse gear using a brass punch. 14.
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TRANSMISSION 18. Place the transmission shift housing onto a flat surface as shown. Apply a bead of crankcase sealant onto the mating surfaces. Align the dowels and install the transmission case half onto the shift housing while rotating the input shaft, using care not to damage the seal surfaces. 20. Install the (2) shift housing case screws to the backside as shown. Torque to specification. NOTE: Shift cable bracket installation is required. 2871557 Apply Sealant PN 2871557 To Case Mating Surfaces 19.
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TRANSMISSION TROUBLESHOOTING Troubleshooting Checklist Check the following items when shifting difficulty is encountered: • Idle speed adjustment • PVT alignment • Transmission oil type/quality • Transmission torque stop adjustment (where applicable) • Engine torque stop adjustment (where applicable) • Drive belt deflection • Loose fasteners on rod ends • Loose fasteners on selector box • Worn rod ends, clevis pins, or pivot arm bushings • Linkage rod adjustment and rod end positioning • Shift selector rail
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TRANSMISSION TRANSMISSION EXPLODED VIEWS Shift Housing / Transfer Case Exploded View Shift Housing Transfer Case 8.
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BRAKES CHAPTER 9 BRAKES GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE SYSTEM SERVICE NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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BRAKES GENERAL SPECIFICATIONS FRONT BRAKE SYSTEM Item Standard Service Limit Front Brake Pad Thickness .300 ± .007" (7.62 ± .178 mm) .180" (4.6 mm) Front Brake Disc Thickness .188" (4.76 mm) .170" (4.32 mm) - .010" (.254mm) Front Brake Disc Runout REAR BRAKE SYSTEM Item Standard Service Limit Rear Brake Pad Thickness .298 ± .007" (7.57 ± .178 mm) .180" (4.6 mm) Rear Brake Disc Thickness .188" (4.76 mm) .170" (4.32 mm) - .010" (.
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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. • Optional pads are available to suit conditions in your area. Select a pad to fit riding style and environment. • Do not over-fill the master cylinder fluid reservoir.
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BRAKES HYDRAULIC BRAKE SYSTEM OPERATION The Polaris brake system consists of the following components or assemblies: brake pedal, master cylinder, hydraulic brake lines, brake calipers, brake pads, and brake discs, which are secured to the drive line. Brake fluid level is critical to proper system operation. Too little fluid will allow air to enter the system and cause the brakes to feel spongy. Too much fluid could cause brakes to drag due to fluid expansion.
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BRAKES MASTER CYLINDER CAUTION Removal 1. Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact with finished surfaces. Locate the master cylinder above the LH front tire in the wheel well area. Master Cylinder NOTE: Make note of front and rear brake line locations to master cylinder. 4. Loosen the brake line banjo bolts (C) and allow fluid to drain. NOTE: Dispose of fluid properly. Do not re-use. 5.
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BRAKES BRAKE BLEEDING / FLUID CHANGE 4. Begin bleeding procedure with the caliper that is farthest from the master cylinder. Install a box end wrench on caliper bleeder screw. Attach a clean, clear hose to fitting and place the other end in a clean container. Be sure the hose fits tightly on fitting. 5. Have an assistant slowly pump foot pedal until pressure builds and holds. 6. Hold brake pedal on to maintain pedal pressure, and open bleeder screw. Close bleeder screw and release foot pedal.
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BRAKES FRONT BRAKE PADS 5. Push mounting bracket inward and slip outer brake pad past edge. Then remove inner pad. Pad Removal 1. Elevate and support front of vehicle. CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. 2. Remove the front wheel. Loosen pad adjuster screw 2-3 turns. Pad Inspection 1. 3. Measure the thickness of the pad material. Replace pads if worn beyond the service limit.
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BRAKES Pad Assembly / Installation 1. 5. Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease (PN 2871423), and install rubber dust boots. Install the adjustment set screw and turn clockwise until stationary pad contacts disc, then back off 1/2 turn (counterclockwise). 1/2 Turn 6. 2. Compress mounting bracket and make sure dust boots are fully seated. Install pads with friction material facing each other.
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BRAKES FRONT CALIPER SERVICE Caliper Exploded View Apply Polaris DOT 4 Brake Fluid to Component C E Apply Polaris All Purpose Grease A 47 in. lbs. (5.3 Nm) B F G D H I D A. Socket Set Screw B. Bleeder Screw C. Caliper Assy. D. Boot E. Square O-ring (thick) F. Square O-ring (thin) G. Piston H. Caliper Mount I. Brake Pads Caliper Removal 1. Elevate and safely support the front of the vehicle. 2. Remove the (4) wheel nuts and the front wheel. 5.
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BRAKES 6. Remove the two caliper mounting bolts and remove the caliper assembly from the front hub. 3. Remove mounting bracket, pin assembly and dust boot. 4. Thoroughly clean the brake caliper before disassembly and prepare a clean work area to disassembly the caliper. 5. Use low pressure compressed air to remove the pistons from the caliper. Remove Caliper Disassembly 1. Push brake pad retainer pin inward and slip brake pads past the edge.
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BRAKES 8. Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol. 2. Clean Components Inspect piston for nicks, scratches, pitting or wear. Measure piston diameter and replace if damaged or worn beyond service limit. NOTE: Be sure to clean seal grooves in caliper body. = In. / mm. Caliper Piston O.D.: Std: 1.002” (25.45 mm) Service Limit: 1.000” (25.4 mm) Caliper Inspection 1. Inspect caliper body for nicks, scratches, pitting or wear.
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BRAKES 3. Lubricate the mounting bracket pins with Polaris Premium All Season Grease (PN 2871423), and install the rubber dust seal boots. 6. Install brake line and tighten securely with a line wrench. Torque the banjo bolt brake line(s) to the proper torque specification. 15 ft.lbs. (20 Nm) 4. Compress the mounting bracket and make sure the dust seal boots are fully seated. Install the brake pads. Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt, oil or grease.
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BRAKES FRONT BRAKE DISC 3. Remove the hub assembly from the vehicle and remove the (4) bolts retaining the disc to the hub. Disc Inspection (4) Bolts 1. Visually inspect disc for scoring, scratches, or gouges. Replace the disc if any deep scratches are evident. 2. Use a 0-1” micrometer and measure the disc thickness at eight different points around the pad contact surface. Replace disc if worn beyond service limit. Cotter Pin Washers Measure Thickness Nut Front View Side View 4.
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BRAKES REAR BRAKE PAD 5. Push caliper piston into the caliper bore slowly using a Cclamp or locking pliers with pads installed. Pad Removal 1. Elevate and support rear of vehicle. CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls. 2. Remove the rear wheel. 3. Loosen pad adjuster screw 2-3 turns.
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BRAKES Pad Inspection 3. 1. Clean the caliper with brake cleaner or alcohol. 2. Measure the thickness of the pad material. Replace pads if worn beyond the service limit. Install caliper and torque mounting bolts to specification. 18 ft. lbs. (24 Nm) Measure Thickness =T Rear Brake Pad Thickness New .298” ± .007” (7.57 mm ± .178 mm) Service Limit .180” (4.6 mm) Rear Caliper Mount Bolt Torque: 18 ft. lbs. (24 Nm) 4. Slowly pump the brake pedal until pressure has been built up.
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BRAKES REAR CALIPER SERVICE Caliper Exploded View Apply Polaris DOT 4 Brake Fluid to Component D 47 in. lbs. (5.3 Nm) G Apply Polaris All Purpose Grease I K A. Brake Pad B. Mount Bracket C. Piston D. Caliper Assy. E. Square Ring (thick) F. Square Ring (thin) G. Boot, Pin Bushing H. Boot, Pin Seal I. Bleeder Screw K. Set Screw A H E F C B Caliper Removal 1. Elevate and safely support the rear of the vehicle. CAUTION Use care when supporting vehicle so that it does not tip or fall.
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BRAKES Caliper Disassembly Caliper Inspection 1. Remove brake pad adjustment set screw (K). 1. 2. Push upper pad retainer pin inward and slip brake pads past the edge and remove from the caliper. 3. Remove mounting bracket (B) and dust boots (G) and (H). 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. D G K Pads H E F C B 4. = In. / mm.
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BRAKES Caliper Assembly Caliper Installation 1. 5. Install new caliper seals (A) in the caliper body (B). Be sure groove is clean and free of residue or brakes may drag upon assembly. Install the rear caliper with the mounting bolts. Torque mounting bolts to 18 ft. lbs. (24 Nm). 18 ft. lbs. (24 Nm) B D A 2. 3. Coat piston with clean Polaris DOT 4 Brake Fluid (PN 2872189). Install piston (D) with a twisting motion while pushing inward.
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BRAKES REAR BRAKE DISC 3. Remove the hub assembly from the vehicle and remove the (4) bolts retaining the disc to the hub. Disc Inspection 1. 2. (4) Bolts Visually inspect disc for scoring, scratches, or gouges. Replace the disc if any deep scratches are evident. Cotter Pin Use a 0-1” micrometer and measure the disc thickness at eight different points around the pad contact surface. Replace disc if worn beyond service limit. Front View Washers Side View Nut Measure Thickness 4.
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BRAKES TROUBLESHOOTING Brakes Squeal / Poor Brake Performance • Air in system • Water in system (brake fluid contaminated) • Caliper or disc misaligned • Caliper dirty or damaged • Brake line damaged or lining ruptured • Worn disc and/or friction pads • Incorrectly adjusted stationary pad • Worn or damaged master cylinder or components • Damaged break pad noise insulator • Brake pads dragging • Brake caliper dragging Pedal Vibration • Disc damaged • Disc worn (runout or thickness variance exceeds service l
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ELECTRICAL CHAPTER 10 ELECTRICAL GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 UNDER-DASH COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.
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ELECTRICAL CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21 CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21 CHARGING SYSTEM “BREAK EVEN” TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21 CHARGING SYSTEM ALTERNATOR TESTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22 CHARGING SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . .
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ELECTRICAL GENERAL INFORMATION Under-Dash Components Special Tools The following switches and components can be accessed underneath the instrument / dash panel: Part Number Tool Description • Speedometer PV-43568 Fluke™ 77 Digital Multimeter • Speedometer Mode Switch 2870630 Timing Light • Digital Wrench Diagnostic Connector 2870836 Battery Hydrometer • Digital Wrench / ECU Reflash 9 Vdc Battery Plug 2460761 Hall Effect Sensor Probe Harness • AWD Switch 2871745 Static Timing Light Harnes
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ELECTRICAL SWITCHES / CONTROLS AWD SWITCH Headlamp Switch 1. Disconnect the headlamp switch harness (Brown, Green, and Red/Yellow), by depressing the connector lock and pulling on the connector. Do not pull on the wiring. 2. Test the switch connections and check for continuity at the following pins as shown in the illustration. HEADLAMP SWITCH BACK VIEW OF SWITCH 1 ON 2 3 X X 4 5 6 7 8 X X X OFF SWITCH BACK LIGHT Brake Light Switch 1.
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ELECTRICAL INSTRUMENT CLUSTER Rider Information Display Overview The rider information display is located in the instrument cluster. All segments will light up for 2.5 seconds at start-up. The instrument cluster senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as time, hours of operation and engine RPM.
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ELECTRICAL Standard Display Modes Clock Screen Use the mode button (location shown in the illustration on page 10.5) to toggle through the mode options. Odometer Mode The odometer records the miles or kilometers traveled by the vehicle. Trip Meter Mode The trip meter records the miles or kilometers traveled by the vehicle on each trip if it's reset before each trip. To reset the trip meter, select the trip meter mode. Press and hold the mode button until the display reads 0.
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ELECTRICAL AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the AWD coil. Gear Circuit Diagnostic Screen This screen displays the resistance value (in ohms) being read at the gear switch input of the gauge. NOTE: A 10 - 20% variance from these readings is within normal parameters. 10 10.
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ELECTRICAL Programmable Service Interval When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. When this feature is enabled, it provides a convenient reminder to perform routine maintenance. NOTE: If you scroll past the intended number, press and hold the button until the hours cycle back to zero. 5. When the desired setting is displayed, wait until the wrench icon stops flashing.
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ELECTRICAL 4. 5. Turn the key switch off and on three times in less than five seconds, then leave the switch on. The word “Wait” will appear on the screen along with a flashing “Check Engine” light. 2. Push the instrument cluster out from the back side of the dash while securely holding the dash and rubber mount. Push Instrument Cluster Outward Dash Panel Any blink code numbers stored in the EFI module will display, one at a time, on the screen. Example below shows a Blink Code of “42”.
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ELECTRICAL INSTRUMENT CLUSTER TROUBLESHOOTING TESTS TEST 1 - No All Wheel Drive .OTE )F !7$ ICON COMES ON INSTRUMENT CLUSTER IS / + 0ROCEED TO MECHANICAL TESTS OUTLINED IN #HAPTER #HECK THE !7$ ICON ON INSTRUMENT CLUSTER TO VERIFY ITS OPERATION 4HE !7$ SWITCH IS DIRECTLY POWERED BY SWITCHED VOLTS ORANGE WHITE 4HE GEAR SWITCH ONLY INTERFACES WITH THE INSTRUMENT CLUSTER 4O ENABLE !7$ THE CLUSTER MUST BE DISPLAYING LOW HIGH OR REVERSE GEAR 34!24 (%2% 30%%$ 2%!$/54 /+ .
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ELECTRICAL TEST 2 - No Display 1RWH %HIRUH VWDUWLQJ GLDJQRVLV WXUQ RII VSHHGRPHWHU DQG ZDLW VHFRQGV WKHQ WXUQ RQ DJDLQ WR VHH LI SUREOHP FOHDUV 67$57 +(5( 6 < &+(&. )25 0,1,080 9'& 21 3,1 % 72 3,1 & 3LQ &RQQHFWRU 5(3/$&( 63(('2 .(< 6:,7&+ 21 $ ' & 3RZHU % 6LJQDO & *URXQG < 5(3/$&( 63(('2 32,17(5 029(" &+(&. :+((/ 63((' 6(1625 6(( 7(67 1 &+(&. 6(1625 32:(5 6833/< 3,1 $ < 3,1 0($ 685( 9'& 21 3,16 $1' 1 6 5(3/$&( 63(('2 0($685( %$&. 2) 63(('2 6 < $7 %$&.
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ELECTRICAL TEST 4 - No AWD Hub Safety Limiter 127( ,) 7+( $:' ,&21 '2(6 127 &20( 21 25 ,) 9'& ,6 127 5(*,67(5,1* $1' $:' ,6 (1*$*,1* $%29( 530 ,7 0$< %( $ 0(&+$1,&$/ 352%/(0 ,6 63(('2 )81&7,21,1* &255(&7/<" < ,1 1(875$/ < 67$57 +(5( 72**/( 72 7$&+20(7(5 6(77,1* 5(9 (1*,1( 1 &+(&. 63(('2 7(67 +2/' 817,/ ',63/$< 67$%,/,=(6 '2(6 ,7 $33($5 $&&85$7(" 5(67$57 1 (1*,1( ,'/,1* 0($685( $& 92/7$*( %(7:((1 3,1 $1' 3,1 29(5 9$&" 7851 .(< 6:,7&+ 2)) 5(029( 3,1 &211(&725 )520 %$&.
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ELECTRICAL TEST 5 - Fuel Gauge Display Not Working 3LQ &RQQHFWRU 67$57 +(5( ,167580(17 &/867(5 )81&7,21 2." 1 &+(&. 63(('20(7(5 3(5)250 7(67 < 7851 .(< 6:,7&+ 2)) *$,1 $&&(66 72 )8(/ 6(1'(5 :,5,1* &+(&. )25 &217,18,7< 21 9,2/(7 :+,7( *$,1 $&&(66 72 %$&. 2) *$8*( 1 &+(&. &211(&7,21 $7 *$8*( 3,1 5HG 9 &RQVWDQW 5HG :KLWH 9 6ZLWFKHG *UH\ 2UDQJH 0RGH EXWWRQ 1 & *UHHQ %OXH
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ELECTRICAL ALL WHEEL DRIVE COIL GEAR POSITION INDICATOR SWITCH Operation Overview Test Diagram • When the AWD switch is “ON”, 12 VDC power is present at the hub coil. Continuity Table A B C • If the criteria is met, the instrument cluster provides a ground path at pin #16. When this occurs the AWD icon should display in the instrument cluster. HIGH • The AWD system must be grounded to operate.
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ELECTRICAL HEAD LIGHTS 6. Headlight Adjustment WARNING The headlight beam is adjustable. 1. Adjust the beam to desired position. Repeat the procedure to adjust the other headlight. Due to the nature of light utility vehicles and where they are operated, headlight lenses become dirty. Frequent washing is necessary to maintain lighting quality. Riding with poor lighting can result in severe injury or death. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.
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ELECTRICAL Headlamp Housing Removal TAIL / BRAKE / WORK LIGHTS 1. Disconnect the headlamp from the wiring harness. Be sure to pull on the connector, not on the wiring. Bulb Replacement 2. Remove the O-rings (A) from the headlamp brackets on both sides of the headlamp. Before replacing the bulb, use a digital multi-meter to test the harness to ensure the lamp is receiving 12 volts and that a ground path is present. 3. Remove the headlamp from the front bumper. A A Headlamp Housing Installation 1.
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ELECTRICAL COOLING SYSTEM SCHEMATIC Cooling System Break-Out Diagram 10 10.
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ELECTRICAL Fan Control Circuit Operation / Testing EFI DIAGNOSTICS Power is supplied to the fan via the Orange/Black wire when the relay is ON. The ground path for the fan motor is through the Brown harness wire. Refer to “RELAYS” later in this chapter for more information on fan functions. EFI Component Testing CAUTION Keep hands away from fan blades during operation. Serious personal injury could result. All EFI component information and diagnostic testing procedures are located in Chapter 4.
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ELECTRICAL RELAYS FAN RELAY Operation COLOR FUNCTION Located in the fuse box under the dash, the relays assist with component operation like the fan, fuel pump, and EFI system. Red / White Key-On battery power supply, switched on by key switch, enables power to relay. The fan relay, controlled by the ECU and Temp Sensor, operates the fan. Orange / Black Fused 20-Amp power, switched by relay, provides power to Fan Motor.
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ELECTRICAL FUSES / CIRCUIT BREAKER Operation Located in the fuse box under the dash, the fuse panel provides current protection for components such as the Instrument Cluster, ECU, EFI system, Chassis Power and Accessories. A separate 20-amp circuit breaker protects the fan motor circuit (see wire diagram for details). 10.
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ELECTRICAL CHARGING SYSTEM Charging System “Break Even” Test Alternator Output CAUTION RPM AMPS VOLTS 2500 20 13.2 Vdc Do not allow the battery cables to become disconnected with the engine running. Follow the steps below as outlined to reduce the chance of damage to electrical components. Current Draw - Key Off CAUTION Do not connect or disconnect the battery cable or ammeter with the engine running. Damage will occur to electrical components.
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ELECTRICAL Charging System Alternator Tests Three tests can be performed using a multi-meter to determine the condition of the stator (alternator). TEST 3: Measure AC Voltage Output of Each Stator Leg at Charging RPM 1. Set the selector dial to measure AC Voltage. 2. Start the engine and let it idle. 3.
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ELECTRICAL Charging System Testing Flow Chart Whenever charging system problems are suspected, proceed with the following system check after verifying that all wires are in good condition, connected and not exposed or pinched.: Using a multitester set on D.C. volts, measure the battery open circuit voltage (See earlier test). It should be 12.4 volts or more. Is it? No Remove the battery and properly service. Reinstall the fully charged battery or a fully charged shop battery.
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ELECTRICAL BATTERY SERVICE CONVENTIONAL BATTERY Battery Identification Battery Activation IMPORTANT: Identify what type of battery you have installed in your vehicle. Different types of batteries require different service procedures. Proper servicing and upkeep of your battery is very important for maintaining long battery life. WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing.
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ELECTRICAL 4. Add electrolyte to bring level back to upper level mark on case. NOTE: This is the last time that electrolyte should be added. If the level becomes low after this point, add only distilled water. 5. 6. Battery Removal 1. Remove the battery holder strap. 2. Disconnect battery negative (-) (black) cable first, followed by the positive (+) (red) cable. Charge battery at 1/10 of its amp/hour rating. Examples: 1/ 10 of 9 amp battery = .9 amp; 1/10 of 14 amp battery = 1.
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ELECTRICAL OCV - Open Circuit Voltage Test Battery voltage should be checked with a digital multitester. Readings of 12.6 volts or less require further battery testing and charging. See the following charts and Load Test. NOTE: Lead-acid batteries should be kept at or near a full charge as possible. Electrolyte level should be kept between the low and full marks.
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ELECTRICAL Off Season Storage Charging Procedure (Conventional) To prevent battery damage during extended periods of non-use, the following basic battery maintenance items must be performed: 1. Remove the battery to prevent damage from leaking or spilled acid during charging. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater. 3.
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ELECTRICAL LOW MAINTENANCE BATTERY General Battery Information NOTE: All Low Maintenance batteries are fully charged and tested at the factory before installation. Expected shelf life varies upon storage conditions. As a general rule before placing the battery into service, check the battery condition and charge accordingly. 1. Check the date label on the side of the battery to calculate when to check voltage. The battery should be checked every 3 months. 2.
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ELECTRICAL Battery Testing Load Test Whenever a service complaint is related to either the starting or charging systems, the battery should be checked first. Following are two tests which can easily be made on a Sealed Low Maintenance battery to determine its condition: OCV Test and a Load Test. OCV - Open Circuit Voltage Test Battery voltage should be checked with a digital multitester. Readings of 12.8 volts or less require further battery testing and charging. See charts and Load Test.
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ELECTRICAL Charging Procedure (Low Maintenance) STARTING SYSTEM If battery voltage is 12.8 V or less, the battery may need recharging. When using an automatic charger, refer to the charger manufacturer’s instructions for recharging. When using a constant current charger, use the following guidelines for recharging. Troubleshooting NOTE: Always verify battery condition before and 1-2 hours after the end of charging.
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ELECTRICAL Voltage Drop Test The Voltage Drop Test is used to test for bad connections. When performing the test, you are testing the amount of voltage drop through the connection. A poor or corroded connection will appear as a high voltage reading. Voltage shown on the meter when testing connections should not exceed .1 VDC per connection or component. NOTE: Note the alignment marks on both ends of the starter motor casing. These marks must align during reassembly. 3.
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ELECTRICAL 2. 3. Measure resistance between insulated brush and starter housing. Reading should be infinite (OL). Inspect insulation on brush wires for damage and repair or replace as necessary. Brush Replacement 1. Remove terminal nut with lock washer, flat washer, large phenolic washer, the small phenolic spacers, and sealing O-ring. Inspect O-ring and replace if damaged. 2. Slide positive brush springs to the side, pull brushes out of their guides and remove brush plate.
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ELECTRICAL 4. Measure the resistance between each commutator segment and the armature shaft. The reading should be infinite (no continuity). 2. Install O-ring, two small phenolic spacers, large phenolic washer, flat washer, lock washer, and terminal nut. 3. While holding brush springs away from brushes, push brushes back and hold in place. 4. Slide armature into field magnet housing. Release brushes. 5. Lightly grease the drive roller bearing and reinstall drive end frame on armature.
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ELECTRICAL NOTE: It is important to tighten the bottom starter bolt first (circle), as the bottom hole acts as a pilot hole to properly align the starter drive (bendix) with the flywheel. This helps to prevent binding and starter damage. 2. Remove the retaining ring, thrust washer, spring retainers and clutch return spring. Screw the overrun clutch off the end of the pinion shaft. Remove the old spring and install a new one.
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ELECTRICAL Starter Exploded View * Indicates - Do not reuse. Replace with new parts. 1. Rubber Ring* 2. Brush Spring 3. Thrust Washer 4. Gear Assembly 5. O-Ring* 6. Brush Complete 7. O-Ring* 8. Thrust Washer 9. Shaft Complete 10. Gear Assembly 11. Through Bolt 12. Cover 13. Stopper 14. Snap Ring 15. Washer 16. Flange Bolt 17. Thrust Washer 18. Flange Bushing 10 10.
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ELECTRICAL STARTING SYSTEM TESTING FLOW CHART Condition: Starter fails to turn over the engine. With the tester on the VDC position, place the tester's black lead on the battery negative and the red lead on the battery positive. Reading should be 12.4 V D. C. or greater. No Remove battery and properly service. Install fully charged shop battery to continue test. Yes Disconnect 2-wire connector at the solenoid.
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ELECTRICAL ELECTRICAL BREAKOUT DIAGRAMS 12V Key-On Power Circuit Starting System Circuit 10 10.
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ELECTRICAL Instrument Cluster Circuit Transmission Switch Circuit 10.
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ELECTRICAL Wheel Speed Sensor Circuit AWD Circuit 10 10.
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ELECTRICAL Fuel Gauge Display Circuit Cooling Fan Circuit 10.
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ELECTRICAL Charging System Circuit 10 10.
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A Air Filter Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12 All Wheel Drive (AWD) Coil . . . . . . . . . . . . . . . . . . . 10.14 AWD Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 AWD, Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14 AWD, Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13 B Balance Shaft Gear, Removal . . . . . . . . . . . . . . . . . . . . . 3.42 Ball Joint Service . . . . . . .
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Engine Cooling System Troubleshooting . . . . . . . . . . . .3.63 Engine Crankcase Assembly . . . . . . . . . . . . . . . . . . . . . .3.47 Engine Crankshaft Gear Removal . . . . . . . . . . . . . . . . . .3.43 Engine Crankshaft Installation . . . . . . . . . . . . . . . . . . . .3.48 Engine Cylinder Head Assembly . . . . . . . . . . . . . 3.31, 3.56 Engine Cylinder Head Inspection . . . . . . . . . . . . . . . . . .3.26 Engine Cylinder Head Removal . . . . . . . . . . . . . . . . . . .3.
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Ignition Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . 4.31 Ignition Coil Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.31 Indicator, Service Interval . . . . . . . . . . . . . . . . . . . . . . . 10.8 Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 K Keys, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 Kilometers to Miles Toggle . . . . . . . . . . . . . . . . . . . . . . 10.8 L Leakdown Test . . . . . .
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Specification, Cylinder Head Warp . . . . . . . . . . . . . . . . .3.26 Specification, Cylinder Taper Limit . . . . . . . . . . . . . . . .3.34 Specification, Cylinder Warp Limit . . . . . . . . . . . . . . . .3.34 Specification, Oil Pump Bolt Torque . . . . . . . . . . . . . . .3.51 Specification, Oil Pump Rotor Clearance . . . . . . . . . . . .3.43 Specification, Timing Gear Alignment . . . . . . . . . . . . . .3.39 Specification, Valve Seat Contact Width . . . . . . . . . . . .3.
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WIRE DIAGRAM 2008 RANGER RZR 11.
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WIRE DIAGRAM 2008 RANGER RZR 11.