Manual de Serviço Ranger 1000

2021 RANGER XP 1000
Service Manual
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
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 the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.
Publication Printed November 2020 (PN 9850046 R01)

© Copyright 2020 Polaris Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting
or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
SAFETY WARNINGS
The following signal words and symbols appear throughout this manual and on the vehicle. Your safety is involved
when these words and symbols are used. Become familiar with their meanings before reading the manual.
DANGER
DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.
WARNING
SAFETY ALERT WARNING indicates a hazardous situation which, if not avoided, COULD result in death or serious
injury.
CAUTION
SAFETY ALERT CAUTION indicates a hazardous situation which, if not avoided, COULD result in minor to moderate
injury.
NOTICE
NOTICE provides key information by clarifying instructions.
IMPORTANT
IMPORTANT provides key reminders during disassembly, assembly and inspection of components.
TRADEMARKS
POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:
Loctite, Registered Trademark of the Loctite Corporation
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity-Vac, Registered Trademark of Neward Enterprises, Inc.
Torx, Registered Trademark of Textron
Hilliard, Trademark of the Hilliard Corporation
Warn, Trademark of Warn Industries
FOX, Registered Trademark of FOX RACING SHOX
RydeFX, Registered Trademark of ArvinMeritor
Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from
www.purepolaris.com or by contacting the nearest Polaris dealer.
REVISION INDEX
REV DATE CHANGES
R01 11/16/2020 Initial release
FEEDBACK FORM
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with an overall satisfaction rating for this service manual, provide comments on your
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2021 RANGER XP 1000
Service Manual
Chapter Summary
CHAPTER 1 : GENERAL INFORMATION

CHAPTER 2 : MAINTENANCE
CHAPTER 3 : ENGINE / COOLING / HVAC SYSTEM
CHAPTER 4 : ENGINE ELECTRICAL
CHAPTER 5 : FUEL SYSTEM
CHAPTER 6 : PVT SYSTEM
CHAPTER 7 : TRANSMISSION
CHAPTER 8 : FINAL DRIVE
CHAPTER 9 : STEERING / SUSPENSION
CHAPTER 10 : BRAKE SYSTEM
CHAPTER 11 : BODY / FRAME
CHAPTER 12 : CHASSIS / BODY ELECTRICAL
CHAPTER 13 : FACTORY-INSTALLED OPTIONS
GENERAL INFORMATION
CHAPTER 1 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MODEL NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
VEHICLE AND ENGINE SERIAL NUMBER LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
REFERENCE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
SERVICE RULES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
SPECIAL TOOLS WEBSITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
SPECIAL TOOLS INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
MASTER TORQUE LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
2021 VEHICLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.19
VEHICLE SPECIFICATIONS NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.19
MODEL SPECIFICATIONS - 3 SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.19
MODEL SPECIFICATIONS - CREW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.28
MODEL SPECIFICATIONS - INTERNATIONAL MODELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.36
CLUTCH SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.42
CLUTCH CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.42
GENERAL DIAGNOSTICS INFORMATION OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.43
GUIDED SYMPTOM DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.43
GUIDED SYMPTOM REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.44
ENGINE AND DRIVABILITY DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.45
ENGINE CRANKS BUT DOES NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.48
NO CRANK NO START OR SLOW CRANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.50
OVER HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.51
WARNING LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.52
ENGINE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.53
COOLING TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.55
DIGITAL WRENCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.56
DIGITAL WRENCH® SOFTWARE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.56
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.56
GUIDED DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.56
DIGITAL WRENCH® SOFTWARE INSTALLATION AND UPDATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.57
DIGITAL WRENCH® COMMUNICATION ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.58
DIGITAL WRENCH® - DIAGNOSTIC CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.58
DIGITAL WRENCH® SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.58
DIGITAL WRENCH® FEATURE MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.59
ENGINE CONTROLLER REPROGRAMMING (REFLASH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.60
POLARIS MOBILE DIGITAL WRENCH® (PMDW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.61
ENGINE ELECTRICAL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.62
9850046 R01 - 2021 RANGER XP 1000 Service Manual

© Copyright Polaris Inc. 1.1
GENERAL INFORMATION
DIAGNOSTIC TROUBLE CODES OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.62

MASTER TROUBLE CODE LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.63
CYLINDER MISFIRE DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.74
FLUID LEAKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.75
FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.75
FUEL SYSTEM DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.76
FUEL SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.76
PVT SYSTEM DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.78
PVT SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.78
PVT SYSTEM OVERHEATING / DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.80
TRANSMISSION DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.81
HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.81
TRANSMISSION ISOLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.81
FINAL DRIVE DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.82
ALL WHEEL DRIVE (AWD) CONCERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.82
DRIVESHAFT (HALF SHAFT) DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.82
BRAKE SYSTEM DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.83
BRAKE NOISE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.83
BRAKE VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.83
CALIPER OVERHEATS (BRAKES DRAG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.84
POOR BRAKE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.84
BRAKES LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.84
STEERING / SUSPENSION DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.85
EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL ON) . . . . . . . . . . . . . . . . . . . . . .1.85
EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL OFF) . . . . . . . . . . . . . . . . . . . . .1.86
EPS TROUBLESHOOTING (USING DIGITAL WRENCH®) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.87
SHOCK ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.88
ELECTRICAL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.89
ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.89
DIGITAL MULTI-METER (DMM) NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.89
STATIC AND DYNAMIC TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.89
CONNECTOR PROBING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.90
TESTING CONTINUITY / RESISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.91
TESTING FOR A SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.91
TESTING FOR A SHORT TO VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.92
TESTING FOR INTERMITTENT CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.93
TESTING CURRENT FLOW (AMPERAGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.93
CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.94
TESTING VOLTAGE DROP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.94

1.2 © Copyright Polaris Inc.
GENERAL INFORMATION
VEHICLE IDENTIFICATION
MODEL NUMBER DESIGNATION 1
Example: R18RRE99AS
GROUP MODEL YEAR MAKE / CHASSIS CODE ENGINE CODE REGION OPTION
1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th 10th**
R 1 8 R R E 9 9 A S
* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively
** = 10th digit will be used on color/featured versions of models (not including the base)
First 3 digits and 10th digit are used in model number only. They are not used with the 17 digit VIN.
Digits 1 through 8 determine Digital Wrench calibration.
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION

Example: 4XAKA09A0E3000000
VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS

ENGINE MODIFIER
MFG. LOCATION
MODEL YEAR *
CHECK DIGIT
ENGINE SIZE
CATEGORY
DRIVELINE
CHASSIS
WORLD MFG. ID
INDIVIDUAL SERIAL NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4 X A K A 0 9 A 0 E 3 0 0 0 0 0 0
* Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G = 2016; H = 2017; J = 2018; K= 2019; L=2020;
M=2021
ENGINE DESIGNATION NUMBER

1205551 - 18: 999cc Twin Cylinder, Liquid Cooled, 4-Stroke DOHC, Electric Start

GENERAL INFORMATION
VEHICLE AND ENGINE SERIAL NUMBER LOCATION

Whenever corresponding about a Polaris ORV, refer to the vehicle identification number (VIN) and the engine serial
number.
The engine serial number can be found on a decal applied to the front of the engine crankcase q or stamped into the
crankcase on the PTO side of the engine w.
The VIN can be found stamped on a portion of the left rear frame e, above the PVT cover.

GENERAL INFORMATION
REFERENCE INFORMATION
SERVICE RULES 1
In order to perform service work efficiently and prevent costly errors, technicians should read the text in this manual
and familiarize themselves with the procedures before beginning. Notice, Cautions and Warnings have been included
for clarification of text and safety concerns. Knowledge of mechanical theory, tool use and shop procedures are
necessary to perform some procedures in this manual safely and correctly.
Use only genuine Polaris service parts, including fasteners that require replacement if removed. Do NOT substitute
fasteners or hardware.
Cleanliness of parts and tools as well as the work area is of primary importance. Dirt and foreign matter will cause
damage to precision parts. Clean the vehicle before beginning service. Clean all parts before installing.
If difficulty is encountered in removing or installing a component, look to see if a cause for the difficulty can be found. If
it is necessary to tap the part into place, use a soft face hammer and tap lightly.
Always follow torque specifications as outlined throughout this manual. Incorrect torquing may lead to serious machine
damage or in the case of steering, driveline, and chassis components, can result in loss of control during operation of
the vehicle, which may result in severe personal injury or death.
If a torquing sequence is indicated for nuts, bolts or screws of a certain component, start all fasteners and hand
tighten. Following the method and sequence indicated, tighten evenly to the specified torque value. When removing
nuts, bolts or screws from a component with several fasteners, loosen them all about 1/4 turn before removing them to
prevent distortion of that component.
Replace all oil seals, sealing washers, gaskets, and O-rings with new ones during assembly. Be sure the mating
surfaces for the gasket are clean and smooth to avoid leaks and maintain specified tolerances.
Some procedures require removal of retaining rings or clips. Removal can weaken and deform these parts, therefore,
they should always be replaced with new parts. When installing new retaining rings and clips, use care not to expand
or compress them beyond what is required for installation.
Polaris lubricants and greases have been specially formulated to provide maximum performance and protection when
applied properly. In some applications, warranty coverage may be void if improper lubricants are used.
Parts requiring grease should be cleaned thoroughly and fresh grease applied before reassembly. Deteriorating
grease loses lubricity and may contain abrasive foreign matter. Always replace locking hardware such as lock nuts or
lock washers, fasteners that have pre-applied locking agent, or any other fasteners as noted in this service manual
with genuine Polaris hardware from an authorized Polaris dealer. Working with batteries can be hazardous. Review all
battery warnings and cautions.

GENERAL INFORMATION
REPLACEMENT KEYS
Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the
original key and refer to the chart to the right for the proper part number.
(i.e. In this example, the first two digits are 31 which would use key blank PN 4110141.)
SERIES# PART NUMBER

20 4010278
21 4010278
22 4010321
23 4010321
27 4010321
28 4010321
31 4110141
32 4110148
67 4010278
68 4010278

GENERAL INFORMATION
SPECIAL TOOLS WEBSITE

Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while
other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools
1
when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, Bosch
Automotive Service Solutions, by phone at 1-800-345-2233 or on-line at http://polaris.service-solutions.com/

GENERAL INFORMATION
SPECIAL TOOLS INDEX ENGINE / COOLING / EXHAUST

MAINTENANCE Flywheel Puller Piston Ring Valve Spring
PA-49316 Compressor Compressor
Oil Filter Wrench Shock Spanner Wrench
Pliers PV-1253 or PV-
PU-50105 2877408
PV-43570-1 4019
Cylinder Holding Crank Seal

& Camshaft Installation Tool
Timing Plate PU-52493
PU-50563
ENGINE / COOLING / EXHAUST
Oil Filter Oil Pressure Oil Pressure
Wrench Gauge Gauge Adapter
PU-50105 PV-43531 PU-52492
FUEL SYSTEM
Fuel Pressure Fuel Pressure Fuel Pressure
Gauge Kit Gauge Adapter Gauge Adapter
PU-43506-A PA-48838 PS-48762
Engine Stand Engine Stand Engine Stand
(2” Bore) Adapter (Mounts Sleeve Adapter
PU-50624 To The Engine) (Use With 2”
PU-50562 Bore Stand)
PU-50625
Fuel Pump
Service Tool
PU-50326
Engine Stand Water Pump Valve Spring

Sleeve Adapter Mechanical Seal Compressor
(Use With Installer Adapter
2.375” Bore PU-50564 PV-43513-A
Stand)
PW-47054

GENERAL INFORMATION
PVT SYSTEM STEERING / SUSPENSION

Drive Clutch Drive Clutch Clutch Ball Joint Tool Spring Compressor Tool 1
Holding Fixture Puller Compressor PU-50506 2870623
PU-52430 PU-52422 Tool
PU-50518–A
Clutch Bushing Piston Pin Puller Driven Clutch

Replacement Kit 2870386 Separator Tool
2871226–A 2875911 BRAKE SYSTEM
Mityvac® Pressure Test Tool
2870975
TRANSMISSION
Snorkel Tool Rear Driveshaft Rear Output
PU-52547 Seal Guide Seal Driver
2871699 2871698
Bearing Seal Crankcase BODY / FRAME

Driver (50 mm) Sealant
2871282 2871557 (3 Multi-Function Pliers
bond) 2876389
or
3233901
(Loctite® 680)
FINAL DRIVE
Roll Pin Axle Boot CV Boot Clamp
Removal Tool Clamp Tool Pliers
2872608 PU-48951 8700226

GENERAL INFORMATION
ELECTRICAL
Digital Wrench® Digital Wrench® Digital Wrench®
Diagnostic Kit Vehicle Interface PC Interface
PU-47063-B Cable Cable
PU-47469 PU-47470
Digital Wrench® Digital Wrench® Wireless Vehicle

SmartLink SmartLink Kit Link (WVL)
Module PU-47471 PU-51435
PU-47468
MultiLink XP Vehicle Interface MultiLink XP

Module Harness USB Cable
PU-52789 PU-52790 PU-52791
Fluke™ 77 Static Timing Hall Effect
Digital Light Harness Sensor Probe
Multimeter 2871745 Harness
PV-43568 2460761
Battery Connector Test Timing Light

Conductance Kit 2870630
Analyzer (MDX- PV-43526
610P)
PU-50296
Relay Bypass
PU-49466

GENERAL INFORMATION
MASTER TORQUE LIST ENGINE / COOLING / EXHAUST
MAINTENANCE TORQUE 1
PART DESCRIPTION SPECIFICATION
TORQUE Air Duct Clamps 35 in-lbs (4 Nm)
Battery Bracket Fastener 42 in-lbs (5 Nm) Airbox Mount Fastener 35 in-lbs (4 Nm)
Airbox Mount Fastener - High 42 in-lbs (5 Nm)

Battery Terminal Fastener 40 in-lbs (5 Nm)
Lifter
Caliper Bleeder Screw 4 ft-lbs (5.4 Nm) Cam Chain Tensioner 15 ft-lbs (20 Nm)
Coolant Hose Clamp 35 in-lbs (4 Nm) Camshaft Carrier Fastener 7 ft-lb (10 Nm)
Crankcase Drain Plug 12 ft-lbs (16 Nm) Camshaft Sprocket Fastener 14 ft-lbs (19 Nm)
Front Gearcase Fill / Drain Plug 10 ft-lbs (14 Nm) Connecting Rod Fastener
Step 1: 9 ft-lbs (12
Outer Clutch Cover Fastener 35 in-lbs (4 Nm) Nm)
Step 2: 22 ft-lbs
Plunger Fastener 15 ft-lbs (20 Nm) (30 Nm)
Shock Mounting Fastener 44 ft-lbs (60 N·m) Step 3: Tighten
additional 90°
Spark Arrestor Fastener 10 ft-lbs (14 Nm)
Coolant Bleed Fastener 6 ft-lbs (8 Nm)
Spark Plug 9 ft–lbs (12 Nm)
Coolant Hose Clamp 35 in-lbs (4 Nm)
Tensioner Mounting Fastener 7 ft-lbs (10 Nm)
Coolant Hose Mounting Bracket 3.5 lb-ft (4.7 Nm)
Tie Rod Jam Nut 13 ft-lbs (18 Nm) Fastener
Transmission Fill / Drain Plug 12 ft-lbs (16 Nm) Coolant Reservoir Fasteners 24 in-lbs (3 Nm)
Valve Cover Fastener 7 ft-lbs (10 Nm) Cooling Fan Fasteners 35 in-lbs (4 Nm)
Wheel Lug Nuts 120 ft-lbs (163 Nm) Cooling Fan Shroud Fasteners 6 ft-lbs (8 ft-lbs)
Wheel Hub Castle Nut (rear) Crankcase Drain Plug 12 ft-lbs (16 Nm)
180 ft-lbs (245 N·m)
Wheel Hub Castle Nut (front) Crankcase Oil Gallery Plug 22 ft-lbs (30 Nm)
Cylinder Head Fastener (M8

Bolts) 7 ft-lb (10 Nm)
Cylinder Head Fastener (M11 Torque in

Bolts) sequence
Step 1: 13 ft-lbs
(18 Nm)
Step 2: 26 ft-lb (35
Nm)
Step 3: Tighten
additional 360°
Engine Mount Fastener 40 ft-lbs (54 Nm)
Engine Mount Isolator Nuts 22 ft-lbs (30 Nm)
Exhaust Head Pipe Mounting 18 ft-lbs (24 Nm)

Fastener
Exhaust Headpipe Stud - High 21 ft-lbs (28 Nm)
Lifter

GENERAL INFORMATION
TORQUE TORQUE
PART DESCRIPTION SPECIFICATION PART DESCRIPTION SPECIFICATION
Exhaust Head Pipe Upper Heat Oil Sump Cover Fastener (M8) 26 ft-lbs (35 Nm)
6 ft-lbs (8 Nm)
Shield Fastener - High Lifter
Oil Sump Cover Fastener (M6) 9 ft-lbs (12 Nm)
Exhaust Heat Shield Fasteners -
42 in-lbs (5 Nm)
High Lifter One Way Clutch Retaining 9 ft-lbs (12 Nm)
Fastener
Exhaust Manifold Fasteners -
18 ft-lbs (24 Nm) Outer Clutch Cover Fastener 35 in-lbs (4 Nm)
High Lifter
Exhaust Silencer Heat Shield Oxygen Sensor 18 ft-lbs (24 Nm)

6 ft-lbs (8 Nm)
Fastener - High Lifter
Shock Mounting Fastener 44 ft-lbs (60 N·m)
Exhaust Stud w/Spring 21 ft-lbs (28 Nm)
Spark Plug 9 ft–lbs (12 Nm)
Flywheel Retaining Fastener
Step 1: Torque to Starter Motor Fastener 7 lb-ft (10 Nm)
133 ft-lbs (180 Nm)
Stator Cover Fastener 9 ft-lbs (12 Nm)
Step 2: Back out
bolt 180° Tensioner Mounting Fastener 7 ft-lbs (10 Nm)
Step 3: Torque to
133 ft-lbs (180 Nm) Thermostat Cover Fastener 7 ft-lbs (10 Nm)
Heat Shield Fastener 42 in-lbs (5 Nm) Upper Crankcase Fastener (M8) 26 ft-lbs (35 Nm)
HVAC Outer Alternator Cover 48 in-lbs (5.4 Nm) Upper Crankcase Fastener (M6) 7 ft-lbs (10 Nm)
Intake Duct Hose Clamp 35 in-lbs (4 Nm) Valve Cover Fastener 7 ft-lbs (10 Nm)
Intake Air Duct Covers - High 7 ft-lbs (10 Nm)

10 in-lbs (1 Nm) Water Pump Impeller Fastener (Apply Loctite® 204™
Lifter
to bolt threads)
Intake Duct Hose Clamp - High 24 in-lbs (3 Nm)
Lifter Water Pump Mounting Fastener 7 ft-lbs (10 Nm)
Intake Manifold Boot Clamp 17 in-lbs (2 Nm) Wheel Lug Nut 120 ft-lbs (163 Nm)
Isolator Fastener 40 ft-lbs (54 Nm)
Lambda Sensor - High Lifter 35 ft-lbs (47 Nm)
Lower Crankcase Fastener (M10) Step 1: 9 ft-lb (12

Nm)
Nm)
Step 3: Tighten
additional 90°
Lower Crankcase Fastener (M8) 26 ft-lbs (35 Nm)
Lower Crankcase Fastener (M6) 9 ft-lbs (12 Nm)
Lower Intake Plenum Fastener 18 ft-lbs (24 Nm)
Muffler Mount Fastener 10 ft-lbs (14 Nm)
Oil Cooler Retaining Fastener 7 lb-ft (10 Nm)
Oil Filter Adapter 21 ft-lbs (28 Nm)
Oil Pump Mounting Fastener 7 ft-lbs (10 Nm)
Oil Pump Pick-Up Retaining 7 ft-lbs (10 Nm)

Fastener

GENERAL INFORMATION
ENGINE ELECTRICAL PVT SYSTEM

PART DESCRIPTION TORQUE SPECIFICATION TORQUE 1
CPS Retaining Fastener 9 ft-lbs (12 Nm)
Drive Clutch Cover Fastener 100 in-lbs (11 Nm)
ECT Sensor 16 ft-lbs (22 Nm)
Driven Clutch Helix Fastener 44 ft-lbs (60 N·m)
ECU Retaining Fastener 22 in-lbs (2.5 Nm)
Driven Clutch Retaining Fastener 20 ft-lbs (27 N·m)
ETC Housing Retaining 5 ft-lbs (7 Nm)
Fastener Drive Clutch Retaining Fastener
96 ft-lbs (130 Nm)
(Moveable sheave removed only)
Ignition Coil Bracket 7 ft-lbs (9 Nm)
Fastener
Step 1: 110 ft-lbs
Ignition Coil Retaining 6 ft-lbs (8 Nm) (149 Nm)
Fastener Drive Clutch Retaining Fastener
(Stationary sheave completely Step 2: Loosen
removed) Fastener
Oxygen Sensor 18 ft-lbs 24 Nm)
Step 2: 96 ft-lbs
Spark Plug 9 ft–lbs (12 Nm) (130 Nm)
T-MAP Retaining Fastener 3 ft-lbs (4.5 Nm) Outer PVT Cover Fasteners 35 in-lbs (4 Nm)
Starter Cable Wiring Nuts 48 in-lbs (5 Nm) PVT Air Duct to Close Off Panel -
35 in-lbs (4 Nm)
High Lifter
Starter Motor Fasteners 7 lb-ft (10 Nm)
PVT Cover to Engine Fastener 37 ft-lbs (50 Nm)
FUEL SYSTEM PVT Cover to Transmission 50 ft-lbs (68 Nm)

Fastener
TORQUE
PART DESCRIPTION PVT Hose Adapter Clamps 35 in-lbs (4 Nm)
SPECIFICATION
Fuel Pump Nut 70 ft-lbs (95 Nm) PVT Inlet Duct Fastener 54 in-lbs (6 Nm)
Fuel Rail Mounting Fastener 5 ft-lbs (7 Nm) PVT Inlet Hose Clamp 35 in-lbs (4 Nm)
Fuel Tank Bracket Fastener 6 ft-lbs (8 Nm) PVT Inner Cover Fastener Refer to PVT Inner
Lower Intake Plenum Fastener 18 ft-lbs (24 Nm) Cover Assembly
page
Throttle Pedal Mounting 8 ft-lbs (11 Nm)
Fasteners PVT Outlet Duct Fastener 54 in-lbs (6 Nm)
Shift Weight Fastener 20 in-lbs (2 N·m)
Windage Plate Fastener 4 ft-lbs (6 N·m)

GENERAL INFORMATION
TRANSMISSION FINAL DRIVE

TORQUE TORQUE
Bearing Cover Retaining Differential Solenoid Nut 25 ft-lbs (34 N·m)
9 ft-lbs (12 Nm)
Fastener
Front Gearcase Cover Plate 9 ft-lbs (12 N·m)
Bell Crank Nut 14 ft-lbs (19 Nm) Fastener
Differential Cover Fastener 26 ft-lbs (35 Nm) Front Gearcase Fill / Drain Plug 10 ft-lbs (14 Nm)
Fork Retainer Fastener 9 ft-lbs (12 Nm) Front Gearcase Mounting 44 + 90° ft-lbs (60 + 90°
Fastener N·m)
Park Plate Fastener 9 ft-lbs (12 Nm)
Prop Shaft Pinch Bolt Fastener 22 ft-lbs (30 N·m)
Rear Mount Bracket Fastener 20 ft-lbs (27 Nm)
Prop Shaft Carrier Fastener 40 ft-lbs (54 Nm)
Rear Transmission Mount 40 ft-lbs (54 Nm)
Bracket Fastener Rear Wheel Hub Castle Nut 180 ft-lbs (245 N·m)
Rear Transmission Mount 22 ft-lbs (30 Nm) Rear Prop Shaft (to transmission) 22 ft-lbs (30 Nm)
Fastener Fastener
Ring Gear Fasteners 28 ft-lbs (38 Nm)
Sector Cover Fastener 10 ft-lbs (14 Nm)
Shift Cable Bracket Fasteners 37 ft-lbs (50 Nm)
Shift Cable Fastening Nut 13 ft-lbs (18 Nm)
Shift Cable Locknut 13 ft-lbs (18 Nm)
Snorkel Locking Fastener 9 ft-lbs (12 Nm)
Solenoid 25 ft-lbs (34 Nm)
Speed Sensor 10 ft-lbs (14 Nm)
Transmission Case Fastener 20 ft-lbs (27 Nm)
Transmission Fill / Drain Plug 12 ft-lbs (16 Nm)
Transmission Mount to Engine 37 ft-lbs (50 Nm)

Fastener

GENERAL INFORMATION
STEERING / SUSPENSION BRAKE SYSTEM

TORQUE TORQUE 1
Front Upper Ball Joint Pinch 42 ft-lbs (57 N·m) Brake Line Banjo Bolt 15 ft-lbs (20 Nm)
Fastener
Caliper Bleed Screw 4 ft-lbs (5.4 Nm)
Front Lower Ball Joint Nut 45 ft-lbs (61 Nm)
Front Brake Disc Mounting 18 ft-lbs (24 Nm)
Lower Steering Shaft Pinch 25 ft-lbs (34 Nm) Fastener
Fastener
Front Caliper Mounting Fastener 28 ft-lbs (38 Nm)
Lower Steering Shaft to Rack 48 ft-lbs (65 Nm)
Pinch Fastener Front Parking Brake Assembly
7 ft-lbs (9.5 Nm)
Mounting Fasteners
Power Steering Mount Fastener 30 ft-lbs (41 Nm)
Front Parking Brake Fastener: 15 ft-lbs (20 Nm)
Power Steering Unit Frame 14 ft-lbs (19 Nm) M6
Fastener
Front Parking Brake Fastener: 22 ft-lbs (30 Nm)
Rear Upper A-Arm to Bearing 44 ft-lbs (60 N·m)
M8
Carrier Fastener
Master Cylinder Banjo Fastener 15 ft-lbs (20 Nm)
Rear Lower A-Arm to Bearing 30 ft-lbs (40 N·m) +
Carrier Fastener 180° Master Cylinder Mounting 20 ft-lbs (27 Nm)
Rear A-Arm to Frame Fastener 81 ft-lbs (110 N·m) Fastener
44 ft-lbs (60 N·m) Parking Brake Caliper Fasteners 37 ft-lbs (50 Nm)
Shock Mounting Fastener
17 ft-lbs (23 Nm) Parking Brake Disc Fastener 20 ft-lbs (27 Nm)
Stabilizer Bar Link Fastener
Stabilizer Bar Link Nut 40 ft-lbs (54 Nm) Parking Brake Handle Fastener 22 in-lbs (2.5 Nm)
Stabilizer Bar Mount Fastener 31 ft-lbs (42 Nm) Parking Brake Locknuts 13 ft-lbs (17.6 Nm)
Steering Adjustment Shock 7 ft-lbs (10 Nm) Pedal Bracket Nuts 8 ft-lbs (11 Nm)
Assembly Nut
Rear Brake Disc Mounting 28 ft-lbs (38 Nm)
Steering Rack Mounting Nuts 40 ft-lbs (54 Nm) Fastener
Rear Caliper Mounting Fastener 46 ft-lbs (62 Nm)
Steering Wheel Nut 65 ft-lbs (88 Nm)
Steering Wheel Tilt Assembly Nut 40 ft-lbs (54 Nm)
Tie Rod Jam Nut 13 ft-lbs (18 N·m)

Tie Rod Retaining Nut Nm)
Step 2: Tighten
additional 90°
Upper Steering Shaft Pinch 25 ft-lbs (34 Nm)
Fastener

GENERAL INFORMATION
BODY / FRAME TORQUE

TORQUE
PART DESCRIPTION SPECIFICATION Fender-Rear, Rocker Fastener 42 in-lbs (5 Nm)
1/4 Turn Glovebox Latch 36 in lbs (4 Nm) Filter Support Fastener 18 in-lbs (2 Nm)
AC Hose Clamp Fastener 6 ft lbs (8 Nm) Front Bumper Fastener 30 ft-lbs (41 Nm)
AC Hose, Condenser to 12 ft-lbs (16 Nm) Front Fender Fasteners 22 in lbs (3 Nm)
Evaporator
Front ROPS Fastener - Crew 40 ft-lbs (54 Nm)
AC Pressure Hose 18 ft-lbs (24 Nm)
Front Seat Bracket Fasteners 6 ft-lbs (8 Nm)
AC Suction Hose 18 ft-lbs (24 Nm) (INTL)
Air Distributor Manifold Fastener 18 in-lbs (2 Nm) Glovebox Fastener 42 in-lbs (5 Nm)
Air Filter Band Clamp 24 in-lbs (3 Nm) Handle, Grab Fastener 10 ft-lbs (14 Nm)
Body Fastener 42 in-lbs (5 Nm) Headliner Fastener 42 in-lbs (5 Nm)
Bolster, Bracket Fastener 6 ft-lbs (8 Nm) HVAC Condenser Fastener 35 in-lbs (4 Nm)
Buckle, Seat Mounting Fastener 40 ft-lbs (54 Nm) HVAC Unit Mounting Bracket 6 ft-lbs (8 Nm)
Fastener
Cargo Box Bracket Fastener 5 ft-lbs (7 Nm)
HVAC Unit Mounting Fastener 8 ft-lbs (11 Nm)
Cargo Box Fastener 42 in-lbs (5 Nm)
Inner Cargo Box Fastener 8 in lbs (1 Nm)
Cargo Box Frame Fastener 14 ft lbs (19 Nm)
Instrument Cluster Fastener 12 in lbs (1 Nm)
Cargo Box Heat Shield Fastener 18 in lbs (2 Nm)
14X5/8 Lower Door Panel Bracket Trim 6 ft-lbs (8 Nm)
Cargo Box Heat Shield Fastener 42 in-lbs (5 Nm) Lower Tailgate Support Fastener 10 ft lbs (14 Nm)
M6X1.0
Outer Cargo Box Panel Fastener 8 in lbs (1 Nm)
Cargo Box Latch Bushing 13 ft lbs (18 Nm)
Fastener Outer Tailgate Panel Fastener 22 in lbs (2 Nm)
Center Roof Screw (CREW) 24 in-lbs (3 Nm) Outer Tailgate Panel Fastener 22 in lbs (2 Nm)
Cross Bar Fastener 14 ft-lbs (19 Nm) Overhead Light Fastener 18 in lbs (2 Nm)
Dash Bracket Fastener 6 ft-lbs (8 Nm) Plate, Windshield Mount 36 ft-lbs (49 Nm)
Fastener
Dash, Main Fastener 42 in-lbs (5 Nm)
Rear Bumper Hinge Fastening 14 ft-lbs (Nm 19 Nm)
Dash, Storage Fastener 42 in-lbs (5 Nm) Nut
Dash, Upper Storage Fastener 10 in-lbs (1 Nm) Rear Bumper Upper Fastener 10 ft-lbs (14 Nm)
Door Bracket Fasteners 17 ft-lbs (23 Nm) Rear Close Off Panel Fastener 42 in-lbs (5 Nm)
Door Handle Fastener - High 42 in-lbs (5 Nm) Torque until lock and
Lifter Rear Glass Fastener ride clamps are fully
seated
Door Hinge Fastener 17 ft-lbs (23 Nm)
Rear Seat Bracket Fasteners 6 ft-lbs (8 Nm)
Door Hinge Fastener - High Lifter 17 ft-lbs (23 Nm) (INTL)
Door Latch Fastener 8 ft-lbs (11 Nm) Rear View Mirror Fastener Torque until fully
seated
Door Panel Fastener - High Lifter 42 in-lbs (5 Nm)
Roof Bracket Fastener 42 in-lbs (5 Nm)
Door Retainer Fastener 6 lb-ft (8 Nm)
Roof Fastener 42 in-lbs (5 Nm)
Door Striker Fastener 17 ft-lbs (23 Nm)

GENERAL INFORMATION
TORQUE CHASSIS / BODY ELECTRICAL

TORQUE 1
ROPS Fastener 45 ft-lbs (61 N·m) PART DESCRIPTION SPECIFICATION
Seat Back Frame Fastener 10 ft lbs (14 Nm) Alternator Hot Wire at Terminal 40 in-lbs (4 Nm)
Block
Seat Base Fastener 10 ft-lbs (14 Nm)
Audio Bar Fasteners 6 ft-lbs (8 Nm)
Seat Base Fasteners (INTL) 7 ft-lbs (9 Nm)
Battery Box Fastener 42 in-lbs (5 Nm)
Seat Bracket Hinge Fastener 6 ft lbs (9 Nm)
Battery Bracket Fastener 42 in-lbs (5 Nm)
Seat Bracket Pivot Fastener 10 ft lbs (14 Nm)
Battery Terminal Fastener 40 in-lbs (5 Nm)
Seat Bracket Pivot Mounting 10 ft lbs (14 Nm)
Fastener Brake Switch 15 ft-lbs (20 Nm)
Seat Shock Ball End Fastener 7 ft lbs (9 Nm) CPS Retaining Fastener 9 ft-lbs (12 Nm)
Seat Slide Assembly Fastener 6 ft lbs (8 Nm) Torque until fully
Dome Light Fasteners
seated
Seat Slider Assembly Fasteners 18 ft-lbs (24 Nm)
(INTL) Door Speaker Cover Fasteners Torque until fully
seated
Seat, Frame Fastener 18 ft-lbs (24 Nm)
Door Speaker Fasteners Torque until fully
Seat-Back, Fastener 18 inch-lbs (2 Nm) seated
ECT Sensor 16 ft-lbs (22 Nm)
Seat-Belt, Fastener 40 ft-lbs (54 Nm)
ECU Retaining Fastener 24 in lbs (2.7 Nm)
Side Net Fastener 6 ft-lbs (8 Nm)
6 ft-lbs (8 Nm) ETC Housing Retaining Fastener 5 ft-lbs (7 Nm)

Skid Plate Fastener
Tailgate Cap Fastener 22 in lbs (2 Nm) Front Speaker Cover Fasteners 6 ft-lbs (8 Nm)
Tailgate Latch Fastener 7 ft lbs (9 Nm) Front Speaker Fasteners Torque until fully
seated
Tailgate Support Fastener 42 in-lbs (5 Nm) Headlight Fastener 5 ft-lbs (7 Nm)
Tip-Out Windshield Fasteners 17 ft-lbs (23 Nm) HVAC Alternator Harness 54 in-lbs (56 Nm)
Bracket
Upper Glovebox Mounting 10 in-lbs (1 Nm)
Fastener Ignition Coil Retaining Bolt 8 lb-ft (11 Nm)
Washer Fluid Reservoir Torque until fully Oxygen Sensor 18 ft-lbs (24 Nm)
Fasteners seated
Weld, Cab Frame Fastener 36 ft-lbs (54 N·m) Rear Speaker Bracket Fasteners 6 ft-lbs (8 Nm)
Weld, Seat Bolster Fastener 10 ft-lbs (14 Nm) Rear Speaker Fasteners 6 ft-lbs (8 Nm)
Window Motor Fastener Torque until fully Ride Command Monitor

12 in-lbs (1.3 Nm)
seated Mounting Bracket Fasteners
Window Regulator Fasteners 8 ft-lbs (11 Nm) Spark Plug 9 ft–lbs (12 Nm)
Window Regulator Glass Torque until fully Speed Sensor 10 ft-lbs (14 Nm)
Fasteners seated
Starter Cable Wiring Nuts 48 in-lbs (5 Nm)
Window Regulator Support 6 ft-lbs (8 Nm)
Bracket Starter Motor Fasteners 7 lb-ft (10 Nm)
Windshield Motor Trim Panel Torque until fully Subwoofer Amplifier Mounting Torque until fully
Fasteners seated Fasteners seated
Subwoofer Cover Fasteners 6 ft-lbs (8 Nm)
Subwoofer Fasteners 6 ft-lbs (8 Nm)

GENERAL INFORMATION
TORQUE
Tail Light Fasteners 4 lb-ft (5 Nm)
Terminal Block Cables 30 in-lbs (3.5 Nm)
Terminal Block Fasteners 24 in-lbs (3 Nm)
T-MAP Retaining Fastener 3 ft-lbs (4.5 Nm)

GENERAL INFORMATION
2021 VEHICLE SPECIFICATIONS

VEHICLE SPECIFICATIONS NOTICE 1
IMPORTANT
All vehicle specifications in the following sections are based off of the base models shown. Any additional features,
options, or accessories that are added to the vehicle may cause the vehicle specifications to vary from shown.
MODEL SPECIFICATIONS - 3 SEAT

MODEL MODEL NUMBERS MODEL IMAGE
R21RRE99A9 / AW / AP / AC / B9 /
RANGER XP 1000 PREMIUM
BW / BP / BC
RANGER XP 1000 PREMIUM RIDE R21RRK99A9 / AW / AP / B9 / BW /

COMMAND BP
RANGER XP 1000 NORTHSTAR R21RRU99A9 / AW / AP / AC / B9 /

PREMIUM BW / BP / BC

GENERAL INFORMATION
RANGER XP 1000 NORTHSTAR R21RRY99A9 / AW / AP / AC / B9 /

ULTIMATE BW / BP / BC
RANGER XP 1000 NORTHSTAR R21RRZ99A9 / AW / AP / AC / B9 /

ULTIMATE MB QUART AUDIO BW / BP / BC
RANGER XP 1000 TRAIL BOSS R21RRH99AC / BC
RANGER XP 1000 NORTHSTAR

R21RRV99AC / BC
TRAIL BOSS

GENERAL INFORMATION

1
RANGER XP 1000 HIGH LIFTER R21RRM99AG
RANGER XP 1000 TEXAS EDITION R21RRF99AK

GENERAL INFORMATION
GENERAL SPECIFICATIONS
NORTHSTAR TRAIL
RANGER XP 1000
RANGER XP 1000
RIDE COMMAND
TEXAS EDITION
QUART AUDIO
ULTIMATE MB
HIGH LIFTER
NORTHSTAR
NORTHSTAR
NORTHSTAR
TRAIL BOSS
ULTIMATE
PREMIUM
BOSS
122 in
Length 120 in (305 cm)
(309 cm)
65 in (165
Width 62.5 in (158 cm) 65 in (165 cm) 62.5 in (158 cm)
cm)
78 in (198 78 in (198 79.5 in 78 in (198

Height 77 in (195 cm) 79.5 in (202 cm)
cm) cm) (202 cm) cm)
Wheel 81 in (206 cm)

Base
Ground 15 in (38
Clear- 13 in (33 cm) 14 in (36 cm)
cm)
ance
Dry 1922 (872 1955 (887 1607 (729 1684 (763 1775 (805
1593 (723 kg) 1937 (879 kg)
Weight kg) kg) kg) kg) kg)
Gross
Vehicle 3600 (1632 kg)
Weight
Cargo
1000 (455 kg)
Box
600 (272 kg) (EVAP Models)
Capacity
Cargo
Box
36.75 x 54.25 x 12.5 in
Dimen-
(93 x 138 x 32 cm)
sions
(Inside)
1500 (680
Maximum
1500 (680 kg) kg)
Weight 1275 (578 kg)
1100 (499 kg) (EVAP 1100 (499 1500 (680 kg)
Capacity 1100 (499 kg) (EVAP Models)
Models) kg) (EVAP
(Payload)
Models)
Hitch
Towing 2500 (1134 kg)
Capacity
Hitch
Tongue 10% of Towing Capacity
Capacity

GENERAL INFORMATION
ENGINE
ALL MODELS 1
Platform 4-Stroke, DOHC, Twin Cylinder
Engine Displacement 999 cm3
Number of Cylinders 2
Bore & Stroke 93 mm x 73.5 mm
Compression Ratio 10.8:1
Engine Idle Speed 1250 ± 100 RPM
Engine Max Speed 8000 RPM
Valve Clearance (Int) .006 ± .002 in (0.15 ± 0.05 mm)
Valve Clearance (Exh) .010 ± .002 in (0.25 ± 0.05 mm)
Engine Over Temperature
Warning Instrument Cluster Indicator
Lubrication Wet Sump

Oil Requirements PS-4 5W-50 Full Synthetic
Oil Capacity 2.5 Qt. (2.4 L)
Coolant Capacity 5.0 Qt (4.75 L)
FUEL SYSTEM
ALL MODELS
Fuel Delivery Electronic Fuel Pump (in-tank)
Fuel Pressure 58 ± 2 PSI (400 ± 14 kPa)
11.5 Gal (43.5 L)
Fuel Capacity / Requirement
87 Octane (minimum)

GENERAL INFORMATION
ELECTRICAL SYSTEM
NORTHSTAR TRAIL
RANGER XP 1000
RANGER XP 1000
RIDE COMMAND
TEXAS EDITION
QUART AUDIO
ULTIMATE MB
HIGH LIFTER
NORTHSTAR
NORTHSTAR
NORTHSTAR
TRAIL BOSS
ULTIMATE
PREMIUM
BOSS
Alterna- 900 Watts
tor Max 660 Watts @ 3000 1288 Watts @ 3000 RPM 660 Watts @ 3000
@ 3000
Output RPM RPM
RPM
Dual LED
Head-
Dual lamps Dual Dual
Main Beam (2300lm Beam Beam
Head- Halogen High Halogen Dual LED Headlamps (2300lm High Beam/1250lm Low Beam) Halogen
lights (H4 60/ Beam/ (H4 60/ (H4 60/
55W Bulb) 1250lm 55W Bulb) 55W Bulb)
Low
Beam)
Taillights 10 L.E.D. (.28W)
Brake
10 L.E.D. (3.1W)
Lights
Ignition
Digital CDI
System
Spark
Plug / NGK MR7F / 0.7-0.8 mm
Gap
Battery / 12 V Flooded / 575 CCA

CCA
DC
Standard 12 Volt
Outlet

GENERAL INFORMATION
DRIVETRAIN
1
NORTHSTAR TRAIL
RANGER XP 1000
RANGER XP 1000
RIDE COMMAND
TEXAS EDITION
QUART AUDIO
ULTIMATE MB
HIGH LIFTER
NORTHSTAR
NORTHSTAR
NORTHSTAR
TRAIL BOSS
ULTIMATE
PREMIUM
BOSS
Transmis-
sion Type Polaris Automatic PVT
Shift Type In Line Shift - H / L / N / R / P

Transmis- High: 4.35:1 / Rear 13.01:1
sion Gear Low: Front 9.65:1/ Rear 28.84:1
Ratios: Reverse: Front 9.16:1 / Rear 27.39:1
Front
Drive 3.25:1
Ratio
Front
Gearcase Demand Drive Fluid
Lubricant 8.5 oz (250 mL)
Require-
ment
Transmis-
sion AGL Gearcase Lubricant
Lubricant 52 fl oz ( 1550 mL)
Require-
ment

GENERAL INFORMATION
STEERING / SUSPENSION
NORTHSTAR TRAIL
RANGER XP 1000
RANGER XP 1000
RIDE COMMAND
TEXAS EDITION
QUART AUDIO
ULTIMATE MB
HIGH LIFTER
NORTHSTAR
NORTHSTAR
NORTHSTAR
TRAIL BOSS
ULTIMATE
PREMIUM
BOSS
Steering
Wheel
0.8-1.0 in (20-25 mm)
Free-
Play
Wheel 1/8-1/4 in (3.2-6.4 mm)

Toe Out
Front Independent, Arched
Independent, Arched
Suspen- Dual A-Arm Dual A-Arm Lower A-arms,
Lower A-Arms
sion
Front 11.0 in (27.9 cm) 10.0 in (25.4 cm) 10.0 in (25.4 cm) 10.0 in (25.4 cm)
Travel
Independent, Arched
Rear Lower A-Arms, Nivomat Independent, Arched
Suspen- Dual A-Arm, IRS Dual A-Arm, IRS Load- Lower A-arms,
sion
Adaptive
Rear 11.0 in (27.9 cm) 10.0 in (25.4 cm) 10.0 in (25.4 cm) 10.0 in (25.4 cm)
Travel
Spring
Adjust- Threaded Spanner Wrench
ment

GENERAL INFORMATION
WHEELS / BRAKES
1
NORTHSTAR TRAIL
RANGER XP 1000
RANGER XP 1000
RIDE COMMAND
TEXAS EDITION
QUART AUDIO
ULTIMATE MB
HIGH LIFTER
NORTHSTAR
NORTHSTAR
NORTHSTAR
TRAIL BOSS
ULTIMATE
PREMIUM
BOSS
Front /
Rear
Wheel Aluminum 14"
Type /
Size
Front Tire 30 x 9.5 -
Size / 27 x 9-14; Maxxis® MU511 29 x 9-14; Maxxis® MU511 14 Outlaw
Model 2
Rear Tire 30 x 11 -
Model 2
Front Tire 10 psi (69
Air 12 psi (83 kPa) 10 psi (69 kPa) 10 psi (69 kPa)
kPa)
Pressure
Rear Tire 14 psi (97 kPa) 12 psi (83
Air 14 psi (97 kPa) 12 psi (83 kPa)
kPa)
Pressure
Brake
System Foot Activated, 4 wheel hydraulic disc with dual-bore front calipers
Front &
Rear
Brake
DOT 4
Fluid

GENERAL INFORMATION
MODEL SPECIFICATIONS - CREW

R21RSE99A9 / AW / AP / AC / B9 /
RANGER XP 1000 PREMIUM
BW / BP / BC
RANGER XP 1000 PREMIUM RIDE R21RSK99A9 / AW / AP / B9 / BW /

COMMAND BP
RANGER XP 1000 NORTHSTAR R21RSU99A9 / AW / AP / AC / B9 /

PREMIUM BW / BP / BC
RANGER XP 1000 NORTHSTAR R21RSY99A9 / AW / AP / AC / B9 /

ULTIMATE BW / BP / BC

GENERAL INFORMATION

1
RANGER XP 1000 NORTHSTAR R21RSZ99A9 / AW / AP / AC / B9 /

ULTIMATE MB QUART AUDIO BW / BP / BC
RANGER XP 1000 TRAIL BOSS R21RSH99AC / BC
RANGER XP 1000 NORTHSTAR

R21RSV99AC / BC
TRAIL BOSS
RANGER XP 1000 HIGH LIFTER R21RSM99AG
RANGER XP 1000 TEXAS EDITION R21RSF99AK

GENERAL INFORMATION
NORTHSTAR TRAIL
RANGER XP 1000
RANGER XP 1000
RIDE COMMAND
TEXAS EDITION
QUART AUDIO
ULTIMATE MB
HIGH LIFTER
NORTHSTAR
NORTHSTAR
NORTHSTAR
TRAIL BOSS
ULTIMATE
PREMIUM
BOSS
65 in (165
Width 62.5 in (158 cm) 65 in (165 cm) 62.5 in (158 cm)
cm)
78 in (198 78 in (198 79.5 in 78 in (198

Height 77 in (195 cm) 79.5 in (202 cm)
cm) cm) (202 cm) cm)
Wheel 113 in (287 cm)

Base
Ground 15 in (38
Clear- 13 in (33 cm) 14 in (36 cm)
cm)
ance
Dry 2359 2405 2135 (968
1929 (875 kg) 2370 (1076 kg) 1942 (881 kg)
Weight (1070 kg) (1091 kg) kg)
Gross
Vehicle 3750 (1701 kg)
Weight
Cargo
1000 (455 kg)
Box
600 (272 kg) (EVAP Models)
Capacity
Cargo
Box
36.75 x 54.25 x 12.5 in
Dimen-
(93 x 138 x 32 cm) in
sions
(Inside)
1275 (578 1690 (767

Maximum
1690 (767 kg) kg) kg)
Weight 1225 (556 kg) 1690 (767 1500 (680
1350 (612 kg) (EVAP 1275 (578 1350 (612
Capacity 1225 (556 kg) (EVAP Models) kg) kg)
Models) kg) (EVAP kg) (EVAP
(Payload)
Models) Models)
Hitch
Towing 2500 (1134 kg)
Capacity
Hitch
Tongue 10% of Towing Capacity
Capacity

GENERAL INFORMATION
ENGINE
ALL MODELS 1
Engine Displacement 999 cm3
Engine Over Temperature
Warning Instrument Cluster Indicator

FUEL SYSTEM
ALL MODELS
11.5 Gal (43.5 L)
Fuel Capacity / Requirement
87 Octane (minimum)

GENERAL INFORMATION
ELECTRICAL SYSTEM
NORTHSTAR TRAIL
RANGER XP 1000
RANGER XP 1000
RIDE COMMAND
TEXAS EDITION
QUART AUDIO
ULTIMATE MB
HIGH LIFTER
NORTHSTAR
NORTHSTAR
NORTHSTAR
TRAIL BOSS
ULTIMATE
PREMIUM
BOSS
Alterna- 900 Watts
tor Max 660 Watts @ 3000 1288 Watts @ 3000 RPM 660 Watts @ 3000
@ 3000
Output RPM RPM
RPM
Dual LED
Head-
Dual lamps Dual Dual
Main Beam (2300lm Beam Beam
Head- Halogen High Halogen Dual LED Headlamps (2300lm High Beam/1250lm Low Beam) Halogen
lights (H4 60/ Beam/ (H4 60/ (H4 60/
55W Bulb) 1250lm 55W Bulb) 55W Bulb)
Low
Beam)
Brake
10 L.E.D. (3.1W)
Lights
Ignition
Digital CDI
System
Spark
Plug / NGK MR7F / 0.7-0.8 mm
Gap
Battery / 12 V Flooded / 575 CCA

CCA
DC
Standard 12 Volt
Outlet

GENERAL INFORMATION
DRIVETRAIN
1
NORTHSTAR TRAIL
RANGER XP 1000
RANGER XP 1000
RIDE COMMAND
TEXAS EDITION
QUART AUDIO
ULTIMATE MB
HIGH LIFTER
NORTHSTAR
NORTHSTAR
NORTHSTAR
TRAIL BOSS
ULTIMATE
PREMIUM
BOSS
Transmis-
sion Type Polaris Automatic PVT

Transmis- High: 4.35:1 / Rear 13.01:1
sion Gear Low: Front 9.65:1/ Rear 28.84:1
Ratios: Reverse: Front 9.16:1 / Rear 27.39:1
Front
Drive 3.25:1
Ratio
Front
Gearcase Demand Drive Fluid
Lubricant 8.5 oz (250 mL)
Require-
ment
Transmis-
sion AGL Gearcase Lubricant
Lubricant 52 fl oz ( 1550 mL)
Require-
ment

GENERAL INFORMATION
NORTHSTAR TRAIL
RANGER XP 1000
RANGER XP 1000
RIDE COMMAND
TEXAS EDITION
QUART AUDIO
ULTIMATE MB
HIGH LIFTER
NORTHSTAR
NORTHSTAR
NORTHSTAR
TRAIL BOSS
ULTIMATE
PREMIUM
BOSS
Steering
Wheel
0.8-1.0 in (20-25 mm)
Free-
Play
Wheel 1/8-1/4 in (3.2-6.4 mm)

Toe Out
Front Independent, Arched
Independent, Arched
Suspen- Dual A-Arm Dual A-Arm Lower A-arms,
Lower A-Arms
sion
Front 11.0 in (27.9 cm) 10.0 in (25.4 cm) 10.0 in (25.4 cm) 10.0 in (25.4 cm)
Travel
Independent, Arched
Rear Lower A-Arms, Nivomat Independent, Arched
Suspen- Dual A-Arm, IRS Dual A-Arm, IRS Load- Lower A-arms,
sion
Adaptive
Rear 11.0 in (27.9 cm) 10.0 in (25.4 cm) 10.0 in (25.4 cm) 10.0 in (25.4 cm)
Travel
Spring
Adjust- Threaded Spanner Wrench
ment

GENERAL INFORMATION
WHEELS / BRAKES
1
NORTHSTAR TRAIL
RANGER XP 1000
RANGER XP 1000
RIDE COMMAND
TEXAS EDITION
QUART AUDIO
ULTIMATE MB
HIGH LIFTER
NORTHSTAR
NORTHSTAR
NORTHSTAR
TRAIL BOSS
ULTIMATE
PREMIUM
BOSS
Front /
Rear
Wheel Aluminum 14"
Type /
Size
Front Tire 30 x 9.5 -
Model 2
Rear Tire 30 x 11 -
Model 2
Front Tire 18 psi
Air 18 psi (124 kPa) 23 psi (159 kPa) 14 psi (97 kPa)
(124 kPa)
Pressure
Rear Tire 25 psi (172 kPa) 20 psi
Air 20 psi (138 kPa) 16 psi (110 kPa)
(138 kPa)
Pressure
Brake
System Foot Activated, 4 wheel hydraulic disc with dual-bore front calipers
Front &
Rear
Brake
DOT 4
Fluid

GENERAL INFORMATION
MODEL SPECIFICATIONS - INTERNATIONAL MODELS

RANGER XP 1000 EU R21RRE99FP / F9
RANGER XP 1000 ZUG R21RRS99FP / F9
RANGER XP 1000 ISRAEL R21RRE99JA

GENERAL INFORMATION

1
RANGER XP 1000 TRACTOR R21RRS99CP / CK / C9
RANGER XP 1000 ABS TRACTOR R21RRP99CW

GENERAL INFORMATION
TRACTOR / ISRAEL
RANGER XP 1000
RANGER XP 1000
RANGER XP 1000
ABS TRACTOR
EU / ZUG
Width 62.5 in (159 cm)
Height 77 in (195 cm)
Wheel Base 81 in (206 cm)
Ground 13 in (33 cm)

Clearance
Dry Weight 1574 (714 kg) 1616 (733 kg)
Gross Vehicle 2989 (1356 kg)

3400 (1542 kg)
Weight
Cargo Box
1000 (454 kg)
Capacity
Cargo Box
36.5 x 54 x 11.5 in
Dimensions
(93 x 137 x 29 cm)
(Inside)
Maximum
Weight
1627 (738 kg) 1318 (598 kg)
Capacity
(Payload)
Hitch Towing Maximum Braked Trailer Mass: 2205 (1000 kg)

2500 (1136 kg)
Capacity Maximum Unbraked Trailer Mass: 1609 (730 kg)
Hitch Tongue
150 (68 kg)
Capacity

GENERAL INFORMATION
ENGINE
ALL MODELS 1
Engine Displacement 61 ci (999 cc)
Engine Over
Temperature Warning Instrument Cluster Indicator

FUEL SYSTEM
ALL MODELS
Fuel Capacity / 11.5 Gal (43.5 L)
Requirement 87 Octane (minimum)
ELECTRICAL SYSTEM
TRACTOR / ISRAEL
RANGER XP 1000
RANGER XP 1000
RANGER XP 1000
ABS TRACTOR
EU / ZUG
660 Watts @ 3000 RPM

Alternator Max
660 Watts @ 3000 RPM (if equipped with cab heater) 900 660 Watts @ 3000 RPM
Output
W @ 3000 RPM
Main Headlights Dual LED Headlamps (2300lm High Beam/1250lm Low Beam)
Brake Lights 10 L.E.D. (3.1W)
Ignition System Digital CDI
Spark Plug /
Gap NGK MR7F / 0.7-0.8 mm
Battery / CCA 12 V Flooded / 530 CCA

DC Outlet Standard 12 Volt

GENERAL INFORMATION
DRIVETRAIN
TRACTOR / ISRAEL
RANGER XP 1000
RANGER XP 1000
RANGER XP 1000
ABS TRACTOR
EU / ZUG
Transmission
Type Polaris Automatic PVT

High: Front 4.35:1 / Rear 13.01:1
Transmission
Low: Front 9.65:1/ Rear 28.84:1
Gear Ratios:
Reverse: Front 9.16:1 / Rear 27.39:1
Non-ADC Models: 3.25:1
3.08:1 3.25:1
Front Drive Ratio ADC Models: 3.08:1
Front Gearcase
Demand Drive Fluid
Lubricant
8.5 oz (250 mL)
Requirement
Transmission
AGL Gearcase Lubricant
Lubricant
52 fl oz ( 1550 mL)
Requirement
ALL MODELS
Steering Wheel Free-
0.8-1.0 in (20-25 mm)
Play
Wheel Toe Out 1/8-1/4 in (3.2-6.4 mm)
Front Suspension Dual A-Arm
Front Travel 11.0 in (27.9 cm)
Rear Suspension Dual A-Arm, IRS
Rear Travel 11.0 in (27.9 cm)
Spring Adjustment Threaded Spanner Wrench

GENERAL INFORMATION
WHEELS / BRAKES
1
TRACTOR / ISRAEL
RANGER XP 1000
RANGER XP 1000
RANGER XP 1000
ABS TRACTOR
EU / ZUG
Front / Rear
Wheel Type / Aluminum 12"
Size
27 x 9-12; Maxxis® MU51
Front Tire Size / 27 x 9-12; Maxxis® MU51 27 x 9-12; Maxxis® MU51
Israel Models: 26 x 9-12, PXT, E-
Model
Mark
27 x 11-12; Maxxis® MU51
Rear Tire Size / 27 x 11-12; Maxxis® MU51 27 x 11-12; Maxxis® MU51
Israel Models: 26 x 11-12, PXT, E-
Model
Mark
Front Tire Air 10 psi (69 kPa)
Pressure
Rear Tire Air 14 psi (97 kPa)
Pressure
Brake System Foot Activated, 4 wheel hydraulic disc
Front & Rear
Brake Fluid DOT 4

GENERAL INFORMATION
CLUTCH SETTINGS
CLUTCH CHART
BASE AND CREW
CLUTCHES
SHIFT DRIVE DRIVEN
ALTITUDE
WEIGHT SPRING SPRING
0-1800 Meters 32–114
(0-6000 Feet) 7045326 7044761
1323697
1800-3700
Meters 32–106 Black
(6000 - 12000 (1323458) 103–200 7044761
Feet) 7045326

GENERAL INFORMATION
GENERAL DIAGNOSTICS INFORMATION OVERVIEW

NOTICE 1
General Diagnostics is a section within the Service Manual that contains information relating to various vehicle
diagnostics. These procedures are not vehicle specific and can be used for troubleshooting many different vehicles.
For vehicle specific troubleshooting and diagnostic information please refer to the specific system chapters for more
information.
GUIDED SYMPTOM DIAGNOSTIC

Is this the first time that the
vehicle concern has been
diagnosed?
→ No
Refer to Guided Symptom
References
Yes ↓
If the concern has not been
→ →
able to be duplicated gather
more information about the If the same concern is present
Has the concern been on the like vehicle, it is likely
concern. After the concern
duplicated and compared to a that the concern is a normal
has been duplicated, please
like vehicle? No Yes operational characteristic.
compare to a like vehicle. Is
the concern present on that
vehicle?
Yes ↓ ↙ No
Are there any bulletins related

to the concern? →Yes
Proceed with instruction from
the bulletin. Has the problem
been resolved?
→
Yes
Concern has been repaired.
Return the vehicle to the
consumer at this time.
No ↓ ↙ No
Connect Digital Wrench and

check for any trouble codes.
Are there any codes present?
→Yes
Refer to Digital Wrench
Guided Diagnostic.
Has concern been repaired
after Guided Diagnostic?
→
Yes
Concern has been repaired.
Return the vehicle to the
consumer at this time.
No ↓ ↙ No

GENERAL INFORMATION
Refer to, Engine Cranks but

does Not Start page 1.48 or
→
No Crank No Start or Slow
Crank page 1.50.
Is the concern Starting Pay close attention to what is
Related? noted in the Occurrence
Yes Checklist for conditions when
concern is present. This will
help in determining cause of
concern.
No ↓ Refer to Engine and

Drivability Diagnostic
Is the concern related to

Engine Performance or a
Running concern?
→ Yes
Procedures page 1.45.
Pay close attention to what is
noted in the Occurrence
Checklist for conditions when
concern is present. This will
help in determining cause of
concern.
No ↓
Have any concerns in the
Transmission / Final Drive
Category been selected? → Refer to the Transmission or
Final Drive Chapters for
further diagnostic information.
No ↓
Is the concern related to a
Noise? → Yes
Refer to necessary service
information for pin-pointing
noise location and diagnosis.
GUIDED SYMPTOM REFERENCES

• For concerns that have not been able to be duplicated or are repeat concerns :
– Refer to the Customer Questionnaire and gather more information from the Consumer.
– Gather the information from previous repairs including Ask Polaris Cases.
– Verify that the concern can be consistently duplicated. When the concern is duplicated, please note the conditions
under which the concern is happening. Refer to the Symptom Checklist for various conditions.
– If the concern has been verified and all of the information has already been collected, please start an Ask Polaris
case at this time. If this information has not yet been gathered, gather this information first.

GENERAL INFORMATION
ENGINE AND DRIVABILITY DIAGNOSTIC PROCEDURES

NOTICE 1
The following chart is to prevent overlooking a simple problem. These basic systematic procedures should be
checked before further testing is performed.
Yes • Proceed to step w

q What is the
customers concern
and can the concern
be duplicated at this • If the concern can not be duplicated, check for any bulletins related to the
time? No concern. Gather more information from the consumer. Proceed to step e. If
the concern still can not be duplicated proceed to step u.
Yes • Proceed to bulletin for repair procedure. If problem is still present, return to
w Are there any chart.
Team-Tips, Recalls,
or Other Bulletins for
this concern? No • Proceed to step e
• For CHECK ENGINE LIGHT or PERFORMANCE LIMITED LIGHT

– Connect to Digital Wrench®. Check codes and continue with Digital
Wrench® Guided diagnosis.
– Certain failures may not display a CEL / MIL on the instrument cluster. In
this instance record CEL’s from the instrument cluster and refer to the
necessary section in the Service Manual.
– Refer to Warning Lights page 1.52.
• For ENGINE HOT WARNING
– Check Coolant level. If not full, fill to correct level.
– Check Oil level. If not full, fill to correct level.
– Visually inspect for Oil or Coolant leaks. If any leaks are present repair
e Are there any Yes
before continued diagnosis.
warning lights or – Refer to Warning Lights page 1.52.
messages on – Refer to Over Heating page 1.51.
vehicle? (Reference
• For EPS WARNING (if applicable) Refer to STEERING - EPS
necessary manual
TROUBLESHOOTING.
for light
identification) – Check battery voltage and connections.
– Check connections at EPS unit. If any connection or wiring damage is
found, repair before proceeding.
– Refer to EPS Troubleshooting (Using Digital Wrench®) page 1.87. Check
codes and continue with diagnosis.
– If no codes are present, refer to EPS Troubleshooting (Power Steering
Non-Functional with MIL OFF) page 1.86
– If codes are present, refer to EPS Troubleshooting (Power Steering Non-
Functional with MIL ON) page 1.85
• Connect to Digital Wrench®. Check codes and continue with Digital

No Wrench® Guided diagnosis.
• If no codes are present, proceed to step r

GENERAL INFORMATION
• Check Oil level. If not full, fill to correct level.

• Check Fuel Level. (Check tank using flash light - gauge may not be accurate
Yes - add fuel if needed)
• Check Coolant level. If not full, fill to correct level.
Continue to step t
• Check Oil level. If oil is low concern may be caused by lack of oil or oil
r Does the engine pressure. Suspect internal engine issue. Refer to Chapter 3 Engine / Cooling
crank? System.
• Check for battery power. Voltage should be ~ 12.6 V.
No • Load test battery. If battery fails the load test, charge / replace battery as
needed. Retest for concern before proceeding.
• Check Ignition Switch and connections. Concern may be caused by faulty
Ignition Switch.
• Refer to No Crank No Start or Slow Crank page 1.50 for further diagnostic
procedures
Yes • Continue to step y
• Check air filter for blockage.

• Check for spark. Refer toEngine Cranks but does Not Start page 1.48 for
t Does the engine quick check.
stay running?
• Check fuel supply using fuel pressure gauge. Is fuel pressure within
No
specification?
• Check exhaust for blockage.
• After checking for air supply and fuel pressure, perform leakdown test.
• Refer to Engine Cranks but does Not Start page 1.48 for more information.

GENERAL INFORMATION
Yes • Continue to step u 1

• Remove PVT cover if necessary and check belt for damage or unusual wear.
Refer to Belt Inspection for more information.
y Will the vehicle • If no damage is found, using the aid of an assistant slowly rev engine
move under its own observing clutch engagement. If no engagement is seen refer to PVT System
power? Troubleshooting.
No
• Using the aid of an assistant verify the propshaft is turning, while the clutch is
engaged. If the driveshaft is turning refer to Differential Diagnosis /
Disassembly in the applicable service manual.
• If the driveshaft is not moving, concern may be within transmission. Refer to
the necessary section in the applicable service manual.
• If the concern is related to the PVT system, Transmission, or Final Drive,

refer to the applicable section in the service manual.
• If the concern is electrical systems related, refer to Electrical
Troubleshooting.
• If the concern is overheating or related to the cooling system, first refer to
u Test drive vehicle Over Heating page 1.51 , then Cooling Troubleshooting page 1.55.
for concern.
• If the concern is driveability related (lack of power, misfire, etc.), refer to Fuel
System Troubleshooting page 1.76, or Cylinder Misfire Detection page 1.74.
These concerns may also be caused by a mechanical failure.
• If the concern can not be diagnosed or repaired using normal diagnostic
means, please contact Polaris Technical Service Team.

GENERAL INFORMATION
ENGINE CRANKS BUT DOES NOT 6. Check fuses or fuel system relays (where applicable).
START • If any fuel related system fuses are blown, replace
1. Check battery voltage while cranking. If voltage is fuses and recheck. Wiring concern or faulty parts may
below 10.8V, vehicle may not start. cause fuse to blow.
• Perform Voltage Drop Test on Starter Circuit. Refer • It is advisable to try swapping a relay with a known
to Testing Voltage Drop page 1.94 for more good relay to check operation. Swap relay with like
information. Acceptable drop is 0.1V per relay and see if vehicle starts.
connection, if too much drop is detected concern
may be caused by faulty starter, or solenoid. 7. Check fuel lines and fittings for leaks or damage.
• Charge battery. • If leak or damage is found repair, replace as
• If equipped with a serviceable battery, check necessary and recheck concern.
battery electrolyte level. Fill following procedure if • If no concerns are found proceed with fuel pressure
low. testing.
• If battery voltage is not ~12.6 V charge battery at
8. Perform a fuel pressure test during engine cranking.
recommended rate. Attempt starting after charging.
• Verify that battery voltage is present at the fuel
• If battery still does not reach ~12.6 V, battery may pump. A low voltage concern may cause the pump
require replacement. to be inoperable.
2. Visually inspect vehicle for any electrical connectors • Check using fuel pressure gauge to see that fuel
or wiring that may be loose or damaged. Check pressure is within specification.
connectors for water intrusion or corrosion.
• If not within specification, if equipped check fuel
• If connections are found to be loose, repair filter / screen for restriction.
connector as necessary.
• If no concern is found with filter or pressure is still
• If connector is found to have corrosion or water low after filter replacement, suspect weak or faulty
within connectors, clean, dry, and reconnect. fuel pump.
• Repair any damage to wiring.
9. Inspect spark plug wiring, spark plug, and check for
3. Check vehicle for trouble codes. Refer to Digital spark.
Wrench® Diagnostic. • Check to make sure that spark plug is tight.
• If codes are present proceed with testing per Digital • Inspect spark plug for fouling. Inspect plug gap
Wrench®. using feeler gauge or similar tool. Adjust to
specification if needed.
4. Check air box and filter for debris or moisture.
• Disconnect plug wire and install an inline spark
• If debris is found clear debris and recheck for tester between the spark plug wire and spark plug.
concern. Check for spark. If a spark tester is not available,
• If water is found within air box, dry box and filter. It remove the spark plug and reinstall wire to plug
is possible that engine may have ingested water. connection. Using caution crank engine while
This could cause engine failure, refer to Engine watching spark plug for spark.
Troubleshooting page 1.53
CAUTION
5. Check fuel level and condition in vehicle.
DO NOT TOUCH SPARK PLUG DURING TEST.
• Possible to have incorrect reading from fuel gauge. TOUCHING SPARK PLUG COULD RESULT IN
Using a flashlight, check for fuel in tank. If no fuel is ELECTRIC SHOCK.
visible, fill with fuel before further diagnostic.
• Check fuel quality, pull fuel sample or drain tank • If plug does not spark in previous test, check
and refill with fresh fuel from a reliable source. connections at ignition coil. Ensure that the ignition
IMPORTANT coil has power and is receiving signal from the
ECU. Concern may be caused by faulty ignition coil
When filling with fuel, ensure that the fuel being used or electrical concern.
meets the correct octane rating specific to the vehicle.
10. Listen for unusual noises while cranking.
• If filled with fuel, vehicle starts, and gauge still is not
reading test the fuel sending unit.

GENERAL INFORMATION
• Broken or damaged flywheel, starter motor gear, or

starter motor drive could sound like engine
cranking but crankshaft may not be turning. 1
• Unusual noise could suggest that there may be a
mechanical engine concern. Proceed to step f
11. Check ECU and connections.

• ECU could be faulty causing concern.
• Check ECU for power and grounds to make sure that
computer is turning on.
12. If all previous checks pass, concern may be caused

by internal engine issue.
• Refer to Cylinder Leakdown Test.
• Previous testing may be caused by or lead to
replacement of one or more of the following:
– Cylinder head gasket leak
– No valve clearance (cam wear)
– Cylinder or piston worn
– Piston rings worn, leaking, broken, or sticking
– Bent valve or stuck valve
– Valve spring broken or weak
– Valve not seating properly (bent or carbon
accumulated on sealing surface)
– Rocker arm sticking

GENERAL INFORMATION
NO CRANK NO START OR SLOW • Using Digital Wrench® verify that the Brake Switch
CRANK is changing state from “Active” when the brake is
depressed to “Inactive” when the brake is released.
1. Verify that battery is charged and has ~12.6 V using
DMM or battery tester. • Most vehicles need to see brake being depressed
before vehicle will start. If brake lights do not light
• Check battery electrolyte level. If low top off battery. when brake is depressed, concern may be caused
See Maintenance — Electrical and Ignition by brake switch operation.
Systems.
• Charge battery at recommended rate. See. Attempt 6. Possible faulty key switch.
starting after charging. • Attempt turning key switch on and off multiple
times.
• If battery will not reach ~12.6 V could be caused by
battery draw. Refer to Diagnostic — Electrical • Wiggle key switch while turning.
Diagnostics.
• If vehicle starts, concern may be caused by key
• If battery will not reach ~12.6 V, load test battery. switch or connection to switch. Refer to Electrical
Replace if necessary. Refer to Electrical — Battery Chapter.
Removal / Installation.
7. Check for communication with ECU using Digital
2. Verify connections at battery are installed correctly Wrench®
and are tight. • If there is no communications with ECU there may
• If battery terminals are not installed correctly, install be a concern with the CAN system or ECU causing
terminals correctly the no start.
• Make sure terminals are clean of dirt and corrosion. 8. Concern may be caused by mechanical engine
If not refer to Maintenance — Battery Maintenance. concern.
3. Visually inspect vehicle for any electrical connectors • Refer to Engine Troubleshooting.
or wiring that may be loose or damaged.
• If wiring issues are found, repair as necessary.
Refer to wiring diagrams if needed.
• Check battery ground. Follow Negative (-) Cable
from battery to chassis and make sure connection
is clean and tight.
4. Check connections at starter and starter solenoid.

Refer to Electrical Chapter.
• Make sure connections are clean and tight. If not
repair before further diagnosis.
• Check Positive (+) terminals at starter and solenoid
for available voltage using DMM. Readings should
be ~12.6 V
• With battery disconnected check cables for high
resistance. Reading should be less than 1 Ohm. If
resistance is higher than specification replace
wiring.
• Reconnect battery and perform voltage drop test
on wiring to starter and to starter solenoid. Concern
may still be caused by high resistance in wires
even if resistance is within specification when
disconnected.
• If voltage drop test fails, continue testing to isolate
component that will require replacement (starter /
starter solenoid / wiring). Acceptable voltage drop
during cranking is 0.1 V per connection.
5. Check Brake Switch operation.

GENERAL INFORMATION
OVER HEATING • Make sure the cooling fan is engaging. Command

cooling fans on and off using Digital Wrench to
1. Verify coolant is filled to correct level. check operation. 1
• If coolant is low, fill to correct level.
• Monitor engine temperature using Digital Wrench®
2. Test and check for correct coolant mixture. viewing the Engine Temperature PID. Once engine
has reached running temperature cooling fan
• If coolant mix is incorrect, correct mixture as should engage.
necessary.
8. Water Pump / Thermostat / Radiator may be suspect
• If incorrect coolant was used in vehicle, flush cooling of concern.
system and bleed, fill to correct level, and recheck.
• Thermostat could be opening too slowly or stuck
closed. Check temperature using Digital Wrench®
3. Check cooling system using combustion leak tester viewing the Engine Temperature to check for
for any combustion gasses entering the cooling correct operation.
system. This may suggest a head gasket, cylinder
head failure, or other engine damage. Adding coolant • Water pump may be faulty or not circulating
before test may dilute the system and cause enough coolant to keep temperature within
inaccurate test results. specification.
4. Check Radiator and cooling fans for restrictions or • Radiator core may not be functioning correctly or
damage failed causing concern.
• Check for debris, dirt, or mud between fan and
9. Faulty Temp Sensor / Circuit / ECU.
radiator restricting air flow. If present, clean and
recheck. • Confirm engine is overheating. It could be possible
that the coolant sensor is sending an incorrect
• Check for damage to radiator or cooling fans. If signal causing the ECU to think the vehicle is
damage is found to components repair or replace overheating when it is running at the proper
as necessary. temperature.
• Inspect for any aftermarket modifications that may • Check connections at temp sensor and wiring. If
be restricting air flow. (Radiator Modifications, Grille damage is found repair, as needed.
Modifications, Aftermarket Bumpers, Lightbars,
etc.) Pay close attention to the Radiator Shroud • Resistance test sensor, refer to ECT Sensor test. If
presence and placement. test fails, replace sensor.
• If concern is still present after sensor replacement
5. Check for coolant leaks / air pockets.
suspect the ECU is not receiving correct signal
• Visually check all hoses and radiator for leaks. If input. Inspect circuit wiring.
leaks are found repair as necessary.
10. Engine Damage
• Check cooling system using coolant pressure
tester. If leaks can not be seen on visual inspection, • The overheating concern may be caused by an
refer to Engine / Cooling system for more engine concern.
information. • Refer to the necessary section in the Service
• Check for air in cooling system. Bleed the cooling Manual for further engine testing.
system if needed.
11. Inspect ECU calibration level.
6. Check Oil level. • If any ECU calibrations are available, update at this
• Low oil level or oil in need of changing may cause time.
increase in engine temperature.
• Too high of oil level may cause engine
temperatures may cause increase in engine
temperature.
• Check level and correct as necessary. Check
maintenance history to determine if oil need to be
changed.
7. Check Cooling Fan operation.

GENERAL INFORMATION
WARNING LIGHTS
1. CHECK ENGINE
• Engine fault has been detected. Refer to Digital
Wrench for codes.
• Proceed with diagnosis after checking codes.
2. EPS WARNING (If applicable)

• Power steering fault has been detected.
• Check for codes using Digital Wrench. If no codes
present refer to EPS System – Troubleshooting
• Check connections at battery, could be caused by
voltage concern.
• Visually inspect connections at EPS Unit.
• For further diagnosis refer to Steering System –
Steering Assembly EPS
3. ENGINE HOT
• Over temperature condition detected.
• Check coolant level. If not full fill to correct level.
Bleed the cooling system to ensure there are no air
pockets present.
• Visually inspect hoses and radiator for coolant
leaks. Repair as necessary.
• Pressurize cooling system and look for pressure
losses. This indicates a leak in the cooling system.
Inspect for external leaks, if none are found it is
possible there is an internal leak.
• Check cooling system using combustion leak tester
for any combustion gasses entering the cooling
system. This could indicate possible Head /
Headgasket failure.
• Check oil level. Verify that oil is filled to the correct
level. Engine oil that is low, or overfull can cause
overheating concerns. Check maintenance history
to see if oil needs to be changed.
• Visually inspect for oil leaks.
• Refer to Over Heating page 1.51 for more info.
4. PERFORMANCE LIMITED
• Check for codes using Digital Wrench. Refer to
Guided Diagnostic for further diagnosis.
5. BRAKE WARNING
• Detects brake system failure.
• Inspect brake system for leaks, damage, etc. Refer
to Brake System chapter for more information.

GENERAL INFORMATION
ENGINE TROUBLESHOOTING
SPARK PLUG FOULING 1
• Spark plug cap loose or faulty • Injector Spray Pattern • Oil contaminated with fuel
• Incorrect spark plug heat range or • High Leakdown • Weak ignition (loose coil ground,
gap faulty coil, or stator)
• Valvetrain / Valve Clearances
• PVT system calibrated incorrectly/ • Restricted engine breather system
• Restricted exhaust
components worn or mis-adjusted
• Restricted air filter (main or pre-
• Vehicle not reaching operating cleaner) or breather system
• Fuel quality poor (old) or octane
temperature (Short tripping)
too high
• Improperly assembled air intake
system
ENGINE TURNS OVER BUT FAILS TO START
• No fuel • Fuel pump inoperative/restricted • Low compression (high cylinder

leakage)
• Dirt in fuel line or filter • Tank vent plugged or pinched
• No spark (Spark plug fouled)
• Fuel will not pass through fuel • Engine flooded
ignition component failure
valve
• Injector control circuit failure
• Intake leak / vacuum leak
• Clogged / Failed Fuel Injector
ENGINE DOES NOT TURN OVER
• Battery, Starter, and Ground Cable • Starter motor does not turn • Dead battery
Connections
• Starting system circuit concern
• Engine seized, rusted, or (blown fuse / failed relay /
mechanical failure damaged wiring)
ENGINE RUNS BUT WILL NOT IDLE
• Restricted fuel supply • Low compression • Throttle Body (installed incorrect /

electrical concern / failed)
• Intake leak / vacuum leak • TPS (installed incorrect / electrical
concern / failed sensor) • Crankcase breather restricted
ENGINE IDLES BUT WILL NOT ACCELERATE
• Spark plug fouled/weak spark • Air box removed (reinstall all • Cam worn excessively
intake components)
• Broken throttle cable • Restricted exhaust system
• Incorrect ignition timing
• Obstruction in air intake • Low fuel pressure
• Throttle Body

GENERAL INFORMATION
ENGINE HAS LOW POWER
• Spark plug fouled • PVT not operating properly • Restricted exhaust muffler
• Cylinder, piston, ring, or valve • Cam worn excessively • Low fuel pressure
wear or damage (check
compression)
• Poor fuel quality
PISTON FAILURE - SCORING
• Lack of lubrication • Dirt entering engine through • Engine oil dirty or contaminated
cracks in air filter or ducts
• Improper air filter maintenance
EXCESSIVE SMOKE (BLUE / BLACK) AND CARBON BUILDUP
• Excessive piston-to-cylinder • Worn rings, piston, or cylinder • Restricted breather

clearance
• Worn valve guides or seals • Air filter dirty or contaminated
• Wet sumping
LOW COMPRESSION
• Cylinder head gasket leak • Cylinder or piston worn • Piston rings worn, leaking, broken,
or sticking
• No valve clearance (cam wear) • Bent valve or stuck valve
• Valve spring broken or weak
• Valve not seating properly (bent or
carbon accumulated on sealing
surface)
BACKFIRING
• Ignition system faulty: • Intake system air leaks • Exhaust system air leaks
– Spark plug cap cracked / • Fouled spark plug or incorrect plug • Valve sticking
broken or plug gap
– Ignition coil faulty • Throttle Body (installed incorrect /
– Ignition or kill switch circuit • Low fuel pressure electrical concern / failed)
faulty
• Poor fuel quality
– Poor connections in ignition
system
– Ignition timing incorrect
– Sheared flywheel key

GENERAL INFORMATION
COOLING TROUBLESHOOTING
OVERHEATING 1
• Low coolant level • Restricted system (mud or debris • Electrical malfunction
in radiator fins causing restriction
• Air in cooling system • Water pump failure/ Loose
to air flow, passages blocked in
impeller
• Wrong type/mix of coolant radiator, lines, pump, or water
jacket, accident damage) • Thermistor failure
• Faulty pressure cap or system
leaks • Lean mixture (vents, fuel pump) • Low oil level
• High oil level • Fuel pump output weak • Thermostat stuck closed or not
• Cooling fan inoperative or turning opening completely
• Spark plug incorrect heat range
too slowly (perform current draw
• Radiator test)
• Faulty hot light circuit
LEAK AT WATER PUMP WEEP HOLE
• Faulty water pump mechanical seal (coolant leak) • Faulty pump shaft oil seal (oil leak)
TEMPERATURE TOO LOW
• Thermostat stuck open • Contaminated coolant

• Thermostat opening too soon

GENERAL INFORMATION
DIGITAL WRENCH
DIGITAL WRENCH® SOFTWARE OVERVIEW
The Polaris Digital Wrench® software allows a technician to perform the following tasks:
• Analyze real-time engine data

• Create customer service account records
• Generate / upload service reports
• Perform guided diagnostic procedures
• Perform output state control tests (most models)
• Reflash ECU calibration files
• View or clear trouble codes and freeze time data
See “Digital Wrench® Software Installation and Updates” for information on the latest software and updates.
For information on how to use the Digital Wrench® software, refer to the Digital Wrench® System Help. To access the
Digital Wrench® System Help, do one of the following:
• Expand the Digital Wrench® Help drop-down on the left side of the main screen and click System Help.
• Select the ‘Display Diagnostic System Help’ menu icon (question mark) on the main screen.
SPECIAL TOOLS
SPECIAL TOOL PART NUMBER
Digital Wrench® Diagnostic Kit PU-47063-C, which includes the following:
• Digital Wrench® Software: PU-48731-A
• Standard Interface Cable: PU-47151
• SmartLink Module Kit: PU-47471
• USB-Serial Adapter Cable: PU-50621
Wireless Vehicle Link (WVL) PU-51435
GUIDED DIAGNOSTICS
Guided diagnostics are available within Digital Wrench® for all supported Trouble Codes (that is, any fault that will turn
on the ‘Check Engine’ indicator).
In addition, guided diagnostics are also available for many other electrical sub systems.

GENERAL INFORMATION
DIGITAL WRENCH® SOFTWARE INSTALLATION AND UPDATES

Polaris recommends that you check your Digital
Wrench® software version often and upgrade when
3. Select the Digital Wrench X.X Updates link. 1
available to make sure you are using the most current
software. New programming files and diagnostic
procedures are added to subsequent versions of the
software as they become available.
To identify which Digital Wrench® software version is
installed on your PC, do the following:
1. Launch the Digital Wrench® software.

2. On the Digital Wrench® main screen, locate the
following information in the lower, right-hand corner:
• Base Version q (for example, Version: 4.1).
4. Select the update you want to install on your PC.
• Update w (release date), if available.
IMPORTANT
You must have the latest Base Version installed on your
PC before you can install the update. Updates will not
install on older Base Versions of Digital Wrench®. If you
do not have the latest Base Version installed on your
PC, skip this section and proceed to “Installing a New
Digital Wrench® Base Version”.
NOTICE
If you are using Internet Explorer, do NOT select “Run”.
Instead, select “Save” and save the file to your PC
before you run the install.
NOTICE
5. Follow the on-screen prompts to install the update.
If no updates for the Base Version are available, the
information in the lower, right-hand corner displays only 6. Once the update is complete, launch the Digital
the Base Version (for example, Version: 4.1 Base). You Wrench® software and verify the information in the
will not see an update (release date). lower, right-hand corner matches the update you just
installed.
CHECKING FOR DIGITAL WRENCH® INSTALLING A NEW DIGITAL WRENCH®

SOFTWARE UPDATES BASE VERSION
To check if a Digital Wrench® software update is To install a new Digital Wrench® Base Version, do the
available, do the following: following:
1. Open a web browser and log on to the Polaris dealer 1. Open a web browser and log on to your Polaris dealer
website (www.polarisdealers.com). website (www.polarisdealers.com).
2. From the Service and Warranty drop-down, select 2. From the Service and Warranty drop-down, select
Digital Wrench, and then click Digital Wrench Digital Wrench, and then click Digital Wrench Base
Updates. Version Installer.
NOTICE
If you are using Internet Explorer, do NOT select “Run”.
Instead, select “Save” and save the file to your PC
before you run the install.
3. Follow the on-screen prompts to install the new Base

Version.

GENERAL INFORMATION
4. Once the installation is complete, launch the Digital 1. Assemble the MultiLink Module and attach the PC
Wrench® software and verify the information in the Interface Cable to your laptop.
lower, right-hand corner matches the new Base
2. Remove the protective cap from the Digital Wrench®
Version you just installed.
connector.
3. Connect the Vehicle Interface Cable to the Digital
DIGITAL WRENCH® COMMUNICATION Wrench® diagnostic connector.
ERRORS 4. Turn the ignition key to the ‘ON’ position, select the
If you experience problems connecting to a vehicle, or appropriate vehicle and wait for the status to display
any other Digital Wrench® software-related problem, visit ‘Connected’ in the lower left corner of the screen.
the Digital Wrench® home page (www.polaris.diagsys. 5. Once connected, proceed with using Digital
com) and locate the following information under Wrench®.
Knowledge Base:
• Errors and Troubleshooting
• Frequently Asked Questions (FAQs)
DIGITAL WRENCH® SERIAL NUMBER
LOCATION
• Procedures and Solutions
To locate the Digital Wrench® serial number, do the
following:

2. On the Digital Wrench® main screen, select the
‘Configure the Diagnostic System Software’ menu
icon.
3. Locate the serial number on the right side of the

System Configuration screen.
DIGITAL WRENCH® - DIAGNOSTIC
CONNECTOR
The diagnostic connector is located under the storage
tray below the middle seat and is connected to a sealed
plug. To access the diagnostic connector lift up the
passenger seat and remove the storage tray.
Follow these steps to connect the diagnostic interface

cable to the vehicle to allow Digital Wrench® use:

GENERAL INFORMATION
DIGITAL WRENCH® FEATURE MAP

1
View and / or clear trouble

codes in the Engine Add and / or update vehicle
Controller Memory. and customer information.
View sensor and ECU

Add and / or update vehicle
information in a grid, meter,
and customer information.
or chart format.
Also view ECU
This is the most viewed
Identification.
screen.
View information from the Access the Vehicle Home

main ECU sensors. Page.
Set up data capture and Access the System

record functions. Configuration screen.
Perform specialized testing

Access the Digital Wrench®
and adjustment functions
System Help.
service reports.
Open the ASSERT ASK Print the current screen as a

form. formatted printout.

GENERAL INFORMATION
ENGINE CONTROLLER REPROGRAMMING (REFLASH)

OVERVIEW 5. Select the Year, Product Line, and Description.
The Digital Wrench® Engine Controller Reprogramming
(or “Reflash”) feature allows reprogramming of the ECU
fuel and ignition map. To successfully reprogram the
ECU, an Authorization Key must be obtained by entering
a Request Code in the field provided on the Reflash
Authorization site. The Request Code is automatically
generated by Digital Wrench® during the reprogramming
process.
REPROGRAMMING (REFLASH) TIPS
• Check the Vehicle’s Battery Voltage
Make sure the vehicle’s battery voltage (no load) is at
minimum 12.8 volts (12.5 volts with the key ON). If 6. Select the ‘Special Tests’ menu icon.
necessary, connect a battery charger to bring voltage
level above minimum.
• Use a Dedicated PC for Diagnostics Only
– Best results are obtained using a PC that is
dedicated to Digital Wrench® diagnostics only.
Running Digital Wrench® software on a PC that
includes other non-essential programs might affect 7. Select Engine Controller Reprogramming from the
the software performance. Special Tests menu.
– Make sure the PC is plugged in and charging
before you attempt to reprogram. 8. Follow the on-screen prompts to perform the reflash.
– Avoid using the PC while reprogramming is in 9. Copy the Request Code in Digital Wrench®.
progress.
10. Open a web browser and log on to your Polaris dealer
• Understand the Process website (www.polarisdealers.com).
Review the Digital Wrench® System Help before you 11. From the Service and Warranty drop-down, select
attempt to reprogram. See “Digital Wrench® Software Digital Wrench, and then click Reflash Authorization.
Overview” for information on how to access the
System Help. 12. Paste the Request Code from Digital Wrench® into
the field provided on the Reflash Authorization site
REPROGRAMMING (REFLASH) and click Continue.
PROCEDURE 13. Continue to follow the on-screen prompts.
1. Verify the most current version of the Digital Wrench® 14. Copy and paste the Authorization Key into the field
software is installed on your PC. provided in Digital Wrench® and click Continue.
2. Connect the SmartLink Module cables to your PC and 15. Once the reflash is complete, click Finish. Then verify
the vehicle. the reflash worked by starting the vehicle.
4. Select the ‘Change Vehicle’ menu icon.

GENERAL INFORMATION
POLARIS MOBILE DIGITAL ADDITIONAL INFORMATION

WRENCH® (PMDW) • An electronic user’s guide is provided within the 1
Polaris Mobile Digital Wrench® (PMDW) is a diagnostic PMDW app. To access the user’s guide, launch the
software application (app) designed specifically for app, and then click “Help” under the Settings /
Android™ devices. When paired with the Wireless Preferences menu.
Vehicle Link (WVL) (PU-51435), the PMDW app provides
many of the same features and functions as the Digital • Only CAN-based vehicles are compatible with the
Wrench® software. PMDW app and the WVL. See the user’s guide for a
complete list of compatible vehicles.
You can download the PMDW app on your Android

device from the Polaris dealer website. From the Service
and Warranty drop-down, select Digital Wrench, and
then click Mobile Digital Wrench App Download.
MINIMUM SPECIFICATIONS FOR AN-

DROID DEVICES
• Minimum operating system: Android 3.1 “Honeycomb”
or higher (Android 4.0 or higher preferred)
NOTICE
The PMDW app will not work on Microsoft Windows 8™
or Apple IOS™ products.
• Dual core processor / 2 GB internal memory / external

micro SD (32 or 64 GB) slot / 500 MB RAM
• Rear facing camera with minimum 3.0 mega pixel
resolution with auto / continuous focus
• Video, microphone, and voice-to-text capable
• Internet and Bluetooth wireless technology capable
• Device must be set to allow the installation of non-
market applications

GENERAL INFORMATION
ENGINE ELECTRICAL DIAGNOSTICS

DIAGNOSTIC TROUBLE CODES
OVERVIEW
NOTICE
The diagnostic mode is accessible only when the check
engine MIL has been activated.
If there is a diagnostic problem with the power steering
system, the power steering MIL will illuminate and blink
in place of the check engine MIL.
Use the following procedure to display diagnostic trouble

codes that were activated during current ignition cycle
causing the MIL to illuminate. Error codes are not stored.
When the key is turned OFF, the code and message is
lost, but will reappear if the fault reoccurs after restarting
the engine.
If the CHECK ENGINE lamp or the EPAS lamp
illuminates, retrieve the active error codes from the
display.
1. Press and hold the MODE button to enter the settings
menu.
2. Press either toggle button to cycle to the
“DIAGCODE” option. Press MODE to select.
3. More than one diagnostic code may be present.
Press the toggle UP button to see if more codes are
present. Press MODE to select a code.
4. Record the three numbers displayed.
• The first number (located top) can be 1 to 2 digits in

length. This number equates to the fault mode
(FMI).
• The second number (located middle) can be 2 to 6
digits in length. This number equates to the
suspected area of fault (SPN).
• The third number (located bottom) can range from
0 to 9. This number represents the total number of
trouble code present (example: 2 means there are
3 codes present).
5. Press MODE to exit to the settings menu.

GENERAL INFORMATION
MASTER TROUBLE CODE LIST

IMPORTANT 1
Not all codes that are listed in this chart will be applicable to all vehicles. For vehicle specific codes, and pin-point
testing. Please refer to Digital Wrench for more information.
SPN COMPONENT FMI CONDITION CODE

0 Data Valid But Above Normal Operational Range P350A
2 Not Plausible P1225
29 Accelerator Position 2
3 Voltage Too High P1228
4 Voltage Too Low P1227
0 Data Valid But Above Normal Operational Range P1123
1 Data Valid But Below Normal Operational Range P1122
2 Signal Out of Range P0121
51 Throttle Position Sensor 1 3 Voltage Too High P0123

10 Abnormal Rate Of Change P0120
13 Out Of Calibration P1120
70 Parking Brake Switch 19 Received Network Data In Error U25CD

0 Data Valid But Above Normal Operational Range P0500 / C1704 / C1057
1 Data Valid But Below Normal Operational Range P0502
2 Data Erratic or Intermittent (or missing) P0503 / C1058
4 Voltage Below Normal, Or Shorted To Low Source P1506
84 Vehicle Speed Sensor
8 Abnormal Frequency Or Pulse Width Or Period P0501
9 Abnormal Update Rate P160A
10 Abnormal Rate Of Change C1068 / C1705
12 Bad Intelligent Device Or Component P3503
19 Received Vehicle Speed Has Error P106B / C1069 / P306B
91 Accelerator Position 1
2 Data Erratic, Intermittent Or Incorrect P0461
3 Voltage Above Normal, Or Shorted To High Source P0463
96 Fuel Level Signal 4 Voltage Too Low P0462

16 Data Valid But Above Normal Operating Range P1462
18 Data Valid But Below Normal Operating Range P1463
98 Engine Oil Level Sensor/Switch 4 Voltage Too Low P1526

17 Data Valid But Below Normal Operating Range - Least Severe Level P250F
1 Data Valid But Below Normal Operational Range - Most Severe Level P1524
5 Current Below Normal Or Open Circuit P1521
100 Engine Oil Pressure 12 Bad Intelligent Device Or Component P3020
17 Data Valid But Below Normal Operating Range - Least Severe Level P0524
18 Data Valid But Below Normal Operating Range - Moderately Severe P1523
Level
102 Manifold Absolute Pressure Sensor
7 Mechanical System Not Responding Or Out Of Adjustment P1106

GENERAL INFORMATION

0 Data Valid But Above Normal Operational Range - Most Severe Level P1111
Intake Air Temperature Sensor (T-
105 MAP) 4 Voltage Too Low P0112
0 Data Valid But Above Normal Operational Range P110B
1 Data Valid But Below Normal Operational Range P110A
106 Intake Air Pressure Sensor 2 Data Erratic, Intermittent Or Incorrect P1109
Engine Air Filter 1 Differential 4 Voltage Too Low P1283

107
Pressure Sensor
16 Data Valid But Above Normal Operating Range - Moderately Severe P1281
Level
108 Barometric Pressure Sensor
0 Engine Overheat Shutdown P1217
110 Engine Temperature Sensor 10 Abnormal Rate Of Change P0119

16 Temperature Too High P0217
17 Data Valid But Below Normal Operating Range P0128
19 Received Network Data In Error U25C6
157 Fuel Rail Pressure Sensor
15 Data Valid But Above Normal Operating Range - Least Severe Level P0199
158 Battery Potential
162 Transmission Range 2 Invalid U108D

167 Alternator Power Supply Potential 4 Voltage Below Normal, Or Shorted To Low Source P1568
Level
Level

GENERAL INFORMATION

1
2
Data Valid But Below Normal Operational Range - Most Severe Level
Data Erratic, Intermittent Or Incorrect
P1563
P0561
1
3 Voltage Too High C1063 / P0563 / C1820
168 System Power 4 Voltage Too Low P0562

Level
Level
171 Ambient Air Temperature 19 Received Network Data In Error U25C7
173 Exhaust Temperature Sensor
175 Oil Temperature Sensor
12 Bad Intelligent Device Or Component P3097
0 Data Valid But Above Normal Operational Range - Most Severe Level P0219 / C1059
1 Data Valid But Below Normal Operational Range - Most Severe Level C1060
2 Data Erratic, Intermittent Or Incorrect C1061
190 Engine Speed
19 Received Engine Speed Has Error P3219 / C1066
31 Error in Engine Speed Computation P121C
400 Engine Speed 31 Error in Engine Speed Computation P121D

523 Gear Sensor Signal 4 Voltage Too Low P0916

9 Abnormal Update Rate P1914
11 Root Cause Not Known P0915
525 Transmission Requested Gear 19 Received Network Data In Error U255C
527 Cruise Control Panel Switches 31 Condition Exists P153D

563 ABS active 19 Received Network Data In Error U25C9
9 Abnormal Update Rate C1240
597 Brake Switch
10 Abnormal Rate Of Change C2453
19 Received Network Data In Error C1340
627 System Voltage
12 Bad Intelligent Device Or Component P1602 / C1073
628 ECU Memory
13 Out Of Calibration P0601 / C1601
630 Calibration 19 Checksum/CRC Error C1074
634 Idle Air Control 5 Current Below Normal Or Open Circuit P0505
2 Plausibility Fault P0335
636 Crankshaft Position Sensor
637 Camshaft Position Sensor
645 Tachometer Driver Circuit 3 Voltage Above Normal, Or Shorted To High Source P1739

GENERAL INFORMATION

4 Voltage Below Normal / Shorted To Low Source / Driver Circuit P1262
651 Injector 1 (MAG) Grounded.
5 Current Below Normal / Open Circuit / Driver Circuit Open / Grounded P0261
3 Voltage Above Normal, Or Shorted To High Source / Driver Circuit Short P0265
to B+
652 Injector 2 (PTO) 4 Voltage Below Normal, Or Shorted To Low Source / Driver Circuit P1265
Grounded
5 Current Below Normal Or Open Circuit / Driver Circuit Open / Grounded P0264
677 Starter Solenoid Driver Circuit 4 Voltage Below Normal, Or Shorted To Low Source P0616
731 Knock Sensor 1
3 Driver Circuit Short to B+ P1692
746 Rear Differential Output (Turf) 4 Driver Circuit Grounded P1693

5 Driver Circuit Open / Grounded P1691
876 AC Compressor Clutch Relay 4 Voltage Below Normal, Or Shorted To Low Source P0646
3 Voltage Above Normal, Or Shorted To High Source C1231
4 Voltage Below Normal, Or Shorted To Low Source C1331
5 Current Below Normal Or Open Circuit C1631
6 Current Above Normal Or Grounded Circuit C1B31
7 Mechanical System Not Responding Or Out Of Adjustment C1731
905 Wheel Speed Sensor (Front Left)
8 Abnormal Frequency Or Pulse Width Or Period C1431
14 Special Instructions C1531
20 Data Drifted High C1931
21 Data Drifted Low C1A31
31 Condition Exists C0032
906 Wheel Speed Sensor (Front Right)
8 Abnormal Frequency Or Pulse Width Or Period C1334
14 Special Instructions C1434
31 Condition Exists C1C34
2 Data Erratic, Intermittent Or Incorrect C103D
Wheel Speed Sensor (Rear or 3 Voltage Above Normal, Or Shorted To High Source C113D
907 Rear Left)
4 Voltage Below Normal, Or Shorted To Low Source C123D

GENERAL INFORMATION

5
6
Current Below Normal Or Open Circuit
Current Above Normal Or Grounded Circuit
C163D
C1B3D
1
7 Mechanical System Not Responding Or Out Of Adjustment C173D
8 Abnormal Frequency Or Pulse Width Or Period C133D
10 Abnormal Rate Of Change C183D
11 Root Cause Not Known C2429
14 Special Instructions C143D
20 Data Drifted High C193D
21 Data Drifted Low C1A3D
31 Condition Exists C1C3D
908 Wheel Speed Sensor (Rear Right)
31 Condition Exists C1C47
3 Voltage Above Normal P1482
1071 Fan Relay Driver Circuit 4 Voltage Below Normal P1483

1127 Boost Pressure Sensor 3 Voltage Above Normal P0238

4 Voltage Below Normal P0237
31 Condition Exists P1234
Ignition Coil Primary Driver 1 4 Voltage Below Normal P1361
1268 (MAG)
1269 Ignition Coil Primary Driver 2 (PTO) 4 Voltage Below Normal P1362
1321 Starter Enable Circuit 4 Voltage Below Normal P1616

4 Voltage Below Normal P0231
1347 Fuel Pump Driver Circuit
1352 Knock Level Cylinder 1 (MAG)
1353 Knock Level Cylinder 2 (PTO)
1485 EFI Relay Control Circuit 4 Voltage Below Normal P0686

1557 Fan Driver 2

GENERAL INFORMATION

13 Out Of Calibration C1261
1809 Lateral Acceleration Sensor 19 Received Network Data In Error U25CA

1810 Longitudinal Acceleration Sensor
19 Received Network Data In Error U25CB
1888 PTO Solenoid Driver Circuit 4 Voltage Below Normal, Or Shorted To Low Source P1312
2584 Brake Pressure Switches 13 Out Of Calibration C1263

17 Data Valid But Below Normal Operating Range - Least Severe Level C2144
2590 Vehicle Speed
Level
Speed Key Selected Maximum 19 Received Network Data In Error U255A

2596 Vehicle Speed Limit Message 31 Condition Exists U2259
Engine Turbocharger 1
2629 Compressor Outlet Temperature 4 Voltage Below Normal, Or Shorted To Low Source P1236
3056 Oxygen Sensor Bank 1 Sensor 1 4 Voltage Below Normal, Or Shorted To Low Source P0131 / C1049
12 Bad Intelligent Device Or Component P113A
17 Data Valid But Below Normal Operating Range - Least Severe Level C2049
3057 Oxygen Sensor Bank 1 Sensor 2 3 Voltage Above Normal, Or Shorted To High Source P0138
0 Data Valid But Above Normal Operational Range - Most Severe Level P16A3
1 Data Valid But Below Normal Operational Range - Most Severe Level P16A6
3 Voltage Above Normal, Or Shorted To High Source P16A2
3597 ECU Output Supply Voltage 1 4 Voltage Below Normal, Or Shorted To Low Source P16A1
16 Data Valid But Above Normal Operating Range - Moderately Severe P16A5
Level
18 Data Valid But Below Normal Operating Range - Moderately Severe P16A7
Level
0 Data Valid But Above Normal Operational Range - Most Severe Level P16AA
1 Data Valid But Below Normal Operational Range - Most Severe Level P16AC
3 Voltage Above Normal, Or Shorted To High Source P16A9
3598 ECU Output Supply Voltage 2 4 Voltage Below Normal, Or Shorted To Low Source P16A8
16 Data Valid But Above Normal Operating Range - Moderately Severe P16AB
Level
18 Data Valid But Below Normal Operating Range - Moderately Severe P16AD
Level
0 Data Valid But Above Normal Operational Range - Most Severe Level P17AC
1 Data Valid But Below Normal Operational Range - Most Severe Level P17AE
3599 ECU Output Supply Voltage 3
3 Voltage Above Normal, Or Shorted To High Source P17AA
4 Voltage Below Normal, Or Shorted To Low Source P17AB

GENERAL INFORMATION

16 Data Valid But Above Normal Operating Range - Moderately Severe
Level
P17AD
1
18 Data Valid But Below Normal Operating Range - Moderately Severe P17AF
Level
8014 Battery Charger Level
31 Condition Exists P0762
11 Root Cause Not Known P1130 / U2101
65559 CAN1 Bus Hardware
ETC Accelerator Position Sensor 2 Data Erratic, Intermittent Or Incorrect P1135
65613
Correlation
516125 CAN 1 9 Abnormal Update Rate U25E9
516178 Idle Engine speed 19 Received Network Data In Error U25C0
520129 ABS Low Pressure Feed Circuit 1 31 Condition Exists C1012

520130 ABS Low Pressure Feed Circuit 2 31 Condition Exists C1013
520131 ABS Valve Relay 12 Bad Intelligent Device Or Component C2420
ABS Pressure Sensor Supply Out 31 Condition Exists C2423

520132 of Range
520133 ABS Internal Pressure Sensor
12 Bad Intelligent Device Or Component C2424
520134 ABS Motor Supply Failure 31 Condition Exists C2425
520137 ABS Manually Disabled 31 Condition Exists C2433
520140 ABS Internal ECU Failure 12 Bad Intelligent Device Or Component C2437
520141 CAN1 Bus Wiring 31 Condition Exists C2438
520152 ABS Solenoid (Rear Left In) 31 Condition Exists C1324
520153 ABS Solenoid (Rear Left Out) 31 Condition Exists C1325

520194 Throttle Release Signal
520198 Throttle Position Sensor 2
520201 Overheat Indicator Lamp 4 Voltage Below Normal, Or Shorted To Low Source P1657
520202 Canister Purge Valve 4 Voltage Below Normal, Or Shorted To Low Source P0445
Front Wheel Back Drive (Active 4 Voltage Below Normal, Or Shorted To Low Source P1687
520203 Descent System)
520204 Fuel Correction Front
520205 Fuel Correction Rear
520206 Reverse Alarm

GENERAL INFORMATION

520207 All Wheel Drive Control Circuit 4 Voltage Below Normal, Or Shorted To Low Source P1834
520208 Chassis Relay 4 Voltage Below Normal, Or Shorted To Low Source P1613
520211 Idle Speed
520219 Accessory Relay 4 Voltage Below Normal, Or Shorted To Low Source P1645
3 Voltage Above Normal, Or Shorted To High Source P163D
520220 Battery Charge Relay 4 Voltage Below Normal, Or Shorted To Low Source P163A
5 Current Below Normal Or Open Circuit P163C
6 Current Above Normal Or Grounded Circuit C1050
520221 Steering Over Current Shut Down
12 Bad Intelligent Device Or Component C102E
520222 Steering Excessive Current Error 6 Current Above Normal Or Grounded Circuit C1051
520223 Steering Torque Partial Failure 31 Condition Exists C1052
520224 Steering Torque Full Failure 31 Condition Exists C1053

0 Data Valid But Above Normal Operational Range - Most Severe Level C1055
12 Bad Intelligent Device Or Component C102F
520225 EPS Inverter Temperature
16 Data Valid But Above Normal Operating Range - Moderately Severe C1054
Level
2 Data Erratic, Intermittent Or Incorrect U0100
EPS Communications Receive
520226
Data Error 31 Condition Exists C1067
EPS CAN Communications 2 Data Erratic, Intermittent Or Incorrect U1100
520227
Transmit Error
11 Root Cause Not Known C1065
520228 Position Encoder Error 12 Bad Intelligent Device Or Component C106A

31 Condition Exists C106B
520229 Software Error
31 Condition Exists C106F
520230 IC CAN Communication with EPS 31 Condition Exists U0131
520231 EPS Power Save Condition 31 Condition Exists C1071
ABS Solenoid (Rear or Right Rear 5 Current Below Normal Or Open Circuit C1024
520252 In) 31 Condition Exists C1330
ABS Solenoid (Rear or Right Rear 5 Current Below Normal Or Open Circuit C1025
520253 Out) 31 Condition Exists C1332
ABS Solenoid (Front or Front Left 5 Current Below Normal Or Open Circuit C1026
520254 In) 31 Condition Exists C1326
ABS Solenoid (Front or Front Left 5 Current Below Normal Or Open Circuit C1027
520255 Out) 31 Condition Exists C1327
520256 ABS Solenoid (Front Right In)
520257 ABS Solenoid (Front Right Out)
520260 ABS Motor 3 Voltage Above Normal, Or Shorted To High Source C1020

GENERAL INFORMATION

4
6
Voltage Below Normal, Or Shorted To Low Source
Current Above Normal Or Grounded Circuit
C1021
C101E
1
8 Abnormal Frequency Or Pulse Width Or Period C101F
12 Bad Intelligent Device Or Component C101C
0 Data Valid But Above Normal Operational Range - Most Severe Level C2422
ABS/Brake Controller Source 1 Data Valid But Below Normal Operational Range - Most Severe Level C2421
520262 Voltage 3 Voltage Above Normal, Or Shorted To High Source C1039 / C1241
520264 ABS/Brake Controller ECU 12 Bad Intelligent Device Or Component C1243

520265 ABS Module 7 Mechanical System Not Responding Or Out Of Adjustment C1042
520266 ABS Brake Switch (Front/Rear)
520272 Glow Plug Relay Driver Circuit 4 Voltage Below Normal, Or Shorted To Low Source P1383
Fuel Pull Solenoid Relay Driver 4 Voltage Below Normal, Or Shorted To Low Source P125C
520273 Circuit (Low Side)
5 Current Below Normal Or Open Circuit P125A
Accelerator Position/Brake Position 31 Condition Exists P150A / U1007

520275
Interaction
Throttle Position Sensor (1 or 2 2 Data Erratic, Intermittent Or Incorrect P150C

520276 Indeterminable) 12 Bad Intelligent Device Or Component P150B
2 Data Erratic, Intermittent Or Incorrect P151A
Throttle Body Control - Power 4 Voltage Below Normal, Or Shorted To Low Source P150E
520277 Stage
8 Abnormal Frequency Or Pulse Width Or Period P151B
31 Condition Exists P153F
Throttle Body Control - Return 31 Condition Exists P151C
520278 Spring Check Failed
Throttle Body Control - Adaption 31 Condition Exists P151D
520279
Aborted
Throttle Body Control - Limp Home 31 Condition Exists P151E
520280
Position Check Failed
Throttle Body Control - Mechanical 31 Condition Exists P152A
520281 Stop Adaptation Failure
Throttle Body Control - Repeated 31 Condition Exists P152B
520282 Adaptation Failed
2 Data Erratic, Intermittent Or Incorrect P152F
520283 Throttle Body Control 3 Voltage Above Normal, Or Shorted To High Source P152C
4 Voltage Below Normal, Or Shorted To Low Source P152D
Throttle Body Control - Position 31 Condition Exists P152E

520284
Deviation Fault
Brake Switch (1 or 2 2 Data Erratic, Intermittent Or Incorrect P153E
520285 Indeterminable)
520286 ECU Monitoring Error 31 Condition Exists P1540
520287 ECU Monitoring Error (Level 3) 31 Condition Exists P1541
ECU Monitoring of Injection Cut Off 31 Condition Exists P1542

520288 (Level 1)
ECU Monitoring of Injection Cut Off 31 Condition Exists P1543
520289 (Level 2)

GENERAL INFORMATION

Throttle Body Control - Requested 31 Condition Exists P1530
520305 Throttle Angle Not Plausible
520306 ECU ADC Fault - No Load 31 Condition Exists P1531
520307 ECU ADC Fault - Voltage 31 Condition Exists P1532
Accelerator Sensor Sync Fault - 31 Condition Exists P1533

520308
Sensor Diff Exceeds Limit
520309 ECU Fault - ICO 31 Condition Exists P1534
520311 ECU Fault - Hardware Disruption 31 Condition Exists P1537

520331 Knock Sensor Positive Line
3 Voltage Above Normal, Or Shorted To High Source P132A
520332 Knock Sensor Negative Line
4 Voltage Below Normal, Or Shorted To Low Source P132B
520341 Wastegate Solenoid Driver 4 Voltage Below Normal, Or Shorted To Low Source P0246
520342 Idle Fuel Correction Bank 1 15 Data Valid But Above Normal Operating Range - Least Severe Level P116C
15 Data Valid But Above Normal Operating Range - Least Severe Level P116E
520343 Idle Fuel Correction Bank 2
520344 Adaptive Fuel Correction Bank 1
Internal fault - Chassis Output 31 Condition Exists P1618

520376
Disabled
Non Functional Application SW 31 Condition Exists C1681
520381
Installed
520496 Intercooler Pump Driver Circuit 4 Voltage Below Normal, Or Shorted To Low Source P107C
5 Current Below Normal Or Open Circuit P107E
520498 Stator
2 Data Erratic, Intermittent Or Incorrect P1140 / P1368
520513 Motor Controller Encoder
31 Condition Exists P1141 / P1369
3 Voltage Above Normal, Or Shorted To High Source P1142 / P1165
Motor Controller Temperature 4 Voltage Below Normal, Or Shorted To Low Source P1143 / P1166
520514
Sensor
31 Condition Exists P1144 / P1167
0 Data Valid But Above Normal Operational Range - Most Severe Level P1145 / P1168
520515 Electric Motor Temperature
4 Voltage Below Normal, Or Shorted To Low Source P1B0D / P1169
520516 Motor Controller Temperature 0 Data Valid But Above Normal Operational Range - Most Severe Level P1146 / P116A
3 Voltage Above Normal, Or Shorted To High Source P1147 / P1184
6 Current Above Normal Or Grounded Circuit P1148 / P1185
520517 Motor Controller
12 Bad Intelligent Device Or Component P1149 / P1186
19 Received Network Data In Error P1150 / P1187
5 Current Below Normal Or Open Circuit P1151 / P1177
520518 Motor Controller Contactor
6 Current Above Normal Or Grounded Circuit P1152 / P1178
520519 Motor Controller Speed Sensor 31 Condition Exists P1153 / P116B
520520 BMC CAN Communication 31 Condition Exists P0754
520522 Display Relay 5 Current Below Normal Or Open Circuit P3038

2 Data Erratic, Intermittent Or Incorrect P153C
524067 Drive Mode Select Switch 3 Voltage Above Normal, Or Shorted To High Source P153A
4 Voltage Below Normal, Or Shorted To Low Source P153B
524070 Operator Presence Switch 3 Voltage Above Normal, Or Shorted To High Source P251C

GENERAL INFORMATION
524075
Hydraulic Oil Pressure Sensor/
Switch
1
524076 Engine Oil Pressure Sensor/Switch 17 Data Valid But Below Normal Operating Range - Least Severe Level P151F
524085 EPS Fault Lamp Driver Circuit 12 Bad Intelligent Device Or Component C106C
3 Voltage Above Normal, Or Shorted To High Source C106D
524086 EPS SEPIC Voltage Error
4 Voltage Below Normal, Or Shorted To Low Source C106E

GENERAL INFORMATION
CYLINDER MISFIRE DETECTION If a misfire code has been set and there is no observed
misfire, cycle the key and allow 4000 engine revolutions
NOTICE to see if the check engine light turns off. If it does not turn
This process only applies to some MY15 and later off, diagnose by verifying the following items:
models.
• Low battery voltage (loose connection, low charge,
Refer to this procedure only if one of the codes shown
bad battery)
below is displayed in Digital Wrench.
• Faulty voltage regulator
The ECU monitors crankshaft speed via the crankshaft • Ignition Coil and connections are good
position sensor. A misfire will cause a fluctuation in
crankshaft speed. A code will set and turn on the check • Spark plugs wires are secure
engine light after an engine misfire threshold/rate is • The correct spark plugs are installed and the plugs are
detected that is above a pre-determined limit. This not fouled
threshold varies based on engine speed.
• Crankshaft Position Sensor tests good
One or more of the following codes will be set if a misfire
occurs: • Wiring to the Crankshaft Position Sensor, ECU and
Ignition Coil are not damaged. Chassis ground is clean
• P0301 (SPN 65591/FMI 7) Misfire Detected, Cylinder and tight
1 (MAG)
• Fuel pressure is within specification
• P0302 (SPN 65592/FMI 7) Misfire Detected, Cylinder
2 (PTO) • Fresh/good quality fuel is in the fuel tank
• P0314 (SPN 65590/FMI 7) Misfire Detected, Cylinder • Engine mechanical is good (leak down, timing)
Not Identified • Confirm the belt is in good condition, specifically
looking for signs of hour-glassing
Once a cylinder misfire code is set, the following events • Confirm primary clutch operation (worn/incorrect
will occur: weights, loose spider/jam nut)
• Check Engine Light illuminates • Confirm secondary clutch operation (sliders, rollers,
• If the cylinder can be detected by the ECU (code helix)
P0301 or P0302), the ECU will deactivate the fuel
injector for that cylinder. This will remain in effect until
the key is cycled off and back on.
• If the cylinder with the misfire cannot be detected
(code P0314), the ECU will limit available power by
limiting how far the throttle plate opens.
One the key is cycled, the trouble code(s) will show

current but there will be no fuel injector deactivation or
throttle limitation unless the misfiring continues to occur.
The check engine light will remain illuminated until there
are 4000 engine revolutions (i.e. 4000 RPM for one
minute) without a significant misfire being detected.
Once this condition is met, the check engine light will turn
off and the code(s) will show as historic.

GENERAL INFORMATION
FLUID LEAKS
Fluid leaks can apply to multiple different systems used in the vehicle. Leaks can be a common cause of concerns
within these systems. Procedures that are used for checking leaks can apply to multiple systems.
1
When diagnosing fluid leaks, refer to the appropriate “Level Inspection” procedure, Fluid Inspection page 1.75, or the
appropriate chapter in the Service Manual before proceeding with any repairs or parts replacement.
FLUID INSPECTION
OVERVIEW
Multiple vehicle systems will contain different fluids or lubricants within the system.
These fluids should be inspected for condition and level. Refer to Fluid Condition and the appropriate level check
within the Service Manual for more information.
Most of these systems should be inspected for leaks using the same methods. Refer to Fluid Leak for more
information.
FLUID LEAK
Perform the following inspection prior to replacement of any seals or gaskets.
1. Inspect the fluid level prior to any checks to verify that the system is currently leaking.
NOTICE
If the system is not low at this time, clean and continue to monitor. It is possible that the fluid is residual from
manufacturing or previous repairs.
2. Thoroughly clean the area using an appropriate cleaner (Brake cleaner, Throttle Body cleaner, Soap, etc.) prior to
diagnosing the leak.
3. Operate the vehicle under the condition that the leak presented and re-inspect for leak.
4. Pinpoint location of leak. Check for any damage to parts and repair the leak as necessary.
NOTICE
If the leak can not be pin-pointed using this method, the leak may require dye to be added to the system, operated
and inspected for leaks using a UV light.
FLUID CONDITION
Refer to the appropriate “Level Check” procedure for the fluid being inspected. When the fluid is inspected it should
be compared to NEW recommended replacement fluid.
INSPECTION ITEMS CAUSE

Inspect for the following:
• The fluid has been contaminated with another fluid
• Unusual Color (cross-contamination, ex. Oil mixing with Coolant).
• Unusual Odor • Fluid overheated
• Fluid Contamination • Natural fluid breakdown (replace fluid per
recommended maintenance interval / fluid
replacement procedure).
• If a fluid is contaminated with metal or debris, suspect
that there is a mechanical failure causing the fluid
contamination. Refer to the Service Manual
information related to the system in question.

GENERAL INFORMATION
FUEL SYSTEM DIAGNOSTICS

FUEL SYSTEM TROUBLESHOOTING
FUEL STARVATION / LEAN MIXTURE
SYMPTOMS CAUSES
• Hard start or no start • No fuel in tank

• Bog • Restricted tank vent, or routed improperly
• Backfire • Fuel lines or fuel injectors restricted
• Popping through Intake / Exhaust • Fuel filter plugged
• Hesitation • Fuel pump inoperative
• Detonation • Air leak in system
• Low Power • Intake air leak (throttle shaft, intake ducts, air box
cover)
• Spark plug erosion / fouling
• Faulty oxygen sensor
• Engine runs hot
• Surging
• High / Erratic idle
RICH MIXTURE
SYMPTOMS CAUSES
• Hard start or no start • No fuel in tank

• Bog • Restricted tank vent, or routed improperly
• Backfire • Fuel lines or fuel injectors restricted
• Popping through Intake / Exhaust • Fuel filter plugged
• Hesitation • Fuel pump inoperative
• Detonation • Air leak in system
• Low Power • Intake air leak (throttle shaft, intake ducts, air box
cover)
• Spark plug erosion / fouling
• Faulty oxygen sensor
• Engine runs hot
• Surging
• High / Erratic idle

GENERAL INFORMATION
POOR IDLE
SYMPTOMS CAUSES 1
• Idle Too High (if > 1400 RPM when warm). • Throttle stop screw tampering
• Throttle cable sticking, improperly adjusted, routed
incorrectly
• Faulty electrical connection
• Idle Too Low (if < 1100 RPM when warm). • Plugged air filter
• Leaking injector (rich condition)
• Belt dragging
• Throttle stop screw tampering
• Erratic Idle • Throttle cable incorrectly adjusted

• Air Leaks, dirty injector
• TMAP damaged (check with Digital Wrench®)
• Tight valves (low compression or high leakdown)
• Ignition timing incorrect
• Belt dragging
• Dirty air filter
• High percentage of cylinder leakdown (worn engine)
• Low compression (worn engine)
• Spark plug(s) fouled
• Spark plug wires loose or worn
• Faulty electrical connection

GENERAL INFORMATION
PVT SYSTEM DIAGNOSTICS

PVT SYSTEM TROUBLESHOOTING
SITUATION PROBABLE CAUSE REMEDY
Wrong or broken drive clutch spring. Replace with recommended spring.
Engine RPM
below specified Install correct shift weight kit to match engine
Drive clutch shift weight too heavy.
operating range, application.
although engine
is properly tuned. Driven clutch spring broken or installed in Replace spring; refer to proper installation
wrong helix location. location.
Disassemble drive clutch; inspect shift weights
for wear and free operation.
Drive clutch binding. Clean and polish stationary shaft hub;
reassemble clutch without spring to determine
Erratic engine problem area.
operating RPM
during Belt worn unevenly - thin / burnt spots. Replace belt.
acceleration or
load variations. Replace ramp buttons.
Driven clutch malfunction. Inspect movable sheave for excessive bushing
clearance.
Sheave face grooved. Replace the clutch.
Incorrect drive clutch spring (too high of Install correct recommended spring.
rate).
Drive clutch shift weights incorrect for Install correct recommended shift weights.
application (too light).
Disassemble and clean clutch, inspecting shift
Engine RPM weights and rollers. Reassemble without the
Drive clutch binding.
above specified spring and move sheaves through entire range
operating range. to further determine probable cause.
Disassemble, clean, and inspect driven clutch,
Driven clutch binding. noting worn sheave bushing and ramp buttons
and helix spring location.
Converter sheaves greasy; belt slipage. Clean sheaves with denatured alcohol or brake
cleaner, install new belt.
Drive belt worn too narrow. Replace belt.
Harsh drive clutch
engagement. Excessive belt / sheave clearance with new Perform belt / sheave clearance adjustment with
belt. shim washers beneath spider.
Drive belt turns Wrong belt for application. Replace with correct belt.
over
Abuse (continued throttle application when Caution operator to operate machine within
vehicle is stationary, excess load) guidelines.
Belt burnt, thin Dragging brake Inspect brake system.
spots
Slow, easy clutch engagement Fast, effective use of throttle for efficient
engagement.

GENERAL INFORMATION

Plugged air intake or outlet. Clear obstruction 1
Belt slippage due to water, oil, grease, etc., Inspect system. Clean , repair or replace as
rubbing on cover. necessary. Seal PVT system ducts.
PVT cover
Clutches or weight being applied to cover Remove weight. Inform operator.
overheating
while in operation.
(melting)
Instruct operator on guidelines for operation in
High vs. low range. proper driving range for different terrain as
outlined in Owner’s Safety and Maintenance
Manual.
Cover seals or ducts leaking Find leak and repair as necessary.
Water ingestion Instruct operator on guidelines for operation in
Operator error wet terrain as outlined in Owner’s Safety and
Maintenance Manual.
Belt worn out Replace belt.
Belt slippage Water ingestion Inspect and seal PVT system.
Belt contaminated with oil or grease Inspect and clean.
Belt worn or separated, thin spots, loose belt Replace belt.
PVT noise Broken or worn clutch components, cover Inspect and repair as necessary.
hitting clutches
Replace belt. Refer to belt burnt troubleshooting
Engagement Thin spots on belt, worn belt
and instruct operator.
erratic or stabby
Drive clutch bushings stick Inspect and repair clutches.

GENERAL INFORMATION
PVT SYSTEM OVERHEATING / DIAGNOSIS

During routine maintenance, or whenever PVT system overheating is evident, it’s important to check the inlet and
outlet duct for obstructions. Obstructions to air flow through the ducts will significantly increase PVT system operating
temperatures. The vehicle should be operated in Low when extended low vehicle speed operation is anticipated.
CLUTCH DRIVE BELT & COVER RELATED ISSUES: DIAGNOSIS

POSSIBLE CAUSES SOLUTIONS / WHAT TO DO
Loading the vehicle into a tall trailer when in
Shift transmission to Low during loading of the vehicle to prevent belt burning.
high range.
Starting out going up a steep incline from a When starting out on an incline, use Low gear. Shift transmission to Low during
stopped position. loading of the vehicle to prevent belt burning.
Driving at low RPM or low ground speed (at Drive at higher speed or use Low. The use of Low is highly recommended for
approximately 3-7 MPH). cooler PVT operating temperatures and longer component life.
Warm engine at least 5 min., then with transmission in neutral, advance throttle to
Insufficient engine warm-up when exposed
approx. 1/8 throttle in short bursts, 5 to 7 times. The belt will become more flexible
to low ambient temperatures.
and prevent belt burning.
Slow and easy clutch engagement. Fast, effective use of the throttle for efficient engagement.
Shift the transmission to Low, carefully use fast, aggressive throttle application to
Stuck in mud or snow. engage clutch. WARNING: Excessive throttle may cause loss of control and
vehicle overturn.
Climbing over large objects from a stopped Shift the transmission to Low, carefully use fast, aggressive, brief throttle
position. application to engage clutch. WARNING: Excessive throttle may cause loss of
control and vehicle overturn.
Remove the PVT drain plug. Shift the transmission to neutral. Using the throttle,
Belt slippage from water or snow ingestion vary the engine rpm from idle to full throttle. Repeat several times as required.
into the PVT system. During this procedure, the throttle should not be held at the full position for more
than 10 seconds. Clutch seals should be inspected for damage if repeated leaking
occurs.
Clutch component inspection should be performed by a Polaris MSD certified
Clutch malfunction.
technician.
Fouled spark plugs, foreign material in fuel tank, restricted fuel lines, or faulty fuel
Poor engine performance.
pump may cause symptoms similar to clutching malfunction.
Low: Basic operational speeds less than 7 MPH, riding through rough terrain
(swamps, mountains, ect.), or low ground speeds and when continuously
GENERAL RANGE OPERATION
operating at speeds less than 30 mph in sand/dune environments.
GUIDELINES:
High: High ground speeds, or speeds above 7 MPH.
Operating in Low Gear

Low gear should be used when riding through rough terrain or when basic operational ground speeds are less than 7
MPH. Use High gear when basic operational ground speeds are more than 7 MPH.
General Sand / Dune Driving
The use of Low gear when continuously operating at speeds less than 30 mph will greatly increase belt life in sand/
dune environments.
NOTICE
Do not shift from Low to High without coming to a complete stop.
Using High gear for heavy loads, hilly terrain, sand/dune environments, or in wet, muddy conditions will increase the
chance of drive belt burning.

GENERAL INFORMATION
TRANSMISSION DIAGNOSTICS
HARD SHIFTING 1
SYSTEM DIAGNOSIS
Difficulty shifting, or harsh shifting are generally caused by the Transmission or PVT Systems. The system causing the
difficult shifting concern can generally be diagnosed using the following information.
SYMPTOM CAUSE
Vehicle is difficult to shift ONLY with the engine running Refer to PVT System Chapter for more information
Vehicle is difficult to shift all the time Refer to Transmission Isolation this will help determine
if the concern is internal or external to the transmission.
After isolation proceed with diagnosis.
ADDITIONAL HARD SHIFTING CAUSES

SHIFTING CAUSES
• Shift cable adjustment/condition • Loose fasteners on sector gear cover

• PVT alignment (clutch center distance) • Worn rod ends, clevis pins, or pivot arm bushings
• Transmission lubricant type/quality • Shift selector rail travel
• Transmission leaks / fluid level • Worn, broken or damaged internal transmission
components
TRANSMISSION ISOLATION
To determine if shifting difficulty or problem is caused by an internal transmission problem or external concern the
transmission should be isolated using the following information.
After the transmission is isolated refer to Additional Shifting Causes or the proper chapter in the service manual for
additional information.
1. Disconnect the shift cable from the bellcrank.
2. With the shift cable disconnected from the transmission shift the vehicle using the shift lever.
• If the shift lever continues to bind the concern is likely caused by the shift cable. Refer to the proper service
information for replacement.
• If the shift lever moves freely proceed to step 3.
3. With the shift lever disconnected manually select each gear range at the transmission bellcrank.
• If the bellcrank requires more than approximately 15 ft-lbs (20 N·m) to rotate, the shifting concern is most likely
caused by an internal transmission concern.
• If the bellcrank moves freely, manually select each gear range at the transmission bellcrank and test ride vehicle.
If it functions properly then there is likely still an outside concern causing the issue.

GENERAL INFORMATION
FINAL DRIVE DIAGNOSTICS

ALL WHEEL DRIVE (AWD) CONCERNS
All Wheel Drive (AWD) concerns are generally caused by a mechanical concern within the front gearcase, or electrical
concern. The following chart will help finding the root cause and assist with basic checks of the front gearcase and
AWD system. Refer to the proper chapter in the service manual for additional vehicle specific information.
SYMPTOM CAUSE
AWD stays engaged even when switch is OFF
• Rollers flat-spotted. Remove all and roll across a table
to check for flat spots
• Inside of ring gear is dimpled from harsh engagement.
Check the ramps and low spots inside ring gear.
Should be smooth.
• Output Hub races are flat spotted/dimpled. Run your
finger along the outer surface that goes inside of the
cage. Should be uniform with no high points.
• Armature plate or coil magnetized. Rule out armature
plate by putting it close to something metal to see if it
tries to stick.
• Drivetrain wedged. Often caused by torsion spring
coming out of place.
AWD Does not engage

• Roller cage is broken. Can typically find debris in the
oil if drained
• No power to AWD coil. Jump power and ground
directly to the coil and verify AWD function. If AWD
functions this confirms an electrical issue is causing
the concern. Verify fuses are in good condition and
inspect the wiring harness for damage or broken
wires. Check all connections for damaged pins or bad
connection.
• Weak magnetism. With power and ground to the coil,
armature plate should not be able to be pried off with
fingers.
• Armature plate bent/damaged. Check flatness and
look for uneven wear marks
• Prop shaft not turning at transmission snorkel shaft.
Internal transmission damage
DRIVESHAFT (HALF SHAFT) DIAGNOSTICS

Driveshaft (Half Shaft) operation can cause various customer concerns. For more information related to Driveshaft
concerns or failures CLICK HERE to view the “Half Shaft Analysis” poster.

GENERAL INFORMATION
BRAKE SYSTEM DIAGNOSTICS

BRAKE NOISE TROUBLESHOOTING 1
Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise (squeal caused by vibration).
If cleaning does not reduce the occurrence of brake noise, Permatex™ Disc Brake Quiet can be applied to the back of
the pads. Follow directions on the package. This will keep pads in contact with caliper piston(s) to reduce the chance
of squeaks caused by dirt or dust.
POSSIBLE CAUSE REMEDY

Spray disc and pads with CRC Brakleen™ or an
equivalent non-flammable aerosol brake cleaner.
Dirt, dust, or imbedded material on pads or disc
Remove pads and/or disc hub to clean imbedded
material from disc or pads.
Pad(s) dragging on disc due to:
Improper adjustment Adjust pad stop
Master cylinder reservoir overfilled Set to proper level
Master cylinder compensating port restricted Clean compensating port
Master cylinder piston not returning completely Inspect. Repair as necessary
Caliper piston(s) not returning Clean piston(s) seal
Operator error (riding the brake) Educate operator
Check wheel and hub for abnormal movement. Check

Loose wheel hub or bearings
axle nut torque. Inspect/replace bearing if needed.
Brake disc warped or excessively worn Replace disc
Brake disc misaligned or loose Inspect and repair as necessary
If noise does not change when brake is applied check
Noise is from other source (axle, hub, disc or wheel)
other sources. Inspect and repair as necessary
BRAKE VIBRATION
PEDAL / LEVER VIBRATION (VIBRATION IS ONLY FELT IN PEDAL OR LEVER WHILE BRAKING)
• Brake Disc worn (runout or thickness variance • Brake Pad wear (uneven / unusual wear)
exceeds service limit)
• Brake Disc damaged
VEHICLE VIBRATION (VIBRATION FELT THROUGH ENTIRE VEHICLE / CHASSIS WHILE BRAKING)
• Worn Suspension components • Alignment issues

GENERAL INFORMATION
CALIPER OVERHEATS (BRAKES DRAG)

CALIPER OVERHEATS (BRAKES DRAG)
• Compensating port plugged • Parking brake left on (If Equipped)

• Pad clearance set incorrectly • Residue build up under caliper seals
• Parking brake lever incorrectly adjusted (If Equipped) • Incorrect operation of brakes
– Operator using the throttle and brakes at the same
• Brake pedal or brake lever binding or unable to return
time.
fully
– Excessive use of the brakes.
• Incorrect brake fluid level (Overfilled Fluid Reservoir)
POOR BRAKE PERFORMANCE

POOR BRAKE PERFORMANCE
• Air in system • Incorrectly adjusted stationary pad

• Water in system (brake fluid contaminated) • Worn or damaged master cylinder or components
• Caliper or disc misaligned • Damaged brake pad noise insulator
• Caliper dirty or damaged • Brake pads dragging
• Brake line damaged or lining ruptured • Brake caliper dragging
• Worn disc and/or friction pads
BRAKES LOCK
BRAKES LOCK
• Alignment of caliper to disc • Failed brake hose / line

• Caliper pistons sticking • Improper assembly of brake system components
• Failed master cylinder • Faulty distribution block (INTL models only )

GENERAL INFORMATION
STEERING / SUSPENSION DIAGNOSTICS

EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL ON) 1
IMPORTANT
READ BEFORE YOU REPLACE THE EPS UNIT!
Verify the EPS unit has the latest software version and calibration loaded before replacing the EPS unit. If not, update
to the latest version for each and follow the guided diagnostic procedure(s) available in Digital Wrench®.
Power Steering Non Functional, MIL is ON
↓
Cycle the ignition switch. Is MIL on? → No
There is no issue. MIL on due to 5-minute
timeout. Verify code using Digital Wrench.
No ↓
Is Battery Voltage >11 and <16VDC? → No
Determine cause of incorrect battery voltage and
repair
Yes ↓
Is EPS Fuse OK? → No
Replace EPS Fuse.
Yes ↓
12 VDC and GND across 2 Pin EPS Connector
with Key On? → No
Check EPS Power Relay and Circuit
Yes ↓
12 VDC on Pin 3 of the 8 pin EPS Connector? → No
Check wiring from Connector to Ignition Switch
Circuit
Yes ↓
Begin Digital Wrench EPS Troubleshooting
Procedure

GENERAL INFORMATION
EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL OFF)

IMPORTANT
READ BEFORE YOU REPLACE THE EPS UNIT!
Verify the EPS unit has the latest software version and calibration loaded before replacing the EPS unit. If not, update
to the latest version for each and follow the guided diagnostic procedure(s) available in Digital Wrench®.
Power
Steering
Non
Functional,
MIL is OFF
↓ Determine
Is Battery
Voltage >11
and
<16VDC?
→ No
cause of
incorrect
battery
voltage and
repair
Yes ↓
Is EPS Fuse
OK?
→ No
Replace
EPS Fuse.
Yes ↓
12 VDC and
GND across
2 Pin EPS
Connector
with Key
→ No
Check EPS
Power
Relay and
Circuit
On?
Yes ↓
Check
12 VDC on
Pin 3 of the
8 pin EPS
Connector?
→ No
wiring from
Connector
to Ignition
Switch
Circuit
Yes ↓ MIL Lamp

Begin EPS MIL should Trouble-
← → →
Digital turns on come on
→
Instrument shoot per
Wrench during briefly Cluster EPS “Non
EPS Instrument during
Yes No MIL lamp No Functional
Trouble- Cluster Instrument OK? and MIL
shooting Power Up Cluster ON”
Procedure Self Test? Power Up.
↑ ← ← ← ↓
GENERAL INFORMATION
EPS TROUBLESHOOTING (USING DIGITAL WRENCH®)

Troubleshooting 1
Procedure Advises
Digital Wrench
↓
Connect Digital Wrench
to Diagnostic Connector
↓
Check wire harness for
Is Digital Wrench able to damaged/shorted CAN
Turn key to “On”Position → establish a connection to → → → bus wires. Repair or
No replace harness if
EPS?
necessary
Yes ↓ ↓
Trace/Repair CAN bus
Follow Digital Wrench
wiring and ignition power
← Is DW able to establish a
instructions No connection to the ECM?
wires
↓ Yes ↓
Replace Power Steering
Module if any of the Error
codes are present from
Table 1. Replace EPS
Perform further testing if
Error Codes are present
from Table 2.
TABLE 1
• Position Encoder Error • Phase Sensing Excessive Current

• EPS Software Error • Torque Sensor Range
• Steering Torque Sensor Full Failure • Rotor Encoder Communication
• Steering Excessive Current Error* • Rotor Encoder Variance
• Steering Over Current Shutdown* • SEPIC Voltage Low/High
• Phase Sensing Over Current • EEPROM Failure
*These Error Codes must have multiple occurrences or you must be able to duplicate the condition before replacing
the EPS unit.
TABLE 2
• EPS Inverter Temperature Test • Battery Voltage Over / Under Test

1. Verify that the Power Steering module heat sink surface (top 1. Disconnect 2 pin power connector to EPS and verify battery
surface) is clean and free of mud and dirt. Make a note of how voltage (12-14 VDC) is present on pins with key on. If voltage is
much debris was on heat sink before cleaning. Record all power low, investigate and correct cause. If voltage at pins is correct,
steering error codes. EPS inverter temperature can be monitored cheak all connections for corrosion, damage, and tightness.
through Digital Wrench. Check pin 3 on 8 pin connector for 12V signal with key on.
2. Allow vehicle to set and cool for at least 2 hours.
3. Drive vehicle for 30 minutes of left and right turning and then
connect to Digital Wrench and read Power Steering Error Codes. • Calibration Error - Reflash EPS Unit
If inverter temperature error code is present, replace Power
Steering Module. If error is not present, Module is OK. EPS
inverter temperature can be checked using Digital Wrench.

GENERAL INFORMATION
SHOCK ANALYSIS
Shock “misting” q or “weepage” w is common and should be present during normal vehicle operation. All Shock
Absorber Seals are designed to allow a thin film of oil to pass into and out of the shock. This thin film of oil lubricates
the Seal to ensure low friction and reduces the corrosion rate of the Piston Rod.
Vehicle operating conditions have a high impact on how much shock oil might be present on the seal and shock body
(i.e. road conditions and operating temperature). It is important to properly identify the difference between normal
operation (weepage or misting) and a shock that has a leak. Below are some images to help determine what is normal
and what could be identified as a bad shock.
MISTING OR WEEPAGE LEAKAGE

GENERAL INFORMATION
ELECTRICAL DIAGNOSTICS
ELECTRICAL SERVICE NOTES STATIC AND DYNAMIC TESTING 1
Keep the following notes in mind when diagnosing an There are many methods for testing a DC circuit. These
electrical problem. methods fall into one of two categories, either static or
dynamic.
• Refer to wiring diagram for stator and electrical
component resistance specifications. STATIC TESTING
The two most common forms of static testing are:
• When measuring resistance of a component that has a
low resistance value (under 10 Ohms), remember to • Resistance testing (the Ohms setting on your DMM)
subtract meter lead resistance from the reading.
Connect leads together and record the resistance. The • Measuring voltage with the circuit open, such as when
resistance of the component is equal to tested value the harness connector is off a sensor you are testing.
minus the lead resistance. This is commonly referred to as measuring “Available
Voltage”.
• Become familiar with the operation of your meter. Be
sure leads are in the proper jack for the test being
These two tests will help you find the majority of electrical
performed (i.e. 10A jack for current readings). Refer to
issues. If they do not, we must remember that static
the Owner’s Manual included with your meter.
circuit testing does not take into account how current
• Voltage, amperage, and resistance values included in actually flows in that circuit. That is only accomplished
this manual are obtained with a Fluke™ 77 Digital with dynamic testing.
Multimeter (PV-43568). This meter is acceptable for
Before attempting dynamic testing (as it is intrusive on
use when diagnosing electrical problems. Readings
sealed connectors and damage could be done if not
obtained with other meters may differ.
careful), verify the following:
• Pay attention to the prefix on the meter reading (K, M,
etc.) and the position of the decimal point. • Static voltage testing advised for that circuit has been
completed, and is in spec.
• For resistance readings, isolate component to be
tested. Disconnect wire harness or power supply. • All associated circuits have under 1 ohm of resistance
from end to end. Testing Continuity / Resistance page
1.91
• All associated circuits have no shorts to ground.
DIGITAL MULTI-METER (DMM) NOTES Testing For A Short To Ground page 1.91
Polaris advises to only use a high quality DMM that
meets the same standards as the Fluke™ 77 (PV-43568) • All associated circuits have no shorts to voltage.
for electrical testing. Testing For A Short To Voltage page 1.92
Unless you are very familiar with Ohm’s Law, and have
complete information about the circuit you are trying to DYNAMIC TESTING
diagnose, test lights are likely to provide results that There are two types of dynamic testing we will advise to
would be misleading. This is especially true if any solid use when diagnosing electrical concerns:
state component is involved, where you will almost
• Current flow testing (Amperage) Testing Current Flow
certainly not have complete circuit information.
(Amperage) page 1.93. Measuring Amperage is not a
Polaris also specifically advises against the use of other common practice, as you will not typically have a spec
circuit testing devices, including but not limited to: to compare your reading to. Also, many components
on this machine flow over 10 Amps, which will blow the
• Short finders majority of DMM fuses. The exception to this is a
• Simplified circuit testers parasitic draw test refer to Current Draw - Key Off
page 1.94.
• Fuse piggy-back devices
• Measuring voltage drop. Performing this test correctly
Testers beside a DMM will only work in one scenario, will give you understanding of how electrical pressure
and slight variables can provide you with misleading (voltage) varies in a circuit as current is flowing.
results. The testing practices described in this chapter Testing Voltage Drop page 1.94
are more certain and rely only on the DMM and your
knowledge.

GENERAL INFORMATION
CONNECTOR PROBING GUIDELINES For a video demonstration, scan the QR code below, or
FRONT PROBING right click it and select “open in new tab”.
Front probing is accomplished by pulling the harness
connector from the component, and then taking a
measurement from the terminal face. This is the
measurement taken in most situations.
The terminals in electrical connectors are small and
fragile. Do not probe directly with your meter leads, as
the meter leads are larger than almost all terminals.
Probing with a meter lead will likely damage the terminal
by spreading it beyond it’s design limits, causing no
tension. If there is no tension, you will have either no
connection or a poor connection.
BACK PROBING
To avoid causing damage, use of the appropriate
Back probing is typically not advisable on sealed
adapters is required. Most terminals used on Polaris
connectors, as it can easily cause damage to the wire,
machines can be tested using terminal test kit PV–
terminal, connector body, or body to wire seal.
43526. It includes male and female adapters that can be
plugged into banana connectors to adapt to your meter.
NOTICE
There are commercially available back probe kits. Fine,
narrow needles with no coating to block current flow
also work well for back probing.
If back probing must be done to see voltage drop while

current is flowing in the circuit (dynamic testing), ensure
it is done only on connectors that are large enough to
accommodate the probe. Ensure back probing is done
gently and carefully. Ensure no damage has been done
after probing.
For a video demonstration, scan the QR code below, or
right click it and select “open in new tab”.
PV–43526 adapters are also used as known good

terminal drag testers. Insert the male tester terminal into
the female connector on the harness. There should be a
noticeable amount of force to install and remove the
tester, and you should be able to tip the harness
connector with the tester hanging from the connector,
and not have the tester fall out.
If very little or no resistance is felt, or if the tester falls out
when the connector is held upside down, this is an
indication that the female connector in the harness has BREAK OUT
insufficient tension and will cause connection issues. You This is a method of front probing to achieve the goal of
can either replace that harness, or service it by replacing back probing, which is to measure the circuit while it is
the terminal or attempting to adjust/tighten the tang in the functioning.
female terminal.
You can use test probe kit PV–43526, test leads, and
electrical tape to create a bridge with exposed testing
areas to have everything exposed but still working.
IMPORTANT
Use electrical tape to cover the exposed conductive
parts of the circuit, mainly the clamps of your test leads.
If they contact each other, circuit or component damage
could occur from a short.

GENERAL INFORMATION
TESTING CONTINUITY / RESISTANCE TESTING FOR A SHORT TO GROUND

Testing using the Ohmmeter function of your DMM is one
of the first things you will do when troubleshooting an
Shorts to ground happen when the current flowing in a
given circuit bypasses the load. The current flowing from
1
electrical issue. It is especially convenient when the B+ finds an easier way to return to ground (B-), so much
wiring diagram provides a resistance spec for the more of it can flow than the circuit is designed for. This
component in the circuit you are diagnosing. It can causes the circuit’s protection device (either a fuse or
quickly give you a good idea if you simply need to circuit breaker) to open, protecting the circuit from
replace a part, or if there might be another circuit issue. damage.
Using the following points in conjunction with your DMM There are many possible causes of a short to ground,
owner’s manual will ensure your resistance testing is here are some:
always accurate:
• The harness rubbing against a component that is
• Only measure resistance on an isolated part of the grounded, such as the frame, chassis component, or
circuit. This means if you are testing internal resistance engine.
of a component, it cannot be connected to the
• A component’s internal circuitry contacting its case.
harness. If you are measuring a wire (typically from the
ECU to a sensor) both the sensor and ECU would • Wire-to-wire chaffing causing contact with the
need to be unplugged. Most Ohmmeters provides a conductor of a ground side circuit.
precise amount of current to determine resistance. Any
other sources will make your reading inaccurate. • Corrosion/moisture in a component providing a ground
path.
• Ensure you are making good contact by using the
proper terminal adapters. Connector Probing • Moisture in a connector body providing a ground path.
Guidelines page 1.90
• If you are not using a self ranging meter, double check NOTICE
your range setting. This test is typically done right after checking continuity
• If your continuity is under 1 ohm, leave the harness from sensor to ECU when diagnosing an EFI DTC. It
disconnected and move on to Testing For A Short To can also be used to help diagnose concerns about
Ground page 1.91 and Testing For A Short To Voltage blowing fuses. Ensure you are able to duplicate the
page 1.92. concern before testing so that your results point you in
the right direction.Testing for Intermittent Conditions
For a video demonstration, scan the QR code below, or page 1.93
right click it and select “open in new tab.”
TESTING PROCEDURE
1. Consult the wiring diagram. Determine which circuit
you will be testing.
2. Ensure that any static voltage checks advised in
relation to the DTC or concern you are diagnosing
have been performed and are in spec.
3. Ensure you have checked continuity of the circuit.
Testing Continuity / Resistance page 1.91
4. Ensure that neither end of the circuit is connected.
5. Set your DMM to Ohms.
6. Connect one meter lead securely to the battery
negative post.
7. Connect the other lead to either end of the
disconnected circuit. Ensure you are using the correct
adapter.Connector Probing Guidelines page 1.90
8. If there is continuity, the harness is damaged and
should be repaired or replaced.
9. If the DMM reads OL, there is no short to ground.
Leave the harness disconnected on both sides, and
proceed to check for a short to voltage. Testing For A
Short To Voltage page 1.92

GENERAL INFORMATION
For a video demonstration, scan the QR code below, or TESTING FOR A SHORT TO VOLTAGE
right click it and select “open in new tab”. There are three possible short to voltage causes:
1. Internal electronic component short.
2. Harness chaffing leading to contact of the circuit
being diagnosed to one with B+ or a different
reference voltage.
3. Moisture in a connector or component.
TESTING PROCEDURE
1. Consult the wiring diagram. Determine which circuit
you will be testing.
2. Ensure that any static voltage checks advised in
relation to the DTC or concern you are diagnosing
have been performed and are in spec.
3. Ensure you have checked continuity of the circuit.
Testing Continuity / Resistance page 1.91
4. Ensure you have checked for a short to ground.
Testing For A Short To Ground page 1.91
5. Ensure that neither end of the circuit is connected.
6. Set your DMM to DC volts.
7. Connect one meter lead securely to the battery
negative post.
8. Connect the other lead to either end of the
disconnected circuit. Ensure you are using the correct
adapter.Connector Probing Guidelines page 1.90
9. If there is voltage present, the harness is damaged
and should be repaired or replaced. You may need to
remove the protective tape and tubing to inspect.
10. If the DMM reads 0 volts, the concern may be in a
component related to the circuit. If so, checking
internal continuity of non-electronic components may
reveal the concern, but diagnosis at this point may
require using known good parts.

GENERAL INFORMATION
TESTING FOR INTERMITTENT TESTING CURRENT FLOW

CONDITIONS (AMPERAGE) 1
Intermittent conditions are very difficult to diagnose, as Performing a current flow test requires the meter leads
when you are testing the circuit, you may not have the be inserted into the correct cavities in the meter, and be
circuit failing to indicate where the issue is. Intermittent placed in series in the circuit to be tested. Refer to your
electrical failures are almost always related to a poor Digital Multi Meter’s owner’s manual for potential model
connection that only goes open in specific situations, specific instructions. Ensure you are using acceptable
such as going over a certain kind of bump, at a certain adapters to avoid damaging the connector terminals.
temperature, or when the machine is torque loaded in See Connector Probing Guidelines page 1.90.
one way.
NOTICE
Here is a list of possible failures that can be associated
with an intermittent electrical failure: Amperage specs are generally not provided for circuits/
components. Please only perform this test when
• Loose female terminal in an electrical connector. advised in the manual.
NOTICE
If the terminals in question are the correct size/series, IMPORTANT
always use PV–43526 to test the drag when inserting Many circuits on this machine will exceed the 10 Amp
and removing the test terminal adapters. Compare the fuse in most Digital Multi Meters in normal operation.
effort to the drag against the known good tester
terminal for reference.
• Poor terminal to wire crimp.

• Terminal crimp that occurred at least partially on
insulation instead of the conductor wire strands.
• Terminal fretting corrosion
• Contamination/moisture corrosion
• A full or partial break of the conductor wires in the
insulation, with or without visible insulation damage.
• Improper routing, especially when it leads to chaffing
or heat damage, especially near exhaust.
You may need to use different techniques to duplicate

these concerns. These include but are not limited to:
• Moving the harness by wiggling it or flexing certain
areas.
• Pulling at or near the suspected connector.
• Pushing in different directions to flex the connector
body and try to isolate poor connections.
• Changing the temperature. This can be accomplished
with either heat guns or cold air guns.
WARNING
Always exercise caution when using these tools, and
use them for short periods of time when changing the
temperature of an area. Failure to do so can lead to
serious injury and/or damage to the machine.

GENERAL INFORMATION
CURRENT DRAW - KEY OFF 6. Momentarily key the ignition switch on, then off.
Parasitic draw is when there is excessive current flow
IMPORTANT
with the key off.
Ensure all electrical components are switched off, or
While the most common causes of draws are improperly damage to your jumper and/or meter will occur.
installed accessories (tapping into un-switched B+
instead of switched) there can be electronic component
failures that can cause this as well. 7. Wait 10 minutes before checking the value. Vehicles
will vary, but electronic components will take time to
IMPORTANT fully go to sleep after switched power is removed.
Do not connect or disconnect the battery cable, or 8. Maximum allowable is 10 milliamps. If your meter is
ammeter with the engine running. Damage will occur to ranged to the 10 Amp scale, this will appear as 0.010
electrical components. Amps.
Current Draw - Key Off:
IMPORTANT
Maximum of .01 DCA (10 mA)
Charging system damage will occur if incompatible
components are installed. Always reference the Polaris
Electronic Parts Catalog for the proper part numbers. 9. If over 10 milliamps, go to the fuse block and start
systematically removing one fuse at a time until the
value drops, indicating the circuit that requires
NOTICE attention.
Wait ten minutes with the key off for the ECU to power
down. This will avoid a faulty readout while testing
amperage draw. TESTING VOLTAGE DROP
NOTICE
TESTING PROCEDURE
If you disconnect the connector at the load, and
1. Remove the negative cable from the battery. measure voltage with one lead on the power supply
wire, and one to ground, you will be measuring
2. Connect a jumper from the negative battery cable
available voltage. This is a static test and not dynamic
terminal to the negative battery post.
voltage drop testing. Refer to Static and Dynamic
3. Ensure your meter leads and selector dial are set to Testing page 1.89.
measure amperage.
4. Connect your red lead to the battery negative cable The measurement of voltage is the DIFFERENCE in
terminal. electrical pressure between the two points your DMM
leads are touching.
Most circuits will have one load. The load is the
component in the circuit that uses the current flow to do
work, such as move a solenoid or light a bulb.
Voltage coming into the load should be near battery
voltage with current flowing. There will be some loss from
moving through electrical contacts in connectors and
relays, but it will be minimal.
NOTICE
You will need to backprobe to perform this test. For
information about doing this safely, refer to Connector
Probing Guidelines page 1.90.
Voltage should be near fully depleted by the load. This

5. Connect your black lead to the battery negative post. means that when measuring on the ground side of the
circuit, immediately after the load, back to battery
negative, you should have near zero pressure difference
(voltage).

GENERAL INFORMATION
If you do have a difference in pressure, this means there

is something adding resistance to the circuit such as
corrosion. 1

GENERAL INFORMATION
NOTES

MAINTENANCE
CHAPTER 2
MAINTENANCE
2
GENERAL INFORMATION - MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
SERVICE NOTES - MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
SPECIAL TOOLS - MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
SERVICE SPECIFICATIONS - MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
PERIODIC MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
PERIODIC MAINTENANCE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
PRE-RIDE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
MAINTENANCE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27
GREASE LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29
MAINTENANCE LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31
POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32
ENGINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.33
ENGINE OIL LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.33
ENGINE OIL AND FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.34
ENGINE CRANKCASE BREATHER HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.35
VALVE CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.36
CAM CHAIN TENSIONER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38
COOLING SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.39
LIQUID COOLING SYSTEM OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.39
COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.39
COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.40
COOLING SYSTEM HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.41
RADIATOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.41
COOLANT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.42
AIR INTAKE AND EXHAUST MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.43
AIR FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.43
AIR DUCT INSPECTION - HIGH LIFTER / BACK COUNTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.44
EXHAUST SPARK ARRESTOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.44
EXHAUST HEAT SHIELD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.45
FUEL SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.46
FUEL LINE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.46
FUEL PUMP / FILTER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.46
FUEL TANK VENT LINE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.47
IGNITION SYSTEM MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.48
SPARK PLUG REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.48
PVT SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.49
DRIVE BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.49
PVT SYSTEM DRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.49
TRANSMISSION AND FRONT GEARCASE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.50

MAINTENANCE
TRANSMISSION FLUID LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.50

TRANSMISSION FLUID REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.50
SHIFT CABLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.51
SHIFT CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.52
FRONT GEARCASE FLUID LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.54
FRONT GEARCASE FLUID REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.54
FINAL DRIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.56
DRIVE SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.56
WHEEL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.56
TIRE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.57
TIRE PRESSURE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.57
STEERING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.58
STEERING SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.58
STEERING WHEEL FREE-PLAY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.58
TIE ROD END INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.59
WHEEL TOE MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.59
WHEEL TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.60
SUSPENSION MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.61
SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.61
SPRING PRE-LOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.61
SHOCK POSITION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.61
BRAKE SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.62
BRAKE FLUID LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.62
BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.62
BRAKE DISC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.63
BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.63
ELECTRICAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.64
THROTTLE PEDAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.64
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.65
LEAD ACID CONVENTIONAL BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.65
DRY SHIPPED AGM BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.65
LEAD ACID LOW MAINTENANCE BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.65
AGM LOW MAINTENANCE BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.66

MAINTENANCE
GENERAL INFORMATION - MAINTENANCE

SERVICE NOTES - MAINTENANCE SPECIAL TOOLS - MAINTENANCE
Inspect, clean, lubricate, adjust and replace parts as TOOL DESCRIPTION PART NUMBER
necessary. When inspection reveals the need for
replacement parts, use genuine Polaris parts available Oil Filter Wrench PU-50105
from your Polaris dealer.
Shock Spanner Wrench 2877408 2
Inspection, adjustment and lubrication of important
components are explained in the periodic maintenance Bosch Automotive Service Solutions: 1-800-328-6657
chart. or https://polaris.service-solutions.com/
IMPORTANT
Service and adjustments are critical. If you’re not
familiar with safe service and adjustment procedures,
have a qualified dealer technician perform these
operations.
NOTICE
Gasoline is extremely flammable and explosive under
certain conditions.
Always stop the engine and refuel outdoors or in a well
ventilated area.
Do not smoke or allow open flames or sparks in or near
the area where refueling is performed or where
gasoline is stored.
Do not overfill the tank. Do not fill the tank neck.
If you get gasoline in your eyes or if you swallow
gasoline, seek medical attention immediately.
If you spill gasoline on your skin or clothing,
immediately wash it off with soap and water and
change clothing.
Never start the engine or let it run in an enclosed area.
Engine exhaust fumes are poisonous and can result in
loss of consciousness or death in a short time.
Never drain the fuel when the engine is hot. Severe
burns may result.

MAINTENANCE
SERVICE SPECIFICATIONS - FLUID SPECIFICATIONS

MAINTENANCE ITEM FLUID TYPE CAPACITY
GENERAL SPECIFICATIONS Premium All-Season
Grease Fittings -
SERVICE Grease
ITEM STANDARD LIMIT U-Joint Premium U-Joint -
Cylinder Lubricant Lubricant
- 20%
Leakage 87 Octane
11.5 Gal
Intake Valve Fuel (minimum) 10%
.006 ± .002 in (0.15 ± (43.5 L)
Clearance - Ethanol (maximum)
0.05 mm)
(Cold)
Exhaust Valve
.010 ± .002 in (0.25 ±
Clearance -
0.05 mm)
(Cold)
Front Tire Air Refer to Tire Pressure
-
Pressure Inspection page 2.57.
Rear Tire Air Refer to Tire Pressure
-
Pressure Inspection page 2.57
Steering Wheel
0.8-1.0 in (20-25 mm) -
Free-Play
1/8-1/4 in (3.2-6.4
Wheel Toe Out -
mm)
Spring Threaded Spanner -
Adjustment Wrench
Brake Pad 0.040 (1
-
Thickness mm)
Brake Disc 0.170 (4.32

-
Thickness mm)
Spark Plug
NGK MR7F -
Type
FLUID SPECIFICATIONS
ITEM FLUID TYPE CAPACITY
PS-4 5W-50 Full
Synthetic /
2.5 Qt. (2.4
Engine Oil PS-4 10W-50
L)
Extreme Duty Full
Synthetic
50 / 50 Extended Life 5.0 Qt

Engine Coolant
Antifreeze (4.75 L)
Front 8.5 oz (250

Demand Drive Fluid mL)
Gearcase Fluid
Transmission AGL Gearcase 52 fl oz (
Fluid Lubricant 1550 mL)
Brake Fluid DOT 4 -

MAINTENANCE
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE OVERVIEW BREAK-IN PERIOD
Inspection, adjustment and lubrication of important The break-in period consists of the first 25 hours of
components are explained in the periodic maintenance operation. Careful treatment of a new engine and drive
chart. components will result in more efficient performance and
longer life for these components.
Inspect, clean, lubricate, adjust and replace parts as 2
necessary. When inspection reveals the need for • Drive vehicle slowly at first while varying the throttle
replacement parts, use genuine Pure Polaris parts position. Do not operate at sustained idle.
available from your Polaris dealer.
• Perform regular checks on fluid levels and other areas
outlined on the daily pre-ride inspection checklist.
WARNING
Service and adjustments are critical. If you’re not • Change both the engine oil and filter after 25 hours or
familiar with safe service and adjustment procedures, one month.
have a qualified dealer perform these operations. • See “Owner’s Manual” for additional break-in
information.
Maintenance intervals in the following chart are based
upon average riding conditions and an average vehicle
speed of approximately 10 mph (16 km/h). Vehicles
subjected to severe use must be inspected and serviced
more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level

during cold weather can indicate contaminants collecting
in the oil sump or crankcase. Change oil immediately if
the oil level begins to rise. Monitor the oil level, and if it
continues to rise, discontinue use and determine the
cause or see your dealer.

MAINTENANCE
PRE-RIDE INSPECTION
The following items should be inspected pre-ride:
ITEM INSPECTION / CHECK
• Air Filter / Air box is clean

Air Filter • Filter is properly installed
• Air Box cover is secured and fastened
• Check for proper EPS operation

Steering System
• Check for tightness/play in the steering wheel when turned
lock to lock
• Inspect bushings
Front / Rear Suspension • Check for damaged to the control arms / trailing arms
• Check for leaking shocks
• Check for proper air pressure in all tires

Tires • Inspect for tire damage / nails in tire
• Verify there is adequate tread depth
Wheels / Lug Nuts • Ensure rim is not cracked / bent

• Verify proper lug nut torque
• Ensure all lights are operational

Headlights / Taillights
• Adjust headlight aim as required
• Check brake fluid level is between MIN and MAX
Brake System • Check brake pedal is not soft when pushed

• Verify brakes stop and hold the vehicle
• Inspect for leaks
Engine Oil Level Verify oil level is in the SAFE range on the dipstick
Intake Drain Inspect / drain intake as needed
• Verify coolant level is filled to the FULL COLD mark on

Coolant Level coolant reservoir (if engine is cold)
• Inspect hoses and radiator for leaks
Auxiliary Brake (if equipped) Inspect / adjust as needed

PVT Outlet Duct Screen Inspect / clean often
Spark Arrester Inspect / clean after operating in mud and water

MAINTENANCE
MAINTENANCE INTERVALS
The maintenance interval charts outline required maintenance and inspection based on vehicle hours / miles. Each
table states the number of hours / miles that service is required on the vehicle. Some items or components may need
to be serviced more often due to severe use, such as operation in water or under severe loads. When the vehicle goes
beyond 500 hours / 5000 miles, return to the 25 hours / 250 mile chart and start the interval process over.
25 HOUR / 250 MILE (400 KM) SERVICE 2

COMPONENT REMARKS
XU / D Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear
Fuel System Turn key on to pressurize fuel pump; check lines / fittings for leaks and
abrasion
XU / D Parking Brake Cable Adjustment (INT’L) Inspect; adjust tension after first 25 hours
XU / E Engine Breather Inspect; clean
Battery Check terminals; clean; test
XU Front Gearcase Lubricant Initial fluid level inspection; add lubricant if needed
XU Transmission Lubricant (AGL) Initial fluid level inspection; add lubricant if needed
Perform a break-in oil and filter change at 25 hours or one month; perform
XU / E Engine Oil & Filter Change (Break-In)
every 100 hours or 1 year after initial break-in oil change
XU - Perform these procedures more often for vehicles subjected to severe use.
D - Have an authorized Polaris dealer perform these services.
E - Emission Control System Service (California)

MAINTENANCE
50 HOUR / 500 MILE (800 KM) SERVICE

ITEM REMARKS
XU / D Brake Pads / Parking Brake Pads (INT’L) Inspect pad wear; replace if worn beyond service limit
E EVAP System Inspect Fuel and EVAP system if equipped.
Turn key on to pressurize fuel pump; check lines / fittings for leaks and
Fuel System
abrasion. Replace as needed.
XU Front Gearcase Lubricant Inspect / add lubricant if needed
XU Transmission Lubricant (AGL) Inspect / add lubricant if needed
XU General Lubrication Lubricate all fittings, pivots, cables, etc.
D/E Throttle Pedal Inspect; replace if it sticks
E Throttle Body Intake Ducts/Flange Inspect ducts for proper sealing / air leaks
Shift Cable / Linkage Inspect; adjust as needed
D Steering Lubricate (if applicable)
XU Front / Rear Suspension Lubricate (if applicable)
D Cooling System Inspect coolant strength seasonally; pressure test system yearly
D Drive Belt Inspect; replace as needed
XU Engine Oil Lines/Fasteners Inspect for leaks and loose fittings

MAINTENANCE
75 HOUR / 750 MILE (1200 KM)SERVICE

COMPONENT REMARKS
Fuel System
abrasion. Replace as needed. 2

MAINTENANCE

ITEM REMARKS
Fuel System
XU / E Engine Oil & Filter Change Change oil and filter, inspect used oil for contaminants
XU Front Gearcase Lubricant Change lubricant
XU Transmission Lubricant (AGL) Change lubricant
Fuel System
D/E Spark Plug Inspection Inspect; replace as needed; torque to specification
XU Radiator Inspect; clean external surfaces
XU Cooling Hoses Inspect for leaks; pressure test system
XU Engine Mounts Inspect, torque to specification
Exhaust Silencer / Pipe Inspect
Inspect for wear, routing, security; inspect connectors subjected to water,
XU Wiring
mud, etc.
D Front Wheel Bearings Inspect; replace as needed
XU Shocks Visually inspect shock seals; change oil and seals if leaking
Cam Chain Tensioner Inspect/clean; replace as needed

MAINTENANCE

COMPONENT REMARKS
Fuel System

MAINTENANCE

ITEM REMARKS
Fuel System

MAINTENANCE

COMPONENT REMARKS
Fuel System

MAINTENANCE

ITEM REMARKS
D/E EVAP System Inspect Fuel and EVAP system if equipped.
D/E Fuel System
XU / D Clutches (Drive and Driven) Inspect; clean; replace worn parts
XU Wiring Inspect routing and for wear; inspect connectors subjected to water/mud.
XU / D Shocks Change shock oil and inspect seals
D Brake Fluid Change every two years (DOT 4)
Clean daily if driven in mud / water; replace a damaged arrestor before
Spark Arrestor
operating
D/E Valve Clearance Inspect; adjust as needed

MAINTENANCE

COMPONENT REMARKS
Fuel System

MAINTENANCE

ITEM REMARKS
Fuel System

MAINTENANCE

COMPONENT REMARKS
Fuel System

MAINTENANCE

ITEM REMARKS
EVAP System Inspect Fuel and EVAP system if equipped.
D/E Fuel System
XU Wiring
mud, etc.
XU Shocks Visually inspect shock seals; change oil and seals if leaking

MAINTENANCE

COMPONENT REMARKS
Fuel System

MAINTENANCE

ITEM REMARKS
Fuel System

MAINTENANCE

COMPONENT REMARKS
Fuel System

MAINTENANCE

ITEM REMARKS
D/E EVAP System Inspect Fuel and EVAP system if equipped.
Fuel System
XU / D Clutches (Drive and Driven) Inspect; clean; replace worn parts
XU Wiring
mud, etc.
Clean daily if driven in mud / water; replace a damaged arrestor before
Spark Arrestor
operating

MAINTENANCE

COMPONENT REMARKS
Fuel System

MAINTENANCE

ITEM REMARKS
Fuel System

MAINTENANCE

COMPONENT REMARKS
Fuel System

MAINTENANCE

ITEM REMARKS
Fuel System
XU Wiring
mud, etc.
D/E Spark Plug Replacement Replace; torque to specification
XU Coolant Replace coolant
D Toe Adjustment Inspect periodically; adjust when parts are replaced
When the vehicle goes beyond 500 hours / 5000 miles, return to the 25 hours / 250 mile chart and start the interval
process over.

MAINTENANCE
MAINTENANCE QUICK REFERENCE

ITEM LUBE REC METHOD FREQUENCY*
Perform a break-in oil and
filter change at 25 hrs or
Oil Fill Cap q : Polaris PS-4 5W-50 Full
- Under Cargo Box Synthetic or Add oil to proper level on one month; Perform oil
Oil Filter w / Dipstick e : Polaris PS-4 10W-50 Extreme dipstick and filter change at 100
hours / 1000 miles / 12
2
- On Front Side of Engine Duty Full Synthetic
months, whichever comes
first
Engine Coolant Polaris 50 / 50 Extended Life Maintain coolant level in Check level daily; change
- Under Front Hood Antifreeze coolant reservoir bottle r. coolant every two years
* More often under severe use, such as operation in water or under severe loads.

MAINTENANCE
ITEM LUBE REC METHOD FREQUENCY*

Maintain fluid level between
Check level during pre-ride inspection;
Brake Fluid Polaris DOT 4 “MAX and “MIN” lines on the
change fluid every two years
master cylinder reservoir q
Add lubricant until it is visible at
Polaris Demand the fill hole threads w. (8.5 oz
Front Gearcase Initial level check at 25 hours or 1
Drive Fluid (250 mL)).
month; Change lubricant at 200 hours /
Polaris AGL Add lubricant until it is visible at 2000 miles / 12 months, whichever
Transmission Gearcase the fill hole threads e (52 fl oz comes first
Lubricant ( 1550 mL))
* More often under severe use, such as operation in water or under severe loads.

MAINTENANCE
GREASE LUBRICATION POINTS

There are grease fittings at each front and rear torsion bar bushing and on the front propshaft yokes. Apply grease until
all traces of water have been purged out at each of these areas.
ITEM LUBE REC METHOD FREQUENCY

Grease fittings every 500
miles (800 km); Grease
2
before long periods of
Propshaft Yoke Premium U-Joint Lubricant Grease middle q fitting storage, and after
thoroughly washing or
submerging the vehicle
BASE

MAINTENANCE
CREW

MAINTENANCE
MAINTENANCE LUBRICANTS
PART # DESCRIPTION PART # DESCRIPTION
Engine Lubricants Additives / Sealants / Thread Locking Agents /
PS-4 Full Synthetic 5W-50 (Qt) Misc.
2876244
Loctite® Threadlock 242
2876245 PS-4 Full Synthetic 5W-50 (Gal) 2871950 (6 mL) (12 count)
PS-4 Extreme Duty Full Synthetic 10W-
2
2878920 Premium Carbon Clean
50 (Qt) 2871326 (12 oz) (12 count)
PS-4 Extreme Duty Full Synthetic 10W- Fuel Stabilizer (16 oz) (12 count)
2878919 2870652
50 (Gal)
2872189 DOT 4 Brake Fluid (12 count)
2540086 Engine Oil Filter
2871557 Crankcase Sealant, 3-Bond 1215 (5 oz)
2879723 Engine Oil Change Kit (PS-4)
Engine Oil Change Kit (PS-4 Extreme NOTICE
2879324 Duty)
The number count indicated by each part number in the
Gearcase / Transmission Lubricants
table above indicates the number of units that are
AGL Gearcase Lubricant (Qt) (12 shipped with each order.
2878068 count)
AGL Gearcase Lubricant (Gal) (4
2878069 count)
AGL Gearcase Lubricant (2.5 Gal) (2
2878070 count)
2877922 Demand Drive Fluid (Qt)
2877923 Demand Drive Fluid (2.5 Gal)
Grease / Specialized Lubricants
Premium All-Season Grease (3 oz) (24
2871322 count)
Premium All-Season Grease (14 oz) (10
2871423 count)
Premium U-Joint Lubricant (3 oz) (24
2871515 count)
Premium U-Joint Lubricant (14 oz) (10
2871551 count)
2871329 Dielectric Grease (Nyogel™)
Coolant
2880514 50/50 EL Anti-Free (Qt) (12 count)
2880513 50/50 EL Anti-Free (Gal) (4 count)
2880512 50/50 EL Anti-Free (55 Gal Drum)
NOTICE
Each item can be purchased separately at your local
Polaris dealer.

MAINTENANCE
POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS

PART NO. DESCRIPTION PART NO. DESCRIPTION
Engine Lubricant Additives / Sealants / Thread Locking Agents / Misc.
2870791 Fogging Oil (12 oz. Aerosol) Loctite® Threadlock 242
2871950 (6 ml.) (12 count)
2876244 PS-4 Synthetic 4-Cycle Engine Oil (Quart)
Premium Carbon Clean
2876245 PS-4 Synthetic 4-Cycle Engine Oil (Gallon) 2871326 (12 oz.) (12 count)
PS-4 Extreme Duty Synthetic 4-Cycle Fuel Stabilizer (16 oz.) (12 count)
2878920 2870652
Engine Oil (Quart)
2872189 DOT 4 Brake Fluid (12 count)
PS-4 Extreme Duty Synthetic 4-Cycle
2878919 Engine Oil (Gallon) Crankcase Sealant, 3-Bond 1215 (5 oz.)
2871557
2540086 Engine Oil Filter
NOTICE
2879723 Engine Oil Change Kit (PS-4)
The number count indicated by each part number in the
2879324 Engine Oil Change Kit (PS-4 Extreme Duty) table above indicates the number of units that are
Gearcase / Transmission Lubricants shipped with each order.
2878068 (1 Qt.) (12 Count)
2878069 (1 Gal.) (4 Count)
2878070 (2.5 Gal.) (2 Count)
2877922 Demand Drive Fluid (Quart)
2877923 Demand Drive Fluid (2.5 Gallon)
2870465 Oil Pump for 1 Gallon Jug
Grease / Specialized Lubricants
2871312 Grease Gun Kit
Premium All Season Grease
2871322 (3 oz. cartridge) (24 Count)
Premium All Season Grease
2871423 (14 oz. cartridge) (10 Count)
2871460 Starter Drive Grease (12 Count)
2871515 Premium U-Joint Lube (3 oz.) (24 Count)
2871551 Premium U-Joint Lube (14 oz.) (10 Count)
2871329 Dielectric Grease (Nyogel™)
Coolant
2880514 50/50 EL Anti-Freeze (Quart) (12 Count)
2880513 50/50 EL Anti-Freeze (Gallon) (4 Count)
2880512 50/50 EL Anti-Freeze (55 Gal Drum)
NOTICE
Each item can be purchased separately at your local
Polaris dealer.

MAINTENANCE
ENGINE MAINTENANCE
ENGINE OIL LEVEL INSPECTION 5. Remove the dipstick and check the oil level.
This engine has a wet-sump design, meaning the engine
IMPORTANT
oil is contained in the bottom of the crankcase. To check
the oil level, follow the procedure listed below: The oil level should be within the SAFE range on
dipstick. Do not overfill (see NOTE below).
FLUID CAPACITY
2
Recommended Engine Oil:
Capacity: 2.5 Qt (2.4 L)
PS-4 5W-50 Full Synthetic
Ambient Temp Range: -35° F to 100° F
PS-4 10W-50 Extreme Duty Full Synthetic

Ambient Temp Range: 0° F to 120° F
1. Position vehicle on a level surface and place the

transmission in PARK.
2. Stop the engine and allow it to cool down before
removing the dipstick.
3. Raise the cargo box. Unlock the dipstick lever q. NOTICE
Remove the dipstick and wipe it dry with a clean
A rising oil level between checks during cold weather
cloth.
operation can indicate contaminants such as gas or
moisture collecting in the crankcase. If the oil level is
over the upper mark, change the oil immediately.
6. If needed, add engine oil through the oil fill cap w

located on top of the valve cover, under the cargo
box.
4. Reinstall the dipstick and push it into place. Do not

lock the dipstick.
NOTICE
Make certain the dipstick is inserted all the way into the
dipstick tube to keep the depth of the dipstick
consistent.
7. Recheck the oil level and ensure if is within the SAFE
range on the dipstick.
8. When finished, reinstall dipstick and lock the lever.
Lower the cargo box and secure in position.

MAINTENANCE
ENGINE OIL AND FILTER SERVICE 7. Using the Oil Filter Wrench (PU-50105), turn the oil
Always change engine oil and filter at the intervals filter w counter-clockwise to remove it.
outlined in the Periodic Maintenance Chart. Always
change the oil filter whenever changing the engine oil.
The engine oil dipstick is located on the right front side of
the engine. The engine oil fill cap is located on top of the
valve cover. Access the oil dipstick and oil fill cap by
tilting the rear cargo box.
The crankcase drain plug is located on the bottom of the
crankcase. Access the drain plug through the skid plate
access hole located directly under the crankcase.
1. Position vehicle on a level surface and place the

transmission in PARK.
2. Stop the engine and allow it to cool down.
3. Clean the area around the crankcase drain plug.
8. Using a clean dry cloth, clean the filter sealing
CAUTION surface on the engine crankcase.
Use caution when performing this procedure. Do not 9. Lubricate the O-ring on the new oil filter with a film of
allow hot engine oil to come into contact with skin, as fresh engine oil. Check to make sure the O-ring is in
serious burns may result. good condition. Install it to specification.
TORQUE
4. Place a drain pan under the engine crankcase and
Oil Filter:Turn by hand until filter O-ring contacts
remove the drain plug q. Allow the oil to drain
sealing surface, then turn an additional 3/4 turn.
completely.
10. Replace the sealing washer on drain plug.

NOTICE
The sealing surface on the drain plug should be clean
and free of burrs, nicks or scratches.
11. Reinstall the engine crankcase drain plug. Torque

drain plug to specification.
TORQUE
Crankcase Drain Plug:
12 ft-lbs (16 Nm)
5. Remove all cargo from the cargo box. 12. Fill engine with recommended engine oil. Refer to
Engine Oil Level Inspection.
CAUTION FLUID CAPACITY
Always remove all cargo from the cargo box before Recommended Engine Oil:
lifting the box to access the engine.
PS-4 5W-50 Full Synthetic
Ambient Temp Range: -35° F to 100° F
6. Pull up on the cargo box release lever to tilt the box.
PS-4 10W-50 Extreme Duty Full Synthetic
Ambient Temp Range: 0° F to 120° F
Capacity:
2.5 Qt. (2.4 L)

MAINTENANCE
13. Verify the transmission is still in PARK. ENGINE CRANKCASE BREATHER HOSE
14. Start the engine and allow it to idle for 30 seconds. INSPECTION
The engine crankcase is equipped with a breather hose.
15. Stop the engine and inspect for oil leaks. Wait at least
Inspect the breather hose for possible kinks or wear. The
15 seconds before removing the dipstick.
hose is form fitted for proper fit.
16. Unlock the dipstick lever. Remove the dipstick and
wipe it dry with a clean cloth.
Follow the breather hose q from the crankcase fitting w
to the airbox e.
2
17. Reinstall the dipstick and push it into place. Do not
lock the dipstick.
NOTICE
Make certain the dipstick is inserted all the way into the
dipstick tube to keep the depth of the dipstick
consistent.
18. Remove the dipstick and check the oil level.

19. Add the recommended oil as necessary to bring the
oil level within the SAFE range on dipstick. Do not
overfill.
IMPORTANT
Make sure hoses are not kinked or pinched.
20. When finished, reinstall the oil fill cap, oil dipstick and
lock the lever.
21. Dispose of used oil and filter properly.

MAINTENANCE
VALVE CLEARANCE INSPECTION 5. Remove the four bolts w and rubber isolators e
retaining the valve cover r. Note the location and
NOTICE use of the grounding washer t for assembly.
Valve clearance inspection should be performed on a
cold engine, at room temperature.
1. Tilt the rear cargo box to access the valve cover.

2. Disconnect the negative (-) battery cable.
3. Remove the eight screws that retain the outer clutch
cover and remove the cover from the vehicle in order
to rotate the engine (refer to Belt Removal page 6.6
procedure).
NOTICE
Replace rubber isolators e upon assembly.
6. The engine will need to be rotated four times to

inspect all eight valve clearances. Two valves can be
measured at each camshaft lobe position.
4. Remove the spark plug wires q from the engine.
NOTICE
Remove spark plugs to aid engine rotation.
7. Rotate the drive clutch counter-clockwise until the

cam lobes above the valves you are inspecting are
facing up.

MAINTENANCE
8. Measure the valve clearance using a feeler gauge. 16. Install the outer clutch cover and eight retaining
screws (Refer to Belt Installation page 6.8
procedure). Torque the screws to specification.
TORQUE
Outer Clutch Cover Screws:
35 in-lbs (4 Nm) 2
17. Connect the negative (-) battery cable to the battery.
18. Start the engine to ensure proper operation.
9. If the valve clearance is out of specification, refer to

Valve Clearance Adjustment page 3.94 procedure.
MEASUREMENT
Intake Valve Clearance (cold):
.006 ± .002 in (0.15 ± 0.05 mm)
Exhaust Valve Clearance (cold):
.010 ± .002 in (0.25 ± 0.05 mm)
10. Repeat steps 7-9 until all eight valves have been
inspected.
11. If previously removed, apply anti-seize compound to
the spark plug threads and reinstall the spark plugs.
Torque spark plugs to specification.
TORQUE
Spark Plug:
9 ft–lbs (12 Nm)
12. Inspect the valve cover seal and replace if necessary.

13. Replace the rubber isolators around each T-40 bolt.
14. Install valve cover and the four bolts. Torque bolts to
specification.
TORQUE
Valve Cover Bolts:
7 ft-lbs (10 Nm)
15. Install the spark plug wire(s). Ensure wires are

pushed down all the way so they engage onto the
spark plug(s).
NOTICE
The engine will misfire if the spark plug wires are
installed incorrectly. The spark plug wires are marked
with PTO and MAG and should be installed to the
corresponding cylinder.

MAINTENANCE
CAM CHAIN TENSIONER INSPECTION 5. Retract the plunger all the way in and install into the
cylinder.
1. Locate the cam chain tensioner on the MAG side of
the engine near the starter. IMPORTANT
2. Remove the plunger bolt q and the spring. Ensure the plunger and spring are not installed when
installing the tensioner.
3. Remove the two tensioner mounting bolts w and
tensioner gasket.
6. Install the two mounting bolts. Torque fasteners to

4. Push on the tensioner lock e and manually move the
specification.
plunger in and out. It should move freely. If it does not
move freely, replace the tensioner assembly. TORQUE
Tensioner Mounting Bolts:
7 ft-lbs (10 Nm)
7. Install the plunger bolt. Torque fastener to

specification.
TORQUE
Plunger Bolt:
15 ft-lbs (20 Nm)
8. Turn the engine over by hand to ensure proper chain

tension is applied.

MAINTENANCE
COOLING SYSTEM MAINTENANCE

LIQUID COOLING SYSTEM OVERVIEW • A 50/50 mixture of extended life antifreeze and distilled
The engine coolant level is controlled or maintained by water will provide the optimum cooling, corrosion
the recovery system. The recovery system components protection, and antifreeze protection.
are the recovery bottle, radiator filler neck, radiator • Do not use tap water, straight antifreeze, or straight
pressure cap and connecting hose. water in the system. Tap water contains minerals and
impurities which build up in the system.
2
As coolant operating temperature increases, the
expanding (heated) excess coolant is forced out of the • Straight water or antifreeze may cause the system to
radiator past the pressure cap and into the recovery freeze, corrode, or overheat.
bottle. As engine coolant temperature decreases the
contracting (cooled) coolant is drawn back from the tank FLUID CAPACITY
past the pressure cap and into the radiator. Recommended Anti-Freeze/Coolant:
Premium Pre-Mixed Extended Life Antifreeze
NOTICE (PN 2880514) (Quart)
Some coolant level drop on new machines is normal as (PN 2880513) (Gallon)
the system is purging itself of trapped air. Observe
coolant levels often during the break-in period.
CAUTION
Overheating of engine could occur if air is not fully
purged from system.
Polaris Premium 50/50 Extended Life coolant is already

premixed and ready to use. Do not dilute with water.
COOLANT STRENGTH / TYPE

Test the strength of the coolant using an antifreeze
hydrometer.

MAINTENANCE
COOLANT LEVEL INSPECTION 4. If the coolant level is below the “MIN” mark, inspect
The recovery bottle q and radiator pressure cap w are the coolant level in the radiator.
located under the hood. NOTICE
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.
CAUTION
Never remove the pressure cap when the engine is
warm or hot. Escaping steam can cause severe burns.
The engine must be cool before removing the pressure
cap.
5. Remove the pressure cap. Using a funnel, add

coolant to the top of the radiator filler neck.
6. Reinstall the pressure cap.
With the engine at operating temperature, the coolant
level should be between the “MAX” and “MIN” marks on NOTICE
the recovery bottle. If not, perform the following:
Use of a non-standard pressure cap will not allow the
1. Position the vehicle on a level surface recovery system to function properly.
2. Remove the hood from the front cab.
7. Remove the recovery bottle cap and add coolant
3. Check the coolant level in the recovery bottle. The using a funnel.
coolant level must be maintained between the “MAX”
and “MIN” levels indicated on the recovery bottle. 8. Fill the recovery bottle to the “MAX” mark with the
recommended pre-mix coolant. You may use a 50/50
or 60/40 mixture of antifreeze and distilled water as
required for freeze protection in your area.
FLUID CAPACITY
Recommended Anti-Freeze/Coolant:
(PN 2880514) (Quart)
(PN 2880513) (Gallon)
9. Reinstall the recovery bottle cap.

10. If coolant was required, start engine and check for
leaks. Ensure coolant level is correct after running the
engine.
11. Make sure radiator fins are clean to prevent
overheating.

MAINTENANCE
COOLING SYSTEM HOSE INSPECTION RADIATOR INSPECTION

1. Inspect all vehicle hoses for cracks, deterioration, 1. Check radiator air passages for restrictions or
abrasion or leaks. Replace if necessary. damage. Refer to Front Fascia Service page 11.25 as
needed to gain access to the radiator.
2. Inspect all engine hoses for cracks, deterioration,

abrasion or leaks. Replace if necessary. ITEM DESCRIPTION
q Radiator
w Shroud
e Fan
2. Carefully straighten any bent radiator fins.

3. Remove any obstructions with low pressure
compressed air or low pressure water.
CAUTION
Washing the vehicle with a high-pressure washer could
damage the radiator fins and impair the radiators
effectiveness. Use of a high-pressure washer is not
recommended.
3. Check tightness and condition of all hose clamps. Do
not over-tighten hose clamps at radiator, or radiator
fitting may distort.
TORQUE
Coolant Hose Clamp:
35 in-lbs (4 Nm)

MAINTENANCE
COOLANT REPLACEMENT
1. Allow the vehicle to cool down if recently operated.
CAUTION
Escaping steam can cause burns. Never remove the
pressure cap while the engine is warm or hot. Always
allow the engine to cool before removing the pressure
cap.
3. Slowly remove the pressure cap to relieve any

cooling system pressure.
4. Place a drain pan under the lower radiator hose.
5. Slide the clamp back and remove the lower radiator
hose to drain the coolant from the radiator.
6. Allow the coolant to completely drain. Properly

dispose of the used coolant.
7. Reinstall coolant hose and reposition the spring
clamp.
8. Remove the pressure cap. Using a funnel, add the
recommended coolant to the top of the filler neck and
fill the recovery bottle to the MAX level.
Refer to Cooling System Bleeding Procedure.
FLUID CAPACITY
Recommended Anti-Freeze/Coolant:
(PN 2880514) (Quart)
(PN 2880513) (Gallon)

MAINTENANCE
AIR INTAKE AND EXHAUST MAINTENANCE

AIR FILTER REPLACEMENT 4. Inspect the airbox for oil or water deposits. Wipe
Inspect the air filter at the intervals outlined in the away any deposits with a clean shop towel.
Periodic Maintenance Chart. In extremely dusty
NOTICE
conditions, air filter replacement will be required more
often. If the filter has been soaked with fuel or oil it must be
replaced. 2
1. Tilt the rear cargo box to access the airbox. DO NOT attempt to clean the air filter.
2. Release the three airbox cover latches and lift the
cover up and out to access the air filter element. 5. Place the air filter into the airbox. Reposition the
lower airbox cover and install the three retaining
latches.
NOTICE
Make sure the hinge pins are properly seated when
reassembling the airbox
3. Remove the air filter element q.

MAINTENANCE
AIR DUCT INSPECTION - HIGH LIFTER / EXHAUST SPARK ARRESTOR

BACK COUNTRY INSPECTION
• Inspect the air and PVT air ducts for debris and clean
as necessary. WARNING
Do not clean spark arrestor immediately after the
engine has been run, as the exhaust system becomes
very hot. Serious burns could result from contact with
the exhaust components. Allow components to cool
sufficiently before proceeding. Wear eye protection and
gloves.
Never run the engine in an enclosed area. Exhaust
contains poisonous carbon monoxide gas that can
cause loss of consciousnessor death in a very short
time.
Periodically clean spark arrestor to remove accumulated

carbon.
1. Remove the retaining screw q and nut w.
2. Remove the spark arrestor e from the end of the
silencer r.
3. Use a non-synthetic brush to clean the arrestor
screen. A synthetic brush may melt if components are
warm. If necessary, blow debris from screen with
compressed air.
4. Inspect the screen for wear and damage. Replace if
needed.
5. Reinstall the arrestor and torque the retaining screw
to specification.
TORQUE
Spark Arrestor:
10 ft-lbs (14 Nm)

MAINTENANCE
EXHAUST HEAT SHIELD INSPECTION

IMPORTANT
Inspect Exhaust Heat Shields and make sure they are in good condition and are secured properly.
NOTICE
2
Refer to Exhaust System Assembly View - HVAC, High Lifter & Back Country page 3.24 for High Lifter exhaust heat
shield inspection.
ITEM DESCRIPTION
q Chassis Shield
w Headpipe Shield, Top
e Headpipe Shield, Bottom
r Silencer Outlet Shield, End
t Silencer Shield, Main
y Silencer Outlet Shield, Elbow

MAINTENANCE
FUEL SYSTEM MAINTENANCE

FUEL LINE INSPECTION FUEL PUMP / FILTER INSPECTION
The fuel pump assembly q is located in the fuel tank
1. Check the quick-connect fuel line q at the fuel pump under the driver’s seat. Inspect the exterior of the pump.
for signs of wear, deterioration, damage or leakage.
Inspect the fuel pump filter only as needed.
Replace line if necessary.
2. Tilt the rear cargo box and check the quick-connect NOTICE
fuel line w at the fuel rail for signs of wear, The serviceable, high-volume, high-pressure, fuel
deterioration, damage or leakage. Replace line if pump assembly includes a non-serviceable preliminary
necessary. filter w. If the filter needs to be replaced, the fuel pump
3. Inspect the protective sleeve e and ensure it is must be replaced as an assembly. Refer to Fuel Pump
located as shown below. Replacement page 5.25 procedure.
4. Be sure fuel lines are routed and retained properly.
NOTICE
Make sure lines are not kinked or pinched.

MAINTENANCE
FUEL TANK VENT LINE INSPECTION

NOTICE
If the vent line fitting is remove them the chassis, it must
be replaced. The fitting will not hold properly once
removed.
2
1. Check the fuel tank vent line q for signs of wear,
deterioration, damage or leakage.
NOTICE
Replace vent line if it appears to be damaged or
deteriorating due to age.
• EVAP MODELS:
2. Be sure vent line is routed properly and secured.

IMPORTANT
Be sure vent line is not kinked or pinched.

MAINTENANCE
IGNITION SYSTEM MAINTENANCE 8. Measure gap with a wire gauge. Adjust gap if
necessary by carefully bending the side electrode.
SPARK PLUG REPLACEMENT
9. If necessary, replace spark plug with proper type.
Inspect and replace the spark plugs at the intervals
outlined in the Maintenance Intervals page 2.7.
CAUTION
1. Tilt the rear cargo box to access the top of the engine. Severe engine damage may occur if the incorrect spark
plug is used.
WARNING
A hot engine can cause serious burns. Allow engine to Recommended Spark Plugs:
cool or wear protective gloves when removing the spark
NGK MR7F
plugs.
10. Apply anti-seize compound to the spark plug threads.

2. Remove the spark plug caps q.
11. Install spark plugs and torque to specification.
TORQUE
Spark Plug:
9 ft–lbs (12 Nm)
12. Install the plug caps to the appropriate cylinder by

referencing the MAG and PTO spark plug wire decals
(B). Ensure wires are pushed down all the way so
they engage onto the spark plugs.
NOTICE
MAG and PTO reference decals on spark plug wires for
reassembly.
3. Clean out plug wells with compressed air to remove

any loose dirt or debris.
4. Rinse plug wells with water and dry with compressed
air.
NOTICE
Spark plug wells have drain holes built into the cylinder
head to allow water to drain out.
5. Remove spark plugs using a 5/8” spark plug socket

with an extension.
6. Inspect electrodes for wear and carbon buildup. Look
for a sharp outer edge with no rounding or erosion of
the electrodes.
7. Clean with electrical contact cleaner or a glass bead
spark plug cleaner only.
CAUTION
A wire brush or coated abrasive should not be used.

MAINTENANCE
PVT SYSTEM MAINTENANCE

DRIVE BELT INSPECTION PVT SYSTEM DRYING
1. Remove PVT Cover. Refer to Belt Removal page 6.6 IMPORTANT
After operating in water, the vehicle’s PVT system
should be checked immediately. Use the following
instructions to dry it out before operating. 2
The PVT drain plug is located at the bottom of the outer
clutch cover. Access the drain plug through the left rear
wheel well.
1. Using a flat blade screwdriver, remove the PVT drain
plug q and O-ring from the outer clutch cover.
2. Inspect belt for hour glassing (extreme circular wear

in at least one spot and on both sides of the belt).
Hour glassing occurs when the drive train does not
move and the drive clutch engages the belt.
3. Inspect belt for loose cords, missing cogs, cracks,
abrasions, thin spots, or excessive wear. Compare
belt measurements with a new drive belt. Replace if
necessary.
4. Belts with thin spots, burn marks, etc., should be
replaced to eliminate noise, vibration, or erratic PVT 2. Allow the water to drain out completely.
operation. Refer to “PVT Troubleshooting” page
6.46 for possible causes. 3. Reinstall the drain plug and O-ring.
5. Click HERE to view the Drive Belt analysis poster or 4. Place the transmission in PARK, apply the brake and
scan the QR Code. start the engine.
5. Apply varying throttle for 10-15 seconds to expel the
moisture and air-dry the belt and clutches.
CAUTION
Do not hold the throttle pedal wide open for more than 5
seconds.
6. Allow the engine RPM to return to idle, then shift the

transmission into low gear.
7. Test the PVT system for belt slippage. If the belt slips,
repeat the process or remove the outer clutch cover
to inspect the PVT system.
CAUTION
If the vehicle has ingested a large amount of water into
the PVT system and has not been operated for a period
of time, be sure to check the PVT system components
for water damage.

MAINTENANCE
TRANSMISSION AND FRONT GEARCASE MAINTENANCE

TRANSMISSION FLUID LEVEL TRANSMISSION FLUID REPLACEMENT
INSPECTION The drain plug is located on the bottom of the
transmission gearcase. Access the drain plug through
NOTICE the drain hole in the skid plate.
It is important to follow the transmission maintenance
intervals described in the Periodic Maintenance Chart. 1. Remove the fill plug.
2. Place a drain pan under the transmission drain plug.
The transmission lubricant level should be checked and
3. Remove drain plug w and allow lubricant to drain
changed in accordance with the maintenance schedule.
completely.
The fill plug is located on the rear portion of the
transmission gearcase. Access the fill plug at the rear of
the vehicle. Maintain lubricant level even with the bottom
of the fill plug hole.
1. Position vehicle on a level surface.
2. Check vent hose to be sure it is routed properly and
unobstructed.
3. Remove the fill plug q and check the lubricant level.
4. Clean the drain plug magnetic surface.

5. Reinstall drain plug with a new O-ring and torque to
specification.
TORQUE
Transmission Fill / Drain Plug:
12 ft-lbs (16 Nm)
4. If lubricant level is not even with bottom threads, add 6. Add the recommended amount of lubricant through
recommended lubricant as needed. Do not overfill. the fill plug hole. Maintain the lubricant level at the
bottom of the fill plug hole when filling the
5. Reinstall the fill plug and torque to specification. transmission. Do not overfill.
TORQUE FLUID CAPACITY
Transmission Fill / Drain Plug: Recommended Transmission Lubricant:
12 ft-lbs (16 Nm) AGL Gearcase Lubricant
(PN 2878068) (Quart)
Capacity: 52 fl oz ( 1550 mL)
7. Reinstall fill plug with a new O-ring and torque to

specification.
TORQUE
Transmission Fill / Drain Plug:
12 ft-lbs (16 Nm)
8. Check for leaks. Dispose of used lubricant properly.

MAINTENANCE
SHIFT CABLE INSPECTION 4. Push shifter into Park while looking for dash
movement. If the plastic dash moves and the shifter
1. Place the vehicle on a flat surface in park, chock the
contacts the cut-out before a shift is complete, the
wheels, and turn the ignition key off.
shift cable is not adjusted correctly.
2. Remove rubber bezel surrounding the shifter.
5. If the shift cable is found to be out of adjustment,

3. Push shifter into High Gear while looking for dash proceed with Shift Cable Adjustment.
movement. If the plastic dash lifts and the shifter
contacts the cut-out before a shift is complete, the STOP!
shift cable is not adjusted correctly. If the shifter does not contact the dash in park or high
the shift cable requires no further adjustment, reinstall
the rubber bezel.
Shift cable adjustment may be necessary if symptoms

include:
• No gear position or incorrect gear position shown.

• AWD light displayed on instrument cluster
• Ratcheting noise on deceleration
• Inability to engage into a gear
• Excessive gear lash (noise)
• Gear selector moving out of desired range
Inspect shift cable, clevis pins, and pivot bushings and

replace if worn or damaged.

MAINTENANCE
SHIFT CABLE ADJUSTMENT 3. Locate the shift cable q through the right rear wheel
Shift cable adjustment may be necessary if symptoms well area.
include:


1. Shift to High Gear, release the shifter. Measure the
distance between shifter and top side of the dash
4. Inspect shift cable q, dust boot w, clevis pin and
opening.
pivot bushings e, and mount r. Verify there is no
wear or damage. Replace if wear or damage is found.
2. Shift to Park, release the shifter. Measure the

distance between shifter and bottom side of the dash
5. Loosen the lower jam nut t and pull the cable out of
opening.
the mount bracket to move the upper jam nut y.
NOTICE
For optimal shift cable adjustment, the gap
measurements in High and Park should be equal. This
will ensure the shifter will not contact the dash.

MAINTENANCE
6. With the cable removed from the bracket, turn the 8. While holding the upper jam nut y use a crows foot
upper jam nut y to adjust the cable. Moving the to tighten the lower jam nut t. Torque to
upper jam nut y closer to the shift cable boot creates specification.
a larger gap in high. Moving the upper jam nut y
away from the shift cable boot creates a larger gap in IMPORTANT
park. When setting torque using a crows foot, the socket
NOTICE must be at a 90° angle to the torque wrench as shown. 2
1 full turn of the adjustment nut y equals approximately
1 mm of dash gap.
CLOSER TO DASH IN HIGH GEAR
CLOSER TO DASH IN PARK
TORQUE
Lower Jam Nut:
13 ft-lbs (18 N·m)
9. After adjustment verify there is no contact with the

dash in both Park/High. If the shifter is still contacting
the dash, repeat the adjustment procedure until there
is no contact with the dash.
10. Reinstall the rubber bezel.
11. With the engine off, check the following:
• Shifter fully engages all gears.
7. Reinstall the cable in the bracket. • Dash is not moving when shifting into Park/High

MAINTENANCE
FRONT GEARCASE FLUID LEVEL FRONT GEARCASE FLUID

INSPECTION REPLACEMENT
NOTICE The drain plug is located on the bottom of the front
gearcase. Access the drain plug through the access hole
It is important to follow the front gearcase maintenance in the frame underneath the front gearcase.
intervals described in the Periodic Maintenance Chart.
1. Remove the fill plug q.
The front gearcase fluid level should be checked and
changed in accordance with the maintenance schedule.
The fill plug is located on the bottom right side of the front
gearcase. Access the fill plug through the right front
wheel well. Maintain fluid level even with the bottom of
the fill plug hole.
1. Position vehicle on a level surface.

2. Check vent hose to be sure it is routed properly and
unobstructed.
3. Locate the gearcase fill plug q through the right front
wheel well area.
2. Place a drain pan under the front gearcase drain

plug.
3. Remove the drain plug w and allow fluid to drain
completely.
4. Remove the fill plug and check the fluid level.

5. If fluid level is not even with the bottom threads, add
the recommended fluid as needed. Do not overfill.
6. Reinstall the fill plug and torque to specification.
TORQUE
Front Gearcase Fill / Drain Plug: 4. Clean the drain plug magnetic surface.
10 ft-lbs (14 Nm)
5. Reinstall drain plug with a new O-ring and torque to
specification.
TORQUE
Front Gearcase Fill / Drain Plug:
10 ft-lbs (14 Nm)

MAINTENANCE
6. Add the recommended amount of fluid through the fill

hole. Maintain the fluid level even with the bottom
threads of the fill plug hole.
FLUID CAPACITY
Recommended Front Gearcase Fluid:
Polaris Demand Drive Fluid 2
(PN 2877922) (Quart)
Capacity:8.5 oz (250 mL)
7. Reinstall fill plug with a new O-ring and torque to

specification.
TORQUE
10 ft-lbs (14 Nm)
8. Check for leaks. Dispose of used fluid properly.

MAINTENANCE
FINAL DRIVE MAINTENANCE

DRIVE SHAFT BOOT INSPECTION 6. Install the wheel on the wheel hub with the valve stem
Inspect the front and rear drive shaft boots q for toward the outside. Be sure rotation arrow on the tire
damage, tears, wear or leaking grease. If the boots (if applicable) point toward forward rotation.
exhibit any of these symptoms, they should be replaced. 7. Attach the wheel nuts q and finger tighten them.
Check to see the boot clamps w are properly positioned.
8. Carefully lower the vehicle to the ground.
CAUTION
Limited Edition models with aluminum wheels require a
thin wall socket to loosen or tighten the wheel nuts
without damaging the finish of the rim. The wheel nut
requires a 19 mm thin wall socket with an O.D. less
than 24.7 mm to allow it to clear the rim.
9. Torque wheel nuts q and/or hub nut r to the proper

specification.
TORQUE
Wheel Lug Nuts (Aluminum Wheels):
120 ft-lbs (163 Nm)
WHEEL REPLACEMENT Wheel Hub Castle Nut (front):
80 ft-lbs (108 Nm)
1. Position the vehicle on a level surface.
Wheel Hub Castle Nut (rear):
2. Place the transmission in PARK and stop the engine. 110 ft-lbs (149 Nm)
3. Loosen the wheel nuts q slightly. If wheel hub
removal is required, remove the wheel cap w, cotter NOTICE
pin e and loosen the hub nut r slightly.
Do not lubricate the stud or the lug nut.
CAUTION
Models with aluminum wheels require a thin wall socket 10. If wheel hub nut was removed, install a new cotter pin
to loosen or tighten the wheel nuts without damaging e after the hub castle nut has been tightened. If the
the finish of the rim. The wheel nut requires a 19 mm holes do not line up, turn the castle nut counter-
thin wall socket with an O.D. less than 24.7 mm to allow clockwise until the cotter pin can be installed.
it to clear the rim.
CAUTION
If wheels are improperly installed it could affect vehicle
handling and tire wear. On vehicles with tapered wheel
nuts, make sure tapered end of nut goes into taper on
wheel.
4. Elevate the appropriate side of the vehicle by placing

a suitable stand under the frame.
5. Remove the wheel nuts q and remove the wheel t.

MAINTENANCE
TIRE INSPECTION TIRE PRESSURE INSPECTION

• Improper tire inflation may affect vehicle Remove the valve stem cap q and check tire pressure
maneuverability. using the tire pressure gauge included in the vehicle’s
tool kit.
• When replacing a tire always use original equipment
size and type.
• The use of non-standard size or type tires may affect 2
vehicle handling.
CAUTION
Maintain proper tire pressure.
Refer to the warning tire pressure decal applied to the
vehicle.
MEASUREMENT
Tire Lug Service Limit: MODEL FRONT REAR
Replace if 1/8″ (3 mm) or less. RANGER 10 psi / 69 kPa 14 psi / 96 kPa
XP 1000
WARNING RANGER
XP 1000 14 psi / 96 kPa 16 psi / 110 kPa
Operating with worn tires will increase the possibility of Crew
the vehicle skidding easily with possible loss of control.
Worn tires can cause an accident. Always replace tires RANGER
when the usable tread depth has worn out. Northstar 14 psi / 96 kPa 16 psi / 110 kPa
Edition
RANGER
Northstar 18 psi / 124 kPa 20 psi / 138 kPa
Crew
Edition
RANGER
XP 1000 10 psi / 69 kPA 12 psi / 82 kPa
High Lifter
RANGER
XP 1000 14 psi / 96 kPa 14 psi / 96 kPa
High Lifter
Crew

MAINTENANCE
STEERING MAINTENANCE
STEERING SYSTEM INSPECTION STEERING WHEEL FREE-PLAY
Steering system components should be checked INSPECTION
periodically for loose fasteners q, worn tie rod ends / tie
rod fasteners w, loose steering shaft U-joints e, worn A- 1. Position the vehicle on level ground.
arm ball joints and general damage. 2. Lightly turn the steering wheel left and right.
Replace any worn or damaged steering components. 3. There should be about 0.8-1.0″ (20-25 mm) of free-
Steering should move freely through the entire range of play.
travel without binding. Check routing of all cables, hoses,
and wiring to be sure the steering mechanism is not 4. If there is excessive free-play or the steering feels
restricted or limited. rough, inspect the following components.
• Tie Rod Ends q.
• Steering Shaft U-Joints w.
• Steering Gearbox e.
NOTICE
Check front end alignment whenever steering
components are replaced.
WARNING
Due to the critical nature of the procedures outlined in
this chapter, Polaris recommends steering component
repair and adjustment be performed by an authorized
Polaris MSD certified technician.

MAINTENANCE
TIE ROD END INSPECTION WHEEL TOE MEASUREMENT

• To check for play in the tie rod end q, grasp the IMPORTANT
steering tie rod, pull in all directions feeling for Make sure tire pressures are set the same on the right
movement. and left tires.
1. Place machine on a smooth level surface and set 2

steering wheel in a straight ahead position. Secure
the steering wheel in this position.
2. Place a chalk mark on the center line of the front tires
approximately 10 in (25.4 cm) from the floor or as
close to the hub/axle center line as possible q.
• Replace any worn steering components. Steering

should move freely through entire range of travel
without binding.
• Elevate front end of machine so front wheels are off
the ground. Check for any looseness in front wheel/
hub assembly by grasping the tire firmly at top and
bottom first, and then at front and rear. Try to move the
wheel and hub by pushing inward and pulling outward.
NOTICE
It is important the height of both marks be equally
positioned to get an accurate measurement.
• If abnormal movement is detected, inspect the hub and

wheel assembly to determine the cause (loose wheel
nuts or loose front hub nut).

MAINTENANCE
3. Measure the distance between the marks and record WHEEL TOE ADJUSTMENT
the measurement. Call this measurement w. PRELIMINARY INFO
NOTICE
If toe alignment is incorrect, measure the distance
between vehicle center and each wheel. This will
indicate which tie rod needs adjusting.
4. Rotate the tires 180° by moving the vehicle forward.

Position chalk marks facing rearward, even with the
hub/axle center line.
5. Measure the distance between the marks and record.
Call this measurement e. Subtract measurement e
from measurement w, this is the vehicle toe. The
recommended vehicle toe tolerance is 1/8-1/4 in (3.2-
6.4 mm) toe out. This means the front of the tire w is IMPORTANT
wider than the measurement at the rear e. Ensure the steering wheel is straight before
determining which tie rod needs adjustment.
MEASUREMENT Measurements should be equal.
Wheel Toe-Out:
1/8-1/4 in (3.2-6.4 mm)
CAUTION
If the rod end is positioned incorrectly it will not pivot,
and may break.
ADJUSTMENT
1. Hold tie rod end to keep it from rotating.
2. Loosen jam nuts at both end of the tie rod.
3. Adjust the tie rod as needed to achieve the proper toe
setting.
IMPORTANT
When tightening the tie rod end jam nuts, the rod ends
must be held parallel to prevent rod end damage and
premature wear. Damage may not be immediately
apparent if done incorrectly.
4. After alignment is complete, torque jam nuts to

specification.
TORQUE
Tie Rod Jam Nut:
13 ft-lbs (18 Nm)

MAINTENANCE
SUSPENSION MAINTENANCE
SUSPENSION INSPECTION SHOCK POSITION ADJUSTMENT
Compress and release the suspension. Damping should The front and rear shock position may be adjusted to
be smooth throughout the range of travel. provide a stiffer suspension operation if necessary.
• Check all suspension components and mounting 1. Elevate vehicle and safely support the main frame.
fasteners for wear or damage. 2
WARNING
• Inspect each shock body for leakage.
Serious injury may result if machine tips or falls. Be
sure machine is secure before adjusting.
SPRING PRE-LOAD ADJUSTMENT
The front and rear shock absorber springs are 2. Remove the upper shock mounting bolts q from
adjustable. Rotate the adjuster cam q either direction to each side of the vehicle.
increase or decrease spring tension. Always adjust both 3. Reposition the upper shock mounts to the outside
left and right sides equally. mounting holes w.
NOTICE FRONT SHOCK
Adjusting all shock cams equally will only affect ride
height as the weight transfer will not be changed.
REAR SHOCK
Vehicle loads effect suspension spring pre-load

requirements. Use Spanner Wrench to adjust pre-load as
necessary to avoid bottoming of the shocks.
Shock Spanner Wrench:

2871095
4. Reinstall the upper shock mounting bolts and torque

to specification.
TORQUE
Shock Mounting Bolts:
40 ft-lbs (54 Nm)

MAINTENANCE
BRAKE SYSTEM MAINTENANCE

BRAKE FLUID LEVEL INSPECTION BRAKE PAD INSPECTION
Always check the brake pedal travel and inspect the 1. Check the brake pad material for wear, damage, or
brake fluid reservoir level before each operation. If the looseness.
fluid level is low, add DOT 4 brake fluid only.
Brake fluid should be changed every two years. The fluid
should also be changed anytime the fluid becomes
contaminated, the fluid level is below the minimum level,
or if the type and brand of the fluid in the reservoir is
unknown.
The brake master cylinder reservoir q can be accessed
through the front left wheel well.
2. Inspect the brake pad surface for excessive wear.

3. Pads should be changed when the friction material is
worn below specification. When measuring the brake
pad should be measured from the backing plate, to
the face of the pad material as shown.
1. Position the vehicle on a level surface.

2. Place the gear selector in Park.
3. View the brake fluid level in the reservoir. The level
should be between the MAX and MIN level lines.
4. If the fluid level is lower than the MIN level line, add
brake fluid until it reaches just below the MAX level
line.
5. Install the reservoir cap and apply the brake pedal
forcefully for a few seconds and check for fluid
leakage around the master cylinder fittings and the
brake caliper fittings.
MEASUREMENT
Brake Pad Thickness (Minimum):
.120 in (3 mm)

MAINTENANCE
BRAKE DISC INSPECTION BRAKE HOSE AND FITTING

1. Visually inspect disc for scoring, scratches or gouges. INSPECTION
Replace disc if any are evident. Check brake system hoses and fittings for cracks,
deterioration, abrasion, and leaks. Tighten any loose
2. Use a 0-1" micrometer and measure disc thickness at
fittings and replace any worn or damaged parts.
8 different points around perimeter of disc. Replace
disc if worn beyond service limit. 2
3. The disc(s) should be replaced if thickness is less

than the specified service limit.
MEASUREMENT
Brake Disc Thickness:
Standard: 0.188" (4.78 mm)
Service Limit 0.170" (4.32 mm)
MEASUREMENT
Brake Disc Thickness Variance:
Service Limit: 0.002” (0.051 mm)
difference between measurements

MAINTENANCE
ELECTRICAL MAINTENANCE
THROTTLE PEDAL INSPECTION
Inspect the throttle pedal w for free movement. Be sure
the throttle pedal returns normally when released. Refer
to PPS Test page procedure if experiencing a lack of
throttle response.

MAINTENANCE
BATTERY MAINTENANCE
Keep battery terminals and connections free of DRY SHIPPED AGM BATTERY
corrosion. If cleaning is necessary, remove the corrosion MAINTENANCE
with a stiff wire brush. Wash with a solution of one
tablespoon baking soda and one cup water. Rinse well IMPORTANT
with tap water and dry off with clean shop towels. Coat NEVER add electrolyte or distilled water to the battery
the terminals with dielectric grease or petroleum jelly. once the battery is in service. 2
WARNING If you do not drive the vehicle for more than TWO weeks,
CALIFORNIA PROPOSITION 65 WARNING: maintain the Absorbent Glass Mat (AGM) battery with the
Batteries, battery posts, terminals and related BatteryMINDer® 2012 AGM - 2 AMP charger.
accessories can expose you to chemicals including
lead, which is known to the State of California to cause BatteryMINDer® 2012 AGM - 2 AMP battery charger
birth defects or other reproductive harm. For more 2830438
information go to www.P65Warnings.ca.gov.
If you plan to store the vehicle for ONE month or longer,
remove the battery from the vehicle and store the battery
WARNING in a cool / dry location. Continue to maintain the battery
Battery electrolyte is poisonous. It contains sulfuric with the BatteryMINDer® 2012 AGM - 2 AMP charger
acid. Serious burns can result from contact with skin, and inspect the battery every 60 days.
eyes or clothing. Antidote:
• External: Flush with water. LEAD ACID LOW MAINTENANCE
• Internal: Drink large quantities of water or milk. BATTERY MAINTENANCE
Follow with milk of magnesia, beaten egg, or Recharge the battery to its full capacity every 30 to 60
vegetable oil. Call physician immediately. days.
• Eyes: Flush with water for 15 minutes and get If the battery is stored or used in a partially charged
prompt medical attention. condition, hard crystal sulfation will form on the plates,
reducing the efficiency and service life of the battery.
Batteries produce explosive gases.
Keep sparks, flame, cigarettes, etc. away. Ventilate IMPORTANT
when charging or using in an enclosed space. Always
shield eyes when working near batteries. NEVER add electrolyte or distilled water to the battery.
KEEP OUT OF REACH OF CHILDREN. Doing so will damage the case and shorten the life of
the battery.
LEAD ACID CONVENTIONAL BATTERY Store the battery in the vehicle with the cables
MAINTENANCE disconnected, or store the battery in a cool / dry location.
Recharge the battery to its full capacity every 30 to 60 Batteries will self discharge more rapidly when stored in
days. extreme temperatures.
If the battery is stored or used in a partially charged
condition, hard crystal sulfation will form on the plates,
IMPORTANT
NEVER add electrolyte to the battery once the battery
is in service.
Only add distilled water to the battery if necessary.
Store the battery in the vehicle with the cables

disconnected, or store the battery in a cool / dry location.
Batteries will self discharge more rapidly when stored in
extreme temperatures.

MAINTENANCE
AGM LOW MAINTENANCE BATTERY

MAINTENANCE
IMPORTANT
NEVER add electrolyte or distilled water to the battery.
Doing so will damage the case and shorten the life of
the battery.
If you do not drive the vehicle for more than TWO weeks,
maintain the Absorbent Glass Mat (AGM) battery with the
BatteryMINDer® 2012 AGM - 2 AMP charger.
BatteryMINDer® 2012 AGM - 2 AMP battery charger

2830438

in a cool / dry location. Continue to maintain the battery
with the BatteryMINDer® 2012 AGM - 2 AMP charger
and inspect the battery every 60 days.

ENGINE / COOLING / HVAC SYSTEM
CHAPTER 3
GENERAL INFORMATION - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
SPECIAL TOOLS - ENGINE / COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 3
ENGINE CYLINDER LEAKDOWN TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
OIL PRESSURE TEST (HVAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
ENGINE BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
ENGINE SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
SERVICE SPECIFICATIONS - ENGINE / COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
ENGINE TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.13
INTAKE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15
INTAKE SYSTEM ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15
INTAKE SYSTEM ASSEMBLY VIEW - HIGH LIFTER & BACK COUNTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17
INTAKE MANIFOLD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.18
INTAKE MANIFOLD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20
THROTTLE BODY ADAPTER REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.22
EXHAUST SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.23
EXHAUST SYSTEM ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.23
EXHAUST SYSTEM ASSEMBLY VIEW - HVAC, HIGH LIFTER & BACK COUNTRY . . . . . . . . . . . . . . . . . . . .3.24
MUFFLER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.25
MUFFLER SERVICE HVAC, HIGH LIFTER & BACK COUNTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.26
HEADPIPE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.27
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.29
ACCESSIBLE ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.29
FRONT ENGINE MOUNT ISOLATOR REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.29
CRANKSHAFT PTO SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.30
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.32
ENGINE REMOVAL (HVAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.35
ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.36
ENGINE INSTALLATION (HVAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.40
ENGINE DISASSEMBLY / INSPECTION - TOP END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.42
VALVE COVER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.42
CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.42
CAMSHAFT SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.43
CAMSHAFT / CAMSHAFT BORE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.44
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.46
CYLINDER HEAD WARP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.46
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.47
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.48
COMBUSTION CHAMBER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.49
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.50

ENGINE DISASSEMBLY / INSPECTION - LOWER END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.52

STATOR COVER REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.52
WATER PUMP HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.53
FLYWHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.54
STARTER ONE-WAY CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.55
CRANKCASE DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.56
BALANCE SHAFT REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.59
CRANKSHAFT REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.60
CRANKCASE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.62
CYLINDER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.63
CYLINDER / PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.65
PISTON DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.66
PISTON RING REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.67
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.68
PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.68
CONNECTING ROD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.69
ENGINE ASSEMBLY - BOTTOM END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.71
BEARING SELECTION IDENTIFICATION LETTERS AND NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.71
CONNECTING ROD BEARING SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.72
CRANKSHAFT MAIN BEARING SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.72
UPPER CRANKCASE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.73
PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.73
PISTON / CONNECTING ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.75
CYLINDER / PISTON INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.76
CRANKSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.77
BALANCE SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.79
CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.80
STARTER ONE-WAY CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.84
FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.85
STATOR COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.86
ENGINE ASSEMBLY - TOP END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.87
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.87
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.89
CAMSHAFT INSTALLATION / TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.90
VALVE CLEARANCE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.94
VALVE COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.95
CAMSHAFT TIMING - QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.97
VALVE LASH - TAPPET SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.98
COOLING SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.99
COOLING SYSTEM ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.99
COOLING SYSTEM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.100
COOLING SYSTEM PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.100
RADIATOR CAP PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.101
COOLANT REMOVAL / DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.101
COOLING SYSTEM BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.102
RADIATOR REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.103
RADIATOR SERVICE (HVAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.105

RADIATOR FAN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.107

COOLING FAN SERVICE (HVAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.107
ENGINE OIL COOLER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.113
THERMOSTAT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.115
WATER PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.116
WATER PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.117
WATER PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.118
HVAC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.121
HVAC SYSTEM FASTENER TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.121
SPECIAL TOOLS - HVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.121
3
SAFETY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.121
AIR CONDITIONING DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.122
HVAC SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.122
RECLAMATION AND CHARGING WITH RECOVERY / CHARGING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.125
REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.125
POOR A/C PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.126
TEMPERATURE DOES NOT CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.126
ENGINE COOLANT BYPASSING THE HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.127
TEMPERATURE / PRESSURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.128
BLOWER MOTOR DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.129
BLOWER MOTOR OPERATES NORMALLY BUT AIR FLOW IS INSUFFICIENT . . . . . . . . . . . . . . . . . . . . . 3.130
BLOWER MOTOR DOES NOT OPERATE IN ALL SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.130
COMPRESSOR DOES NOT OPERATE AT ALL OR OPERATES IMPROPERLY . . . . . . . . . . . . . . . . . . . . . 3.131
GAUGE PRESSURE RELATED TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.133
HVAC ASSEMBLY VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.134
A/C SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.136
COMPRESSOR DRIVE BELT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.137
COMPRESSOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.139
COMPRESSOR OIL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.139
COMPRESSOR OIL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.140
ALTERNATOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.141
ALTERNATOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.141
BLOWER UNIT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.142
HIGH PRESSURE CUT-OUT (HPCO) SWITCH OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.142
HPCO SWITCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.142
CONDENSER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.143
HVAC COVER MOUNT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.145
EXPANSION VALVE / EVAPORATOR COIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.147
HEATER / EVAPORATOR UNIT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.147
HEATER COIL SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.149
A/C THERMOSTAT OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.149
HEATER VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.150
COMPRESSOR DRIVE BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.151
A/C CONDENSER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.151
HVAC FILTER INSPECTION / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.153
HVAC CONTROL OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.154
A/C SWITCH TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.154
FAN SWITCH TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.154

TEMPERATURE POTENTIOMETER TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.154

HVAC BREAKOUT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.155

GENERAL INFORMATION - ENGINE

SPECIAL TOOLS - ENGINE / COOLING ENGINE LUBRICATION
SYSTEM SPECIFICATIONS
TOOL DESCRIPTION PART NUMBER FLUID CAPACITY
Engine Stand (2″ Bore) PU-50624 Oil Capacity *
2.5 qt (2.4 L)
Engine Stand Adapter (Mounts
To The Engine) PU-50562
Oil Type
PS-4 Full Synthetic 5W-50
Engine Stand Sleeve Adapter
(Use With 2” Bore Stand) PU-50625 2876244 (quart) 3
2876245 (gallon)
Engine Stand Sleeve Adapter (-35° F to 100° F)
(Use With 2.375” Bore Stand) PW-47054
PS-4 Extreme Duty
Cylinder Holding & Camshaft 2878920 (quart)
Timing Plate PU-50563
2878919 (gallon)
Flywheel Puller PA-49316
Oil Filter Wrench
Mity Vac™ Pressure Test Tool 2870975 PU-50105 or 2.5″ (64 mm)
Oil Filter Wrench PU-50105
Oil Filter
Oil Pressure Gauge PV-43531 PN 2540086
Oil Pressure Gauge Adapter PU-52492 Oil Pressure Minimum Specification (using Polaris
engine oil at operating temperature)
Piston Ring Compressor Pliers PV-43570-1
10 PSI @ 1200 RPM
PV-1253 or PV-4019 40 PSI @ 7000 RPM
Valve Spring Compressor
(Quick Release)
Valve Spring Compressor *Additional oil may be required after complete
Adapter PV-43513-A engine disassembly. Check level after filling and add
oil as needed.
Water Pump Mechanical Seal
PU-50564
Installer
Bosch Automotive Service Solutions: 1-800-345-2233

or http://polaris.service-solutions.com/

ENGINE CYLINDER LEAKDOWN TEST 3. Turn the engine over by hand until the piston in that
OVERVIEW cylinder is at top dead center (TDC).
A cylinder leakdown test used to determine the condition NOTICE
of the engine by introducing compressed air into the
cylinder and measuring the rate at which it leaks out. If engine is not at TDC when air pressure applied to the
Leakdown primarily tests pistons and rings, valve cylinder, the engine will likely turn over. Keeping the
sealing, and the head gasket. A cylinder leakdown test is piston at TDC vertically aligns the piston and
the most accurate test to examine engine condition. connecting rod with the crank
Leaving the remaining spark plugs installed will help
NOTICE provide some additional resistance to the engine
unintentionally turning over.
Leakdown testing is preferred over compression testing
for the following:
CAUTION
• Piston rings take time to seat. Frequently a new
vehicle can have compression below the Remove any tools used to turn the engine over before
specification because of the “Break-In” period and putting air to the cylinder. If the cylinder being tested is
can cause misdiagnosis. not perfectly on TDC, the engine will likely turn over
quickly and tools can strike you or damage the
• Elevation can cause variance in compression machine.
causing compression specifications and testing to be
inaccurate.
4. Install the gauge’s air-fitting adapter into the spark
• Restricted exhaust or intake can affect compression plug hole and connect air pressure to the inlet side of
and could give a false indication that the engine is the gauge. Remember to double-check that your
bad. gauge reads "zero" before you start.
• Compression specification readings on the low end of 5. Gradually increase air pressure up to no more than
a range can cause technicians to suspect engine 100 psi. Ensure piston remains at TDC. If engine
faults and lead to misdiagnosis. turns over, reduce supplied pressure to 0 and rotate
• Even after performing a compression test leakdown engine to TDC.
will need to be performed to diagnose the root cause. 6. Record your leak-down percentage for the cylinder
you’re testing. Test any remaining cylinders using the
same method.
IMPORTANT
IMPORTANT
If a compression test is performed before, or in place of
Refer to the manufacturers instructions to calculate the
a leakdown test, the results should always be
leak. Some testers may not use a calculation and the
compared to other cylinders. If diagnosing an engine
gauge may give you a percent of leak or capacity.
with two or more cylinders, this must be compared to
the adjacent cylinder. If diagnosing a single cylinder
engine, this must be compared to a known good NOTICE
engine.
If the same cylinder is tested multiple times without
running the engine can cause variable readings.
For any additional information needed for testing refer to
the tester manufacturer’s instructions. Never use high
pressure leakage testers as crankshaft seals may Cylinder Leakage Service Limit:
dislodge and leak. 20%
If leakage exceeds service limit, inspect the engine for
TESTING PROCEDURE the cause.
1. Warm up the engine to operating temperature.
2. Remove the spark plug from the cylinder being TROUBLESHOOTING
tested. Test and compare all cylinders before attempting further
repairs. Leak percentage should be consistent between
WARNING cylinders. A 5 to 10 percent variance between cylinders
Use caution when removing the spark plug as the would likely be considered normal.
engine will be hot.

No engine will have a perfect seal with 0 percent loss. A 3. Clean the area around the oil gallery plug q located
leakdown reading of less than 10 percent loss indicates in the upper crankcase on the MAG side of the engine
the engine is in good condition. When performing the test
monitor where the leakage is occurring. At 20 percent,
suspect an internal issue, and an overhaul is likely.
Common leak areas:
• Cylinder Head Gasket

• Piston / Piston Rings / Cylinder Wall
• Intake Valve(s)
3
• Exhaust Valve(s)
• Valve Seat(s)
Pay close attention during testing air that can be heard or

felt is the best indication of where the leak is originating.
Symptom Cause 4. Remove the crankcase gallery plug and thread in the
oil pressure adapter. Torque the adapter to
Air can be heard / felt Suspect a valve sealing specification.
through the intake or issue
exhaust TORQUE
Oil Pressure Gauge Adapter: PU-52492
Air can be heard / felt Air is escaping past piston
22 ft-lbs (30 Nm)
through the oil fillcap or and / or rings. Inspect ring
dipstick area lands, rings, piston and
cylinder 5. Start engine and allow it to reach operating
temperature, monitoring gauge indication.
Bubbles seen / heard in This indicates that the
the cooling system cooling system is NOTICE
pressurizing, suspect a
cylinder head or head Test results are based on the use of the recommended
gasket issue engine oil (Polaris PS-4 or PS-4 Extreme Duty) at
operating temperature, and may vary considerably if
any other oil is used or if engine is not up to
temperature.
OIL PRESSURE TEST
1. Attach the Oil Pressure Gauge Adapter (PU-52492) Oil Pressure Specification (Engine Hot):
to the Oil Pressure Gauge (PV-43531). Minimum @ 1200 RPM: 10 PSI
Minimum @ 7000 RPM: 40 PSI
Oil Pressure Gauge: PV-43531
Oil Pressure Gauge Adapter: PU-52492
6. Upon assembly, torque the crankcase gallery plug to
specification.
2. Raise the cargo box to access the engine.
TORQUE
Crankcase Oil Gallery Plug:
22 ft-lbs (30 Nm)

OIL PRESSURE TEST (HVAC) 5. Remove the alternator harness e through the rear
access hole on the inner cover.
1. Raise the dropbox to access the engine.
2. Clean the area around the main oil gallery plug ,
located in the upper crankcase on the MAG side of
the engine.
3. Remove the fasteners holding the alternator cover to
the vehicle.
NOTICE
Removing the alternator harness gives access to the
crankcase gallery plug.
6. Remove the crankcase gallery plug r, and install the

oil pressure adapter (PU-52492).
4. Disconnect both alternator connections q and
remove the alternator harness bracket fastener w.
7. Install the oil pressure adapter t (PU-52492) into the

crankcase gallery and attach the oil pressure gauge
(PV-43531) to the adapter.

8. Start engine and allow it to reach operating 11. Reconnect both alternator connections u. Install
temperature, monitoring gauge indication. alternator harness bracket with harness and torque to
specification.
NOTICE
Test results are based on the use of the recommended
engine oil (Polaris PS-4 or PS-4 Extreme Duty) at
operating temperature, and may vary considerably if
any other oil is used or if the engine is not up to
operating temperature.
Oil Pressure Specification (Engine Hot): 3

9. Remove the oil pressure adapter and gauge.

Reinstall the crankcase gallery plug y and torque to
specification.
TORQUE
Alternator Harness Bracket:
54 in-lbs (56 Nm)
12. Reinstall the outer HVAC cover. Torque the fasteners

to specification.
TORQUE
Crankcase Oil Gallery Plug:
22 ft-lbs (30 Nm)
10. Reinstall the alternator harness u through the

access hole.
TORQUE
Alternator Cover Fasteners:
48 in-lbs (5.4 Nm)

ENGINE BREAK-IN PERIOD

The break-in period consists of the first 25 hours of
operation, or the time it takes to use 15 gallons (57 liters)
of fuel. Careful treatment of a new engine and drive
components will result in more efficient performance and
longer life for these components.
IMPORTANT
Use only recommended Engine Oil.
Never substitute or mix oil brands. Serious engine
damage and voiding of warranty can result.
Do not operate at full throttle or high speeds for
extended periods during the first three hours of use.
Excessive heat can build up and cause damage to
close fitted engine parts.
1. Fill fuel tank with unleaded fuel which has a minimum

pump octane number of 87 = (R + M)/2.
2. Check oil level indicated on dipstick. Add oil if
necessary. Refer to “Engine Oil Level” page
procedure.
3. Drive slowly at first to gradually bring engine up to
operating temperature.
4. Vary throttle positions. Do not operate at sustained
idle or sustained high speed.
5. Perform regular checks on fluid levels, controls and
all important bolt torques.
6. Change oil and oil filter after 25 hour break-in period.
7. Pull only light loads.

ENGINE SERVICE SPECIFICATIONS

SERVICE SPECIFICATIONS - ENGINE / COOLING
CAMSHAFT / CYLINDER HEAD / CYLINDER
ITEM STANDARD SERVICE LIMIT
Cam Lobe Height - Intake 1.5390 - 1.5429" (39.09 - 39.19 mm) 1.5370" (39.04 mm)
Cam Lobe Height - Exhaust 1.5142 - 1.5181" (38.46 - 38.56 mm) 1.5122" (38.41 mm)
Camshaft Journal O.D. - All .9036 - .9055" (22.954 - 22.999 mm) .9033" (22.944 mm)
Camshaft
Camshaft Carrier Bore I.D. - All .9055 - .9063" (23.000 - 23.021 mm) .9072" (23.044 mm) 3
Camshaft Oil Clearance .0000 - .0026" (0.001 - 0.067 mm) .0039" (0.1 mm)
Camshaft End Play .0040 - .0100" (0.101 - 0.254 mm) .0157" (0.4 mm)
Cylinder - Surface Warp Limit (cylinder head

- .002″ (0.05 mm)
surface)
Cylinder Bore - Standard 3.6614 ± .0003" (93 mm ± 0.008 mm) -

Cylinder
Cylinder Out of Round Limit - .001″ (0.025 mm)
Cylinder Taper Limit - .001″ (0.025 mm)
Cylinder to Piston Clearance .0009 - .0019" (0.025 - 0.050 mm) -
Cylinder Head - Surface Warp Limit - .0039″ (0.1 mm)

Cylinder
Head Cylinder Head - Standard Height 4.717 ± .0019" (119.82 ± 0.05 mm) -
Valve Lash (Cold) - Intake .006 ± .002 in (0.15 ± 0.05 mm) -
Valve Lash (Cold) - Exhaust .010 ± .002 in (0.25 ± 0.05 mm) -
Valve Stem Diameter - Intake .2155 - .2161 in (5.475 - 5.490 mm) -
Valve Stem Diameter - Exhaust .2147 - .2153 in (5.455 - 5.470 mm) -

Valve
Valve Stem Oil Clearance - Intake .0003 - .0015 in (0.010 - 0.040 mm) -
Valve Stem Oil Clearance - Exhaust .0011 - .0023 in (0.030 - 0.060 mm) -
Valve Stem Overall Length - Intake 3.7704 in (95.77 mm) -
Valve Stem Overall Length - Exhaust 3.8023 in (96.58 mm) -
Valve .2165 - .2171" (5.500 - 5.515 mm) -

Valve Guide Inner Diameter
Guide
Valve Seat - Contacting Width - Intake .0393 ± .0039" (1.0 ± 0.10 mm) .0551" (1.4 mm)
Valve Seat - Contacting Width - Exhaust .0590 ± .0039" (1.5 ± 0.10 mm) .0748" (1.9 mm)
Valve Seat
30.0° ± 1.5°
Valve Seat Angles 45.0° ± 0.5° -
60.0° ± 1.5°

PISTON / RINGS / CONNECTING ROD / CRANKSHAFT / BALANCE SHAFT

Standard O.D. - Measured 90° to pin, 0.39
3.6597 ± .0003" (92.959 ± 0.008 mm) -
in. (10 mm) up from piston skirt
Piston Piston Pin Bore I.D. (Standard) .7877 - .7881" (20.009 - 20.018 mm) .7893" (20.05 mm)
Piston Pin O.D. .7873 - .7875" (20.000 - 20.005 mm) .7866" (19.98 mm)
Top Ring .010 - .014" (0.25 - 0.35 mm) .0196" (0.5 mm)
Installed
Second Ring .015 - .025" (0.37 - 0.63 mm) .028" (0.70 mm)
Gap
Piston Ring Oil Control Rails .008 - .028" (0.20 - 0.70 mm) .0354" (0.9 mm)
Ring to Top Ring

Groove .0007 - .0023" (0.020 - 0.060 mm) .0047" (0.12 mm)
Clearance Second Ring
Connecting Rod Small End I.D. .7879 - .7885" (20.015 - 20.030 mm) .7897" (20.06 mm)
1 - Marking Conn. Rod Big End Bore I.D. 1.7318 - 1.7321" (43.989 - 43.996 mm) -
Connecting
Rod 2 - Marking Conn. Rod Big End Bore I.D. 1.7321 - 1.7323" (43.996 - 44.003 mm) -
3 - Marking Conn. Rod Big End Bore I.D. 1.7323 - 1.7326" (44.003 - 44.010 mm) -
B - Marking Main Journal O.D. 1.6140 - 1.6143" (40.996 - 41.004 mm) 1.6129" (40.970 mm)
G-
Main Journal O.D. 1.6137 - 1.6140" (40.988 - 40.995 mm) 1.6129" (40.970 mm)
Marking
Y - Marking Main Journal O.D. 1.6134 - 1.6137" (40.980 - 40.987 mm) 1.6129" (40.970 mm)
B - Marking Rod Journal O.D. 1.6118 - 1.6122" (40.942 - 40.950 mm) 1.6104" (40.906 mm)
Crankshaft
G-
Rod Journal O.D. 1.6115 - 1.6118" (40.934 - 40.941 mm) 1.6104" (40.906 mm)
Marking
Y - Marking Rod Journal O.D. 1.6112 - 1.6115" (40.926 - 40.933 mm) 1.6104" (40.906 mm)
Less than .001″

Crankshaft Runout Limit (PTO and MAG) -
(0.025 mm)
Balance Bearing Journal O.D. (Standard) 1.4939 - 1.4946" (37.946 - 37.962 mm) 1.4921" (37.900 mm)
Shaft

ENGINE TORQUE SPECIFICATIONS

CRANKCASE - UPPER
CRANKCASE - LOWER Start with #12
Step 1: 9 ft-lb (12

Nm)
M10 Bolts: Step 2: 21 ft-lb (28 M8 Bolts: 26 ft-lbs (35 Nm)

Nm)
Step 3: Tighten
additional 90°
M8 Bolts: 26 ft-lbs (35 Nm) M6 Bolts: 7 ft-lbs (10 Nm)
M6 Bolts: 9 ft-lbs (12 Nm)
CAM CARRIER VALVE COVER
Camshaft Carrier Bolts 7 ft-lb (10 Nm) Valve Cover Bolts 7 ft-lbs (10 Nm)

SUMP COVER / OIL PAN CYLINDER HEAD
Torque in sequence
Nm)
M8 26 ft-lbs (35 Nm) M11 Cylinder Head Bolts
Nm)
Step 3: Tighten
additional 360°
M6 9 ft-lbs (12 Nm) M6 Cylinder Head Bolts 7 ft-lb (10 Nm)
STATOR COVER OIL COOLER
Stator Cover Bolts 9 ft-lbs (12 Nm) Oil Cooler 18 ft-lb (24 Nm)

INTAKE SERVICE
INTAKE SYSTEM ASSEMBLY VIEW
ITEM DESCRIPTION TORQUE
q Fresh Air Intake Line NA
w Engine Intake Elbow NA
e Clutch Intake Elbow NA
r Intake Duct Clamps 35 in-lbs (4 Nm)
t Intake Hard Line NA

q Intake to Airbox Hose NA
w Drain Cap NA
e Airbox NA
r Airbox Mount Fastener 35 in-lbs (4 Nm)
t Air Filter NA
y Airbox Cover NA
u Intake Hard Line NA
i Vent Hose NA
o Airbox to Engine Tube NA
a Engine Intake Housing NA
s Intake Duct Clamps 35 in-lbs (4 Nm)

INTAKE SYSTEM ASSEMBLY VIEW - HIGH LIFTER & BACK COUNTRY
REF DESCRIPTION TORQUE
q Intake Hose to Plenum NA
w Airbox Fastener 42 in-lbs (5 Nm)
e Airbox Fastener Washer NA
r Airbox Assembly NA
t Airbox Assembly Cover NA
y Push Rivet NA
u Airbox Cover Fastening Clip NA
i Intake Hose NA
o Intake Air Duct NA
a Top Fresh Air Duct Cover NA
s Fresh Air Duct NA
d Fresh Air Duct Clamp 35 in-lbs (4 Nm)
f Lower Fresh Air Duct Cover NA
g Intake Duct Fastener 42 in-lbs (5 Nm)
h Fresh Air Duct Cover Fasteners 10 in-lbs (1 Nm)
j Engine Vent Hose NA
k Engine Vent Hose Clamp NA

INTAKE MANIFOLD REMOVAL 6. Disconnect Turf Mode connector r.

1. If vehicle was recently operated, allow it to cool down
for one hour to allow fuel pressure to drop down
before attempting to perform any work.
2. Thoroughly clean the engine and chassis.
3. Remove rear cargo box from vehicle. Refer to Cargo
Box Removal page 11.33.
4. Loosen the clamp holding the engine intake hose to
the throttle body. Place clean cloth inside throttle
body inlet to prevent any contaminants from entering
the engine.
7. Disconnect Transmission t, CPS Switch connector

y and Speed Sensor u. Remove clips from retaining
tabs and position harness out of the way.
5. Carefully remove electrical harness from fuel injectors

q, TMAP sensor w, and Throttle Body e.

8. Remove the Fuel Line by carefully opening the 10. Loosen Intake Manifold Mounting Bolt a located at
connector tab i. Then remove the connector to the transmission bracket.
release the line. Refer to Fuel Line Quick Connect
Removal page 5.9.
11. Remove Intake Manifold from engine.
IMPORTANT
A shop towel can be placed around the fuel line to catch
any dripping fuel.
Installing a cap on the end of the fuel rail can prevent
spilling of the fuel that remains in the rail, and will also
prevent debris from entering the fuel rail.
9. Loosen intake boot Hose Clamps o at cylinder head.
IMPORTANT
Make note of Hose Clamps orientation for installation.

INTAKE MANIFOLD INSTALLATION 6. Install electrical harness to engine and plug in Fuel
Injectors q, TMAP sensor w and Throttle Body e.
1. Position new manifold in place, making sure the
intake runners are seated in the manifold boots.
2. Install Lower Intake Plenum Fastener a at
transmission mounting bracket loosely.
7. Connect Turf Mode connector r.
3. Align intake boot hose clamps to orientation noted

during removal.
4. Tighten intake boot hose clamps o. Torque to spec.
8. Connect Transmission t, CPS Switch connector y

and Speed Sensor u.
TORQUE
Intake Manifold Boot Clamp:
17 in-lbs (2 Nm)
5. Torque Lower Intake Plenum Fastener a to

specification.
TORQUE
Lower Intake Plenum Fastener:
18 ft-lbs (24 Nm)
9. Secure harness mounting clips in mounting tabs.

10. Verify the fuel line connection is clean and free of

debris.
NOTICE
The fuel rail connector can be cleaned with a clean
shop towel and rubbing alcohol.
11. Place the fuel line back over the fitting and slide the
connector locking mechanism i back into place.
Verify the connector tabs snap back into place by
pulling outward lightly on connector. 3
12. Install engine intake hose to throttle body. Torque

clamp to specification.
TORQUE
Intake Duct Hose Clamp:
35 in-lbs (4 Nm)
13. Perform ETC Learn Procedure page 4.8, connecting

battery as needed.
14. Inspect engine while running to watch for any fuel
leaks.
15. Perform Cargo Box Installation page 11.33.

THROTTLE BODY ADAPTER REMOVAL / 8. Inspect the gasket and sealing surface of the throttle
INSTALLATION body adapters. If the gasket is damaged or is not
sealing replace as needed. If the gasket is in good
1. If vehicle was recently operated, allow it to cool down condition it may be reused.
before attempting to perform any work.
NOTICE
2. Thoroughly clean the engine and chassis before
disassembly to ensure no dirt or debris may enter The gasket used for sealing the throttle body adapter to
engine during the procedure. the cylinder head is not serviceable. The throttle body
adapter must be replaced as an assembly if
3. Remove the rear cargo box from vehicle. Refer to replacement is required.
Cargo Box Removal page procedure.
4. Remove the Intake Manifold. Refer to Intake Manifold 9. Inspect and clean the intake port surface before
Removal page procedure. reinstalling the throttle body adapters.
5. Remove the (4) fasteners q from the Throttle Body 10. Install the throttle body adapters w.
Adapters w.
11. Install the (4) fasteners q and torque to the correct

6. Remove the throttle body adapters w from the specification.
cylinder head.
TORQUE
Throttle Body Adapter Fastener:
7 lb-ft (10 Nm)
12. Install Intake Manifold. Refer to Intake Manifold

Installation page procedure.
13. Install Cargo Box. Refer to procedure.
7. Inspect the throttle body inside and outside diameters

for any cracking or damage. If any concerns are
found the throttle body adaptor should be replaced.

EXHAUST SERVICE
EXHAUST SYSTEM ASSEMBLY VIEW
q Spark Arrestor Fastener 10 ft-lbs (14 Nm)
w Spark Arrestor NA
e Heat Shield Fasteners 42 in-lbs (5 Nm)
r Heat Shield NA
t Muffler Isolator Mounts NA
y Oxygen Sensor 18 ft-lbs (24 Nm)
u Exhaust Spherical Gasket NA
i Exhaust Stud w/Spring 21 ft-lbs (28 Nm)
o Exhaust Head Pipe Mounting Bolts 18 ft-lbs (24 Nm)
a Head Pipe Gasket NA
s Muffler Mount Fasteners 10 ft-lbs (14 Nm)

EXHAUST SYSTEM ASSEMBLY VIEW - HVAC, HIGH LIFTER & BACK COUNTRY
q Heat Shield Fastener M6X1.0X25 42 in-lbs (5 Nm)
w Headpipe Heat Shield Fastener M6X1.0X10 6 ft-lbs (8 Nm)
e Headpipe NA
r Lambda Sensor NA
t Headpipe Double Gasket NA
y Exhaust Pipe Spring NA
u Exhaust Pipe Stud 21 ft-lbs (28 Nm)
i Exhaust Silencer Heat Shield NA
o Exhaust Silencer Heat Shield Fasteners 6 ft-lbs (8 Nm)
a Exhaust Silencer NA
s Exhaust Silencer Hold Down Spring NA
d Exhaust Isolator NA
f Exhaust Manifold Gasket NA
g Exhaust Manifold Fastener 18 ft-lbs (24 Nm)
h Heat Shield Fastener M6X1.0X20 42 in-lbs (5 Nm)
j Heat Shield Washer NA
k Heat Shield NA

MUFFLER SERVICE INSTALLATION

REMOVAL 1. Install the exhaust muffler and connect the three
1. Remove the oxygen sensor. Refer to Oxygen Sensor isolator mounts e.
Replacement page 4.10.
2. Remove the two spring bolts w securing the muffler
to the head pipe.
2. Install the two spring bolts w to secure the muffler to

the head pipe. Torque to proper specification.
IMPORTANT
IMPORTANT Apply anti-seize lubricant to fasteners prior to
Using air tools or power tools while removing these installation.
fasteners can increase the chances of the fasteners
being damaged. It is recommended to remove these
fasteners using hand tools.
3. Disconnect the three isolator mounts e and remove

the exhaust muffler.
TORQUE
Exhaust Spring Bolt:
21 ft-lbs (28 Nm)
3. Install the oxygen sensor. Refer to Oxygen Sensor


MUFFLER SERVICE HVAC, HIGH LIFTER INSTALLATION

& BACK COUNTRY 1. Install the muffler into the chassis grommet w and
REMOVAL connect the exhaust spring e. Repeat on passenger
side.
1. Remove the two spring bolts q securing the muffler
assembly to the head pipe.
2. Install the two spring bolts q to secure the muffler

assembly to the head pipe. Torque to specification.
IMPORTANT
IMPORTANT
Using air tools or power tools while removing these
fasteners can increase the chances of the fasteners Apply anti-seize lubricant to fasteners prior to
being damaged. It is recommended to remove these installation.
fasteners using hand tools.
2. Remove the muffler from the chassis grommet w and

disconnect the exhaust spring e. Repeat on
passenger side and remove muffler assembly.
TORQUE
Exhaust Spring Bolt:
21 ft-lbs (28 Nm)

HEADPIPE SERVICE 4. Remove the six fasteners t securing the headpipe

REMOVAL y to the engine and remove the headpipe.
1. Remove the muffler assembly. Refer to Muffler
Service page 3.25.
2. Remove the fasteners q securing the upper heat
shield w to the headpipe. Remove the upper heat
shield.
NOTICE
Discard headpipe gasket.
3. Remove the fasteners e securing the lower heat

shield to the headpipe and remove the lower heat
shield r.

INSTALLATION 4. Install the upper heat shield w and secure to the

headpipe using heat shield fasteners q. Torque to
1. Install a new headpipe gasket.
specification.
2. Install the headpipe y and secure to the engine
using headpipe fasteners t. Torque to specification.
TORQUE
Heat Shield Fasteners:
TORQUE 42 in-lbs (5 Nm)
Headpipe Fasteners:
18 ft-lbs (24 Nm)
5. Install the muffler assembly. Refer to Muffler Service
page 3.25.
3. Install the lower heat shield r and secure to the
headpipe using heat shield fasteners e.
TORQUE
42 in-lbs (5 Nm)

ENGINE SERVICE
ACCESSIBLE ENGINE COMPONENTS FRONT ENGINE MOUNT ISOLATOR
The following components can be serviced or removed REPLACEMENT
with the engine installed:
1. Remove the rear skid plate fasteners q and remove
• Camshaft(s) the skid plate from the vehicle.
• Camshaft Sprocket(s)
• Cylinder Head
• Flywheel
• Oil Cooler
3
• Starter Motor / Idler Gear Asm
• Stator (Alternator)
• Thermostat
• Valve Cover
• Water Pump
• Crankshaft PTO Seal 2. Using a commercially available transmission lift or
pump jack, lift the front engine mount to take the
The following components require engine removal for weight off the isolators.
service:
3. Remove the nuts w retaining the isolator mounts to
• Camshaft Timing Chain the frame.
• Connecting Rod(s)
• Counterbalance Shaft / Bearings
• Crankcase
• Crankshaft / Main Bearings
• Cylinder
• Oil Pump / Oil Pump Sprocket or Chain
• Piston / Rings
4. Remove the isolator bolt e and remove the isolator.

5. Install new isolator and bolt. Torque fastener to
specification.
6. Lower the lift or jack and align the isolator tang with
the holes in the frame. Install isolator to frame
fasteners. Torque fasteners to specification.
7. Install rear skid plate. Torque fasteners to
specification.
TORQUE
Isolator Bolts:
40 ft-lbs (54 Nm)
Engine Mount Isolator Nuts:
22 ft-lbs (30 Nm)
Skid Plate Fasteners:
6 ft-lbs (8 Nm)

CRANKSHAFT PTO SEAL REMOVAL

REPLACEMENT 1. Remove the Inner PVT Cover. Refer to PVT Inner
Special Tool PU-52493 allows the replacement of the Cover Disassembly page .
engine crankshaft PTO seal without splitting the engine
2. Using a commercially available seal puller tool,
case.
remove crankcase seal from crankcase.
IMPORTANT IMPORTANT
PU-52493 does NOT work with 2017 and older models. Use care not to scratch the crankcase while removing
seal.
3. Inspect the crankcase and crankshaft surfaces for

any burrs or scratches that could damage the new
seal or prevent it from sealing properly.

INSTALLATION 2. Tighten the drive bolt e until the cylinder r bottoms

out against the crankcase.
1. Install new seal w into crankcase. Thread the drive
bolt of special tool PU-52493 q into the crankshaft.
3. Once the seal is properly installed, loosen the drive

bolt e and remove special tool PU-52493 from the
IMPORTANT crankshaft.
The orientation of the seal is critical. Install the seal with
the flat side of the seal facing out as shown. 4. Refer to PVT Inner Cover Assembly page .
5. Test drive the vehicle and recheck for leaks before
putting back into service.

ENGINE REMOVAL 7. Remove six fasteners e retaining the head pipe to

the cylinder head.
NOTICE
It is recommended to wait 1 hour after key off to allow
the engine to cool and for fuel pressure to drop.
1. Disconnect the battery.

2. Drain coolant and engine oil. See Engine Oil and
Filter Replacement page and Coolant
3. Remove rear cargo box. See Cargo Box Removal
page 11.33.
4. Disconnect Ignition Coil.
5. Disconnect oxygen sensor q.
8. Remove the thermostat housing hose r and the

water pump hose t.
6. Remove three fasteners w retaining the upper heat

shield to the head pipe. Remove the upper heat
shield.
9. Disconnect stator harness and disconnect the
harness retainer from the engine mount.
IMPORTANT
DO NOT remove large heat shield secured to the close
off panel.

10. Carefully disconnect the fuel supply y at the fuel rail. 12. Remove retention clips retaining fuel lines and
Refer to Fuel Line Quick Connect Removal page 5.9. harnesses.
IMPORTANT 13. Loosen and remove clamps retaining intake manifold

to engine u and intake hose i.
A shop towel can be placed around the fuel line to catch
any dripping fuel.
Installing a cap on the end of the fuel rail and fuel line
can prevent spilling of remaining fuel, and will also
prevent debris from entering the fuel rail or line.
11. Disconnect TMAP, CPS, Coolant Temp Sensor, Trans

Switch, Speed Sensor, Injectors, ETC.
IMPORTANT
Make note of Hose Clamps orientation for installation.
14. Remove lower manifold mounting bolt (to trans mount

bracket).

15. Remove intake manifold and throttle body as

assembly.
16. Disconnect the starter wiring.
17. Support the engine.
18. Remove PVT hoses, outer cover and belt. See Belt
Removal page 6.6
19. Remove secondary clutch, belt and primary clutch.
Remove inner clutch cover. See PVT Inner Cover
Disassembly page
20. Remove fasteners retaining engine to the engine
mount bracket.
21. Lift engine out of the chassis, be careful not to snag

any hoses or wiring.
22. If replacing engine: remove applicable coolant
hoses, stator/flywheel, starter and engine sensors.

ENGINE REMOVAL (HVAC) 6. Disconnect the two AC lines on the back of the AC
compressor.
1. Evacuate the AC system. Refer to Reclamation and
Charging with Recovery / Charging Unit page 3.125
and Refrigerant page 3.125 for procedure and system
capacity.
2. Drain engine coolant. Refer to Coolant Replacement
page 2.42.
3. Disconnect the battery.
4. Flip up passenger seat.
3
7. Disconnect the orange alternator hot wire q from the

terminal block.
5. Remove battery cover.
8. Remove passenger side coolant hose w on engine

oil cooler.

9. Remove clamps e and r at engine water pump. ENGINE INSTALLATION

Remove hoses from water pump.
1. If removed from engine: install applicable coolant
hoses, stator/flywheel, starter and engine sensors.
2. Install engine in the chassis, be careful not to snag
any hoses or wiring.
3. Install fasteners retaining engine to the engine mount
bracket. Torque fasteners in sequence shown to
specification.
10. Refer to Engine Removal page 3.32 for next steps.
TORQUE
Engine Mount Fasteners:
40 ft-lbs (54 Nm)
4. Install new foam seal (PN 5416417) around

crankshaft snout prior to installing PVT inner cover.
5. Install the PVT inner cover. Refer to PVT Inner Cover
Assembly page
6. Perform Driven Clutch Alignment. See .
7. Install the drive clutch, belt and driven clutch. Install
snap ring on transmission input shaft before installing
driven clutch mounting bolt. Torque fasteners to
specification.
TORQUE
Drive Clutch Bolt:
96 ft-lbs (130 Nm)
Driven Clutch Bolt:

43 ft-lbs (58 Nm)

8. Install PVT hoses and outer PVT cover. Torque 10. Install throttle body / intake manifold assembly.
fasteners to specification. Tighten clamps e, r retaining intake manifold to
engine. Install lower intake plenum mounting fastener
TORQUE (to trans mount bracket). Torque fasteners to
Hose Clamps: specification.
35 in-lbs (4 Nm)
Outer PVT Cover Fasteners:

35 in-lbs (4 Nm)
9. Connect the starter wiring. Torque starter cable nuts 3

to specification.
TORQUE
Starter Cable Wiring Nuts:
48 in-lbs (5 Nm)
TORQUE
Intake Manifold Boot Clamp:
17 in-lbs (2 Nm)

18 ft-lbs (24 Nm)

11. Install zip ties retaining the harnesses to intake 18. Install the six fasteners e retaining the head pipe to
manifold. the cylinder head. Torque fasteners to specification.
12. Connect harness going to TMAP sensors, CPS, TORQUE

coolant temp sensor, Trans switch, speed sensor,
injectors, ETC. Exhaust Head Pipe Mounting Bolts:
18 ft-lbs (24 Nm)
13. Connect the fuel supply at the fuel rail. Refer to Fuel
Line Removal / Installation page 5.11.
19. Install the upper heat shield to the head pipe. Install
IMPORTANT three fasteners w retaining the upper heat shield to
Retainer latch should be pushed don to latch the line to the head pipe. Torque to specification.
the rail.
14. Pull back lightly on the fuel line to confirm a proper

connection has been made.
15. Connect stator harness.
16. Install the thermostat housing hose r and the water
pump hose t.
TORQUE
Exhaust Head Pipe Upper Heat Shield Fasteners:
6 ft-lbs (8 Nm)
20. Connect oxygen sensor.

21. Connect the ignition coil.
22. Install cargo box. Torque fasteners to specification.
17. Install a new head pipe gasket and install the head
See Cargo Box Installation page 11.33
pipe on the cylinder head studs.
23. Fill coolant reservoir. Bleed system as required. See
Cooling System Bleeding Procedure page 3.102.
24. Check and fill engine oil as required. See Engine Oil
and Filter Replacement page .

25. Connect the battery. Torque fasteners to

specification.
TORQUE
Battery Terminal Fasteners:
40 in-lbs (5 Nm)

ENGINE INSTALLATION (HVAC) 4. Install orange alternator hot wire and torque fastening
nut to specification.
1. Complete Engine Installation page 3.36.
2. Install both coolant hoses onto the water pump. Install
clamp q and w. Torque clamp w to specification.
TORQUE
Alternator wire to Terminal Block:
40 in-lbs (4 Nm)
TORQUE
Coolant hose clamp:
35 in-lbs (4 Nm) 5. Connect both AC lines to the compressor. Torque AC
lines to specification.
3. Attach coolant hose to oil cooler and install clamp e.
TORQUE
AC lines at compressor:
18 ft-lbs (24 Nm)
6. Reinstall the battery cover and flip down the

passenger seat.
7. Fill coolant reservoir. Bleed system as required. See
Cooling System Bleeding Procedure page 3.102.
8. Check and fill engine oil as required. See Engine Oil
and Filter Replacement page .

9. Connect the battery. Torque fasteners to

specification.
TORQUE
40 in-lbs (5 Nm)
10. Recharge the AC system. Refer to Reclamation and

and Refrigerant page 3.125 for procedure and system
capacity. 3

ENGINE DISASSEMBLY / INSPECTION - TOP END

VALVE COVER REMOVAL 1. Rotate the engine so the PTO cylinder is at Top Dead
Center (TDC) to relieve most of the valve spring
NOTICE pressure. The camshaft lobes should face out q and
The valve cover can be removed with the engine the slots on the end of the camshafts should line up.
installed in the chassis.
1. Remove the four valve cover shoulder bolts q and

isolators w using a T40 driver.
2. Remove the cam chain tensioner w from the cylinder.

Replace the sealing washer or gaskete upon
reassembly.
2. Replace isolators w when they are removed and

replace valve cover seal e if oil leaks are evident.
3. Remove the spark plugs r. Stuff spark plug holes
with shop towels to prevent anything from falling into
the combustion chamber.
CAMSHAFT REMOVAL
NOTICE
The camshafts can be removed with the engine
IMPORTANT
3. Remove the two bolts retaining the fixed cam chain
Before removing the camshafts from the cylinder head guide r and remove the assembly from the engine.
valve lash should be measured and recorded to
determine if adjustment is needed on assembly. Refer
to Valve Clearance Inspection page 2.36 for more
information.

4. Remove the remaining two bolts that retain the front 9. Evenly loosen the four bolts retaining each rear
camshaft carrier t and carefully lift the carrier off the camshaft carrier a and carefully lift the carriers off
camshafts. the camshafts.
5. Hold camshafts y with an open-end wrench, and 10. Mark the intake s and exhaust d camshafts to
remove the top bolt u from the camshaft sprockets ensure proper assembly.
i. 11. Carefully remove camshafts from the cylinder head.
CAUTION
While holding the camshaft with an open end wrench CAMSHAFT SPROCKET INSPECTION
ensure that the wrench does not contact the bucket Inspect cam sprocket teeth q for wear or damage.
bore. Wrench contact could cause damage to the Replace timing chain and sprockets if worn or damaged.
bucket bore.
6. Using the drive clutch bolt, rotate the engine and

remove the remaining bolt from each camshaft
sprocket.
7. Using a paint pen, mark the chain and camshaft
sprockets, this will aid in the assembly and timing
procedures. Lift the chain and sprockets off the
camshafts to allow each sprocket to be removed.
8. Using a paperclip or other tool, hold cam chain up to
keep it from falling down into the crankcase.
NOTICE
The crankcase has a built-in lower guide to prevent the
chain from falling off the crankshaft.

CAMSHAFT / CAMSHAFT BORE 4. Measure the diameter of the camshaft journals using
INSPECTION a micrometer. Compare to specification.
Inspect all main journals and cam lobes as described
below and compare to specifications. Replace camshaft
(s) or cylinder head if worn beyond service limit or if any
surface is pitted or damaged.
1. Visually inspect each cam lobe for wear or damage.
2. Measure the height of each cam lobe from the base
circle to highest point on the lobe using a micrometer.
Compare to specification.
NOTICE
Replace camshafts if damaged or if any part is worn
past the service limit.
MEASUREMENT
Camshaft Journal O.D.:
.9036 - .9055" (22.954 - 22.999 mm)
NOTICE Service Limit:

.9033" (22.944 mm)
Replace camshafts if damaged or if any part is worn
past the service limit.
5. Temporarily install the camshaft carriers to measure
the camshaft bore. Torque bolts in sequence to
MEASUREMENT
specification. Replace cylinder head if worn.
Camshaft Lobe Height:
Intake:
1.5390 - 1.5429" (39.09 - 39.19 mm)
Service Limit:
1.5370" (39.04 mm)
Exhaust:
1.5142 - 1.5181" (38.46 - 38.56 mm)
Service Limit:
1.5122" (38.41 mm)
3. Visually inspect each camshaft journal for scoring,

wear or damage.
TORQUE
Camshaft Carrier Bolts:
7 ft-lb (10 Nm)

6. Measure camshaft bore and compare to

specifications.
NOTICE
Replace cylinder head if camshaft journal bores are
damaged or if worn past the service limit.
MEASUREMENT
Camshaft Carrier Bore I.D.:
.9055 - .9063" (23.000 - 23.021 mm)
Service Limit:
.9072" (23.044 mm)
7. Calculate oil clearance by subtracting camshaft

journal O.D.s from camshaft carrier bore I.D.s.
Compare to specification.
MEASUREMENT
Calculated Camshaft Oil Clearance:
.0000 - .0026" (0.001 - 0.067 mm)
Service Limit:
.0039" (0.1 mm)

CYLINDER HEAD REMOVAL 1. Check Engine Timing Camshaft Timing - Quick Refer-
ence page 3.97
NOTICE
The cylinder head can be serviced with the engine
installed in the chassis. CYLINDER HEAD WARP INSPECTION
Thoroughly clean cylinder head surface to remove all
Necessary Preliminary Procedures traces of gasket material and carbon.
• Remove intake Assembly Intake System Assembly
View page 3.15 CAUTION
Use care not to damage gasket sealing surface. All
• Remove exhaust assembly Exhaust System Assembly
gasket surfaces must be clean, dry and free of any oil
View page 3.23
or grease upon assembly. Clean sealing surfaces with
• Remove Valve Cover Valve Cover Removal page 3.42 rubbing alcohol or electrical contact cleaner. Do not
touch sealing surfaces of the new head gasket.
• Remove Camshafts Camshaft Removal page 3.42
1. Remove the two outer M6 bolts q that retain the Lay a straight edge across the surface of the cylinder
cylinder head w to the cylinder. head q at several different points and measure warp by
inserting a feeler gauge between the straight edge and
the cylinder head surface. If warp exceeds the service
limit, replace the cylinder head.
2. Loosen the six cylinder head bolts e evenly 1/8 turn

at a time until all are loose.
3. Remove and discard the cylinder head bolts.
MEASUREMENT
4. Tap cylinder head lightly with a soft faced hammer
until loose. Cylinder Head Warp Limit:
.0039″ (0.1 mm)
NOTICE
Tap only in reinforced areas or on thick parts of the
cylinder head casting.
5. Remove the cylinder head w and head gasket r.

NOTICE
Once the cylinder head is removed, nothing retains the
cylinder to the engine. DO NOT rotate the engine
without using the Cylinder Holding & Camshaft Timing
Plate (PU-50563). Refer to Cylinder / Piston Removal
page 3.65 procedure.
Necessary Subsequent Procedures

CYLINDER HEAD DISASSEMBLY 2. Compress the valve spring by hand using valve
spring compressor adapter (PV-43513-A).
WARNING
Wear eye protection during cylinder head disassembly
and reassembly or when working with the valve springs.
IMPORTANT
Keep mated parts together and in order with respect to
their location in the cylinder head for assembly
purposes. It is important to install cylinder head
components back in the same location. Mark each
3
component or place them in an organized rack as you
remove them.
1. Remove the valve tappet q from the cylinder head.

Note the tappet size w engraved on the underside of
the bucket.
3. Push down on spring and remove split keepers e.
4. Slowly release valve spring pressure and remove the

compressor adapter.
5. Remove the valve retainer r, valve spring t, valve
stem seal y and valve spring seat u. Discard the
valve seal.
IMPORTANT
Replace valve seals whenever cylinder head is
disassembled. Hardened, cracked or worn seals will
cause excessive oil consumption.
6. Lift up the cylinder head and push the valve i out,

keeping it in order for reassembly in the same valve
guide.
7. Repeat the previous steps to remove the remaining
valves.
8. Clean the combustion chamber and head gasket
surface.
9. Check the condition of each valve spring. Replace if
wear or cracking is present on the spring.

VALVE INSPECTION 5. Measure diameter of valve stem with a micrometer in

three places, then rotate 90° and measure again
1. Remove all carbon from valves with a soft wire wheel (take six measurements total). Compare to
or brush. specifications.
2. Check valve face for runout, pitting, and burnt spots.
To check for bent valve stems, mount valve in a drill
or use “V” blocks and a dial indicator.
MEASUREMENT
Valve Stem Diameter:
3. Check the end of the valve stem for flaring, pitting, Intake:
wear or damage. .2155 - .2161" (5.475 - 5.490 mm)
Exhaust:
.2147 - .2153" (5.455 - 5.470 mm)
6. Measure valve guide inside diameter at the top,

middle and end of the guide using a small hole gauge
and a micrometer. Measure in two directions.
4. Inspect split keeper groove for wear or flaring in the

keeper seat area.
NOTICE
The valves can be re-faced or end ground, if necessary.
They must be replaced if extensively worn, burnt, bent
or damaged.
MEASUREMENT
Valve Guide I.D.:
.2165 - .2171" (5.500 - 5.515 mm)
7. Be sure to measure each guide and valve

combination individually.
NOTICE
The valve guides cannot be replaced.

COMBUSTION CHAMBER CLEANING VALVE SEALING TEST

1. Clean and dry the combustion chamber area q.
WARNING
2. Pour a small amount of clean solvent into each
Wear eye protection during combustion chamber intake port w and check for leakage around the
cleaning. valves. The valve seats should hold fluid with no
seepage.
1. Clean all accumulated carbon deposits from
combustion chambers and valve seat area q.
3. Repeat for exhaust valves by pouring fluid into each

exhaust port e.
NOTICE
Carbon Clean Fuel Treatment (2871326) can be used
to help remove carbon deposits.
Do not use a metal scraper, a coarse wire brush or
abrasive cleaners to clean the cylinder head. Damage
may result.
2. Visually inspect cylinder head gasket surface and

combustion chamber for cracks or damage. Pay
close attention to areas around spark plug and valve
seats.

VALVE SEAT RECONDITIONING 4. Inspect the cut area of the seat:

Valve seat reconditioning should be performed by a * If the contact area is less than 75% of the
technician proficient in cylinder head reconditioning circumference of the seat, rotate the pilot 180° and
techniques. Reconditioning techniques vary, so follow make another light cut.
the instructions provided by the valve reconditioning
equipment manufacturer. Do not grind seats more than * If the cutter now contacts the uncut portion of the
necessary to provide proper seat surface, width, and seat, check the pilot. Look for burrs, nicks, or runout.
contact point on valve face. If the pilot is bent it must be replaced.
* If the contact area of the cutter is in the same place,
WARNING the valve guide is distorted from improper installation.
Wear eye protection or a face shield during cylinder * If the contact area of the initial cut is greater than
head disassembly and reassembly. 75%, continue to cut the seat until all pits are
removed and a new seat surface is evident.
Valve Seat Inspection NOTICE
Inspect valve seat in cylinder head for pitting, burnt Remove only the amount of material necessary to
spots, roughness, and uneven surface. If any of the repair the seat surface.
above conditions exist, the valve seat must be
reconditioned. If the valve seat is cracked the cylinder
head must be replaced. 5. To check contact area of the seat on the valve face,
apply a thin coating of Prussian Blue™ paste to the
Valve seat width and point of contact on the valve face is valve seat. If using an interference angle (46°) apply
very important for proper sealing. The valve must contact black permanent marker to the entire valve face q.
the valve seat over the entire circumference of the seat,
and the seat must be the proper width all the way
around. If seat is uneven, compression leakage will
result. If seat is too wide, seat pressure is reduced,
causing carbon accumulation and possible compression
loss. If seat is too narrow, heat transfer from valve to seat
is reduced. The valve may overheat and warp, resulting
in burnt valves.
6. Insert valve into guide and tap valve lightly into place
a few times.
Renewing Valve Seats
7. Remove valve and check where the Prussian Blue™
1. Install pilot into valve guide. or black marker indicates seat contact on the valve
face. The valve seat should contact the middle of the
2. Apply cutting oil to valve seat and cutter. valve face or slightly above, and must be the proper
3. Place 46° cutter on the pilot and make a light cut. width q.

10. Insert the valve into its respective guide and lap using
• If the indicated seat contact is at the top edge of a lapping tool or a section of fuel line connected to the
the valve face and contacts the margin area w it valve stem.
is too high on the valve face. Use the 30° cutter
to lower the valve seat. 11. Rotate the valve rapidly back and forth until the cut
sounds smooth. Lift the valve slightly off of the seat,
• If too low use the 60° or 75° cutter to raise the rotate 1/4 turn, and repeat the lapping process. Do
seat. When contact area is centered on the valve this four to five times until the valve is fully seated,
face, measure seat width. and repeat process for the other valve(s).
• If the seat is too wide or uneven, use both top 12. Thoroughly clean cylinder head and valves.
and bottom cutters to narrow the seat.
• If the seat is too narrow, widen using the 45° 3
cutter and re-check contact point on the valve
face and seat width after each cut.
MEASUREMENT
Valve Seat Width:
Intake:
.0393 ± .0039" (1.0 ± 0.10 mm)
Service Limit:
.0551" (1.4 mm)
Exhaust:
.0590 ± .0039" (1.5 ± 0.10 mm)
Service Limit:
.0748" (1.9 mm)
8. Clean all filings from the area with hot soapy water.
Rinse and dry with compressed air.
9. Lubricate valve guides with clean engine oil and apply
oil or water based lapping compound to the face of
the valve.
NOTICE
Lapping is not required if an interference angle
reconditioning method is used.

ENGINE DISASSEMBLY / INSPECTION - LOWER END

STATOR COVER REMOVAL / 2. Carefully pry the stator cover off the engine using the
INSPECTION two pry areas as shown below.
NOTICE
The stator cover can be removed with the engine
1. Remove the thirteen screws retaining the stator

cover.
WARNING
The flywheel contains powerful magnets. Use caution
when removing and installing the stator cover. DO NOT
place fingers between cover and crankcase at any time
during the removal / installation process or injury could
result.
3. Inspect the condition of the stator windings q and
output wires w. If replacement is required, refer to the
Electrical chapter.
4. Inspect the ball bearing e that supports the starter

motor shaft.

5. If bearing replacement is required, remove the 3. Remove the water pump assembly from the engine
retaining ring and heat the stator cover around the by using a twisting motion as you pull out on the
bearing evenly with a heat gun. Tap cover on a soft housing.
work surface to remove the bearing from the housing.
A blind bearing puller can also be used. Replace
bearing if removed.
WATER PUMP HOUSING REMOVAL

NOTICE
The water pump housing can be serviced with the 3
engine installed in the chassis. Refer to Water Pump
Service page 3.118 procedure.
1. Remove the coolant lines from the thermostat

housing, cylinder inlet and oil cooler. Leave them all
attached to the water pump housing.
2. Remove the three long gold colored bolts q retaining

the water pump housing to the engine.

FLYWHEEL REMOVAL 6. Hold puller body and tighten the center bolt to remove
the flywheel.
NOTICE
The flywheel can be serviced with the engine installed
in the chassis.
1. Remove the stator cover assembly.

2. Remove the starter torque limit gear q as an
assembly.
Starter One-Way Clutch Inspection

NOTICE
The starter one-way clutch can be serviced with the
engine installed in the chassis.
7. Remove the stator cover and flywheel. Refer to Stator

Cover Removal / Inspection page 3.52 procedures.
3. Inspect gear teeth for damage. Inspect fit of shaft
inside gear and replace gear assembly is clearance is 8. Place flywheel on a work bench with the one-way
excessive. Inspect the shaft and bearing surfaces in clutch facing up. Grasp clutch gear and rotate
the crankcase and stator cover for excessive wear. clockwise. It should turn smoothly without binding.
4. Using a commercially available strap wrench, hold 9. Rotate one-way gear counterclockwise. The gear
the flywheel and remove the flywheel retaining bolt should immediately lock in position and not slip.
w. 10. Inspect the one-way gear bushing r for wear or
galling. If service is required, refer to Starter One-
Way Clutch Disassembly page 3.55 procedure.
5. Fully install Flywheel Puller (PA-49316) e on the

threads of the flywheel (left hand thread - turn
flywheel puller counterclockwise to install).

STARTER ONE-WAY CLUTCH 4. Inspect drive surface of starter gear e and bushing
DISASSEMBLY r for wear, damage or uneven surface. If any starter
one-way clutch component is worn or damaged,
1. Lift up to remove starter one-way gear. replace the clutch and starter gear as an assembly.
2. Remove the three one-way clutch retaining screws.
3. Remove the one-way clutch and inspect both sides of

drive rollers q. Inspect the roller contact surface w
inside the hub for wear, damage or uneven surface.

CRANKCASE DISASSEMBLY / 6. Install the Cylinder Holding & Camshaft Timing Plate
INSPECTION (PU-50563) e onto the cylinder. The cylinder holding
tool retains the cylinder and pistons when the engine
1. Remove the oil filter. is rotated.
2. If equipped, remove the three fasteners securing the
oil filter adapter to the engine and remove the oil filter
adapter assembly. Discard oil filter adapter o-ring.
7. Rotate engine to access the crankcase sump cover.

8. Remove the thirteen M6 t and three M8 bolts y
retaining the sump cover r to the crankcase.
3. Remove the four screws retaining the oil cooler q to
the crankcase.
9. Remove the sump cover u from the crankcase.
4. Remove the crankcase drain plug w. Drain any oil

remaining in the engine. Reinstall the plug.
10. Remove and clean oil pump pick-up i.
5. Remove the oil filter.

11. Remove the three bolts o that retain the oil pump a 14. Visually inspect the oil pump and drive sprocket d for
to the crankcase. wear or damage. Replace oil pump drive chain and
sprocket if worn or damaged. If any part of the oil
pump is damaged, the entire assembly must be
replaced. Replace the oil pump seal f during
crankcase assembly.
12. Use one of the oil pump retaining bolts or a pen

magnet to extract the dowel pins s from the oil
pump. Doing so allows for oil pump removal without
having to remove the pump drive sprocket.
NOTICE
Oil pump assembly is non-serviceable
15. Rotate the engine so the cylinder is facing up.

16. Remove the eleven M6 g and two M8 h upper
crankcase bolts.
NOTICE
If unable to extract the dowel pins from the oil pump,
the oil pump sprocket must be removed. Access the
sprocket bolt by removing the case plug.
13. Lift the oil pump drive chain and remove the oil pump.
17. Rotate the engine so the cylinder is facing down.

18. Remove the eight M10 k, two M8 l and one M6 j

lower crankcase bolts. Discard the eight M10 bolts.
19. Tap on the lower crankcase in reinforced areas with a

soft faced hammer to loosen. Carefully lift up and
remove the lower crankcase half.

BALANCE SHAFT REMOVAL / 5. Measure each bearing journal in two locations, 90

INSPECTION degrees apart. Replace balance shaft if either journal
is worn below the service limit specification. If worn
1. Perform Crankcase Disassembly / Inspection page past the service limit, replace the balance shaft
3.56 procedure. assembly.
2. Note timing marks on balance shaft and crankshaft
drive gears. Shafts must be properly timed upon
assembly.
MEASUREMENT
Balance Shaft Diameter (MAG & PTO):
1.4939 - 1.4946" (37.946 - 37.962 mm)
3. Carefully rotate the balance shaft w and remove it Service Limit:
from the crankcase. 1.4921" (37.900 mm)
4. Inspect the balance shaft gear teeth for damage.

CRANKSHAFT REMOVAL / INSPECTION 6. Remove the cam chain e, oil pump drive chain t
and PTO main seal r from the crankshaft.
1. Perform Crankcase Disassembly / Inspection page
3.56 procedure.
2. Perform Balance Shaft Removal / Inspection page
3.59 procedure.
3. For ease of assembly, mark each connecting rod and
end cap.
4. Loosen, remove and discard the four connecting rod
bolts q. Remove the end caps from the crankshaft.
7. Inspect the crankshaft gear u and auxiliary sprocket

y for broken or worn teeth.
5. Carefully lift the crankshaft w out of the crankcase.
8. If the crankshaft gear or sprocket is damaged, the

crankshaft assembly must be replaced.

9. Support crankshaft on V-blocks or on-centers in a 11. Measure each main journal and connecting rod
crankshaft stand or lathe. Measure crankshaft run-out journal in two locations, 90 degrees apart. Replace
and replace if run-out exceeds maximum listed below. crankshaft if any journal is worn below the service
limit specification.
i MAG End d Journal 4 (Rod

MEASUREMENT Bearing)
Crankshaft Maximum Runout:
Less than .001″ (0.025 mm) o Journal 1 (Main f Journal 5 (Main
Bearing) Bearing)
10. Visually inspect surface of crankshaft main and a Journal 2 (Rod g Journal 6 (Main
connecting rod journals. Replace crankshaft if any Bearing) Bearing)
journal is scratched or pitted.
s Journal 3 (Main h PTO End
Bearing)
12. Refer to the six letters stamped onto the PTO end of
the crankshaft.

13. Use the table below to see if the crankshaft bearing CRANKCASE INSPECTION
journals are within specification. If worn past the
1. Remove the oil drain diverter q from the upper
service limit, replace the crankshaft assembly.
crankcase.
CRANKSHAFT BEARING JOURNAL
DIAMETERS
B
1.6140 - 1.6143"
Main Standard (40.996 - 41.004
Bearing mm)

1.6118 - 1.6122"
Conn Rod Standard (40.942 - 40.950
Bearing mm)

G 2. Remove all traces of crankcase sealer from the
1.6137 - 1.6140" crankcase mating surfaces. Inspect the surfaces
Standard (40.988 - 40.995 closely for nicks, burrs or damage.
Main
Bearing mm) 3. Be sure alignment pins are in place where used.
Service Limit 1.6129" (40.970 mm) 4. Be sure oil passages are clean and free of any
cleaning solvent.
1.6115 - 1.6118"
Bearing mm)

Y
1.6134 - 1.6137"
Main Standard (40.980 - 40.987
Bearing mm)

1.6112 - 1.6115"
Bearing mm)
14. Whether installing a new crankshaft or re-installing

the original, refer to the bearing selection chart
provided in the “Crankshaft Main Bearing
Selection” page 3.72 and “Connecting Rod
Bearing Selection” page 3.72 procedures.

5. Remove and discard the plain bearings located in the CYLINDER INSPECTION
upper crankcase w , lower crankcase e and
1. Lay a straight edge q across the top surface of the
connecting rods r. Replace the crankcase assembly
cylinder at several different points and measure warp
if a bearing bore is galled or if bearing inserts have
by inserting a feeler gauge between the straight edge
rotated in the case. Refer to bearing selection
and the cylinder surface. If warp exceeds the service
procedures upon assembly.
limit, replace the cylinder.
MEASUREMENT
Cylinder Warp Limit:
.002″ (0.05 mm)
2. Inspect cylinder for wear, scratches, or damage.

IMPORTANT
DO NOT hone the cylinders or attempt to repair a
damaged cylinder by honing.
3. Inspect taper and out of round with a dial bore gauge.

NOTICE
Always replace plain bearings when the crankcase or
connecting rods have been disassembled. Refer to
Bearing Selection Identification Letters and Numbers.

4. Inspect cylinder for taper and out of round with a

telescoping gauge or a dial bore gauge. Measure in
two different directions, front to back and side to side,
on three different levels (1/2” down from top, in the
middle, and 1/2” up from the bottom).
5. Record measurements. If cylinder is tapered or out of

round beyond specification, the cylinder must be
honed, bored or replaced.
MEASUREMENT
Cylinder Taper:
.001″ (0.025 mm)
Cylinder Out of Round:

.001″ (0.025 mm)
MEASUREMENT
Standard Bore Size:
3.6614 ± .0003" (93 mm ± 0.008 mm)

CYLINDER / PISTON REMOVAL 5. Remove the piston / connecting rod assemblies from
the cylinder.
CAUTION
Pistons must be removed from the cylinders with the
connecting rods attached.
DO NOT attempt to service the cylinder or pistons
without disassembling the crankcase. Although the
cylinder and pistons can be removed without
disassembly, reassembly will not be possible because
of the unique cylinder skirt and crankcase design.
3
1. Perform “ENGINE DISASSEMBLY / INSPECTION -
TOP END” and the “ENGINE DISASSEMBLY /
INSPECTION - LOWER END” procedures.
3. Remove the Cylinder Holding & Camshaft Timing
Plate (PU-50563) q from the cylinder. IMPORTANT
If the pistons are to be reused, mark the pistons so they
are reassembled in the same cylinder bore and
direction from which they were removed (MAG / PTO).
4. Carefully lift the cylinder and pistons from the upper

crankcase.

PISTON DISASSEMBLY / INSPECTION 3. Measure piston pin bore I.D. in two directions (90°
apart). Replace piston and piston pin if out of
NOTICE specification.
New pistons are directional (intake vs. exhaust), but
can be placed in either cylinder.
1. Note location of the piston circlip gap q at the top

(12:00 position) or bottom (6:00 position).
MEASUREMENT
Piston Pin Bore I.D.:
.7877 - .7881" (20.009 - 20.018 mm)
Service Limit:
2. Remove piston circlip and push piston pin out of .7893" (20.05 mm)
piston. If necessary, heat the crown of the piston
slightly with a heat gun if pin cannot be removed by 4. Measure piston pin O.D. in two directions (90° apart)
hand. Discard circlips. at three locations on the length. Replace piston and
piston pin if out of specification.
CAUTION
DO NOT apply heat to piston rings or a loss of radial MEASUREMENT
tension could result.
Piston Pin O.D.:
.7873 - .7875" (20.000 - 20.005 mm)
Service Limit:
.7866" (19.98 mm)

PISTON RING REMOVAL PISTON RING TO GROOVE CLEARANCE

1. Carefully remove top compression ring q by hand or INSPECTION
using a ring removal pliers (PV-43570-1). 1. Measure piston ring to groove clearance q by
placing the ring in the ring land and measuring with a
CAUTION thickness (feeler) gauge. Replace piston and rings if
ring-to-groove clearance exceeds service limits.
DO NOT expand the ring more than necessary to
remove it from the piston or the ring may break or lose
radial tension.
• Piston ring pliers: Carefully expand ring and lift it

off the piston.
3
• By hand: Placing both thumbs on the ring ends,
spread the ring open and push up on opposite side.
Do not scratch ring lands.
MEASUREMENT
Piston Ring to Groove Clearance:
Top / Second Ring:
.0007 - .0023" (0.020 - 0.060 mm)
Service Limit:
.0047" (0.12 mm)
2. Repeat procedure for second compression ring w.

3. The oil control ring e is a three piece design
consisting of a top and bottom steel rail and a center
expander section. Remove top rail first, then bottom
rail, then the expander.

PISTON RING INSTALLED GAP PISTON-TO-CYLINDER CLEARANCE

1. Place each piston ring q inside the cylinder w. Use Measure piston outside diameter at a point 10 mm q up
the piston to push the ring squarely into cylinder, as from the bottom of the piston, at a right angle to piston
shown below. pin bore.
2. Measure installed gap with a feeler gauge e at both Subtract measurement from maximum measurement
the top and bottom of the cylinder. obtained in Step 4 of “Cylinder Inspection” procedure.
NOTICE
A difference between top and bottom end gap
measurements is a general indication of cylinder taper
(wear). The cylinder should be measured for taper and
out of round.
MEASUREMENT
Piston O.D. (Standard):
3.6597 ± .0003" (92.959 ± 0.008 mm)
Piston to Cylinder Clearance:

.0009 - .0019" (0.025 - 0.050 mm)
3. If the installed gap measurement exceeds the service
limit, replace the rings.
MEASUREMENT
Piston Ring Installed Gap:
Top Ring: .010 - .014" (0.25 - 0.35 mm)
Service Limit: 1.6118 - 1.6122" (40.942 - 40.950 mm)
Second Ring: 1.6118 - 1.6122" (40.942 - 40.950 mm)

Service Limit: .028" (0.70 mm)
Oil Control Rails: .008 - .028" (0.20 - 0.70 mm)

Service Limit: .0354" (0.9 mm)
NOTICE
Always check piston ring installed gap when installing
new rings and/or a new cylinder.

CONNECTING ROD INSPECTION 4. Measure small end I.D. in two directions as shown.
Record measurements and compare to
1. The 3 digit numbers stamped onto the intake side of
specifications. Replace connecting rod if worn past
the connecting rod are serial numbers used to match
the service limit specification.
the rod cap w with the rod stem e.
2. The number r and letter t stamped onto the MEASUREMENT

exhaust side of the connecting rod represent the bore Connecting Rod Small End I.D.:
diameter and weight grading of the connecting rod. .7879 - .7885" (20.015 - 20.030 mm)
Service Limit:
.7897" (20.06 mm)
5. Install matching rod cap on connecting rod (without

bearings) and install the bolts.
6. Tighten bolts snug, then torque to 13 ft-lbs (18 Nm).
7. Using a dial bore gauge, measure big end I.D. in two
directions shown. Record measurements and
compare to specifications.
3. Inspect the small end and big end of connecting rod

(and matching rod cap) for damage, galling of surface
or pitting.
8. Refer to the number stamped onto the exhaust side

of the connecting rod. This number represents the
bore diameter.

9. The table below lists the big end bore diameter

specifications.
BEARING SELECTION CHART — ROD BEARINGS
CONNECTING ROD BIG END BORE

DIAMETERS
1 2 3
1.7318 - 1.7321 - 1.7323 -
1.7321" 1.7323" 1.7326"
(43.989 - (43.996 - (44.003 -
43.996 mm) 44.003 mm) 44.010 mm)
10. Whether using new connecting rods or re-installing

the original ones, refer to the bearing selection chart
provided in the “Connecting Rod Bearing
Selection” page 3.72 procedure in this chapter.

ENGINE ASSEMBLY - BOTTOM END

BEARING SELECTION IDENTIFICATION LETTERS AND NUMBERS
q Connecting Rod Bearing w Crankcase Bearing Identification e Crankshaft Bearing Identification

Identification Number ( one number) Number (six numbers) Letters (six letters)
*Some engines may only have 4
digits. The extra two digits will refer
to the balance shaft bearings which
should now all be standard.

CONNECTING ROD BEARING CRANKSHAFT MAIN BEARING

SELECTION SELECTION
In order to select the proper bearing for the connecting In order to select the proper main bearings for the
rods, you must reference the number on each connecting crankshaft, you must reference the six numbers on the
rod u & i and match that up with the rod journal letters crankcase i and match that up with the main journal
on the crankshaft o. letters on the crankshaft u.
In this example, you would use the number 2 as the In this example, you would use the number 2 as the
connecting rod code. You would use letters G and G as crankcase codes (case journals 1, 2, 3, 4). You would
the crankshaft codes (crank journals 2 and 4). Based off use letters G, Y, G, Y as the crankshaft codes (crank
the bearing selection chart, you would use a Green journals 1, 3, 5 and 6). Based off the bearing selection
bearing for each connecting rod chart, you would use:
Green bearing for Main #1
BEARING SELECTION CHART — ROD
Yellow bearing for Main #2
Crankshaft Green bearing for Main #3
Code B G Y Yellow bearing for Main #4
1 Blue Blue Green
Rod BEARING SELECTION CHART — MAIN BEARINGS
2 Blue Green Yellow
3 Green Yellow Yellow Crankshaft
Code B G Y
1 Blue Blue Green
Case
2 Blue Green Yellow
3 Green Yellow Yellow

UPPER CRANKCASE PREPARATION PISTON RING INSTALLATION

IMPORTANT IMPORTANT
Always replace plain bearings when the crankcase or Apply clean engine oil to all ring surfaces and ring lands
connecting rods have been disassembled. Refer to the upon installation. Always check piston ring installed gap
bearing selection chart provided in the “Crankshaft before rings are installed on piston. Refer to PISTON
Main Bearing Selection” page 3.72 and “Connecting RING INSTALLATION GAP procedure. Clean
Rod Bearing Selection” page 3.72 procedures. accumulated carbon from piston ring grooves and oil
ring lube holes if piston has been in service.
1. Remove all traces of crankcase sealer from the
crankcase mating surfaces. Inspect the surfaces
closely for nicks, burrs or damage.
3
2. Clean bolt hole threads to remove any oil or
crankcase sealant.
3. Inspect crankcase bearing bores. Replace the
crankcase assembly if a bearing bore is galled or if
bearing inserts have rotated in the case.
4. Be sure alignment pins are in place where used.
5. Refer to “Engine Oil Flow Chart” page at the
beginning of this chapter and trace the oil paths
through the crankcase and cylinder.
6. Flush all oil passages with solvent and then warm
soapy water. Rinse with clear, warm water and dry
with compressed air. q Top Ring r Spring Expander
7. Be sure passages are clean and dry before
assembling the upper crankcase.
w Second Ring t Lower Rail
e Upper Rail
1. Place oil control ring expander in oil ring groove.

Rotate expander in groove until butt ends are on PTO
side of piston (see illustration below).
NOTICE
Ends must butt squarely together and must not overlap.
2. Install lower rail with end gap positioned on the intake

side of piston.

3. Install upper rail with end gap positioned on the 5. Install top ring with mark facing top of piston. Rotate
exhaust side of piston. ring to position the end gap toward exhaust side of
piston as shown below.
6. Be sure top and second rings rotate freely in their

grooves and do not bind when compressed by hand.
4. Install second ring with marking facing top of piston.

Rotate ring to position the end gap toward intake side
of piston as shown below.

PISTON / CONNECTING ROD 3. Place piston q on connecting rod w. Push piston pin
ASSEMBLY e through rod and piston until it seats against the
installed circlip.
1. Lubricate connecting rod small end, piston pin bore
and piston pin with engine oil.
CAUTION
Do not re-use circlips. Circlips become deformed during
the removal process.
Do not compress the new clip more than necessary to
prevent loss of radial tension. Severe engine damage
may result if circlips are re-used or deformed during
3
installation.
2. Install a new circlip on one side of piston with gap at

the top (12:00 position) or bottom (6:00 position).
CAUTION
Do not tap on pin or cause any sideways force to
connecting rod. Warm piston crown with a heat gun if
pin cannot be installed by hand, or use a piston pin
installation tool.
CAUTION
DO NOT apply heat to piston rings or a loss of radial
tension could result.
4. Install the remaining circlip r with gap at the top

IMPORTANT (12:00 position) or bottom (6:00 position). Push the
piston pin in both directions to make sure the clips are
Never re-use a piston pin circlip.
properly seated in the groove.
If reinstalling the original connecting rods, orientate the
rods the same as when removed. If new connecting
rods are being installed, they can be installed either
way (there is no piston pin offset in the rod), however it
is recommended they be installed with rods facing the
same direction.

CYLINDER / PISTON INSTALLATION 4. Carefully compress the piston rings with your fingers
and install the piston assemblies into the cylinder
CAUTION from the bottom side. Use piston ring compressor
Pistons must be installed into the cylinders with the pliers (PV-43570-1) to aid in assembly, if necessary.
connecting rods attached.DO NOT attempt to service
the cylinder or pistons without disassembling the
crankcase. Although you can remove the cylinder and
pistons without disassembly, you will not be able to
reassemble the engine because of the unique cylinder
skirt and crankcase design.
NOTICE
If the pistons are being reused, reassemble in the same
cylinder bore and direction from which they were
removed (MAG / PTO).
New pistons are directional (intake vs. exhaust), but
can be placed in either cylinder.
NOTICE
1. Apply clean engine oil to each piston assembly,
cylinder bore and bottom tapered portion of each Use a slight front to back rocking motion until all rings
cylinder sleeve. are captive in cylinder and past the cylinder sleeve
opening q.
2. Verify that all ring end gaps are correctly located on
each piston. Refer to PISTON RING INSTALLATION
procedure. 5. Rotate the engine so the crankcase to cylinder
3. Note the piston orientation mark (arrow) located on mounting surface is facing up.
top of the piston. Arrow should point toward the 6. Clean base gasket sealing surface on cylinder and
exhaust side. crankcase to remove all oil and grease.
IMPORTANT
Base gasket and surfaces must be DRY and oil free.
Use care upon assembly to keep oil away.
7. Reinstall dowel pins in crankcase if previously

removed.
8. Install a new cylinder base gasket.
9. Verify piston orientation (arrow pointing toward
exhaust) one last time prior to installation.
10. Carefully place the cylinder and pistons into the upper
crankcase.
NOTICE
Orientation arrow is also located on the bottom side of
piston as an additional reference.

11. Install the Cylinder Holding & Camshaft Timing Plate CRANKSHAFT INSTALLATION
w (PU-50563) onto the cylinder. The cylinder holding NOTICE
tool retains the cylinder and pistons when the engine
is rotated. Whether installing a new crankshaft or re-installing the
original, refer to the bearing selection charts in the
“Crankshaft Main Bearing Selection” page 3.72 and
“Connecting Rod Bearing Selection” page 3.72
procedures.

2. Clean the bearing bore surfaces of upper crankcase 3
(main bearings), connecting rods and connecting rod
caps.
3. Align tab of new main bearing q with the slot in main
bearing bore of crankcase. Press bearing insert firmly
into place. Repeat for all main bearings.
4. Align tab of new connecting rod bearings w with the
slot in the connecting rod stem and connecting rod
end cap. Press bearing insert firmly into place.
Repeat for the other connecting rod.
5. Install oil drain diverter e into the upper crankcase.

6. Apply Polaris PS-4 engine oil to each rod bearing 11. Clean bolt hole threads in connecting rod to remove
journal r and main bearing journal t of crankshaft. all oil.
12. Install matching rod cap on connecting rod with 3 digit
serial number stampings aligned w & e.
7. Loop cam chain y and oil pump drive chain i over

crankshaft sprockets.
8. Apply Polaris PS-4 engine oil to the new crankshaft
oil seal u and install the seal on the PTO end of the 13. Install new bolts s and tighten evenly until snug.
crankshaft.
14. Torque connecting rod bolts to specification.

9. Carefully lower the crankshaft into upper crankcase.
Guide connecting rods onto the rod journals of TORQUE
crankshaft as necessary. Connecting Rod Bolts:
Step 1: 9 ft-lbs (12 Nm)
Step 3: Tighten additional 90°
10. Adjust the PTO crankshaft seal so it rests properly in

the upper crankcase.

BALANCE SHAFT INSTALLATION 5. Install the balance shaft, placing the tooth with the
alignment dot r in-line with the dot on the crankshaft
1. Clean the upper crankcase balance shaft bearing
gear (see reference images below).
bore surfaces.
2. Align tab of new balance shaft bearings q with the
slot in each bearing bore of crankcase. Press bearing
insert firmly into place.
3. Apply Polaris PS-4 engine oil to both balance shaft

journals w.
4. Rotate the crankshaft until the alignment dot e on

the crankshaft MAG end gear is visible.

LOWER CRANKCASE PREPARATION 5. Apply a thin, continuous film of Crankcase Sealant

(PN 2871557) to upper crankcase mating surface e
IMPORTANT as shown. Do not allow sealant to dry before
Always replace plain bearings when the crankcase or assembly.
connecting rods have been disassembled. Refer to the
bearing selection chart provided in the “Crankshaft
Main Bearing Selection” page 3.72 and “Connecting
Rod Bearing Selection” page 3.72 procedures.
1. Remove all traces of crankcase sealant from the

crankcase mating surfaces. Inspect the surfaces
closely for nicks, burrs or damage.
2. Clean bolt hole threads to remove any oil or
crankcase sealant.
3. Inspect crankcase bearing bores. Replace the
crankcase assembly if a bearing bore is galled or if
bearing inserts have rotated in the case.
4. Be sure alignment pins are in place where used.
5. Refer to “Engine Oil Flow Chart” page at the CAUTION
beginning of this chapter and trace the oil paths
DO NOT block oil passages r with crankcase sealant.
through the crankcase and cylinder.
6. Flush all oil passages with solvent and then warm
soapy water. Rinse with clear, warm water and dry 6. Carefully place lower crankcase on upper case,
with compressed air. making sure the oil pump drive chain is fed through
the lower crankcase.
7. Be sure passages are clean and dry before
assembling the crankcase.
CRANKCASE ASSEMBLY
1. Check to be sure the PTO crankshaft seal is resting
properly in the upper crankcase.
2. Align tab of new main bearings q and new balance
shaft bearings w with the slot in each bearing bore of
the lower crankcase. Press bearing inserts firmly into
place.
7. Tap lower crankcase with a rubber hammer to seat

the case halves together.
8. Inspect crankcase mating surfaces to be sure they
are joined properly. Investigate the cause of any
gaps.
3. Apply Polaris PS-4 engine oil to the new bearings

installed in the lower crankcase half.
4. Clean crankcase mating surfaces to remove any oil.

9. Install the eight M10 t, two M8 u and one M6 y 12. Install the eleven M6 o and two M8 i upper
lower crankcase bolts. Tighten all bolts lightly by crankcase bolts. Tighten all bolts lightly by hand.
hand.
13. Torque the upper crankcase bolts in sequence to

NOTICE specification (start with #12). Repeat the sequence to
Install new M10 lower crankcase bolts. verify final torque.
10. Torque lower crankcase bolts in sequence to

specification. Repeat sequence to verify final torque.
TORQUE
Upper Crankcase Bolts:
TORQUE
Lower Crankcase Bolts:
M10 Bolts:
Step 1: 9 ft-lb (12 Nm)
15. Install a new seal on the oil pump.
M8 Bolts:
26 ft-lbs (35 Nm)
M6 Bolts:
9 ft-lbs (12 Nm)

16. Lift the oil pump drive chain and install the oil pump. 19. Reinstall oil pump pick-up s. Torque mounting
screws to specification.
TORQUE
Oil Pump Pick-Up Retaining Screw:
7 ft-lbs (10 Nm)
20. Clean the gasket sealing surfaces on oil sump cover

and crankcase to remove old gasket material and any
oil.
IMPORTANT
Gasket surfaces must be DRY and oil free. Use care
upon assembly to keep oil away.
17. Install dowel pins a into oil pump mounting holes. 21. Apply a thin, continuous film of Crankcase Sealant
(PN 2871557) to sump cover mating surface g as
shown. Do not allow sealant to dry before assembly.
18. Install the three bolts f that retain oil pump d to the
crankcase. Torque mounting bolts to specification.
CAUTION
Dipstick must be removed before oil pan is assembled
to the engine. Failure to do this will damage the
dipstick.
22. Install the oil sump cover h onto the crankcase.
TORQUE
Oil Pump Mounting Bolts:
7 ft-lbs (10 Nm)

23. Install the thirteen M6 j and three M8 bolts that 26. Install the oil cooler l. Use new O-rings 1( upon
retain the oil sump cover k to the crankcase. installation.
24. Torque the oil sump cover bolts in sequence to 27. Torque fasteners to specification in sequence shown.
specification. Repeat the sequence to verify final
torque.
TORQUE
Oil Cooler Retaining Bolts:
TORQUE 7 lb-ft (10 Nm)
Oil Sump Cover Bolts:
25. Install the crankcase drain plug if previously removed.

Torque drain plug to specification.
TORQUE
Crankcase Drain Plug:
12 ft-lbs (16 N·m)

28. If equipped install new o ring and the oil filter adapter STARTER ONE-WAY CLUTCH
assembly. Install the three fasteners to secure the oil ASSEMBLY
filter adapter to the engine. Torque to specification.
1. Install one-way clutch in clutch hub with flange of
clutch q engaged in recess.
TORQUE
Oil Filter Adapter Fasteners: 2. Clean screw threads in flywheel to remove all oil or
21 ft-lbs (28 Nm) grease.
3. Place one-way clutch on flywheel and install the three
screws. Torque screws to specification.
29. Install the oil filter.
30. Install the flywheel. Refer to Flywheel Installation TORQUE
page 3.85. One-Way Clutch Retaining Screws:
31. Install the cylinder head. Refer to Cylinder Head 9 ft-lbs (12 Nm)
Installation page 3.89.

4. Reassemble starter one-way clutch and gear using FLYWHEEL INSTALLATION

the following illustration.
1. If previously removed, reinstall the flywheel key.
2. Inspect and clean crankshaft and flywheel taper with
isopropyl alcohol or similar cleaning solution.
Replace crankshaft if surface damage is present.
Clean taper of crankshaft to remove all oil or grease.
3. Using an applicator, apply a 360 degree bead of
Loctite 641 (Yellow) to the internal taper surface on
the flywheel. Apply Loctite bead 5-6 mm from the
center of the taper, offset to the larger diameter of the
taper on the flywheel.
3
4. Using an applicator, apply a 360 degree bead of
Loctite 641 (Yellow) to the external taper surface on
the crankshaft. Apply Loctite bead 5-6 mm from the
center of the taper and offset to the smaller end on
the crankshaft. Be careful to not apply any Loctite to
q Torque Limit Gear Pin t Flywheel the starter gear bearing.
w Starter Gear y One-Way Clutch Retaining 5. Align flywheel key-way with key and install the
Screws 9 ft-lbs (12 Nm)
flywheel, seating it fully on taper.
e One Way Clutch Asm. u Torque Limit Gear Asm. 6. Install flywheel retaining bolt q. Using a
rFlywheel Retaining Bolt commercially available strap wrench , hold flywheel
Step 1: Torque to 133 ft- w and torque the retaining bolt to specification.
lbs (180 Nm)
Step 2: Back out bolt 180°
Step 3: Torque to 133 ft-
lbs (180 Nm)
5. If starter gear was replaced, inspect the torque limit

gear.
6. After assembly, be sure the starter gear rotates in the
clockwise direction only.
NOTICE
If the Cylinder Holding & Camshaft Timing Plate (PU-
50563) is installed, remove it before tightening the
flywheel.
TORQUE
Flywheel Retaining Bolt:
Step 1: Torque to 133 ft-lbs (180 Nm)
Step 2: Back out bolt 180°
Step 3: Torque to 133 ft-lbs (180 Nm)

7. Wipe off excess Loctite and let stand for 1 hour STATOR COVER INSTALLATION
before starting engine.
1. Apply gasket tack adhesive to help hold gasket in
NOTICE place during assembly.
Loctite cures with time, the longer the unit is able to 2. Install a new stator cover gasket over alignment pins.
stand before starting the engine, the stronger the joint
will be. CAUTION
The flywheel contains powerful magnets. Use caution
8. Install the starter torque limit gear as an assembly. when removing and installing the stator cover. DO NOT
place fingers between cover and crankcase at any time
during the removal / installation process or injury could
result.
3. Install stator cover and thirteen screws. Torque

screws in sequence to specification.
TORQUE
Stator Cover Screws:
9 ft-lbs (12 Nm)

ENGINE ASSEMBLY - TOP END

CYLINDER HEAD ASSEMBLY 6. Install the valve spring with widely spaced coils y on
the top and tightly spaced coils u facing down toward
NOTICE the cylinder head.
Assemble the valves one at a time to maintain proper
order.
WARNING
Wear eye protection during cylinder head disassembly
and reassembly or when working with the valve springs. 3
1. Apply engine oil to valve guides and seats.
2. Coat valve stem with Premium Starter Grease (PN
2871460).
3. Install the valve q in the cylinder head, through the
guide.
NOTICE
Valve springs to be installed with paint mark facing up
i.
7. Place the valve retainer on the spring.

8. Compress the valve spring by hand using valve
spring compressor adapter (PV-43513-A). Compress
spring only enough to allow split keeper installation.
Valve spring compressor (PV-1253 or PV-4019
(Quick Release)) can be used if desired to aid in
installation.
4. Dip the new valve seat/seal w in clean engine oil and

carefully install the valve seat/seal on the valve guide
with a rotating motion. Push firmly until seated in
retaining groove and square with the guide.
CAUTION
Valve seals should be installed AFTER the valves are in
the head to avoid valve seal damage.
5. Dip the valve spring e and retainer r in clean

engine oil.
CAUTION
To prevent damage to the valve seals, do not compress
the valve spring more than necessary to install the
keepers.
9. Install split keepers t with gap even on both sides.

10. Repeat this procedure for remaining valves.

11. Install the valve adjustment tappet i for each valve
in the order they were removed.
NOTICE
Refer to VALVE CLEARANCE ADJUSTMENT
procedure for proper tappet selection.
If any valve train components were replaced, refer to
VALVE CLEARANCE ADJUSTMENT procedure prior
to CAMSHAFT INSTALLATION / TIMING procedure.

CYLINDER HEAD INSTALLATION 6. Install new bolts and finger tighten the six cylinder
head bolts t evenly.
7. Install and finger tighten the two outer M6 bolts y
evenly.
Plate (PU-50563) q from the cylinder.
NOTICE
Install new cylinder head bolts.
8. Torque cylinder head bolts in sequence to

specification.
3
IMPORTANT
Once the cylinder head is removed, nothing retains the
cylinder to the engine. DO NOT rotate the engine
without using the Cylinder Holding & Camshaft Timing
Plate (PU-50563).
3. Prepare cylinder head gasket sealing surfaces by TORQUE

cleaning thoroughly to remove all residue. The head Cylinder Head Torque Procedure (M11 Bolts):
gasket must be installed clean and dry, free from oil Torque in sequence
or grease.
NOTICE
Do not touch sealing surfaces of gasket.
4. Guide cam chain w through a new head gasket e
and install the gasket on the cylinder, locating it on TORQUE
the alignment pins. Cylinder Head Torque Procedure (M6 Bolts):
7 ft-lb (10 Nm)
5. Carefully set the cylinder head r in place on

alignment pins.

CAMSHAFT INSTALLATION / TIMING 2. Reference the intake and exhaust markings made
during disassembly. If installing new camshafts or if
NOTICE camshafts were not marked, you can reference the
If any valve train components were replaced, refer to part number stamped on the end of the shafts and
Valve Clearance Adjustment page 3.94 procedure. compare to the electronic parts catalog.
3. Lubricate all camshaft lobes and bearing journal
1. Locate Top Dead Center (TDC). Refer to the surfaces with Polaris PS-4 engine oil prior to
information below. installation.
VEHICLES NOT EQUIPPED WITH HVAC 4. Carefully install the camshafts into the cylinder head.
The PTO camshaft lobes t should face out as
Rotate the engine until the flywheel Top Dead shown.
Center (TDC) mark q is aligned or centered in the
Crankshaft Position Sensor (CPS) mounting hole
w. This places the PTO cylinder at TDC for
camshaft installation.
5. Carefully install the rear camshaft carriers onto the

camshafts. Carrier openings should face each other
when installed properly.
VEHICLES EQUIPPED WITH HVAC 6. Install the four bolts that retain each rear camshaft
carrier y and tighten the bolts evenly until snug.
Rotate the engine until the starter gear’s notch Top
Dead Center (TDC) mark is aligned or centered in
the Crankshaft Position Sensor (CPS) mounting
hole. This places the PTO cylinder at TDC for
camshaft installation.
IMPORTANT
DO NOT use the “V” mark located on the flywheel
opposite of the “I” mark. Only the “I” mark should be
used as a TDC reference.

7. Install the Cylinder Holding & Camshaft Timing Plate 12. Use new camshaft sprocket retaining bolts upon
(PU-50563) into the end of camshafts as shown. Use assembly. Install the top bolt i in each camshaft
a 13/16” open-end wrench to rotate camshafts slightly sprocket u. Do not torque the bolts at this time.
if needed.
NOTICE
8. Verify the TDC mark on the flywheel is still properly
aligned (see Step 1). Use new sprocket retaining bolts upon assembly.
9. Pull cam chain upward, making sure it is engaged

with the drive sprocket on the crankshaft.
10. While lifting the cam chain up, engage the cam
sprockets into the chain with the “I” and “E” marks
facing out.
11. Install the sprockets onto the camshafts and align the
sprocket marks with the valve cover gasket surface
(see CAMSHAFT TIMING — QUICK REFERENCE).
NOTICE
Intake cam sprocket should have “I” marks aligned with
gasket surface and the exhaust cam sprocket should
have “E” marks aligned with gasket surface.
Install the exhaust cam sprocket first (opposite the cam
chain tensioner) to ensure proper cam timing.

13. Verify cam timing is correct. Flywheel TDC mark 14. If timing marks are not aligned, remove sprockets and
should still be aligned (see Step 1) and cam sprocket correct alignment.
markings should line up as shown.
Plate (PU-50563) from the end of the camshafts.
16. Rotate the engine using the flywheel and install the
remaining bolt in each camshaft sprocket. Torque the
sprocket bolts to specification.
TORQUE
Camshaft Sprocket Bolts:
14 ft-lbs (19 Nm)
17. Rotate the engine using the flywheel and torque the
remaining sprocket bolts to specification.
18. Install the front camshaft carrier o and two outer
retaining bolts.
19. Install the fixed cam chain guide a and two retaining
bolts.

20. Torque the camshaft carriers bolts in sequence to 22. Retract the plunger and install the tensioner into the
specification. cylinder assembly.
IMPORTANT
When installing the tensioner into the bore, the “lock”
should be facing up.
TORQUE
7 ft-lb (10 Nm)
21. Apply Polaris PS-4 engine oil to the cam chain 23. Install the two mounting bolts. Torque fasteners to
tensioner bore prior to assembly. Use a new specification.
tensioner sealing washer d.
TORQUE
Tensioner Mounting Bolts:
7 ft-lbs (10 Nm)
24. Install the spring within the plunger bolt and install the
plunger bolt. Torque fastener to specification.
TORQUE
Plunger Bolt:
15 ft-lbs (20 Nm)
25. Rotate crankshaft through two revolutions and verify

camshaft timing is correct.
26. If camshaft timing is not correct repeat the timing
procedure.
IMPORTANT
If camshaft timing is incorrect and the engine is started,
engine damage could occur.

VALVE CLEARANCE ADJUSTMENT 6. Rotate the camshaft until the cam lobes above the
valves you are inspecting are facing up y.
IMPORTANT
Always inspect valve clearance prior to camshaft
installation or final engine assembly.
1. Reference the camshaft intake and exhaust markings

made during disassembly. If installing new camshafts
or if camshafts were not marked, you can reference
the part number stamped on the end of the shafts and
compare to the electronic parts catalog.
2. Lubricate the camshaft bearing journal surfaces with
Polaris PS-4 engine oil prior to installation.
3. Carefully install the camshafts into the cylinder head.
The PTO camshaft lobes e should face out as
shown.
7. Measure the valve clearance u using a thickness
(feeler) gauge. Record the measurement if clearance
is out of specification.
8. Repeat steps 6 and 7 until all eight valves have been
inspected.
MEASUREMENT
Intake Valve Clearance (cold):
.006 ± .002" (0.15 ± 0.05 mm)
Exhaust Valve Clearance (cold):

.010 ± .002" (0.25 ± 0.05 mm)
9. If any of the valve clearance measurements are out of

4. Carefully install the rear camshaft carriers onto the specification, remove the camshaft carriers and
camshafts. Carrier openings should face each other camshafts and proceed with this procedure.
when installed properly.
NOTICE
5. Install the four bolts r that retain each rear camshaft
carrier t and tighten the bolts evenly to specification. If all valve clearance measurements are within
specification, remove the camshaft carriers and
proceed to “Camshaft Installation / Timing”.
TORQUE
7 ft-lb (10 Nm)

10. Remove the valve tappet from a valve that was out of 14. Install the appropriate tappet.
specification.
NOTICE
Lubricate the outer portion of the valve tappet upon
installation.
15. Repeat steps 10-14 until all necessary valves have

been adjusted.
16. Reinstall the camshafts and camshaft carriers and
tighten the bolts evenly to specification.
3
TORQUE
7 ft-lb (10 Nm)
17. Measure and confirm that valve clearance is now

NOTICE
within specification for each valve.
Keep mated parts together and in order with respect to
their location in the cylinder head for assembly 18. If valve clearance is not within specification, repeat
purposes. Mark each component or place them in an this procedure.
organized rack as you remove them. 19. If all valve clearance measurements are now within
specification, remove the camshaft carriers and
proceed to “Camshaft Installation / Timing”.
CAUTION
If performing this procedure with the cylinder head
installed on the engine, cover the spark plug holes and VALVE COVER INSTALLATION
the cam chain opening to prevent a valve adjustment 1. Apply anti-seize compound to spark plug threads.
shim from falling into the cylinder or crankcase.
2. Install spark plugs q and torque to specification.
11. Record the 3 digit number on the bottom of the 3. Prepare valve cover sealing surfaces by cleaning
tappet. i. thoroughly to remove all residue.
4. Install valve cover seal w.
5. Install the four valve cover shoulder bolts e and new
isolators r using a T40 driver.
12. Reference the valve clearance measurement

recorded for that valve, along with the 3-digit tappet
number.
13. Refer to the appropriate tappet selection matrix
(Intake or Exhaust) on the following pages and select
the proper tappet.

6. Torque valve cover bolts to specification.

TORQUE
Spark Plugs:
9 ft–lbs (12 Nm)
Valve Cover Bolts:

7 ft-lbs (10 Nm)

CAMSHAFT TIMING - QUICK

REFERENCE
q Intake Cam r Align marks with surface

w Exhaust Cam t CPS Mounting Hole
e Align marks with surface y Align Flywheel Mark in Mounting Hole
IMPORTANT
DO NOT use the “V” mark located on the flywheel opposite of the “I” mark. Only the “I” mark should be used as a TDC
reference

VALVE LASH - TAPPET SELECTION

A 440 tappet means the thickness of the tappet is 4.40 mm. Part Number: 5138477-XXX (X’s represent 3 digit tappet
size)
An Engine Valve Lash Adjustment calculator has been created and is located under Service and Warranty – News,
Forms and Links.
Click or go to https://www.polarisdealers.com/files/ServWarr/English/Engine%20Valve%20Adjustment%20Calculator.
pdf
The proper valve tappet may also be obtained by completing these steps:
IMPORTANT
The Valve Lash Specification and Measured Valve lash must be calculated in millimeters (mm)
1. Subtract the actual valve lash on the engine from the valve lash specification (i.e. 0.29 mm – 0.20 mm) = 0.09 mm.
2. Divide the 3 digit tappet number by 100 (i.e. 450 / 100) = 4.5 mm.
3. Add the results of step 1 and step 2 (i.e. 0.09 mm + 4.5 mm) = 4.59 mm.
4. Multiply that answer by 100 to obtain the correct new tappet (i.e. 4.59 mm x 100 = 459).
5. Refer to the table below to find the closest available tappet size to the result from step 4 (i.e. 459 should be
rounded to 460 since there is a 460 tappet).
AVAILABLE TAPPETS
440 450 460 470 480 490 500 510 520 530 540
442 452 462 472 482 492 502 512 522 532 542
445 455 465 475 485 495 505 515 525 535 545
448 458 468 478 488 498 508 518 528 538

COOLING SYSTEM SERVICE

COOLING SYSTEM ASSEMBLY VIEW
q Thermostat housing y Filler Neck s Oil Cooler Inlet Hose

w Water Pump u Radiator d Oil Cooler Outlet Hose
e Engine Hoses i Pressure Cap f Bypass Hose
r Lower Radiator Hose o Upper Radiator Hose g Water Pump Outlet Hose
t Fan Assembly a Recovery Bottle

COOLING SYSTEM SPECIFICATIONS CAUTION

COOLING SYSTEM TEMPERATURE Using tap water in the cooling system will lead to a
SPECIFICATIONS buildup of deposits which may restrict coolant flow and
reduce heat dissipation, resulting in possible engine
CONDITION COOLANT TEMP °F (°C) damage. Polaris Premium 60/40 Antifreeze/Coolant is
recommended for use in all cooling systems and comes
Thermostat Open 180° F (82° C) pre-mixed, ready to use.
Fan Off 194° F (90° C)
Fan On 205° F (96° C)

COOLING SYSTEM PRESSURE TEST
Thermostat Full Open 203° F (95° C)
Engine Temperature 232° F (111° C)
Overheat Indicator On WARNING
Engine Temperature Never remove pressure cap q when engine is warm or
221° F (105° C)
Overheat Indicator Off hot. The cooling system is under pressure and serious
burns may result. Allow the engine to cool before
232° F (111° C) to 246° F servicing.
(119° C)
*When power limitation
temperature is reached at 2. Remove pressure cap q and pressure test the
232° F (111° C) the cooling system using a commercially available
vehicle is limited to 30 pressure tester.
mph (50 kph). As
Overheat Protection
temperature increases,
Power Limitation
the limitations will also
increase. At 239° F (115°
C) the vehicle will be
limited to 3–5 mph (5–8
kph). At 246° F (119° C)
the engine will achieve
shutdown.
Engine Protection 246° F (119° C)
Shutdown
COOLING SYSTEM CAPACITY / PRESSURE
ITEM SPECIFICATION
BAS- ITEM DESCRIPTION
5.36 qt (5.0 L)
Cooling System E Pressure Cap (Test Here)
q
Capacity CR- 6.08 qt (5.75 L) w Recovery Bottle
EW
Pressure Cap Relief 13 PSI e To Water Pump
r To Thermostat Housing
Polaris 50/50 Extended Life Anti-freeze
2880514 (quart) 3. The system must maintain 10 psi for five minutes or
2880513 (gallon) longer. If pressure loss is evident within five minutes,
check the filler neck, radiator, hoses, clamps and
Recommended Coolant water pump weep hole for leakage.
Use only high quality antifreeze/coolant mixed with
distilled water in a 50/50 or 60/40 ratio, depending on
freeze protection required in your area.

RADIATOR CAP PRESSURE TEST 3. Lift the radiator access flap up.
WARNING
Never remove pressure cap when engine is warm or
hot. The cooling system is under pressure and serious
burns may result. Allow the engine to cool before
servicing.
2. Remove pressure cap q and test using a pressure

cap tester (commercially available).
3
4. Drain radiator by removing lower radiator hose r.
CAUTION
Catch and dispose of coolant properly.
3. The pressure cap relief pressure is 13 psi. Replace

cap if it does not meet this specification.
COOLANT REMOVAL / DRAINING

1. Remove the hood.
2. Remove four upper radiator support fasteners q &
w. Remove the two radiator support brackets e.
WARNING
The cooling system is under pressure and serious
burns may result.
Allow the engine to cool before servicing.

COOLING SYSTEM BLEEDING 7. Open the bleed screw e to allow any trapped air to
PROCEDURE escape. Close the bleed screw once a steady stream
of coolant begins to drain out.
1. Allow engine and cooling system to cool down.
WARNING
Always wear safety glasses and proper shop clothing
when performing the procedures in this manual. Failing
to do so may lead to possible injury or death.
NOTICE
If the coolant level is LOW in the radiator, or if there are
leaks in the system, the coolant system will not draw
coolant from the reservoir tank.
CAUTION
Escaping steam can cause burns. Never remove the 8. Tighten the bleed screw to specification, top off
pressure cap while the engine is warm or hot. Always coolant and properly install the pressure cap.
cap. TORQUE
Coolant Bleed Screw:
2. Remove the hood from the front cab. 6 ft-lbs (8 Nm)
3. Remove the recovery bottle cap q and fill the bottle
to the MAX line. 9. Start the engine and allow it to idle until the coolant
fan has cycled two times.
IMPORTANT
HVAC models: Cycle the heater to full heat. This will
open the three-way valve and allow coolant to purge
any air trapped in the heating system.
10. Allow engine and cooling system to completely cool

down.
CAUTION
Escaping steam can cause burns. Never remove the
pressure cap while the engine is warm or hot. Always
cap.
4. Remove the pressure cap w and add the necessary
amount of Polaris Premium Antifreeze to the radiator
filler neck. 11. Remove the pressure cap. Add the necessary
amount of Polaris Premium Antifreeze to the radiator
5. Tilt the rear cargo box to the raised position. filler neck.
6. Remove the upper exhaust heat shield to access the 12. Open the bleed screw to allow any trapped air to
coolant bleed screw. escape. Close the bleed screw once a steady stream
of coolant begins to drain out.
13. Tighten the bleed screw to specification, top off
coolant and properly install the pressure cap.
TORQUE
Coolant Bleed Screw:
6 ft-lbs (8 Nm)

14. Fill the recovery bottle to the MAX line. 4. Drain radiator by removing lower radiator hose r. Be
sure to catch and dispose of coolant properly.
15. Reinstall the upper exhaust heat shield.
16. Reinstall the hood.
RADIATOR REMOVAL / INSTALLATION

1. Remove the hood.
2. Remove four upper radiator support fasteners q &
w. Remove the two radiator support brackets e. 3
WARNING
The cooling system is under pressure and serious
burns may result.
5. Remove the upper radiator hose from the radiator.
3. Lift the radiator access flap up.
6. Disconnect the small radiator bypass hose t.

7. Remove four fasteners y securing the radiator fan to 10. Reverse this procedure for installation. Be sure to
the radiator. Separate the fan motor assembly from properly fill and bleed cooling system as outlined in
the radiator. this chapter.
8. Lift the radiator up to remove from the vehicle.

e Upper Radiator Hose y To Radiator Fitting
r Lower Radiator Hose u Fan Motor Assembly
t Recovery Bottle i Radiator
9. Inspect fan blades for damage.

RADIATOR SERVICE (HVAC) 4. Remove the upper radiator hose r from the radiator.
REMOVAL
1. Remove the cooling fan. Refer to Cooling Fan
Service (HVAC) page 3.107.
2. Remove the four 10 mm fasteners q securing the
cooling fan shroud w to the radiator. Pivot the shroud
back and lift straight up to remove from the vehicle.
5. Remove the bypass hose t on the radiator filler

neck.
NOTICE
Removing the condenser mounting fasteners may allow
more clearance to remove the radiator.
3. Remove the lower radiator hose e to drain the

radiator.
IMPORTANT
Properly dispose of drained coolant.
6. Lift the radiator straight up to remove from the

vehicle.
CAUTION
If reusing, do not damage the radiator or condenser
fins.

INSTALLATION 4. Install the lower radiator hose e and secure the hose
clamp.
1. Install the radiator into the vehicle.
CAUTION
Do not damage the radiator or condenser fins.
5. Install the fan shroud and align with mounting holes.

Install the four 10 mm fasteners q to secure the
cooling fan shroud w to the radiator
2. Install the bypass hose t on the radiator filler neck.
TORQUE
Cooling Fan Shroud:
3. Install the upper radiator hose r and secure the hose 6 ft-lbs (8 ft-lbs)
clamp.
6. Install the cooling fan and reassemble the vehicle.
Refer to Cooling Fan Service (HVAC) page 3.107.
7. Fill and bleed the cooling system. Refer to Cooling
System Bleeding Procedure page 3.102.

RADIATOR FAN REMOVAL 5. Disconnect the coolant hose e on the coolant

reservoir.
1. Remove Radiator, See Radiator Removal /
Installation page 3.103 IMPORTANT
2. Disconnect cooling fan electrical connector. Catch and properly dispose of coolant.
3. Tilt radiator fan toward the front of the vehicle, then lift
fan up and out. 6. Remove the two T25 Torx fasteners r securing the
coolant reservoir t and remove the reservoir.
7. Remove the two clamps y securing the intake

COOLING FAN SERVICE (HVAC) snorkel caps u and remove the caps.
REMOVAL
1. Remove the windshield. Refer to Windshield Service
page 13.16.
2. Remove the upper dash panel. Refer to Dash Panels
/ Glove Box Service page 11.34.
3. Remove the front fascia. Refer to Front Fascia
Service page 11.25.
4. Remove the T25 Torx fastener q securing the fresh
air filter w and remove the fresh air filter.
8. Remove the 10 mm fastening nut i securing the

power cable to the terminal block and detach the
power cable.

9. Disconnect the connector o at the terminal block. 12. If equipped, remove the four T25 Torx fasteners d
securing the washer fluid reservoir. Set the washer
fluid reservoir aside.
10. Remove the two 10 mm fasteners a securing the

ground cable to the hood liner and remove the ground
cable. CAUTION
11. Remove the four T25 Torx fasteners s securing the Ensure the washer hoses are not kinked.
terminal block to the hood liner and remove the
terminal block.
13. Remove the washer fluid pump from the washer fluid
reservoir. Feed the pump and lines out of the hood
liner.
IMPORTANT
Ensure the washer fluid pump grommet is not torn or
damaged.

14. Remove the nine push rivets f securing the hood 17. Disconnect the cooling fan connector j.
liner to the vehicle.
18. Remove the four T40 Torx fasteners k securing the
cooling fan assembly.
15. Feed the electrical harness g out of the hood liner.

19. Lift the cooling fan straight up to remove from the
vehicle.
CAUTION
Use care not to damage the radiator fins.
16. Remove the hood liner h from the vehicle to gain

access to the cooling fan.

INSTALLATION 4. Install the hood liner h.

1. Install the cooling fan straight down.
CAUTION
Use care not to damage the radiator fins.
5. Feed the electrical harness g into the hood liner.
2. Install the four T40 Torx fasteners k to secure the

cooling fan assembly.
TORQUE
Cooling Fan Fasteners:
35 in-lbs (4 Nm)
3. Connect the cooling fan connector j.
6. Install the nine push rivets f to secure the hood liner

to the vehicle.

7. If equipped, install the washer fluid pump into the 9. Install the terminal block and four T25 Torx fasteners
washer fluid reservoir. s to secure the terminal block to the hood liner.
IMPORTANT Torque to specification.
Ensure the washer fluid pump grommet is not torn or TORQUE
damaged. Terminal Block Fasteners:
24 in-lbs (3 Nm)
10. Install the ground cable and two 10 mm fastening

nuts a. Torque to specification.
3
8. Install the washer fluid reservoir and the four T25 Torx
fasteners d to secure the washer fluid reservoir to
the hood liner.
CAUTION TORQUE
Ensure the washer hoses are not kinked. Ground Cable Fasteners:
30 in-lbs (3.5 Nm)
11. Connect the terminal block connector o.

12. Install the power cable and 10 mm fastening nut i to
secure the power cable to the terminal block. Torque
to specification.
TORQUE
Washer Fluid Reservoir:
Torque until fully seated
TORQUE
Power Cable Fasteners:
30 in-lbs (3.5 Nm)

13. Install the snorkel caps u and the two clamps y to 16. Install the fresh air filter w and T25 Torx fastener to
secure the intake snorkel caps. Torque to secure the filter to the hood liner. Torque to
specification. specification.
TORQUE TORQUE
Intake Clamps: Fresh Air Filter Fastener:
35 in-lbs (4 Nm) 18 in-lbs (2 Nm)
14. Install the coolant reservoir t and the two T25 Torx 17. Fill and bleed the cooling system. Refer to Cooling
fasteners r to secure the reservoir to the hood liner. System Bleeding Procedure page 3.102.
Torque to specification.
18. Install the front fascia. Refer to Front Fascia Service
TORQUE page 11.25.
Coolant Reservoir Fasteners: 19. Install the upper dash panel. Refer to Dash Panels /
24 in-lbs (3 Nm) Glove Box Service page 11.34.
20. Install the windshield. Refer to Windshield Service
15. Connect the coolant hose e on the coolant reservoir. page 13.16.

ENGINE OIL COOLER SERVICE 5. Discard the oil cooler O-rings t.

REMOVAL
1. Drain engine coolant. Refer to Coolant Removal /
Draining page 3.101.
2. Remove the headpipe assembly. Refer to Headpipe
Service page 3.27.
3. Slide the two hose clamps q back securing the inlet
w and outlet e coolant hoses. Remove coolant
hoses from the oil cooler.
3
CAUTION
Catch and properly dispose of any escaping coolant .
INSTALLATION
1. Install two new oil cooler O-rings t.
4. Remove the four fasteners r securing the oil cooler

t to the engine. Remove the oil cooler.
CAUTION
Catch and properly dispose of any escaping oil or 2. Install the oil cooler assembly t and secure to the
coolant. engine using the four oil cooler fasteners r. Torque
to specification.
TORQUE
Oil Cooler Fasteners:
7 lb-ft (10 Nm)

3. Install the inlet w and outlet e coolant hoses onto

the oil cooler. Slide the hose clamps q over the ends
of the hoses to secure them to the oil cooler.
IMPORTANT
Ensure proper orientation of the inlet and outlet hoses.
Refer to Cooling System Assembly View page 3.99.
4. Fill and bleed the cooling system. Refer to Cooling

System Bleeding Procedure page 3.102.
IMPORTANT
Ensure no leaks are present. Refer to Cooling System
Pressure Test page 3.100 as needed.
5. Install the headpipe assembly. Refer to Headpipe

Service page 3.27.
6. Top off engine oil as needed.

THERMOSTAT REPLACEMENT 8. Lift the cover from the housing and remove the
thermostat.
NOTICE
WARNING
Thermostat has a pop-off relief to allow the bypass
The cooling system is under pressure and serious system to operate until thermostat opens.
burns may result.
9. Install a new thermostat.
2. Remove the pressure cap to relieve any system

pressure. See Cooling System Pressure Test page
3.100
3
3. Drain coolant to a level below the thermostat housing.
4. Remove upper coolant hose from thermostat housing
q.
10. Reverse this procedure for installation. Torque

thermostat cover bolts to specification.
TORQUE
Thermostat Cover Bolts:
7 ft-lbs (10 Nm)
5. Remove the rear bolt w retaining the thermostat 11. Be sure to properly fill and bleed cooling system as
cover. outlined in this chapter.
6. Remove the cargo box access panel.
7. Using an 8 mm swivel socket and long extension,
remove the front bolt e retaining the thermostat
cover.

WATER PUMP REMOVAL 11. Remove the three bolts q & w retaining water pump
to engine block. Note different bolt lengths for
1. Allow engine and cooling system to cool down.
installation.
WARNING
Be sure the engine has cooled and no pressure is built
up in the cooling system before removing the pressure
cap. The coolant may be hot and could cause severe
injury or burns.
2. Flip up passenger seat and remove battery cover.
12. Remove water pump from engine by gently twisting

and rocking the water pump housing while pulling
outward.
13. Maneuver water pump downward and remove it
through the access hole in the skid plate.
14. Plug the water pump drive access hole in the engine
block with a clean shop towel.
3. Disconnect the (-) negative battery cable.

4. Remove all debris and thoroughly clean water pump
area and right-hand side of engine block.
5. Remove the hood.
6. Remove the pressure cap from the filler neck.
7. Drain cooling system as outlined in this chapter.
8. Elevate the rear of the vehicle off the ground using a
suitable ATV lift and remove the right rear wheel.
9. Remove the right rear shock lower mounting bolt.
Discard the nut. Swing and support right rear shock
rearward to gain access to water pump area.
10. Remove the five coolant hoses that are attached to
the water pump. Note location and routing for
installation. Be sure to catch and dispose of coolant
properly.

WATER PUMP INSTALLATION 6. Rotate water pump drive tab r so it matches the
angle of the drive slot in the engine.
1. Replace the two sealing O-rings on the water pump
housing.
IMPORTANT
Do not reuse the water pump O-rings. Always use NEW
O-rings each time the water pump is removed.
2. Lubricate new O-rings q with fresh engine oil.

3
CAUTION
The water pump drive tab and slot must be aligned
properly during installation. Severe engine or water
pump damage will occur if the tab and slot are not in
alignment during water pump installation.
7. Maneuver water pump up through the access hole in

3. Remove the shop towel from the water pump drive the skid plate on the RH side of the vehicle.
access hole in the engine block.
8. Slide water pump into engine crankcase.
4. Clean the O-ring sealing surface w in the engine
block using a clean shop towel. 9. Be sure water pump is fully seated and the drive tab
and slot are properly engaged.
10. Install the three water pump mounting bolts t & y
and torque to specification.
5. Use a shop light to illuminate the water pump drive

access hole in engine crankcase and note orientation
of the water pump drive slot e.
NOTICE
Install different bolt lengths as shown.
TORQUE
Water Pump Mounting Bolts:
7 ft-lbs (10 Nm)

11. Install the four coolant hoses u – a that attach to the WATER PUMP SERVICE
water pump. Be sure orientation and routing are
correct. NOTICE
The water pump cover gasket can be replaced while
the water pump housing is still installed in the engine.
1. Remove water pump assembly as outlined in this

chapter (Engine Disassembly/Inspection - Bottom
End — Water Pump Housing Removal).
2. Remove the three bolts retaining water pump cover
q to water pump housing w. Discard cover gasket
e.
12. Install the right rear lower shock bolt and new nut.
Torque mounting bolt to specification.
TORQUE
Rear Shock Mounting Bolt:
40 ft-lbs (54 Nm)
13. Install the right rear wheel. Torque wheel nuts to

specification.
TORQUE 3. Place the water pump drive tab r vertically into a soft
jaw vice.
Wheel Lug Nuts:
120 ft-lbs (163 Nm) 4. Remove the bolt and washer retaining the water
pump impeller to the shaft. Inspect the impeller veins
and water pump housing for damage. Replace if
14. Connect the (-) negative battery cable. needed.
15. Fill and bleed cooling system as outlined in this
chapter.
16. Install the hood and seats.
NOTICE
The water pump impeller bolt t is left hand thread
(reverse thread).
5. Remove impeller from water pump shaft.

6. Using an appropriate arbor press, properly support 14. Install a NEW mechanical seal into the water pump
the water pump housing and press out the water housing using special tool (PU-50564) u. Press the
pump shaft from the impeller side. new mechanical seal in until it is flush with the water
pump housing.
7. Extract the mechanical seal and the oil seal from the
water pump housing.
15. Rotate water pump shaft after seal installation to

CAUTION verify free movement.
A 5/32" (4 mm) diameter punch y will fit in the 16. Place impeller onto the water pump shaft.
lubrication slot to aid in the removal of the oil seal. Be 17. Apply Loctite® 204™ to the threads of the impeller
sure not to damage the water pump shaft bearing bolt. Install washer and impeller bolt and torque to
surface. specification.
TORQUE
8. Inspect the water pump shaft bore for excessive wear
or damage. Replace water pump housing assembly if Water Pump Impeller Bolt:
necessary. 7 ft-lbs (10 Nm)(Apply Loctite® 204™ to bolt
threads)
9. Clean and inspect water pump shaft for excessive
wear or damage. Replace water pump housing
assembly if necessary, as shaft can not be purchased 18. Clean cover q and housing gasket surfaces w.
separately.
19. Install a new water pump cover gasket e.
10. Thoroughly clean mechanical seal and oil seal bores.
11. Install a NEW oil seal into the water pump housing
until fully seated.
12. Fully install the water pump shaft and two washers
into the housing.
13. Place water pump drive tab vertically into soft jaw
vice as previously shown in this procedure.

20. Install the water pump cover and three retaining bolts TORQUE
i. Torque bolts in sequence to specification. Water Pump Mounting Bolts:
7 ft-lbs (10 Nm)
21. Install two new water pump (O-rings) and lubricate

them with fresh engine oil.
22. Install water pump assembly into engine.
WATER PUMP ASSEMBLY VIEW
o Bolt f Washers k Oil Seal

a Loctite 204 g Drive Tab l Impeller
s Mechanical Seal h Water Pump Shaft 1( Washer
d O-Rings j Water Pump Housing

HVAC SYSTEM
GENERAL INFORMATION - HVAC SAFETY EQUIPMENT
In servicing A/C and heater systems you will be exposed
HVAC SYSTEM FASTENER TORQUES to high pressures, temperatures and several chemical
ITEM TORQUE VALUE hazards. Moving belts and pulleys are normal shop
hazards.
Alternator Mounting Fasteners 37 lb-ft (50 Nm)
In addition to exercising caution in your work, WEAR
Alternator Cover Fasteners 48 lb-in (5.4 Nm) SAFETY GLASSES OR A FACE SHIELD when you are
using R-134a or a leak detector, adjusting service valves
Compressor Low Pressure Hose 25 lb-ft (34 Nm) or the manifold gage set connectors. Safety glasses or a
transparent face shield are practical safety items and one 3
Compressor High Pressure Hose 18 lb-ft (24 Nm) or the other is absolutely required.
Compressor Mounting Fasteners 37 lb-ft (50 Nm)
WARNING
Compressor Oil Drain Plug 10 ft-lbs (14 N·m)
In the event of a leak, wear safety goggles. Escaping
HVAC Timing Wheel Fasteners 9 lb-ft (12 Nm) refrigerant can cause severe injuries to eyes. In contact
with a flame, R-134a refrigerant gives off a toxic gas.
HVAC Cover Mount Fasteners 9 lb-ft (12 Nm)
44 lb-ft (60 Nm) + R-134a inside a canister or in an A/C system is a liquid
HVAC Drive Pulley Fastener
180° under pressure. When it escapes or releases into the air,
ITS TEMPERATURE DROPS TO -5.8°C (21.6°F)
Upper Condenser Hose 18 ft-lbs (24 N·m) “INSTANTLY”. If it spills on your skin or in your eyes you
Lower Condenser / Receiver- should flood the area with cool water and SEEK
12 ft-lbs (16 N·m) MEDICAL ATTENTION FAST! It is a good idea to wear
Drier Hose
gloves to prevent frost bite if you should get refrigerant
Condenser Upper Mounting Bolt 14 ft-lbs (19 N·m) on your hands.
Condenser Lower Mounting 8 ft-lbs (11 N·m)
Bolts WARNING
6 ft-lbs (8 N·m) HFC R-134a refrigerant can be dangerous if not

HPCO Switch
properly handled. Liquid R-134a may cause blindness if
Heater / Evaporator Unit it contacts the eyes and may cause serious frostbite if it
10 lb-ft (14 Nm) contacts the skin.
Mounting Fasteners
Gaseous R-134a becomes lethal (phosgene gas) when
Expansion Valve High / Low 12 ft-lbs (16 N·m) it contacts open flame or very hot substances.
Pressure Hoses NEVER smoke when there is the possibility of even
Expansion Valve Tubes 22 ft-lbs (30 N·m) small amounts of R-134a in the air.
Any servicing work that involves release or addition of
Heater Valve Fasteners 8 lb-ft (11 Nm) R-134a to the system must be done by a competent
refrigeration dealer who has the proper equipment,
knowledge, and experience to service refrigeration
equipment.
SPECIAL TOOLS - HVAC
TOOL DESCRIPTION PART NUMBER
Refrigerant Recovery / Recycle
/Recharging Machine PU-51021
Recharge Service Kit (for PU-

51021) PU-51021-1
HVAC Belt Tool PU-52087

Crankshaft Pulley Holder PU-52254
Bosch Automotive Service Solutions: 1-800-345-2233 or

http://polaris.service-solutions.com.

HVAC SYSTEM OVERVIEW

AIR CONDITIONING DESCRIPTION
In an air conditioning system heat is removed from the cab by circulating R-134a refrigerant through a closed system
containing five major components. At these five points in the system the refrigerant goes through pressure and
temperature changes.
The compressor takes in heated, low pressure refrigerant gas through the suction line (low pressure side) and
pressurizes the heated refrigerant and forces it through the discharge line (high pressure side) to the condenser.
Should the pressure on the high pressure side become too high, the HPCO (High Pressure Cut-Out) switch will cycle
the compressor clutch off.
Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the
refrigerant from a gas to a liquid.
The liquid refrigerant moves on to the receiver / drier where impurities such as moisture and dirt are filtered out. The
receiver / drier also serves as the storage tank for the liquid refrigerant. The liquid refrigerant (still under high pressure)
flows to the expansion valve.
The expansion valve meters the amount of refrigerant into the evaporator coil. As the refrigerant passes through the
expansion valve, an extreme pressure and temperature drop occurs. It becomes a low temperature, low-pressure
liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the evaporator.
The warmer air of the machine's cab is drawn through or blown into the evaporator by the evaporator blower.
Since the refrigerant is colder than the air, it absorbs the heat from the air and produces cooled air, which is pushed
into the cab by the blower. The moisture in the air condenses on the evaporator coil and drips into the drain pan, which
directs the water out of the cab.
The refrigerant cycle is completed when the heated low pressure gas is again drawn into the compressor. The
compressor cycles on and off to maintain the desired cab temperature. The Electronic De-icing Thermostat is a micro
controller based module that measures evaporator coil temperature and cycles the compressor clutch to maintain a
constant evaporator pressure.
HVAC SYSTEM COMPONENTS NOTICE

Compressor: The compressor q is the pump that The A/C system (Compressor) is recommended to be
circulates the refrigerant throughout the system. It raises turned on for at least 5 minutes weekly throughout the
the pressure of the refrigerant for heat transfer through year to lubricate the internal components.
the condenser and evaporator.

Condenser: The condenser w is the unit that receives

the high pressure, high temperature refrigerant vapor
from the compressor and condenses it into a high
temperature liquid.
Heater / Evaporator Unit: The heater / evaporator unit

y is located below the dash on the passenger side. The
unit delivers the cold air for the A/C and warm air for heat
into the cab. The unit contains the heat and A/C coils,
thermostat, and expansion valve.
Receiver / Drier: The receiver / drier e is the unit that
receives the liquid refrigerant from the condenser and
removes moisture and foreign matter from the system. It
also serves as a storage tank for the extra liquid
refrigerant until it is needed by the evaporator.
Pressure Switch: The high pressure switch r will
disengage the compressor clutch at high pressure
readings over 400 psi. (2.8 MPa) and will engage the
clutch when pressures lower to 325 psi (2.2 MPa).
Heater Coil: The heater coil u supplies the warm air into
the cab by passing air through the coil.
Evaporator Coil: The evaporator coil i cools and
dehumidifies the air before it enters the cab.
Expansion Valve: The expansion valve t controls the

amount of refrigerant entering the evaporator coil.

Thermostat: The thermostat o and probe a controls A/C Switch: The rocker switch f will be illuminated
the temperature of the evaporator coil. when the A/C is engaged.
Potentiometer: The potentiometer g controls the
Heater Valve from fully Off to fully On. This can be used
in conjunction with the A/C for defrost of the windows and
temperature control.
Heater Valve: The heater valve h is used to control the
amount of engine coolant that flows to the heater coil.
Heater / Evaporator Blower: The blower s is used to

pull air through the heater and evaporator coils and into
the cab.
Control Panel: The panel has three separate

components.
Fan Switch: This is a four position rotary switch d .

When the fan switch is in the off position the A/C will not
engage, but the heater valve will operate, as it is
controlled by the ignition power.

RECLAMATION AND CHARGING WITH RE- 3. Connect the reclaimer to the A/C charge ports on the
COVERY / CHARGING UNIT utility vehicle.
NOTICE 4. Connect the Blue hose to the low pressure port and
open the valve.
Only A/C trained technicians should perform the
reclaiming and recharging. 5. Connect the Red hose to the high pressure port and
This test is run with the engine OFF, and the A/C switch open the valve.
in the OFF position. 6. Turn the reclaimer unit to the ON position and follow
the on screen instructions.
1. Remove the caps on the low pressure port q and
high pressure port w. NOTICE
The reclaimer unit, has a complete step by step set of
3
instructions to follow for reclimation and recharging of
the A/C system. A trained technician should follow
these instructions as they may very slightly depending
on the model and brand of reclaimer used.
REFRIGERANT
This system uses R-134a refrigerant. Running or mixing
any other refrigerant will contaminate and damage your
A/C Recovery / Recycling / Recharging Machine q as
well as the A/C system on the vehicle.
System Capacity: R134a 1.6 lbs (.726 kg)
CAUTION
Do not use the high pressure port for testing or
charging.
WARNING
refrigerant can cause severe injuries to eyes. In contact
with a flame, R-134a refrigerant gives a toxic gas.
HFC R-134a refrigerant can be dangerous if not

properly handled. Liquid R-134a may cause blindness if
it contacts the eyes and may cause serious frostbite if it
contacts the skin.
Gaseous R-134a becomes lethal (phosgene gas) when

it contacts open flame or very hot substances.
NEVER smoke when there is the possibility of even

small amounts of R-134a in the air.
Any servicing work that involves release or addition of

R-134a to the system must be done by a competent
refrigeration dealer who has the proper equipment,
knowledge, and experience to service refrigeration
equipment.
2. Use an approved recovery / charging unit to

evacuate the system.

TROUBLESHOOTING - HVAC TEMPERATURE DOES NOT CHANGE

POOR A/C PERFORMANCE 1. Verify the heater hose is not hot when the
temperature is set to “full cold.”
1. Start the vehicle. Engage the A/C system with the
blower fan on high. Run the vehicle at 3350 rpm for • If the heater hose is hot, replace the heater valve.
approximately 15 minutes, with the cab doors closed.
2. Verify the heater valve turns to “hot” when the unit is
2. Check the temperature at the louvers q with a turned to key on, engine off.
thermometer.
NOTICE
This is best performed with the fan on “low.” An audible
click can be heard.
3. With the engine running, verify the heater hose

temperature increases.
NOTICE
Coolant flow is optimized at 2000 RPM or higher.
• If the temperature does not increase, verify proper

resistance in the control head.
4. Verify proper resistance at the temperature control

knob.
3. The louver temperature should be approximately 15° • Pins A & B should read ~81.5K ohms on full cold
F (9°C) lower than the ambient air temperature, setting. The resistance should gradually increase to
depending on the humidity in the air. ~ 91.5K ohms on full hot setting
4. If temperature is too high, check the blower fan for • Pins A & C should read 10K ohms at all times.
proper operation or noise, refer to Blower Motor Does
Not Operate page 3.129 repair as necessary. • Replace the control head if these readings are
incorrect.
5. If the blower fan is working properly, inspect
compressor operation. When the compressor is 5. Verify proper power, ground, and signal are present
engaged engine RPM should increase to 1300–1400 at the control head.
RPM.
• Verify power is present on the red/blue wire at the
• Compressor engagement can be caused by an control head and heater valve.
electrical concern or refrigerant charge. Check the
refrigerant charge first, refer to the Temperature / • Verify proper continuity to ground on the black wire
Pressure Chart page 3.128 for more information. at the control head and heater valve.
• If the refrigerant charge is correct, refer to • Verify continuity is present on the red/dark green
Compressor Does Not Operate At All Or Operates wire between the control head and switch.
Improperly page 3.131. • Repair/ replace the harness if any readings are
incorrect.
6. After verifying the A/C charge check symptoms.
• System Low on Refrigerant
– The high side pressure will be low.
– Repair any leaks and recharge the A/C system
• Excessive Refrigerant
– The high pressure side pressure will be high.
– Recover and recharge system to the correct
refrigerant level.

ENGINE COOLANT BYPASSING THE HEAT- 7. Listen for the heater valve t as the key is turned to
ER VALVE the ON position without starting the utility vehicle. The
heater valve should rotate. If it does not rotate, check
1. Push the A/C switch q to the OFF position. Turn the the potentiometer for proper function.
fan switch w to the High Speed position. Turn the
temperature control e to the High A/C position.
8. Replace the heater valve.

2. Start the utility vehicle and run at high idle, for ten
minutes.
3. Check the heater hose r for temperature. If the hose
is hot, the heater valve is leaking by, and needs to be
replaced.
4. Push the A/C switch to the OFF position. Turn the fan
switch to position 1. Turn the temperature control to
the High A/C position.
5. Listen for the heater valve q as the key is turned to
the ON position without starting the utility vehicle. The
heater valve should rotate.
6. Turn the key to the OFF position. Turn the
temperature control to the High Heater position.

TEMPERATURE / PRESSURE CHART

TEMP °F PSIG TEMP °F PSIG
16 15.69 93 110.20
18 17.04 94 112.10
20 18.43 95 114.10
22 19.87 100 124.30
24 21.35 102 128.50
26 22.88 104 132.90
28 24.47 106 137.30
30 26.10 108 141.90
32 27.79 110 146.50
34 29.52 112 151.30
36 31.32 114 156.10
38 33.17 116 161.10
40 35.07 118 166.10
42 37.03 120 171.30
44 39.05 122 176.60
45 40.09 124 182.00
50 45.48 126 187.50
55 51.27 128 193.10
60 57.47 130 198.90
65 64.10 135 213.70
70 71.19 140 229.40
75 78.75 145 245.80
80 86.80 150 263.00
85 95.40 155 281.10
90 104.40 160 300.10
91 106.30 165 320.10
92 108.20 170 340.80
Evaporator
Pressures represent gas temperatures inside the coil, not the coil surface. For an estimate of the temperature of the air
coming off the coil add 8 - 10°F (-13 to -12°C) to the temperature on the chart.
Condenser
Temperatures are not ambient temperatures but condensing temperatures. Add 4.4°C (40°F) to the ambient
temperature to get the condensing temperature and then refer to the pressure chart to see appropriate pressure for
ambient temperature.
Example: Ambient Temperature = 90ºF
90ºF + 40ºF = 130ºF condenser temperature / 200 PSIG
Conditions and pressures will vary from system to system.

BLOWER MOTOR TROUBLESHOOTING

BLOWER MOTOR DOES NOT OPERATE
1. Verify power is present at the blower motor.
• “Low Setting” should have power present on the yellow wire.
• “Medium Setting” should have power present on the red wire.
• “High Setting” should have power present on the red/dark green wire.
• The black wire should have continuity to ground.
• Repair/Replace harness as necessary or replace the blower motor if no issues were found.
3
2. Verify the HVAC control head blower motor switch has proper continuity.
• Pin 5 should have proper continuity to pin 4 on “Low Setting.”
• Pin 5 should have proper continuity to pin 1 on “Medium Setting.”
• Pin 5 should have proper continuity to pin 2 on “High Setting.”
• Pin 5 should have proper continuity to pin 3 in all operating positions.
• Pin 5 should have no continuity to any pins when in the off position.
• If no issues were found, verify all wires between the HVAC control head and blower motor have proper continuity.
3. Verify power is present on the Red/Blue wire at the A/C control head.
• If power is not present, proceed to next step.
• If power is present, replace the A/C head.
4. Verify proper operation of the HVAC relay with the switch on.
• Power out should have continuity to ground when powered on. Fan should also turn on.
– If the fan does not turn on, verify proper continuity to the HVAC control head. Repair/replace harness as
necessary.
• Coil low should have continuity to ground. Repair/replace harness as necessary.
• Power in should have battery voltage present from the HVAC fuse.
• Coil high should have battery voltage with the key turned on.
– If power is not present with the key on, verify continuity between the key switch pin “D” and pin 39. Repair/
replace harness as necessary.
SYMPTOM POSSIBLE CAUSE SOLUTION

1. Blown fuse Inspect the fuse / wiring. Replace fuse / repair wiring
2. Broken wiring / connection Check the fan motor ground and connectors. Repair the wiring or connector
Check the lead wires form the motor with a circuit Replace Motor
3. Fan motor malfunction
tester.
4. Resistor malfunction Check resistor using a circuit tester. Replace Resistor
5. Fan switch malfunction Check power into and out of the fan switch. Replace Fan Switch

BLOWER MOTOR OPERATES NORMALLY BUT AIR FLOW IS INSUFFICIENT

Remove obstruction and clean
1. Evaporator inlet obstruction Check evaporator for plugging.
evaporator fins
Check to make sure air hoses are properly
2. Air leak Repair or adjust
hooked to Louvers, and air ducts.
3. Defective thermostat.
Check thermostat using a circuit tester. Replace thermostat
switch (frozen evaporator)
4. Plugged cab filters Check cab filter condition. Clean or replace filters
BLOWER MOTOR DOES NOT OPERATE IN ALL SETTINGS

1. Verify proper power and ground are present at the blower motor.
2. Verify power is present on the yellow wire when using “Low Setting.”
3. Verify power is present on the red wire when using “Medium Setting.”
4. Verify power is present on the Red/Dark Green wire when using “High Setting.”
• If any power issues are present, replace the switch.
• If no power issues are present, replace the fan motor.

COMPRESSOR TROUBLESHOOTING
COMPRESSOR DOES NOT OPERATE AT ALL OR OPERATES IMPROPERLY
1. Verify A/C pressures.
2. Check for Power at the A/C compressor.
• If power is present, check for ground issues and replace the compressor assembly.
• If power is not present, proceed to step 3.
3. Pull the A/C clutch relay to test for powers and ground.
• Verify Pin 69 has continuity to ground through the compressor clutch. 3
– If ground is not present, check for continuity in the wire to the compressor. If there is no continuity, replace the
harness or repair the wire.
• Verify power is present at coil high.
– If power is not present, proceed to step 4.
• Verify power is present at power in.
• Verify continuity to ground at coil low through the ECU.
– If ground is not present, proceed to step 10.
4. Back probe HVAC power relay for Power out when the A/C is commanded on.
• If there is power present, check continuity to A/C clutch relay coil high. HVAC power relay will also feed power to
the temp sensor, water valve, and the HVAC control.
• If there is not power, check HVAC power in for power. If no power is present, inspect the HVAC fuse.
• Check HVAC relay coil low for continuity to ground.
• Check coil high for power. If not present, check the wire for continuity back to the key switch
• If no issues were found, replace the relay. Repair/replace the harness if necessary.
5. Check the High pressure cutoff switch for power at Pin A when commanded on.
• If power is present replace the HP switch.
• If there is no power present at the HP switch, measure the Pin A wire to the thermostat Pin 1 white wire.
6. Check for continuity to ground on the Black wire and power on the Blue wire at the thermostat switch located in the
HVAC box.
• Jumper the Red wire to the White wire and see if the Compressor engages. If it does, replace or test the temp
switch with a new temp switch.
7. If there is no power on the Blue wire, verify the A/C switch lights up when pressed.
• If not, then inspect the back of the HVAC controls.
8. At the HVAC controls, unplug the A/C switch.

• Verify power is present on the white wire when the fan is on, and ground is present on the black wire. If both are
present and no power is present on the blue wire when plugged in, replace the HVAC control head.
– If ground is not present, replace/repair the wiring
• The Blue wire should have continuity to the Thermostat switch at the HVAC box. If not replace/repair harness.
9. On the fan switch, verify power is present on the white wire. If present, replace/repair the wiring to the switch. If not
present, verify Red/Blue wire has power. This powers the fan and the switch. If power is present, replace the HVAC
control head. If power is not present on the Red/Blue wire, proceed to step 12.

10. Check continuity on the wire back to ECU pin 241. If faulty, replace/repair the harness to the ECU. If continuity is
present, continue to the next step.
11. Proceed to test the A/C switch relay for powers and ground.
• Verify power is present on coil high. If power is not present, check for continuity to the A/C switch on the blue
wire. If continuity is present, proceed to next step.
• Verify ground is present on relay ground. If ground is open, repair/replace harness.
• Verify battery voltage is present on power in.
NOTICE
Volt meter required for this step. Test lights may not illuminate on low amperage circuits.
– If battery voltage is not present, verify continuity back to ECU pin 134. If continuity is not present, repair/
replace harness.
– If continuity is present, re-flash the ECU. If re-flashing the ECU does not remedy the concern, the ECU may
need to be replaced.
• Second ground should have continuity to ground. Repair/replace harness if necessary.

1. Loose drive belt. The belt is vibrating or oscillating. Adjust tension.
2. Internal compressor The compressor is locked up and the belt slips. Replace compressor.
malfunction.
3. Low battery voltage. Clutch slips. Recharge the battery.
4. Faulty coil. Clutch slips. Replace the magnetic clutch.
Clutch slips. Replace or clean the clutch
5. Oil on the clutch surface.
surface.
Clutch does not engage and there is no reading
6. Open coil. when a circuit tester is connected between the coil Replace clutch.
and terminals.
7. Broken wiring / poor Clutch will not engage. Inspect the ground and Repair.
ground. connections.
8. Wiring harness Test the conductance of the pressure switch,
Check operation.
components. thermostat, Relay, etc.

GAUGE PRESSURE RELATED TROUBLESHOOTING

IMPORTANT
When testing compressor pressures, the engine should be ran at approximately 3350 rpm.
Inspect pressures at ambient temperatures of 86 - 96°F (30 - 38°C)
Normal Compressor Pressure
Low pressure (suction) pressure: 15 - 33 psi (103 - 228 kPa) High pressure (discharge) pressure: 210 - 265 psi (1448 - 1827
kPa)
3
NOTICE
High side pressure will be approximately eight times greater then the low side pressure.

Low pressure side too high
1. Expansion valve opens too Frost is present on the suction hose. Replace expansion valve.
far.
The high and low pressure side gauge pressures
2. Defective compressor. Replace compressor.
equalize when the magnetic clutch is engaged.
Low pressure side too low
The high side pressure will be low and bubbles may be Repair leaks and recharge the
1. Low refrigerant charge.
present in sight glass on receive drier. refrigerant to the correct level.
2. Clogged or closed The expansion valve’s inlet side is frosted. Moisture or Clean or replace the expansion
expansion valve. other Contaminants can be the cause. Valve.
3. Restriction between drier Frost on the line between drier and expansion valve. A
Flush system or replace hose.
and expansion valve. Negative low pressure reading may be shown.
Adjust themostat’s temperature
4. Thermostat malfunction. The evaporator is frozen. setting or probe placement or replace
thermostat.
5. Receiver drier restriction Excessive frost on receiver drier. Replace receiver drier.
High pressure side too high
1. Poor condenser Dirty or clogged condenser fins. Condenser fans not
Clean fins, and / or repair the fan.
performance. Operating.
Evacuate and recharge to correct
2. Excessive refrigerant. The high pressure side pressure will be high.
refrigerant level.
Evacuate system. Remove oil from
condenser and compressor. Add
3. Excessive oil charge. The high pressure side will be high. correct oil charge back into
compressor. Flush system with
nitrogen. Replace drier.
Evacuate and recharge with
4. Air in system. Pressure is high on both high and low sides.
Refrigerant.
5. Restriction in drier, Evacuate and flush system replacing
High pressure side will be high, and low pressure side
condenser or high pressure defective parts.
will be low.
line.
High pressure side too low
The high side pressure will be low and bubbles may be Repair any leaks and recharge the
1. Low refrigerant charge.
present in sight glass on receive drier. refrigerant to the correct level.
System pressures equal
1. Clutch not operating. See compressor clutch related topics above.
2. Compressor not pumping. Equal high and low pressures. Replace compressor.

HVAC ASSEMBLY VIEW

HVAC AND HEATER LINES
q HVAC BRACKET MOUNTING NUT o AC HOSE, CONDENSER TO EVAPORATOR

6 ft-lbs (8 Nm) 12 ft-lbs (16 Nm)
w HVAC MOUNTING FASTENER a High Pressure Cut Out (HPCO) Switch

6 ft-lbs (8 Nm) 6 ft-lbs (8 N·m)
e HVAC MOUNTING BRACKET s HEATER RETURN HOSE

r AC HOSE CLAMP FASTENER d HEATER SUPPLY HOSE
6 ft lbs (8 Nm)
t AC HOSE CLAMP f AC SUCTION HOSE

y AC PRESSURE HOSE g HVAC MOUNTING WASHER
18 ft-lbs (24 Nm)
u HVAC CONDENSER h HVAC MOUNTING FASTENER

8 ft-lbs (11 Nm)
i HVAC CONDENSER MOUNTING FASTENER j MAIN HVAC ASSEMBLY

35 in-lbs (4 Nm)

HVAC DUCTING
q VENT, ROUND i FILTER SUPPORT

w DUCTING ASSEMBLY, RH o FILTER SUPPORT FASTENER
18 in-lbs (2 Nm)
e DUCTING ASSEMBLY, CENT RH a AIR FILTER

r AIR DISTRIBUTOR MANIFOLD s AIR FILTER BAND CLAMP
24 in-lbs (3 Nm)
t STRAP PANDUIT d CENTER DASH DUCTING ASSEMBLY

y AIR DISTRIBUTOR MANIFOLD FASTENER f DEFROST VENT
18 in-lbs (2 Nm)
u FRESH AIR HOSE g DUCTING ASSEMBLY, LH

A/C SYSTEM DIAGRAM

A/C COMPRESSOR SERVICE 4. Cut the compressor drive belt to remove it from the
vehicle.
COMPRESSOR DRIVE BELT SERVICE
SERVICE VIDEO
A service video has been created
to help highlight this procedure.
To view the video, either:
• Scan the QR Code with a
mobile device
• From a computer, right click 3
HERE and open link in a new
window.
IMPORTANT
The compressor drive belt is a single use belt as it
stretches onto the pulleys during installation. Do NOT 5. To aid with belt installation, remove the fasteners
reuse a drive belt that has been removed. Always holding the inner alternator cover to the engine.
replace with a NEW belt. Disconnect the air outlet hose and remove the cover
from the vehicle.
1. Position the vehicle on a level surface, place the

transmission in PARK and stop the engine.
2. Tilt the rear cargo box to the upright position.
the vehicle.
6. Loosen the three alternator fasteners enough to slide

the alternator outward with enough room for the
compressor drive belt to slide belt.

7. Route the belt between the alternator pulley and the 10. Route the belt over the wedge of the tool and then
engine HVAC cover to install around the compressor turn the tool counter-clockwise using 3/8-in drive
pulley. ratchet until the belt is fully seated on the pulley.
8. Re-tighten the alternator fasteners and route the belt 11. Verify the belt is properly routed around all of the
around the alternator, compressor and idler pulleys. pulleys.
12. Remove the belt installation tool from the crankshaft
drive pulley.
13. Torque the alternator fasteners to specification in the
sequence as shown.
9. Install drive belt installation tool PU-52087 onto the

crankshaft drive pulley. Ensure the pin is inserted into
one of the pulley holes.
TORQUE
Alternator Mounting Fasteners:
37 lb-ft (50 Nm)
14. Install the inner alternator cover and torque the

fasteners to specification. Reconnect the alternator
air outlet hose.
TORQUE
48 lb-in (5.4 Nm)
15. Install the outer alternator cover and torque the

fasteners to specification.
TORQUE
48 lb-in (5.4 Nm)

COMPRESSOR SERVICE 7. Remove the compressor mounting fasteners.
WARNING
with a flame, R-134a refrigerant gives off a toxic gas.
1. Evacuate the refrigerant using an A/C recovery

system.
2. Remove the compressor drive belt. Refer to
“Compressor Drive Belt Replacement” page 3
3.137 procedure.
3. Disconnect the compressor clutch wire.
8. To install, reverse the procedure.
TORQUE
Compressor Low Pressure Hose:
25 lb-ft (34 Nm)
Compressor High Pressure Hose:

18 lb-ft (24 Nm)
Compressor Mounting Fasteners:

37 lb-ft (50 Nm)
9. Recharge the A/C system.

4. Remove the low pressure hose q from the
compressor.
COMPRESSOR OIL SPECIFICATIONS
The compressor is factory filled with 150 - 170 cc's of
PAG 100 oil (Poly Alkelene Glycol).
It is only necessary to check, replenish or replace the
compressor oil in the following cases:
• When the evaporator, condenser or receiver-drier is

replaced.
• When refrigerant has leaked from the system.
5. Remove the high pressure hose w from the

compressor.
6. Cap and plug the compressor hoses and the fittings
with the proper A/C caps and plugs.

• When refrigerant is suddenly released from the cooling 6. Tighten the oil drain plug to specification.
cycle.
TORQUE
• When any oil related problems occur in the cooling
cycle. Compressor Oil Drain Plug:
10 ft-lbs (14 N·m)
NOTICE
When one of the components (the evaporator, NOTICE
condenser or receiver-drier) is replaced, 1.0 ounce (30
cc) of PAG 100 oil should be added for each component Extract the remaining oil through the discharge-side
replaced. connector by rotating the drive pulley e several times
If the A/C compressor is changed, no oil should be by hand.
added to the system, because the compressor comes
factory filled with oil.
IMPORTANT
Only PAG 100 oil should be used. Never mix R-12 and
R-134a Oils.
COMPRESSOR OIL INSPECTION

The compressor oil should be checked as follows when
oil is being added to an in service utility work machine.
There is a close affinity between oil and refrigerant. 7. Measure the drained oil in a measuring cylinder.
During normal operation, part of the oil circulates with the
refrigerant in the system. Therefore, when checking the 8. Check the oil for contamination, dirt, metal shavings,
amount of oil in the system or replacing any system or varnish color, discard the oil if contaminated.
component, the compressor must be run in advance to
insure return of oil to the compressor. IMPORTANT
If the amount of refrigerant in the system has decreased, If metal shavings are found in the compressor oil,
charge the system. replace the compressor assembly.
1. Open the cab door and windows.
9. Add new compressor oil through the suction side
2. Run the blower at maximum speed. connector r . Add 150 - 170 cc's of PAG 100 oil.
3. Run the compressor for at least 20 minutes at idle. NOTICE
4. Remove the compressor from the vehicle. The suction port on the compressor is marked with an S
and is the larger.
5. Remove the oil drain plug q and drain the oil
through the connectors w and the oil drain hole.

ALTERNATOR SERVICE 6. Torque the alternator fasteners to specification in the

sequence as shown.
ALTERNATOR INSPECTION
1. Disconnect the negative (-) battery cable before
servicing the electrical system.
2. Inspect the electrical harness for cracks, abrasions
and damaged or corroded connectors. ALWAYS keep
the connectors and terminals clean.
3. Start the engine place the Digital Multimeter leads
between the power cable and a clean part of the
engine chassis. Ensure the voltage is within 3
specification.
Alternator Output: 14.4 ± 0.3 V
TORQUE
WARNING
Loose clothing, hair or other items can be caught in the Alternator Mounting Fasteners:
compressor drive belt. Take care not to allow loose 37 lb-ft (50 Nm)
items to get caught in the moving compressor drive
belt.
ALTERNATOR SERVICE
1. Disconnect the negative (-) battery cable before
servicing the electrical system.
“Compressor Drive Belt Replacement” page 3.137
procedure.
3. Disconnect the wire harness connector and power
cable from the alternator.
4. Remove the alternator mounting fasteners.
5. For installation, reverse removal procedure.

BLOWER UNIT SERVICE HPCO (HIGH PRESSURE CUT-OUT)

1. Remove the refrigerant from the A/C system. SERVICE
HIGH PRESSURE CUT-OUT (HPCO) SWITCH
WARNING
OVERVIEW
In the event of a leak, wear safety goggles. Escaping Overview:
with a flame, R-134a refrigerant gives a toxic gas. The HPCO switch will cycle the compressor off if
pressure is too high on the high pressure side.
2. Remove the heater / evaporator unit from the vehicle. Location:

Refer to Heater / Evaporator Unit Replacement The HPCO switch is located on the AC hose coming off
procedure. the receiver / drier.
3. Remove the heater coil from the heater / evaporator
unit. Refer to “Heater Coil Replacement” page
3.149 procedure. HPCO SWITCH SERVICE
4. Remove the fasteners holding the heater coil to the NOTICE
heater / evaporator unit top cover.
Replacement of the high pressure cut out switch does
NOT require discharging/recharging the R-134a
refrigerant.
1. Disconnect the pressure switch connector q from

the wire harness.
WARNING
5. For installation, reverse removal procedure. Tighten

blower motor mounting fasteners until fully secure.
2. Remove the pressure switch w .

3. Install pressure switch and torque the HPCO switch
to specification.
TORQUE
HPCO Switch:
6 ft-lbs (8 N·m)

CONDENSER SERVICE 6. Tilt the condenser cover upwards on the folding

REMOVAL crease r to gain access to the condenser.

2. Remove the front hood panel by turn the 1/4 turn
fasteners.
3. Evacuate the AC system. Refer to Reclamation and
4. Remove the two fasteners q and two fasteners w.
Remove the supporting brackets.
3
7. Remove both AC lines t and y.

NOTICE
Front body panels removed for clarity.
5. Remove the two push rivets e retaining the

condenser cover.
8. Remove the two push rivets u retaining the shroud

and lift the shroud straight up to remove.

9. Remove the two bolts i retaining the condenser to INSTALLATION

the radiator support.
1. Install the condenser straight down and into radiator
support bracket.
10. Pull the condenser forward to release from radiator

support and lift straight up to remove.
2. Reinstall the two condenser retaining fasteners i.
NOTICE
Receiver Drier is contained within the condenser and is
not replaced separately.
3. Install the front shroud and two push rivets u.

4. Reinstall both AC lines t and y. Torque to 6. Reinstall the support brackets. Torque fasteners w
specification. and q to specification.
TORQUE TORQUE
AC Hose Condenser to Evaporator t: Support Bracket Fasteners:
12 ft-lbs (16 Nm) 42 in-lbs (5 Nm)
AC Pressure Hose y:
18 ft-lbs (24 Nm)
7. Recharge the AC system. Refer to Reclamation and
Reinstall the condenser cover r.
8. Reinstall the hood panel and lock the 1/4 turn
fasteners.
HVAC COVER MOUNT SERVICE

“Compressor Drive Belt Replacement” page 3.137
procedure.
2. Remove the alternator. Refer to “Alternator
Replacement” page 3.141 procedure.
3. Remove the compressor. Refer to “Compressor
Replacement” page 3.139 procedure.
5. Install both push rivets e retaining the condenser

cover.

4. Remove the drive pulley fastener and pulley from the 8. Torque NEW timing wheel fasteners to specification.
cover mount, using Crankshaft Pulley Holder PU-
52254 to assist. TORQUE
IMPORTANT HVAC Timing Wheel Fasteners:

9 lb-ft (12 Nm)
Fastener is one time use. Discard after removing.
9. Torque the HVAC cover mount fasteners to

specification in the sequence shown.
5. Remove the fasteners holding the HVAC cover mount

to the engine.
TORQUE
HVAC Cover Mount Fasteners:
9 lb-ft (12 Nm)
10. Install a NEW drive pulley fastener and torque to

specification using Crankshaft Pulley Holder PU-
52254.
IMPORTANT
Ensure the threads are clean and dry before installing
the pulley fastener.
TORQUE
6. If necessary, remove the fasteners holding the timing
wheel and adapter hub to the engine. HVAC Drive Pulley Fastener:
44 lb-ft (60 Nm) + 180°
7. For installation, reverse removal procedure.

HVAC HOUSING / OTHER HVAC 6. If removing the evaporator coil, remove the fasteners
COMPONENTS holding the evaporator coil to the heater coil.
EXPANSION VALVE / EVAPORATOR COIL

REPLACEMENT
1. Remove the refrigerant from the A/C system.
WARNING
with a flame, R-134a refrigerant gives a toxic gas. 3
2. Remove the heater / evaporator unit from the
vehicle. Refer to Heater / Evaporator Unit
Replacement procedure.
3. Remove the fasteners holding the expansion valve to 7. To Install, reverse procedure. Tighten fasteners to
the heater / evaporator unit bottom cover. specification.
TORQUE
Expansion Valve Pressure Hoses:
12 ft-lbs (16 N·m)
Expansion Valve Tubes:

22 ft-lbs (30 N·m)
HEATER / EVAPORATOR UNIT SERVICE

REMOVAL
4. Remove the fasteners holding the top cover of the 1. Remove the refrigerant from the A/C system.
unit to the bottom cover.
WARNING
2. Drain the cooling system. Refer to Radiator

Removal / Installation page 3.103 procedure.
3. Remove the upper and lower dash. Refer to Dash
Panels / Glove Box Service page 11.34 procedure.
4. Disconnect the blower unit connector to the wire
harness.
5. Cap and plug the hoses and the expansion valve
fittings with the proper A/C caps and plugs.

5. Remove the fasteners q holding the air distributor 8. Remove the fasteners holding the heater / evaporator
manifold to the heater / evaporator unit. unit to the vehicle and remove the HVAC unit.
6. Remove the clamps holding the coolant hoses to the INSTALLATION

heater / evaporator unit through the front wheel 1. Reinstall the HVAC unit and torque the mounting
opening. fasteners to specification.
7. Remove the A/C hoses from the expansion valve TORQUE

through the front wheel opening.
Heater / Evaporator Unit Mounting Fasteners:
10 lb-ft (14 Nm)
2. Reinstall both AC hoses

3. Reinstall both heater hoses and install heater hose HEATER COIL SERVICE
clamps.
1. Remove the refrigerant from the A/C system.
WARNING
2. Remove the heater / evaporator unit from the vehicle.

Refer to Heater / Evaporator Unit Replacement 3
procedure.
3. Remove the evaporator coil. Refer to “Expansion
Valve / Evaporator Replacement” page 3.147
procedure.
4. Remove the fasteners holding the heater coil to the
sides of the heater / evaporator unit top cover.
4. Install the air distributor manifold fasteners q and
torque to specification.
5. For installation, reverse removal procedure. Tighten

heater coil mounting fasteners until fully secure.
TORQUE
Air Distributor Manifold Fasteners:
18 in-lbs (2 Nm) A/C THERMOSTAT OVERVIEW
The Electronic De-icing Thermostat (EDT) is a micro
5. Reinstall the blower unit connector. controller based module that measures evaporator coil
temperature and cycles the compressor clutch to
6. Install the upper and lower dash panels. Refer to maintain a constant evaporator pressure.
Dash Panels / Glove Box Service page 11.34
7. Fill and bleed the cooling system. Refer to Cooling NOTICE
System Bleeding Procedure page 3.102 The EDT has a six second delay before start up to
8. Recharge the A/C system. Refer to Refrigerant page protect the compressor clutch.
3.125 for capacity and Reclamation and Charging
with Recovery / Charging Unit page 3.125 for The EDT will turn the clutch on when the evaporator coil
procedure. temperature is above 35.6°F (2°C). If the EDT does not
detect any malfunction, it will continue to operate and the
WARNING status LED will be lit continuously. When the evaporator
In the event of a leak, wear safety goggles. Escaping temperature is below 28.4°F (-2°C), the EDT will turn off
refrigerant can cause severe injuries to eyes. In contact the clutch and status LED.

3. Remove the hose clamps and coolant hoses from

the heater valve.
When the EDT detects an error from the temperature

sensor, the status LED will blink. Refer to the chart
below.
DETECTION NOTICE
MALFUNCTION STATUS LED
INTERVAL
Plug the hoses to prevent contamination and coolant
Temperature loss from the system.
sensor open 1x per second
Continuous
and short
detection 4. Remove the fasteners retaining the heater valve to
the mounting bracket and remove the heater valve
Clutch circuit from the vehicle.
open, short or At A/C start up 2x per second
over current
Compressor
clutch short to Continuous 3x per second
ground
NOTICE
The EDT will attempt to restart every 20 seconds until
the fault is repaired.
HEATER VALVE SERVICE

1. Remove the passenger seat and storage bin.
5. For installation, reverse removal procedure. Torque
2. Disconnect the wiring harness from the heater valve. heater valve fasteners to specification.
TORQUE
Heater Valve Fasteners:
8 lb-ft (11 Nm)
6. Fill and bleed cooling system. Refer to Cooling

System Bleeding Procedure page 3.102

HVAC MAINTENANCE 5. Inspect the drive belt for cracks, damage, wear,
separation or oil. Check for debris or buildup in the
COMPRESSOR DRIVE BELT INSPECTION drive belt splines. If any of these conditions exist,
1. Position the vehicle on a level surface, place the replace the belt.
IMPORTANT
2. Tilt the rear cargo box to the upright position. ALWAYS use the specified drive belt. Using a non-
3. Disconnect the upper duct q. specified belt can shorten the belt life.

the vehicle.
A/C CONDENSER CLEANING
2. Remove the front hood panel by turn the 1/4 turn
fasteners.
3. Remove the two fasteners q and two fasteners w.
Remove the supporting brackets.

4. Remove the two push rivets e retaining the 6. Clean condenser as needed.
condenser cover.
CAUTION
Do not use high pressure washers to clean the
condenser or damage to cooling fins may result.
NOTICE
Front fascia removed or clarity.
5. Tilt the condenser cover upwards on the folding

crease r to gain access to the condenser.
7. Reassemble vehicle.

HVAC FILTER INSPECTION /

REPLACEMENT
1. Remove the filter cover and filter on the underside of
the dash.
2. Remove the hood and the cabin air filter.
3. Clean the filter with low air pressure. Check for

damage, replace if damaged.

HVAC CONTROL SERVICE 3. Use the table to determine if the switch needs to be
replaced.
HVAC CONTROL OPERATION OVERVIEW
Power is supplied to the HVAC system through the 30
amp HVAC fuse located in the fuse / relay box under the
center console. The condenser fan is powered by a 20
amp circuit breaker through the Condenser Fan relay.
The HVAC relay is powered by the 30 Amp HVAC fuse.
When they key is in the ON position, the HVAC relay is
energized. Power is sent on the Red/Green wires to the
blower switch, the temperature knob (temp pot 10k) and
the water valve. Power only travels from the blower
switch to the AC switch on the white wire when the knob
is in the low, medium or high setting. If the AC switch is
ON, power is sent out on the blue wire to power the
condenser fan relay and the thermostat on the AC
evaporator. The evaporator thermostat will send power
on the white wire to the HPCO (high pressure cut-out)
switch located in the AC hose. The switch is normally TEMPERATURE POTENTIOMETER
closed. When the switch is closed, power is sent to the TESTING
AC compressor. When the pressure in the AC line gets
too high, the switch opens and the compressor cycles The Temperature Control potentiometer controls the
off. The condenser fan will always be running when the temperature of the air blowing from the HVAC system.
AC system is on and it is powered by a 20 Amp circuit The Temperature Control potentiometer can be tested
breaker just outside the relay box. using an ohmmeter.
As the temperature knob is moved towards the warm
1. Disconnect the harness going to the Temperature
setting, the voltage through the potentiometer is
Control potentiometer.
interpreted by the water valve to control the flow of warm
water through the heater core to warm the air. 2. With the meter in the ohms mode, place the meter
leads onto the potentiometer flying lead contacts.
The HVAC control panel is a single unit. If any of the
individual switches are found to not be functioning 3. Use the table to determine if the switch needs to be
properly, the whole panel must be replaced. replaced.
KNOB OHMS
PINS
POSITION READING
A/C SWITCH TESTING
The AC switch turns the Air Conditioning system on and Full Cold A to B ~ 14.94 kΩ
off. Between Cold/
A to B ~ 19.40 kΩ
The AC Switch can be tested using an ohmmeter. Hot
Full Hot A to B ~ 24.10 kΩ
1. Disconnect harness from AC Switch.
2. With the meter in the ohms mode, place the leads on Any Position A to C ~ 9.15 kΩ
pins P1 and P3.
3. With the switch off, the reading should be OL. WARNING
4. With the switch on the reading should be less than 1 Keep hands away from fan blades during operation.
Ω. Serious personal injury could result.
FAN SWITCH TESTING

The fan switch controls the blower fan speed.
The fan switch can be tested using an ohmmeter.
1. Disconnect the harness going to the Fan Switch.

2. With the meter in the ohms mode, place the meter
leads onto the switch contacts.

HVAC BREAKOUT DIAGRAM

NOTICE
The image shown refers to the 2018 – 2019 HVAC Breakout Diagram.

NOTES

ENGINE ELECTRICAL
CHAPTER 4
ENGINE ELECTRICAL
ELECTRONIC CONTROL UNIT (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
ECU OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
ECU SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
ECU REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
CRANKSHAFT POSITION SENSOR (CPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
CPS OPERATION OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
CPS TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 4
CPS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
ELECTRONIC THROTTLE CONTROL (ETC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
ETC OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
ETC TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
ETC REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
ETC LEARN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
ACCELERATOR POSITION SENSOR (APS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
APS OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
APS TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
APS REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
OXYGEN SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.10
OXYGEN SENSOR INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.10
OXYGEN SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.10
O2 SENSOR REPLACEMENT - HVAC, HIGH LIFTER & BACK COUNTRY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
OXYGEN SENSOR DIAGNOSTIC TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.12
TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.14
TMAP OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.14
T-MAP SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.14
T-MAP SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.14
ENGINE COOLANT TEMPERATURE SENSOR (ECT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.15
ECT OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.15
ECT SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.15
ECT SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.16
IGNITION SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.17
IGNITION SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.17
IGNITION COIL OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.17
IGNITION COIL / HT LEAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.17
SPARK PLUG INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.18
SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.18
DRIVE MODE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.19
DRIVE MODE SWITCH DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.19
DRIVE MODE SWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.19
COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.20
FAN CONTROL CIRCUIT OPERATION / TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.20

ENGINE ELECTRICAL
FAN CONTROL CIRCUIT BYPASS TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.20

ENGINE ELECTRICAL
ELECTRONIC CONTROL UNIT (ECU)

ECU OPERATION OVERVIEW ECU SERVICE
The ECU is the central processing computer of the entire Never attempt to disassemble the ECU. It is sealed to
EFI fuel and ignition management system. During prevent damage to internal components. Warranty is void
operation, sensors continuously gather data which is if the case is opened or tampered with in any way.
relayed through the wiring harness to input circuits within
All operating and control functions within the ECU are
the ECU. Signals to the ECU include: ignition power (on/
pre-set. No internal servicing or readjustment may be
off), intake air temperature, manifold absolute pressure
performed. If a problem is encountered, and you
(load), engine coolant temperature, crankshaft position
determine the ECU to be faulty, contact the Polaris
and engine speed (RPM), throttle pedal position and
Service Department for specific handling instructions. Do
battery voltage. The ECU compares the input signals to
the programmed maps in its memory and determines the not replace the ECU without factory authorization.
appropriate fuel and ignition requirements for the For the purpose of troubleshooting, a known-good ECU
immediate operating conditions. The ECU then sends of the exact same model and year may be used.
output signals to set injector duration and ignition timing.
4
During operation, the ECU continually performs a

diagnostic check of itself, each of the sensors, and
system performance. If a fault is detected, the ECU turns
on the “Check Engine” light on the instrument cluster and
stores the fault code in its fault memory. Depending on
the significance or severity of the fault, normal operation
may continue, or "Fail-Safe" operation (slowed speed,
richer running) may be initiated. A technician can
determine the cause of the “Check Engine” light by
referencing the “Instrument Cluster Trouble Code
Display” page and “Diagnostic Trouble Code
Table” or by using Digital Wrench®. The ECU requires a
minimum of 7.0 volts to operate. The memory in the ECU
is operational the moment the battery cables are
connected.
To prevent engine over-speed and possible failure,
maximum engine RPM is controlled by the interface
between the ECU and Electronic Throttle Control (ETC).
Max Operating RPM: 8000

ENGINE ELECTRICAL
ECU REPLACEMENT 7. To reinstall, reverse this procedure and tighten the

Although the need for ECU replacement is unlikely, a mounting screws to specification.
specific replacement procedure is required to ensure that
NOTICE
all essential data contained within the original ECU is
transferred to the replacement ECU. Upon installing the ECU connector, you should hear a
“click” when the connector is fully closed.
NOTICE
Refer to this procedure and carefully follow all TORQUE
instructions provided in Digital Wrench®.
ECU Retaining Screws:
24 lb-in (2.7 Nm)
1. The diagnostic connector is located under the
passenger seat connected to a sealed plug. To
access the diagnostic connector lift up the passenger
seat and remove the divider.
2. Connect the Vehicle Interface Cable to the Digital
Wrench® diagnostic connector. Go to the Special
Tests menu and select ECU Replacement. Carefully
follow the ECU replacement instructions.
3. Tilt the cargo box to access the ECU.
4. Remove the four T-25 Torx head screws retaining
ECU to the back of cab.
5. With the ignition turned off, disconnect the wire

harness from the ECU. Lift the connector locking
lever and rotate it up until the connector is free from
the ECU.
NOTICE
Upon removing the ECU connector, you should hear a
“click” when the connector is fully open.
6. Remove the ECU from the vehicle.

ENGINE ELECTRICAL
CRANKSHAFT POSITION SENSOR (CPS)

CPS OPERATION OVERVIEW CPS TEST
Mounted on top of the stator cover, the crankshaft The CPS is a sealed, non-serviceable assembly. If fault
position sensor is essential to engine operation, code diagnosis indicates a problem with this sensor, test
constantly monitoring the rotational speed (RPM) and as follows:
position of the crankshaft.
1. Locate the CPS harness connector q above the shift
cable on the right side of the vehicle and disconnect
the harness.
A ferromagnetic 35-tooth encoder ring with a missing

tooth is built onto the flywheel. Refer to Camshaft Timing
- Quick Reference page 3.97 for further details.
2. Pin q is for the shield circuit and it should be OL to
The inductive speed sensor is mounted 1.0 ± 0.26 mm pins w & e. A resistance reading would indicate a
(0.039 ± 0.010 in.) away from the encoder ring. During shorted sensor.
rotation, an AC pulse is created within the sensor for
each passing tooth. The ECU calculates engine speed
from the time interval between the consecutive pulses.
The encoder ring missing tooth creates an “interrupt”
input signal, corresponding to specific crankshaft
position. This signal serves as a reference for the control
of ignition timing by the ECU. Synchronization of the
CPS and crankshaft position takes place during the first
two revolutions each time the engine is started. This
sensor must be properly connected at all times. If the
sensor fails or becomes disconnected for any reason, the
engine will stop running.
3. Connect an ohmmeter between CPS pin terminals w

& e. A resistance value of 1000Ω ± 10% at room
temperature should be obtained.
CPS Resistance Specification:1000 Ω ± 10%

ENGINE ELECTRICAL
4. If the resistance is correct: CPS REPLACEMENT

• Test the main harness circuit between the sensor 1. Lift the rear cargo box to raised position.
connector terminals and the corresponding pin
2. Disconnect the CPS harness connector q.
terminals at the ECU (see wiring diagram).
• Check the sensor mounting, air gap, flywheel encoder
ring for damage or runout, and flywheel key. Inspect
CPS and flywheel encoder ring for damage. Refer to
CPS REPLACEMENT procedure.
5. If the resistance is incorrect, follow the CPS

REPLACEMENT procedure.
3. Remove CPS wire lead from wire clip e.

4. Remove CPS retaining fastener w and remove the
sensor from the stator cover.
5. Install new sensor using a light coating of oil on the
O-ring to aid installation.
6. Torque CPS retaining fastener to specification.
TORQUE
CPS Retaining Fastener:
9 ft-lbs (12 Nm)
7. Route CPS wire lead through wire clip e and

reconnect CPS harness connector q.
NOTICE
Make sure CPS harness connector standoff r remains
properly secured.

ENGINE ELECTRICAL
ELECTRONIC THROTTLE CONTROL (ETC)

ETC OPERATION OVERVIEW ETC REPLACEMENT
IMPORTANT 1. Lift the rear cargo box to the raised position.
DO NOT attempt to service the ETC. The ETC is a non- 2. Remove wire harness from ETC retainer clip q and
serviceable component and can only be tested using remove the ETC connector w.
Digital Wrench®. If the ETC is faulty, the entire
assembly must be replaced.
3. Loosen the clamp e retaining the intake boot to the

ETC. Remove the boot from the ETC.
Mounted to the intake plenum, the ETC acts as an 4. Remove the four bolts retaining the ETC housing to
electronically controlled throttle body. The ETC controls intake plenum.
engine throttle operation to provide the proper airflow 5. Remove the ETC housing and gasket from intake
needed for engine operation at all RPM ranges. The ETC plenum.
controls engine RPM based off input provided by the
Pedal Position Sensor (PPS) and Electronic Control Unit
(ECU).
ETC TEST
Never attempt to disassemble the ETC assembly.
Warranty is void if the end cover is opened or tampered
with in any way.
All operating and control functions within the ETC are
pre-set. No internal servicing or adjustments may be
performed. If a problem is encountered, and you
determine the ETC to be faulty, contact the Polaris
Service Department for specific handling instructions. Do
not replace the ETC without factory authorization.
Use Digital Wrench® to perform all troubleshooting of 6. Reverse these steps for installation. Torque the ETC
this component. Use a Volt Ohm meter to test the vehicle housing retaining bolts and intake boot clamp to
harness continuity between the ETC connector and ECU specification.
connector. Refer to the wire diagram for pin-out details. If
the ETC is faulty, the entire ETC assembly must be TORQUE
replaced. ETC Housing Retaining Bolts:
5 ft-lbs (7 Nm)
Intake Boot Clamp:

3 lb-ft (4 Nm)

ENGINE ELECTRICAL
ETC LEARN PROCEDURE

IMPORTANT
This procedure MUST be performed on the vehicle
whenever the ECU is replaced or reflashed or the
throttle body is replaced.
1. After the reflash / ECU replacement / throttle body

change, leave the key on (engine not running) for 60
seconds. Do NOT crank the engine during this time.
2. Turn the key off and wait 3 minutes. During this time,
the ECU will write values into memory and then
completely shut down.
3. Turn key back on and start the vehicle. The vehicle
should operate normally.
4. If the procedure was interrupted at any time, start
back at step 1.

ENGINE ELECTRICAL
ACCELERATOR POSITION SENSOR (APS)

APS OPERATION OVERVIEW APS REPLACEMENT
NOTICE NOTICE
DO NOT attempt to service the APS. The APS is a non- The APS is calibrated to the throttle pedal. If the APS is
serviceable component and can only be tested using faulty, the throttle pedal assembly must be replaced.
Digital Wrench®. If the APS is faulty, the entire throttle
pedal assembly must be replaced.
1. Disconnect the APS harness q.
Mounted to the throttle pedal assembly, the APS acts as 2. Remove the three fasteners w retaining the throttle
a pedal position sensor. The APS provides throttle pedal pedal bracket to the chassis.
position to the Electronic Control Unit (ECU) to increase 3. Install new pedal assembly and torque the fasteners
or decrease engine RPM using the Electronic Throttle to specification.
Control (ETC). The APS is the primary input used to
control engine speed during vehicle operation. TORQUE
Pedal Bracket Nuts:
8 ft-lbs (11 Nm)
APS TEST
The APS can be tested utilizing Digital Wrench® by
verifying that throttle position readout varies as the pedal 4. Connect the APS harness.
is pressed. Reference the Data Display section and be
sure Throttle Position is displayed.
SENSOR 1
PEDAL POSITION VOLTAGE READING
Pedal Released 1.2 V
Pedal WOT 4.2 V
SENSOR 2
PEDAL POSITION VOLTAGE READING
Pedal Released 0.6 V
Pedal WOT 2.1 V
The Accelerator Position Sensor is calibrated to the

throttle pedal. If the APS is faulty, the throttle pedal
assembly must be replaced.

ENGINE ELECTRICAL
OXYGEN SENSOR
OXYGEN SENSOR INFORMATION 2. Install the oxygen sensor q and torque to
specification.
• The oxygen sensor, located on the exhaust pipe
before the muffler, uses a 4 wire heated element.
First, verify if there are any stored codes for the oxygen
sensor.
NOTICE
The ECU must first run though the O2 sensor time
delay before a trouble code will be set. This may take
several minutes at idle to occur.
Short drive cycles and cold temperatures will both affect

the delay time of the O2 sensor (increases the delay).
The delay time ensures the oxygen sensor heater has
run long enough to provide accurate data.
TORQUE
OXYGEN SENSOR REPLACEMENT
Oxygen Sensor:
REMOVAL
18 ft-lbs (24 Nm)
1. Remove the right rear lower rocker panel. Refer to
Rocker Panel Service page 11.27.
3. Install the right rear lower rocker panel. Refer to
2. Remove the oxygen sensor q. Rocker Panel Service page 11.27.
3. Disconnect the electrical connector and remove from

the vehicle.
INSTALLATION
1. Apply anti-seize to the O2 sensor threads.
IMPORTANT
Only apply anti-seize to the sensor threads. Do NOT
apply anti-seize to the O2 sensor bulb.

ENGINE ELECTRICAL
O2 SENSOR REPLACEMENT - HVAC,

HIGH LIFTER & BACK COUNTRY
REMOVAL
1. Remove the zip ties q retaining the O2 sensor
harness to the main electrical harness.
2. Disconnect the O2 sensor connector w.
3. Remove the O2 sensor e from the head pipe.
INSTALLATION
1. Apply anti-seize to the O2 sensor threads.
IMPORTANT
Only apply anti-seize to the sensor threads. Do NOT
apply anti-seize to the O2 sensor bulb.
2. Install the O2 sensor einto the head pipe and torque

to specification.
3. Connect the O2 sensor connector w.
4. Install zip ties q to secure the O2 sensor harness to
the main electrical harness.

ENGINE ELECTRICAL
OXYGEN SENSOR DIAGNOSTIC TIPS

O2 SENSOR OPERATING RANGE
DIGITAL WRENCH READING WITH CURRENT ENGINE CONDITION ECU COMMAND
KOER
< 0.45V LEAN ECU Richens injector pulse width
0.45V STOICHIOMETRIC (14.7:1) MAINTAIN
>0.45V RICH ECU Leans injector pulse width
1.0V - 1.64V OPEN LOOP ECU Ignores O2 sensor Readings
INTERPRETING DIGITAL WRENCH READINGS

• The Air/Fuel Ratio reading in Digital Wrench will indicate what action the ECU has taken to reach 14.7:1
Stoichiometric.
– An O2 sensor reading of 0.78V indicates a rich engine condition, therefore the ECU commands the injector pulse
width lean.

ENGINE ELECTRICAL
O2 SENSOR HEATER TESTING

1. Measure the resistance between pins B and D.
CONNECTOR PIN WIRE COLOR PIN AND WIRE CONNECTION
A Gray Sensor Ground
B Black Sensor Output
C White Heater Power
D White Heater Ground
MEASUREMENT
O2 Sensor Heater Resistance:
15.8 Ω - 18.6 Ω

ENGINE ELECTRICAL
TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP)

TMAP OPERATION OVERVIEW T-MAP SENSOR REPLACEMENT
Mounted on the intake plenum, the T-MAP sensor 1. Lift the rear cargo box to the raised position.
performs two functions in one unit.
2. Disconnect the vehicle harness q from the T-MAP
sensor.
Air passing through the intake is measured by the T-MAP

and relayed to the ECU. These signals, comprised of
separate air temperature and manifold absolute pressure 3. Remove the T-MAP sensor retaining fastener w and
readings, are processed by the ECU and compared to its remove the sensor from the intake plenum.
programming for determining the fuel and ignition 4. Apply silicone lubricant to the new sensor o-ring and
requirements during operation. The T-MAP sensor install the new T-MAP sensor into intake plenum.
provides the ECU with engine load data.
5. Install the T-MAP sensor retaining fastener and
T-MAP SENSOR TEST TORQUE
The T-MAP sensor is a non-serviceable item. If it is T-MAP Retaining Fastener:
faulty, it must be replaced.
3 ft-lbs (4.5 Nm)
IMPORTANT
This sensor should only be tested using the Digital
Wrench® Diagnostic Software (dealer only).

ENGINE ELECTRICAL
ENGINE COOLANT TEMPERATURE SENSOR (ECT)

ECT OPERATION OVERVIEW
Mounted in 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.
4
Refer to COOLANT TEMPERATURE SENSOR for
additional ECT sensor information. Polaris dealers can
test the sensor by using Digital Wrench® Diagnostic
Software (dealer only).
ECT SENSOR RESISTANCE READINGS

Coolant passes through the cylinder head and by the
TEMPERATURE °F (°C) RESISTANCE
sensor probe, varying a resistance reading which is
relayed to the ECU. This signal is processed by the ECU -40 °F (-40° C) 45.3k Ω ± 6%
and compared to its programming for determining the
fuel and ignition requirements during operation. The ECU -22 °F (-30 °C) 26.1k Ω ± 6%
also uses this signal to determine when to activate the
cooling fan during operation. -4 °F (-20 °C) 15.5k Ω ± 6%
14 °F (-10 °C) 9.4k Ω ± 6%
ECT SENSOR TEST 32 °F (0 °C) 5.9k Ω ± 6%
To quickly rule out other components and wiring related
to the ECT, disconnect the harness from the ECT sensor 50 °F (10 °C) 3.8k Ω ± 6%
and start the engine. After a few seconds, the fan should 68 °F (20 °C) 2.5k Ω ± 6%
turn on and the “Check Engine” indicator should display
on the instrument cluster. This indicates all other 86 °F (30 °C) 1.7k Ω ± 6%
components are working properly.
104 °F (40 °C) 1.2k Ω ± 6%
NOTICE
122 °F (50 °C) 834 Ω ± 6%
If the coolant temperature sensor or circuit malfunctions
the radiator fan will default to 'ON' while the engine is 140 °F (60 °C) 596 Ω ± 6%
running.
158 °F (70 °C) 435 Ω ± 6%
176 °F (80 °C) 323 Ω ± 6%
194 °F (90 °C) 243 Ω ± 6%
212 °F (100 °C) 186 Ω ± 6%

ENGINE ELECTRICAL
ECT SENSOR REPLACEMENT

CAUTION
It is recommended to allow the vehicle to sit for 1 hour
after key off to allow the coolant to cool and fuel
pressure to drop.
1. Lift the rear cargo box to the raised position.

2. Drain the coolant so the level is below the sensor.
Refer to Coolant Replacement page 2.42.
3. Remove the fuel line from fuel rail. Refer to Fuel Line
Quick Connect Removal page 5.9.
4. Disconnect the vehicle harness q from the ECT
sensor.
5. Using a wrench, loosen and remove ECT sensor from

engine.
6. Apply thread sealant to the new sensor threads and
install it into the cylinder head.
7. Torque the new ECT sensor to specification and
connect the vehicle harness to the sensor.
TORQUE
ECT Sensor:
16 ft-lbs (22 Nm)
8. Reconnect the fuel line to the fuel rail. Refer to Fuel

Line Removal / Installation.
9. Ensure fuel line is properly attached by gently pulling
back on the quick connector.
10. Add the required amount of coolant and bleed the
system. Refer to Cooling System Bleeding
Procedure.
11. Turn the key on to pressurize the fuel system.
IMPORTANT
Ensure no leaks are present at the fuel line to rail
connection.

ENGINE ELECTRICAL
IGNITION SYSTEM SERVICE

IGNITION SYSTEM TESTING IGNITION COIL
The ignition coil can be tested by using an ohm meter.
Use the following illustration and specification table to
IGNITION COIL OPERATION OVERVIEW
test the ignition coil resistance. The ignition coil q is used to provide high voltage to fire
the spark plug(s). When the ignition key is on, DC
voltage is present in the primary side of the ignition coil
IGNITION COIL RESISTANCE READINGS windings. During engine rotation, an AC pulse is created
TEST PIN CONNECTION RESISTANCE within the crankshaft position sensor for each passing
tooth on the flywheel’s encoder ring. The encoder ring
Primary Between 1 & 2
0.4 Ω missing tooth creates an “interrupt” input signal,
Between 2 & 3
corresponding to specific crankshaft position. This signal
Secondary Between High Tension 6.794k Ω ± serves as a reference for the control of ignition timing.
(PTO) Lead Caps 10% The ECU then calculates the time interval between the
Secondary Between High Tension 7.239k Ω ± consecutive pulses, and determines when to trigger the
(MAG) Lead Caps 10% ground path for the ignition coil, causing a voltage spike
that induces the voltage from the primary to the
4
secondary coil windings to fire the spark plug(s).
IGNITION COIL / HT LEAD REPLACEMENT

NOTICE
The engine will misfire if the spark plug wires are
installed incorrectly. The spark plug wires are marked
with PTO and MAG from the factory and should be
installed to the corresponding cylinder and ignition coil
post.
1. Disconnect the (-) negative battery cable.

2. Lift the rear cargo box to the raised position.
3. Disconnect the ignition coil harness and carefully
remove the high tension leads from the coil.
4. Remove the fastener retaining the ignition coil and
remove it from the vehicle. If replacing the high
tension lead(s), remove the other end of the lead(s)
from the spark plug.

ENGINE ELECTRICAL
5. Install the new ignition coil and/or high tension lead 2. Carefully remove the spark plugs q from the cylinder
(s). head.
TORQUE CAUTION
Ignition Coil Retaining Bolt: Use care when handling spark plugs. The insulation
8 lb-ft (11 Nm) can easily be cracked if the plug is dropped.
6. Connect the harness connection to the ignition coil

and then connect the (-) negative battery cable.
SPARK PLUG
SPARK PLUG INSPECTION
• Inspect the insulation q for signs of cracking or
chipping. Replace if any is found.
NOTICE
Cracks can be difficult to see. Any cracking on the
insulation can lead to a drivability concern.
• Inspect the ground electrode w for signs of wear or INSTALLATION

irregular engine conditions. Verify the electrode gap is 1. If reusing spark plugs, refer to Spark Plug Inspection
correct. page 4.18 to ensure they are fit for service.
2. Install the spark plugs q in the cylinder head and
SPARK PLUG SERVICE TORQUE

REMOVAL
Spark Plug:
1. Remove the spark plug leads from the spark plugs. 9 ft–lbs (12 Nm)
3. Reinstall the spark plug leads.

ENGINE ELECTRICAL
DRIVE MODE SWITCH DIGITAL WRENCH VALUES

The drive modes in Digital Wrench data will show Drive
DRIVE MODE SWITCH DESCRIPTION Mode Input and Output Status for 4 Drive Modes. Each
AND OPERATION mode uses one of these input/output sets. Both input and
Some vehicle models are equipped with a drive mode output should show active for the respective number
selection switch that affects throttle map. The switch is when operating correctly.
located on the center dash.
NOTICE
NOTICE
Only three of the four available drive modes are used.
If the drive mode switch is improperly functioning, the
switch will default to Standard mode.
1. Disconnect the drive mode switch harness by

depressing the connector locks and pulling on the
connector. Do not pull on the wiring.
4
2. Test the resistance between pins 9 and 2 the switch.
3. If the resistance is out of specification for any mode,
replace the switch.
The Drive Mode Switch is a three way rocker switch with

internal resistors which allow the ECU to monitor voltage
drop, indicating the selected mode. The modes are:
• PERF – Performance mode. Aggressive pedal feel.
Resistor in the switch for this mode is 4 K Ohms.
• STND – Standard mode. Balanced pedal feel. Resistor
in the switch for this mode is 25 K Ohms
• WORK – Work mode. Smooth pedal tip-in. Resistor in
the switch for this mode is 1.5 K Ohms
DRIVE MODE SWITCH REPLACEMENT

1. Remove the drive mode switch q by lightly prying on
the backside of the switch until the detents are
released.
2. Reinstall the switch by pushing straight in until the

switch detents engage on the dash panel.

ENGINE ELECTRICAL
COOLING FAN
FAN CONTROL CIRCUIT OPERATION /
TESTING
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 Relay
operation for more information on fan functions.
CAUTION
Keep hands away from fan blades during operation.
Serious personal injury could result.
NOTICE
The fan may not function or operation may be delayed if
coolant level is low or if air is trapped in the cooling
system. Be sure cooling system is full and purged of air.
FAN CONTROL CIRCUIT BYPASS TEST

NOTICE
Most vehicles support the output state feature Digital
Wrench®. The fan can also be commanded on and off
from this feature. This is another test that can be used
prior to the circuit bypass test.
1. Disconnect harness from coolant temperature sensor

on the engine cylinder head. Refer to ECT Sensor
Replacement page 4.16 procedure.
2. With the transmission in Park, start the engine. After
a few seconds, the fan should start running and the
“CHECK ENGINE” indicator should display on the
instrument cluster. This indicates all other
components are working properly.
3. If the fan does not run or runs slowly, check the fan
motor wiring, ground, motor condition, circuit breaker
and mechanical relay for proper operation. Repair or
replace as necessary.
4. If the fan runs with the sensor harness disconnected,
but will not turn on when the engine is hot, check the
coolant temperature sensor and connector terminals.

FUEL SYSTEM
CHAPTER 5
FUEL SYSTEM
GENERAL INFORMATION - FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
SERVICE NOTES - FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
SPECIAL TOOLS - FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
SERVICE SPECIFICATIONS - FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
ELECTRONIC FUEL INJECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
FUEL SYSTEM OPERATION OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
FUEL SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
FUEL SYSTEM COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
FUEL LINE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
FUEL LINE QUICK CONNECT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
5
FUEL LINE REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
FUEL VENT LINE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.12
FUEL VENT LINE ROUTING (EVAP MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.13
FUEL VENT LINE ROUTING - HIGH LIFTER & BACK-COUNTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.14
FUEL VENT LINE ROUTING HIGH LIFTER & BACK-COUNTRY (EVAP MODELS) . . . . . . . . . . . . . . . . . . . . .5.15
VENT LINE TERMINATION FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.16
FUEL TANK SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.17
FUEL TANK ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.17
FUEL TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.18
FUEL TANK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.20
FUEL PUMP SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.23
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.23
FUEL SENDER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.23
FUEL PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.24
FUEL PUMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.25
FUEL INJECTOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.28
FUEL INJECTOR OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.28
FUEL INJECTOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.28
FUEL INJECTOR TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.29
FUEL INJECTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.29

FUEL SYSTEM
GENERAL INFORMATION - FUEL SYSTEM

SERVICE NOTES - FUEL SYSTEM • Do not use compressed air if the system is open.
Cover any parts removed and wrap any open joints
WARNING with plastic if they will remain open for any length of
time. New parts should be removed from their
• Gasoline is extremely flammable and explosive under protective packaging just prior to installation.
certain conditions. • Clean any connector before opening to prevent dirt
• EFI components are under high pressure. from entering the system.
• Verify system pressure has been relieved before • Although every precaution has been taken to prevent
disassembly. water intrusion failure, avoid direct water or spray
contact with system components.
• Never drain the fuel system when the engine is hot.
Severe burns may result. • Do not disconnect or reconnect the wiring harness
connector to the control unit or any individual
• Do not overfill the tank. The tank is at full capacity components with the ignition "on." This can send a
when the fuel reaches the bottom of the filler neck. damaging voltage spike through the ECU.
Leave room for expansion of fuel.
• Do not allow the battery cables to touch opposing
• Never start the engine or let it run in an enclosed terminals. When connecting battery cables attach the
area. Gasoline powered engine exhaust fumes are positive (red) cable to positive (+) battery terminal first,
poisonous and can cause loss of consciousness and followed by negative (black) cable to negative (-)
death in a short time. battery terminal.
• Do not smoke or allow open flames or sparks in or • Never start the engine when the cables are loose or
near the area where refueling is performed or where poorly connected to the battery terminals.
gasoline is stored.
• Never disconnect battery while engine is running.
• If you get gasoline in your eyes or if you should
swallow gasoline, seek medical attention • Never use a battery boost-pack to start the engine.
immediately. • Do not charge battery with key switch "on."
• If you spill gasoline on your skin or clothing, • Always disconnect negative (-) battery cable lead
immediately wash with soap and water and change before charging battery.
clothing.
• Always unplug ECU from the wire harness before
• Always stop the engine and refuel outdoors or in a performing any welding on the unit.
well ventilated area.
• For more convenient and accurate testing of EFI

components, it is recommended dealers utilize the
Digital Wrench® Diagnostic Software (dealer only).
Some testing may be done manually using the
procedures provided in this chapter.
• 80% of all EFI problems are caused by wiring
harness connections.
• For the purpose of troubleshooting difficult running
issues, a known-good ECU from another RANGER of
the same model and year may be used without
damaging system or engine components.
• Never attempt to service any fuel system component
while engine is running or ignition switch is "on."
• Cleanliness is essential and must be maintained at all
times when servicing or working on the EFI system.
Dirt, even in small quantities, can cause significant
problems.

FUEL SYSTEM
SPECIAL TOOLS - FUEL SYSTEM Fuel Pressure Gauge Kit - PU-43506-A

TOOL DESCRIPTION PART NUMBER NOTICE
Fuel Pressure Gauge Kit PU-43506-A The EFI fuel system remains under high pressure, even
when the engine is not running. Before attempting to
Fuel Pressure Gauge service any part of the fuel system, pressure should be
Adapter PS-48762
relieved. The Fuel Pressure Gauge Kit has an
integrated pressure relief valve that can be used to
Fuel Pump Service Tool PU-50326 bleed off pressure once you have completed the fuel
Digital Wrench® pressure test.
Diagnostic Kit
PU-47063-B
(PU-48731, PU-47151,
PU-50621, PU-47471)
Digital Wrench® Software PU-48731

Digital Wrench® Standard
PU-47151
Interface Cable
Digital Wrench® USB-
PU-50621
Serial Adapter Cable 5
Digital Wrench®
SmartLink Module Kit
PU-47471
(PU-47470, PU-47469,
PU-47468)
Digital Wrench® PC
PU-47470
Interface Cable
Fuel Pressure Gauge Adapter - PS-48762
Digital Wrench® Vehicle
PU-47469
Interface Cable Used in conjunction with PU-43506-A to check fuel
pressure.
Digital Wrench®
PU-47468
SmartLink Module
Wireless Vehicle Link
(WVL) PU-51435
Bosch Automotive Service Solutions: 1-800-328-6657

or https://polaris.service-solutions.com/
Digital Wrench® Diagnostic Kit - PU-47063-B

This dealer-only software installs on laptop computers
equipped with a CD drive 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.
NOTICE
If the PC you are using is not equipped with a 9-pin
serial port, a USB to serial port adapter will be
necessary. A USB to serial port adapter can be
purchased through Bosch Automotive Service
Solutions (PU-50621) or DSA at: www.diagsys.com

FUEL SYSTEM
Digital Wrench® SmartLink Module Kit - PU-47471 Digital Wrench® - Download Website
This module kit contains the necessary cables and Located at: www.polaris.diagsys.com
hardware to communicate between the vehicle ECU and
the Digital Wrench® diagnostic software. Polaris dealers
can also order the following kit components separately:
SmartLink Module PU-47468, Vehicle Interface Cable
PU-47469 and PC Interface Cable PU-47470. This
module kit is used on all 8 pin connector-based Polaris
EFI systems. This kit is available to Polaris dealers
through our tool supplier Bosch Automotive Service
Solutions: 1-800-345-2233 or http://polaris.service-
solutions.com.
Download Digital Wrench® Updates:
Digital Wrench® - Diagnostic Connector

The diagnostic connector is located under the passenger
seat connected to a sealed plug. To access the
diagnostic connector lift up the passenger seat and
remove the divider. NOTICE
For the most recent information on Digital Wrench®
software and update downloads please visit the
website: www.polaris.diagsys.com
SERVICE SPECIFICATIONS - FUEL

SYSTEM
SERVICE
PART DESCRIPTION
SPECIFICATION
Fuel Pump Output 9.25 gal (35 L)/hr
Fuel Pressure 58 ± 2 psi (400 ± 14 kPa)
Fuel Sender Resistance - 450 Ω ± 5%
Empty
Fuel Sender Resistance - 100 Ω ± 3%
Full
CPS Resistance 1000 Ω ± 10%
Fuel Injector Resistance 11.4 Ω - 12.6 Ω

FUEL SYSTEM
ELECTRONIC FUEL INJECTION

FUEL SYSTEM OPERATION OVERVIEW INITIAL PRIMING / STARTING
The EFI system is designed to provide peak engine PROCEDURE
performance with optimum fuel efficiency and lowest
possible emissions. The ignition and injection functions NOTICE
are electronically controlled, monitored and continually The injection system must be purged of all air prior to
corrected during operation to maintain peak the initial start up, and / or any time the fuel system has
performance. been disassembled.
The central component of the system is the Bosch ME17
Electronic Control Unit (ECU) which manages system If the fuel system is completely out of fuel or has been
operation, determining the best combination of fuel disassembled and repaired:
mixture and ignition timing for the current operating 1. Cycle the key switch from “OFF” to “ON” 6 times,
conditions. waiting for approximately 3 seconds at each “ON”
An electric fuel pump is used to move fuel from the tank, cycle to allow the fuel pump to cycle and shut down.
through the fuel supply line, to the fuel rail. A fuel 2. Once step 1 is completed, turn the key switch to
pressure regulator located in the tank maintains system “START” until the engine starts or 5 seconds has
operating pressure. At the engine, fuel fed to the fuel rail passed.
supplies fuel to the injectors, which inject into the intake
ports. The ECU controls the amount of fuel by varying 3. If the engine failed to start, repeat step 1 for 2 more
the length of time that the injectors are "on." This range cycles and attempt to start the engine. 5
can vary depending on fuel requirements. The controlled If the engine fails to start, a problem may still exist,
injection of the fuel occurs every other crankshaft and should be diagnosed.
revolution, or once for each 4-stroke cycle. When the
intake valve opens, the fuel/air mixture is drawn into the NOTICE
combustion chamber, ignited and burned. Accurate testing of EFI components is recommended
The ECU controls the amount of fuel being injected and utilizing the Digital Wrench® Diagnostic Software
the ignition timing by monitoring the primary sensor (dealer only).
signals for intake air temperature, manifold absolute
pressure (load), engine temperature, engine speed
(RPM) and throttle pedal position. These primary signals
are compared to the programming in the ECU computer FUEL SYSTEM COMPONENTS
chip, and the ECU adjusts the fuel delivery and ignition The Electronic Fuel Injection (EFI) system is a complete
timing based on these values. engine fuel and ignition management design. This
During operation, the ECU has the ability to re-adjust system includes the following principal components:
temporarily; providing compensation for changes in
overall engine condition and operating environment, so it • Check Engine Light
will be able to maintain the ideal air/fuel ratio. • Crankshaft Position Sensor (CPS)
During certain operating periods such as cold starts, • Engine Control Unit (ECU)
warm up, acceleration, etc., a richer air / fuel ratio is
automatically calculated by the ECU. • Engine Coolant Temperature Sensor (ECT)
• Electronic Throttle Control (ETC)
• Fuel Injectors
• Fuel Pressure Regulator
• Fuel Pump
• Fuel Rail / Supply Line
• Ignition Coil
• Intake Plenum
• Accelerator Position Sensor (APS)
• Temp / Manifold Absolute Pressure Sensor (T-MAP)
• Wire Harness Assembly

FUEL SYSTEM
FUEL SYSTEM COMPONENT 4. Temperature / Manifold Absolute Pressure Sensor

LOCATIONS (T-MAP)
1. Electronic Control Unit (ECU) - Located on top of the intake plenum.
- Located behind the driver seat. Tilt the cargo box to

access.
5. Engine Coolant Temperature Sensor (ECT)

- Located on the cylinder head below the intake
2. Electronic Throttle Control (ETC) manifold.
- Located between the intake boot and intake plenum.
6. Accelerator Position Sensor (APS)
3. Crankshaft Position Sensor (CPS) - Located on the side of the throttle pedal assembly.
- Located on top of the stator cover.

FUEL SYSTEM
7. Fuel Injectors 10. Fuel Pump / Regulator / Fuel Level Sender

Assembly q
- Located on the top of the intake plenum in the intake
track, retained on top by the fuel rail. - Located under the driver’s seat.
11. Ignition Coil / High Tension Leads

8. Fuel Rail Assembly 5
- Located on the intake plenum, on top of the fuel - Located next to the airbox behind the driver’s seat.
injectors.
9. Fuel Supply Line

- Connected to the left end of the fuel rail and top of
the fuel pump.

FUEL SYSTEM
FUEL LINES
FUEL LINE ROUTING
The fuel runs from the fuel tank to the fuel rail on the engine. The fuel line is routed from the fuel tank underneath the
driver seat and is secured to the inner clutch cover q. The fuel line then continues under the clutch outlet duct where it
connects to the fuel rail.
NOTICE
Image orientation is from the rear driver-side of the vehicle with the cargo box in the raised position.

FUEL SYSTEM
FUEL LINE QUICK CONNECT REMOVAL 3. Remove quick connect from the fuel fitting.
When properly used, fuel line quick connects can be
disconnected and reconnected multiple times for vehicle
service needs. If the quick connect is damaged, it is not
designed to be serviceable and the fuel line assembly
will require replacement.
There are two methods of disconnecting Fuel line quick
connects, the preferred method is by using a small
straight blade screwdriver.
Screwdriver Method:
1. Insert a #1 flat blade screw driver into the pry slot on
the top of the retaining clip.
Hand Method:
4. Gently pull outward on retaining tabs to unlock
retaining clip.
5
IMPORTANT
To prevent damage to the retaining clip, be sure to use
a flat blade screwdriver that fits into the pry slot.
2. Gently pry the retaining clip upwards into the open

position. IMPORTANT
Do not over-pry or excessively bend the retaining tabs.
This can damage the retaining clip, and require
replacement of the fuel line assembly.
5. Push retaining clip upward into the open position.

FUEL SYSTEM
6. Remove quick connect from the fuel fitting. 4. Quick connect has been twisted from its original
inserted position, or the connector has been
damaged.
Replacement Needs:
Indicators that the quick connect is damaged, and
assembly replacement is needed:
1. The retaining clip can be closed without the insertion
of a hard line end. The retaining clip is designed to
lock only when a hard line end has been fully
inserted.
2. Retaining tabs are deformed and no longer lock into
the body of the quick connect.
3. Broken retaining tabs, or any sign of cracks in the

retaining clip. The retaining clip is responsible for
holding the quick connect on the line when under fuel
pressure.

FUEL SYSTEM
FUEL LINE REMOVAL / INSTALLATION 4. Pull the fuel line outward to remove.
1. Place a shop towel around the fuel line to catch any CAUTION
dripping fuel.
Use care not to damage the fuel line on nearby parts.
2. To remove the fuel line from the tank q or the fuel rail
w, pull open tabs while moving the connector out to
release the line. Refer to Fuel Line Quick Connect 5. To reinstall the line, verify the connections are clean
Removal page 5.9 and free of debris.
6. Place the fuel line back over the fitting and slide the
connector locking mechanism back into place. Verify
the connector tabs snap back into place by pulling out
lightly on connector.
7. Be sure fuel line is routed and retained properly. See
Fuel Line Routing page 5.8.
3. Disconnect the fuel line connector e securing the

fuel line to the inner clutch cover .

FUEL SYSTEM
FUEL VENT LINE ROUTING

The fuel tank is vented through a vent line. The vent line is routed from the fuel tank underneath the driver seat and
secured into a vertical section of the frame with a vent line termination fitting.
NOTICE
Image orientation is from the front driver-side of the vehicle

FUEL SYSTEM
FUEL VENT LINE ROUTING (EVAP MODELS)

The fuel tank is vented through an EVAP system.
The vent line is routed from the fuel tank and into a Evaporative Emissions Canister q. The Purge line runs from the
Evaporative Emissions Canister q and is secured in a horizontal section of the frame r. The purge line is also
supported by the air intake duct in two places. The line connects with a spring clamp (PN 7081432) to a Purge Valve
y. The purge jumper line routes from the purge valve to the air intake manifold. This line assembly is secured to the
purge port on the manifold and to the purge valve using two spring clamps (PN 7041432).
The Fresh Air Lines are secured into a vertical section of the frame with a Vent Line Termination Fitting e and runs
through the Canister Filter w and into the Evaporative Emissions Canister q.
NOTICE
Image orientation is from the front passenger-side of the vehicle
NUMBER PART DESCRIPTION
q Evaporative Emissions Canister
w Canister Filter
e Vent Line Termination Fitting
r Purge Line Routing Clip
t Purge Line
y Purge Valve
u Spring Clamp
i Fresh Air Lines
o Purge Jumper Line

FUEL SYSTEM
FUEL VENT LINE ROUTING - HIGH LIFTER & BACK-COUNTRY
REF DESCRIPTION
q Cable Tie Strap Clip
w Fuel Tank Vent Line
e Front Cab Frame - Left
r Fuel Tank

FUEL SYSTEM
FUEL VENT LINE ROUTING HIGH LIFTER & BACK-COUNTRY (EVAP MODELS)
The fuel tank is vented through an EVAP system.
The vent line is routed from the fuel tank and into a Evaporative Emissions Canister q. The Purge line runs from the
Evaporative Emissions Canister q and is secured in a horizontal section of the frame r. The purge line is also
supported by the air intake duct in two places. The line connects with a spring clamp (PN 7081432) to a Purge Valve
y. The purge jumper line routes from the purge valve to the air intake manifold. This line assembly is secured to the
purge port on the manifold and to the purge valve using two spring clamps (PN 7041432).
The Fresh Air Lines are secured into a horizontal section of the frame with a routing clip e and runs through the
Canister Filter w and into the Evaporative Emissions Canister q.
NOTICE
Image orientation is from the front passenger-side of the vehicle
NUMBER PART DESCRIPTION
q Evaporative Emissions Canister
w Canister Filter
e Vent Line Routing Clip
r Purge Line Routing Clip
t Purge Line
y Purge Valve
u Spring Clamp
i Fresh Air Lines
o Purge Jumper Line

FUEL SYSTEM
VENT LINE TERMINATION FITTING

This fitting should be inspected and tested using a Mity
Vac™ to ensure proper venting. Connect the Mity Vac to
the fitting and give it 5 pumps. The gauge should return
to 0 immediately or there is an obstruction.
NOTICE
If the vent line fitting is removed from the frame, it must
be replaced. The ears on the clip (arrows) will not hold
properly once it is removed.

FUEL SYSTEM
FUEL TANK SERVICE

FUEL TANK ASSEMBLY VIEW
REF DESCRIPTION REF DESCRIPTION

q Fuel Tank Asm y Tank Vent / Rollover Valve
w Fuel Inlet u Fuel Pump / Regulator
e Fuel Cap i Fuel Level Float Arm
r Gasket o Preliminary Fuel Filter
t Fuel Sender Nut

FUEL SYSTEM
FUEL TANK REMOVAL 4. Remove the two fasteners w from the rear of the seat
base bracket e.
WARNING
Relieve system pressure by allowing the vehicle to sit
after key off for 1 hour.
WARNING
Always wear safety goggles when working with high
pressure or flammable fluids. Failure to do so could
result in serious injury or complications.
Image shown with seat cushion removed. This does

not need to be removed for seat removal.
5. Tilt seat forward and remove from the vehicle.
2. Remove the two fasteners q retaining the front of the

driver seat base bracket.
NOTICE
Retain fasteners for reassembly.
6. Remove the seat base.

3. If necessary, slide the seat base forward to access

the fasteners securing the rear of the seat base
bracket.

FUEL SYSTEM
8. Disconnect Positive and Negative battery cables. 12. Remove fasteners and driver-side body panel.
9. Remove Battery Bracket Fastener w and Bracket e. 13. While holding a shop towel around the fuel line
Remove Battery. connectors, disconnect the fuel line q from the fuel
pump. Refer to Fuel Line Removal / Installation page
5.11 procedure. 5
10. Remove Battery Box Fasteners r and remove

Battery Box.
NOTICE
A small amount of fuel may come out of the fuel lines or
pump fitting. Properly drain fuel into a suitable
container.
14. Remove the fuel tank vent line e from the tank fitting.
15. Disconnect the fuel pump electrical harness w.
11. Remove fuel cap.

NOTICE
Syphon as much fuel from the tank as possible before
attempting to remove it from the vehicle.

FUEL SYSTEM
16. Remove the two fuel tank bracket fasteners r that FUEL TANK INSTALLATION
retain the fuel tank in the chassis. Swing the tank
1. Reinstall the fuel tank into the chassis taking care not
brackets clear of the fuel tank for removal.
to damage brake lines or the wire harness.
2. Install seat base fastener y. Torque to specification.
17. Remove the three plastic ties t retaining the main

wire harness to the fuel tank.
TORQUE
Seat Base Fastener:
10 ft-lbs (14 Nm)
3. Install three plastic tie straps t to retain the wire

harness to the fuel tank.
18. Remove seat base fastener y to allow room for fuel

tank to slide out of the frame.
4. Install fuel tank brackets and two fasteners retaining

fuel tank to chassis. Torque fasteners to specification.
TORQUE
Fuel Tank Bracket Fasteners:
6 ft-lbs (8 Nm)
19. Rotate and slide the fuel tank and remove the tank
from vehicle.

FUEL SYSTEM
5. If equipped, partially seat the rubber fuel pump cover. 10. Install Battery. Install Battery Bracket e and Battery
Completely seat around the bottom of the fuel pump Bracket Fastener w. Torque Fastener to
nut after connecting the electrical connector and fuel specification.
line.
TORQUE
6. Reconnect the fuel pump electrical harness.
Battery Bracket Fastener:
5
7. Install the fuel line and vent line, and verify they are 42 in-lbs (5 Nm)
secure.
8. Install driver-side body panel. Torque fasteners to
11. Connect Positive and Negative battery cables. Test
specification.
the fuel pump by turning on the key and listening for
TORQUE the pump to activate.
Body Panel Fasteners: IMPORTANT
42 in-lbs (5 Nm) Ensure no leaks are present between the fuel tank and
lines and that the fuel pump cap is secured over the fuel
pump nut.
9. Install Battery Box and two Battery Box Fasteners r.
TORQUE
Battery Box Fasteners:
42 in-lbs (5 Nm)

FUEL SYSTEM
12. Install battery cover.
13. Install Driver Seat.

• Engage front seat base tabs.
• Push seat down until properly seated.
14. Fold down passenger seat.

FUEL SYSTEM
FUEL PUMP SERVICE

OPERATION OVERVIEW FUEL SENDER TEST
An electric fuel pump assembly q is used to transfer fuel 1. Remove the fuel pump assembly from the fuel tank.
to the EFI system from inside the fuel tank. This Refer to Fuel Pump Replacement page 5.25
assembly includes the fuel pump, fuel filter, regulator and procedure.
fuel level sender. The pump is rated for a minimum
output of 9.25 gal (35 L)/hr at 58 ± 2 psi (400 ± 14 kPa). 2. Using an Ohm meter, measure the resistance of the
fuel sender as shown below.
When the key switch is turned to "ON", the ECU

activates the fuel pump, which pressurizes the system for ITE-
POSITION READING
start-up. M
The ECU switches off the pump preventing the continued q EMPTY position 450 Ω ± 5%
delivery of fuel in these instances:
w FULL position 100 Ω ± 3%
• If the key switch is not promptly turned to the "start" Measure between the two
position. e —
pins
• If the engine fails to start.
• If the engine is stopped with the key switch "on" (as in 3. Allow the sender float to sit in the EMPTY position
the case of an accident). and compare to specification.
4. Slowly move the sender float to the FULL position
In these situations, the “check engine” light will and compare to specification.
illuminate, but turn off after 4 cranking revolutions if the
system functions properly. Once the engine is running, 5. If the readings are out of specification, or if the
the fuel pump remains on to maintain fuel pressure. reading is erratic or LCD display “sticks”, check the
following before replacing the fuel pump assembly:
• Loose float
• Float contact with tank
• Bent float rod
6. If none of the conditions exist, the fuel sender

assembly is faulty. Replace the fuel pump assembly.
Refer to Fuel Pump Replacement page 5.25
procedure.

FUEL SYSTEM
FUEL PUMP TEST 4. Turn on key switch to activate the pump and check
If a fuel delivery problem is suspected, make certain the the system pressure on the gauge. If fuel pressure is
fuel pump filter is not plugged, that the pump is being within specification, the ignition switch, ECU, fuel
activated through the ECU, all electrical connections are pump and pressure regulator are working properly.
properly secured, the fuses are good, and a minimum of Turn the key switch off and turn the relief valve on the
12.0 volts is being supplied. If during starting the battery tester to relieve the system pressure.
voltage drops below 12.0 volts, the ECU will fail to
Fuel Pressure:
operate the system.
58 ± 2 psi (400 ± 14 kPa)
WARNING
NOTICE
Fuel is extremely flammable and may cause severe
burns, injury, or death. If the fuel pressure is out of specification, replace the
Do not use any device that produces a flame or fuel pump assembly.
electrical devices that may spark around
fuel or fuel vapors.
5. If the pump did not activate, disconnect the harness
connector from the fuel pump. Connect a DC
1. Couple Fuel Pressure Gauge Adapter (PS-48762) to voltmeter across terminals “3” and “4” in the plug on
the Fuel Pressure Gauge Kit (PU-43506-A). the vehicle fuel pump harness. Turn on the key switch
and observe voltage to ensure a minimum of 12.0
volts is present.
NOTICE
If the voltage was below 7 VDC, test the battery, ignition
switch, relay(s), wiring harness and ECU.
6. If the reading is between 12.0 and 14.0 volts, turn key

switch off and connect an ohmmeter between
terminals “3” and “4”' at the fuel pump connector to
check for continuity within the fuel pump.
NOTICE
If there was no continuity between the pump terminals,
replace the fuel pump assembly.
7. If voltage at the plug was within the specified range,

and there was continuity across the pump terminals,
reconnect the plug to the fuel pump, making sure you
have a clean connection. Turn on the key switch and
listen for the pump to activate.
NOTICE
If the pump starts, repeat steps 3, 4 and 5 to verify
2. Lift the rear cargo box to the raised position. correct pressure.
3. Install the Fuel Pressure Gauge Adapter (PS-48762)
directly to the fuel rail. 8. If the pump still does not operate, check for correct
ECU operation by plugging in a known-good ECU of
the same model.
NOTICE
If the pump still does not operate, replace the fuel pump
assembly.

FUEL SYSTEM
FUEL PUMP REPLACEMENT 5. While holding a shop towel over the fuel line
connector, disconnect the fuel supply line q from the
1. Move the vehicle to a well ventilated area. Shift the pump. Refer to Fuel Line Removal / Installation
transmission into Park and turn the ignition key off. page 5.11 procedure.
2. Remove the driver seat and storage bin to access the
fuel pump.
WARNING
Always wear safety goggles when working with high
pressure or flammable fluids. Failure to do so could
result in serious injury or complications.
3. Be sure the top of the fuel tank is clean. If it requires

cleaning, hand wash the top of the tank around the
fuel pump to ensure no debris will enter the fuel
system when the fuel pump is removed.
CAUTION
Failure to clean area around fuel pump may lead to
WARNING 5
debris entering the fuel tank during service. Excessive
debris in fuel tank may cause premature wear of fuel It is possible for pressurized fuel to be present when
pump and/or clogging of internal fuel filters. disconnecting the fuel line.
It is recommended to allow the vehicle to sit for a period
of one hour after shutting off the engine before
4. Ensure that static has been discharged by touching a servicing the fuel pump. This allows the fuel pressure to
ground source such as the engine or frame. drop.
NOTICE
A small amount of fuel may come out of the fuel lines or
pump fitting. Properly drain fuel into a suitable
container.
6. Disconnect the fuel pump electrical harness w.

FUEL SYSTEM
7. Place the Fuel Pump Service Tool (PU-50326) over 10. Carefully inspect the inside of the fuel tank for debris
the fuel pump nut. Using a 1/2” drive ratchet or (may require flashlight and mirror). If debris like mud
breaker bar, loosen and remove the nut. Discard the or sand is present, fuel tank should be flushed and
nut. cleaned out prior to installation of new fuel pump
assembly.
CAUTION
It is recommended to remove the fuel tank from the
vehicle and rinse it with a small amount of clean fuel.
Do not use water or any other chemicals to remove
debris.
11. Remove new fuel pump assembly, gasket and nut

from packaging. Use care not to bend float arm
during un-packaging. Do not lift or carry fuel pump
assembly by the float arm.
12. Use cleaning wipes provided to clean fuel tank
surface and threads. Remove all debris, grease and
oil. Allow surfaces to dry completely.
NOTICE
13. Install new gasket onto fuel pump assembly using
Apply light downward force on the fuel pump flange
care not to damage gasket or bend float arm.
while removing the fuel pump nut.
8. Carefully lift the fuel pump out of the fuel tank. As the
fuel pump assembly is being removed, be aware of
float arm and pump pre-filter. Hold the float arm r to
the pump body as you lift and tilt the pump to ensure
that the float arm is not bent when removed from the
tank.
14. Install fuel pump into fuel tank, hold float arm to the
pump body and tilt assembly to ensure float arm does
not get caught or bent during installation.
15. Gently push down on fuel pump flange ensuring
flange is centered.
9. Transfer old fuel pump to a suitable container capable

of safely holding fuel. Fuel pump will retain some fuel.

FUEL SYSTEM
16. Align the outlet port on the fuel pump between the 18. Torque nut to specification using the Fuel Pump
orientation marks on fuel tank to ensure float arm Service Tool (PU-50326) and a calibrated torque
does not get bent or snagged. wrench.
TORQUE
Fuel Pump Nut:
70 ft-lbs (95 Nm)
19. Verify alignment of fuel pump and tank orientation

marks.
20. Connect the fuel supply line to the pump. Refer to
Fuel Line Removal / Installation page 5.11
procedure.
NOTICE
Be sure to engage the retainers on the fuel line until it
snaps into place. Lightly pull on the lines to confirm
connection.
WARNING
21. Connect the fuel pump electrical harness.
5
Failure to align the orientation marks may lead to
interferences with the fuel level float armand cause
22. Test the fuel pump by turning on the key and listening
incorrect function.
for the pump to activate. Cycle the key several times
to prime the system.
17. While maintaining downward pressure, thread new 23. Install storage bin and driver’s seat base.
nut onto fuel tank and hand tighten. Use care when
starting nut, ensuring threads are properly aligned.
Verify orientation marks are still aligned between fuel
pump and fuel tank.

FUEL SYSTEM
FUEL INJECTOR SERVICE

FUEL INJECTOR OPERATION FUEL INJECTOR TEST
OVERVIEW The fuel injectors are non-serviceable. If diagnosis
The fuel injectors are mounted into the intake plenum, indicates a problem with either injector, test the
with the fuel rail retaining them from the top end. O-rings resistance of the fuel injector(s) by measuring between
on both ends of the injector prevent external fuel leaks the two pin terminals:
and also insulate the injectors from heat and vibration.
Fuel Injector Resistance Specification:

When the key switch is on, the fuel rail is pressurized, 11.4 Ω - 12.6 Ω
and the EFI relay provides voltage to the injectors.
During engine operation, the ECU completes the ground
circuit, energizing the injectors. The valve needle in each NOTICE
injector is opened electromagnetically, and the pressure Be sure to connect the PTO harness lead to the PTO
in the fuel rail forces fuel down through the inside. The injector and the MAG harness lead to the MAG injector
“director plate” at the tip of the injector contains a series to ensure proper engine operation. The MAG wire
of calibrated openings which directs the fuel into the colors are Red/Blue and Black; the PTO wire colors are
intake port in a cone-shaped spray pattern. Red/Blue and White.
The amount of fuel injected is controlled by the ECU and
determined by the length of time the valve needle is held
open, also referred to as the “injection duration” or “pulse
width”. It may vary in length depending on the speed and
load requirements of the engine.
The ECU gathers fuel injection timing information from
the Crankshaft Position Sensor (CPS) and the
Temperature / Manifold Absolute Pressure Sensor (T-
MAP) to allow for sequential fuel injection.

FUEL SYSTEM
FUEL INJECTOR TROUBLESHOOTING FUEL INJECTOR REPLACEMENT

Injector problems typically fall into three general 1. Lift the rear cargo box to the raised position.
categories- electrical, dirty / clogged, or leakage. An
electrical problem usually causes one or both of the 2. Be sure the engine has cooled enough to perform this
injectors to stop functioning. Several methods may be procedure.
used to check if the injectors are operating. 3. Used compressed air to remove any debris from
around fuel injectors.
• With the engine running at idle, feel for operational
vibration, indicating that they are opening and closing.
WARNING
• When temperatures prohibit touching, listen for a
Always wear safety glasses and proper shop clothing
buzzing or clicking sound with a screwdriver or
when performing the procedures in this manual. Failing
mechanic's stethoscope.
to do so may lead to possible injury or death.
• Disconnect the electrical connector from an injector
and listen for a change in idle performance (only
running on one cylinder) or a change in injector noise 4. Remove the passenger seat and storage bin and
or vibration. disconnect the negative battery cable.
NOTICE 5. Remove the plastic cap q from the pressure relief /

test valve on the fuel rail. Hold a shop towel over the
Do not apply voltage directly to the fuel injector(s). valve press the relief pin with a small screwdriver to
Excessive voltage will burn out the injector(s). Do not
ground the injector(s) with the ignition on. lnjector(s) will
depressurize the fuel rail. Reinstall the plastic cap. 5
open/turn on if relay is energized.
If an injector is not operating, it can indicate either a bad

injector, or a wiring/electrical connection problem. Check
as follows:
Injector leakage is very unlikely, but in rare instances it
can be internal (past the tip of the valve needle), or
external (weeping around the injector body). The loss of
system pressure from the leakage can cause hot restart
problems and longer cranking times.
Injector problems due to dirt or clogging are unlikely due
to the design of the injectors, the high fuel pressure, the
use of filters and the detergent additives in the gasoline.
Symptoms that could be caused by dirty/clogged 6. Remove the fuel line from the fuel rail. Refer to Fuel
injectors include rough idle, hesitation/stumble during Line Quick Connect Removal page 5.9 procedure.
acceleration, or triggering of fault codes related to fuel
delivery. Injector clogging is usually caused by a buildup 7. Disconnect the fuel injector harness leads.
of deposits on the director plate, restricting the flow of 8. Remove the two fuel rail fasteners that mount the fuel
fuel, resulting in a poor spray pattern. Some contributing rail to the intake plenum.
factors to injector clogging include; dirty air filters, higher
than normal operating temperatures, short operating
intervals and dirty, incorrect, or poor quality fuel.
Cleaning of clogged injectors is not recommended; they
should be replaced. Additives and higher grades of fuel
can be used as a preventative measure if clogging has
been a problem.

FUEL SYSTEM
9. Carefully pull up on the fuel rail and injectors and 19. Turn the key to the on position and wait for fuel pump
remove them from the intake plenum as an assembly. to prime the fuel system.
Take care not to damage the fuel injector ends during
20. Start the engine briefly and inspect the fuel rail and
removal.
injectors for fuel leaks.
10. Pull out on the fuel injector retaining clip and pull the
injector out of the fuel rail. Repeat on the other
injector if removal is necessary.
11. Upon installation of the new fuel injectors, lightly

lubricate the injector O-rings to aid installation.
12. Install the new injector(s) into the fuel rail and reinstall
the retaining clip.
NOTICE
Be sure the retaining clip is positioned on the injector
and fuel rail as shown above.
13. Thoroughly clean the area around the fuel injector

ports on the intake plenum.
14. Lightly lubricate the injector O-rings and reinstall the
fuel rail / injector assembly into the intake plenum.
15. Install the fuel rail mounting fasteners and torque to
specification.
TORQUE
Fuel Rail Mounting Fasteners:
5 ft-lbs (7 Nm)
16. Reinstall the fuel line to the fuel rail. Refer to Fuel
17. Connect the harness leads to the fuel injectors.
NOTICE
Be sure to connect the PTO harness lead to the PTO
injector and the MAG harness lead to the MAG injector
to ensure proper engine operation.
18. Reconnect the negative battery cable and reinstall

the storage bin and passenger seat base.

PVT SYSTEM
CHAPTER 6
PVT SYSTEM
GENERAL INFORMATION - PVT SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
SERVICE NOTES - PVT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
SPECIAL TOOLS - PVT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
SERVICE SPECIFICATIONS - PVT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
CLUTCH CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
PVT SYSTEM OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
DRIVE CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
DRIVEN CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
PVT BREAK-IN (DRIVE BELT / CLUTCHES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
MAINTENANCE / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
DRIVE BELT SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
DRIVEN CLUTCH ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 6
PVT SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.10
PVT COVERS AND DUCTING ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.10
PVT AIR DUCTS - REAR MOUNT (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
PVT DUCT REMOVAL / INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.12
PVT OUTER COVER REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.13
DRIVE CLUTCH REMOVAL / INSTALLATION (NON-EBS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.16
DRIVE CLUTCH REMOVAL / INSTALLATION (EBS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.17
DRIVEN CLUTCH REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.20
PVT INNER COVER REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.21
DRIVE CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.24
DRIVE CLUTCH ASSEMBLY VIEW (NON-EBS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.24
DRIVE CLUTCH ASSEMBLY VIEW (EBS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.25
CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.26
BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.28
BUTTON TO TOWER CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.28
SPIDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.28
ROLLER, PIN, AND THRUST WASHER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.28
SHIFT WEIGHT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.29
DRIVE CLUTCH SPRING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.29
CLUTCH INSPECTION (NON-EBS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.30
CLUTCH INSPECTION (EBS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.31
DRIVE CLUTCH BUSHING INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.33
EBS SLEEVE ASSEMBLY (ONE-WAY BEARING) INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.33
BUSHING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.34
CLUTCH ASSEMBLY (NON-EBS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.36
CLUTCH ASSEMBLY (EBS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.39
DRIVEN CLUTCH SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.42

PVT SYSTEM
DRIVEN CLUTCH ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.42

DRIVEN CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.43
HELIX AND MOVABLE SHEAVE BUSHING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.44
BUSHING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.44
DRIVEN CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.45
PVT SYSTEM DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.46
PVT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.46
OVERHEATING / DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.49
VEHICLE CREEPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.50

PVT SYSTEM
GENERAL INFORMATION - PVT SYSTEM

SERVICE NOTES - PVT SYSTEM SPECIAL TOOLS - PVT SYSTEM
WARNING TOOL DESCRIPTION PART
NUMBER
All PVT maintenance or repairs should be performed by
a certified Polaris Master Service Dealer (MSD) Clutch Bushing Replacement Tool
2871226–A
technician who has received the proper training and Kit
understands the procedures outlined in this manual.
Drive Clutch Holding Tool PU-52430
Because of the critical nature and precision
balance incorporated into the PVT components, it is Drive Clutch Puller PU-52422
absolutely essential that no disassembly or repair
be made without factory authorized special tools Drive Clutch Spider Removal and Standard 3–
and service procedures. Installation Tool Jaw Puller
Piston Pin Puller 2870386
The Polaris Variable Transmission (PVT) consists of
three major assemblies: Primary Moveable Sheave Bushing
Replacement Tool 5020634
1) The Drive Clutch
2) The Driven Clutch Primary One-way Helix Bushing
Replacement Tool 5020636
3) The Drive Belt
Secondary Moveable Sheave
The internal components of the drive clutch and driven Bushing Replacement Tool 5020635
clutch control engagement (initial vehicle movement),
clutch upshift and backshift. During the development of
the Polaris vehicle, the PVT system is matched first to the
Roller Pin Tool 2870910 6
engine power curve; then to average riding conditions Universal Clutch Compressor PU-50518
and the vehicle’s intended usage. Therefore,
modifications or variations of components at random are Clutch Spreader Tool 2875911
never recommended. Proper clutch setup and careful
inspection of existing components must be the primary Bosch Automotive Service Solutions:
objective when troubleshooting and tuning.
1-800-345-2233 or http://polaris.service-solutions.com

PVT SYSTEM
SERVICE SPECIFICATIONS - PVT CLUTCH CHART

SYSTEM BASE AND CREW
PART SERVICE SERVICE CLUTCHES
DESCRIPTION SPECIFICATION LIMIT
SHIFT DRIVE DRIVEN
Drive Clutch 7044697 — ALTITUDE
WEIGHT SPRING SPRING
Spring Part
Number 0-1800 Meters 32–114
(0-6000 Feet) 7045326 7044761
— 1323697
Drive Clutch Black
Spring Color 1800-3700
Meters 32–106 Black
Drive Clutch 7044938: 3.76 in 103–200 7044761
(6000 - 12000 (1323458)
Spring Free (95.43 mm) 7045326
Feet)
Length 7045110: 4.60”
(116.74mm)
7045326: 3.83”
(97.26mm)
EBS Spring Free 0.76 in (17.78 —
Length mm)
Drive Clutch 000-.010” 0.020” (0.508
Button to Tower mm)
Clearance
Drive Clutch 1.413” (35.913 1.416”
Shaft Diameter mm) (35.975 mm)
Flange Sleeve 1.693” (42.98 1.692”
Shaft Diameter mm) (42.993 mm)
Vespel® Thrust 0.030 – 0.040” 0.020” (0.50
Washer (0.76 - 0.96 mm) mm)
Thickness
Drive Clutch Helix Greater than 0.146” (3.71
Thickness 0.146” (3.71 mm) mm)

PVT SYSTEM
PVT SYSTEM OVERVIEW

DRIVE CLUTCH OPERATION PVT BREAK-IN (DRIVE BELT /
Drive clutches primarily sense engine RPM. The two CLUTCHES)
major components which control its shifting function are A proper break-in of the clutches and drive belt will
the shift weights and the coil spring. Whenever engine ensure a longer life and better performance. Break in the
RPM is increased, centrifugal force is created, causing clutches and drive belt by operating at slower speeds
the shift weights to push against rollers on the moveable during the 10 hour break-in period as recommended.
sheave, which is held open by coil spring preload. When Refer to Engine Break-In Period page for break-in
this force becomes higher than the preload in the spring, example). Pull only light loads. Avoid aggressive
the outer sheave moves inward and contacts the drive acceleration and high speed operation during the break-
belt. This motion pinches the drive belt between the in period.
spinning sheaves and causes it to rotate, which in turn
rotates the driven clutch.
At lower RPM, the drive belt rotates low in the drive MAINTENANCE / INSPECTION
clutch sheaves. As engine RPM increases, centrifugal Periodic inspection and maintenance is required to keep
force causes the drive belt to be forced upward on drive the system operating at peak performance. The following
clutch sheaves. list of items should be inspected and maintained to
ensure maximum performance and service life of PVT
components. Refer to “PVT Diagnostics” for more
DRIVEN CLUTCH OPERATION information.
Driven clutches primarily sense torque, opening and
closing according to the forces applied to it from the drive 1. Belt Inspection.
belt and the transmission input shaft. If the torque 2. Drive and Driven Clutch Buttons and Bushings,
resistance at the transmission input shaft is greater than
the load from the drive belt, the drive belt is kept at the
Drive Clutch Shift Weights and Pins, Drive Clutch
Spider Rollers and Roller Pins, Drive and Driven
6
outer diameter of the driven clutch sheaves. Clutch Springs.
As engine RPM and horsepower increase, the load from 3. Sheave Faces. Clean and inspect for wear.
the drive belt increases, resulting in the belt rotating up
toward the outer diameter of the drive clutch sheaves 4. PVT System Sealing. Refer to the appropriate illus-
and downward into the sheaves of the driven clutch. This tration(s). The PVT system is air cooled by fins on the
action, which increases the driven clutch speed, is called drive and driven clutch stationary sheaves. The fins
upshifting. create a low pressure area in the crankcase casting,
drawing air into the system through an intake duct.
Should the throttle setting remain the same and the The opening for this intake duct is located at a high
vehicle is subjected to a heavier load, the drive belt point on the vehicle (location varies by model). The in-
rotates back up toward the outer diameter of the driven take duct draws fresh air through a vented cover. All
clutch and downward into the sheaves of the drive clutch. connecting air ducts (as well as the inner and outer
This action, which decreases the driven clutch speed, is covers) must be properly sealed to ensure clean air is
called backshifting. being used for cooling the PVT system and also to
In situations where loads vary (such as uphill and prevent water and other contaminants from entering
downhill) and throttle settings are constant, the drive and the PVT area. This is especially critical on units sub-
driven clutches are continually shifting to maintain jected to frequent water forging.
optimum engine RPM. At full throttle a perfectly matched
PVT system should hold engine RPM at the peak of the
power curve. This RPM should be maintained during
clutch upshift and backshift. In this respect, the PVT
system is similar to a power governor. Rather than vary
throttle position, as a conventional governor does, the
PVT system changes engine load requirements by either
upshifting or backshifting.

PVT SYSTEM
DRIVE BELT SERVICE

BELT REMOVAL 1. Remove the nine fasteners q that retain the outer
clutch cover.
NOTICE
A video has been created to aid in drive belt service.
NOTICE
Inspect the entire clutch outlet duct (including the outlet
duct screen) when replacing a drive belt. Remove any NOTICE
debris found in the outlet duct or outlet duct screen. Removal of left rear wheel or left rear shock is NOT
necessary for belt replacement.
2. Pull the clutch cover forward and slide towards the

front of the vehicle as shown.

PVT SYSTEM
3. Rotate the clutch cover back and lift up and over the 6. Insert clutch spreader tool e into threaded hole on
control arm mounting w. driven clutch as shown and turn clockwise to spread
clutch.
NOTICE
Use care when lifting clutch cover upwards. Do not
damage cover, intake boot, or electrical harness.
NOTICE
Clutch spreader tool part number 2875911 is found in
vehicle tool kit.
4. Pull clutch cover out towards the rear of the vehicle

as shown. 7. Walk the belt out of the driven clutch and drive clutch.
Remove the belt from the vehicle. 6
BELT INSPECTION
1. Inspect belt for hour glassing (extreme circular wear
in at least one spot and on both sides of the belt).
Hour glassing occurs when the drive train does not
move and the drive clutch engages the belt.
2. Inspect belt for loose cords, missing cogs, cracks,
abrasions, thin spots, or excessive wear. Compare
belt measurements with a new drive belt. Replace if
necessary.
3. Belts with thin spots, burn marks, etc., should be
replaced to eliminate noise, vibration, or erratic PVT
operation. Refer to “PVT Troubleshooting” page
5. Mark the drive belt direction of rotation so that it can 6.46 chart at the end of this chapter for possible
be installed in the same direction. causes.

PVT SYSTEM
BELT INSTALLATION 6. Rotate clutch cover over A-Arm w as shown. Use

care not to damage intake boots or electrical harness.
NOTICE
Be sure to install belt in the same direction as it was
removed.
1. With the clutch spreader tool q installed, loop the

belt over the drive clutch and over the driven clutch.
7. Pull clutch cover backwards and align with bolt holes

on inner clutch cover.
Clutch Spreader Tool

2875911
2. Rotate the driven clutch and walk the belt into the
clutch.
3. Remove the clutch spreader tool from driven clutch.
4. Rotate / spin the driven clutch and belt approximately
5-7 times clockwise to properly seat the belt in the
driven clutch.
5. Install the clutch cover into wheel well as shown.
8. Install and torque the outer clutch cover bolts to
specification.
TORQUE
PVT Outer Cover Fasteners
35 in-lbs (4 Nm)

PVT SYSTEM
DRIVEN CLUTCH ALIGNMENT 7. Reinstall the washers and Driven Clutch Bolt. Torque
Most vehicles require four to six alignment washers (PN to specification.
7557060) for proper alignment. As many as eight
TORQUE
alignment washers or as few as zero may be used.
Driven Clutch Bolt
IMPORTANT 20 ft-lbs (27 N·m)
The main washer directly under the head of the bolt
must always be used. NOTICE
When finished, the driven clutch should not rotate on its
1. Remove the outer clutch cover from the vehicle. own, or should stop with minimal drag when using a
Refer to Belt Removal page 6.6. new bearing.
IMPORTANT
Do NOT remove the belt at this time. Only remove the 8. Remove the drive clutch bolt w and drive clutch.
outer cover. IMPORTANT
Ensure the drive clutch taper and engine taper are
2. Rotate the driven clutch clockwise several times clean and free of debris.
before inspection.
3. Inspect where the belt is riding on the drive clutch.
NOTICE
A mobile device can be used to capture a picture of the
belt tracking to determine if adjustment is needed. 6
4. Remove the drive belt.
5. Remove the Driven Clutch Bolt and washer.
9. Reinstall the drive clutch and bolt. Torque the drive

clutch bolt to specification.
TORQUE
Drive Clutch Retaining Bolt (Movable sheave only
removed):
96 ft-lbs (130 Nm)
TORQUE
6. Add shims q to move the belt closer to the inner
Drive Clutch Retaining Bolt (Stationary sheave
sheave of the drive clutch, or remove shims to move
completely removed):
the belt closer to the outer sheave of the drive clutch.
IMPORTANT
Step 2: Loosen Fastener
Ensure the driven clutch splines and transmission
splines and shaft are clean and free of debris. Step 2: 96 ft-lbs (130 Nm)
10. Reinstall the drive belt and outer cover assembly.

Refer to Belt Removal page 6.6

PVT SYSTEM
PVT SYSTEM SERVICE

PVT COVERS AND DUCTING ASSEMBLY VIEW
q Clutch Cover Fasteners

35 in-lbs (4 Nm) a Inlet Duct
w Drain Plug s Inlet Duct Fasteners

54 in-lbs (6 Nm)
d PVT Hose Adaptor Clamps

e Outer Clutch Cover 35 in-lbs (4 Nm)
r Seal, Outer Cover f PVT Inlet Hose (Tunnel)

g PVT Inlet Hose Clamp
t Inner Clutch Cover 35 in-lbs (4 Nm)
y O-ring h Intake Clutch Duct
u Seal, Inlet Duct j PVT Inlet Hose Clamp

35 in-lbs (4 Nm)
i Outlet Duct k PVT Hose Joint

o Outlet Duct Fasteners
54 in-lbs (6 Nm) l Intake Tube

PVT SYSTEM
PVT AIR DUCTS - REAR MOUNT (IF EQUIPPED)
r Upper Air Duct Clamp

q PVT Outlet Duct 35 in-lbs (4 Nm)
t Air Duct to Close Off Panel Fastener

w PVT Inlet Duct 35 in-lbs (4 Nm)
e PVT Air Duct Clamp y Engine Air Inlet Duct

35 in-lbs (4 Nm)

PVT SYSTEM
PVT DUCT REMOVAL / INSTALL INLET DUCT REMOVAL / INSTALL

OUTLET DUCT REMOVAL / INSTALLATION 1. Remove the Inlet Duct fasteners q.
1. Disconnect the electrical harness from the clutch 2. Remove the Inlet Duct w and the duct seal e.
cover at points shown below q. Inspect for damage and replace if necessary.
2. Remove fasteners w and pull outlet duct e upwards 3. Reinstall the duct seal e and duct assembly w.
to remove from clutch cover.
4. Install fasteners q and torque to specification.
3. Inspect bottom of the duct for damage and replace if
necessary. TORQUE
4. Reinstall duct e and fasteners w. Torque to PVT Inlet Duct Fasteners
specification. 54 in-lbs (6 Nm)
TORQUE
PVT Outlet Duct Fasteners
54 in-lbs (6 Nm)

PVT SYSTEM
PVT OUTER COVER REMOVAL / 3. Loosen the clamp retaining the inner cover intake
INSTALLATION duct.
PRELIMINARY STEPS
NOTICE
These steps are NOT required for PVT system service,
but are recommended to gain clearance for removal
and installation.
1. Loosen the intake duct clamps q. Remove the

breather hose from the intake duct and remove the
intake duct.
REMOVAL
1. Remove the nine fasteners q that retain the outer
clutch cover.
2. Remove the airbox cover. Leave air filter and inner

airbox cover installed.
NOTICE
Removal of left rear wheel or left rear shock is NOT
necessary, but may help in removal of the cover.

PVT SYSTEM
2. Pull the clutch cover forward and slide towards the INSTALLATION
front of the vehicle as shown.
1. Install the clutch cover into wheel well as shown.
3. Rotate the clutch cover back and lift up and over the
control arm mount as shown. 2. Rotate clutch cover over A-Arm as shown. Use care
not to damage intake boots or electrical harness.
NOTICE
Use care when lifting clutch cover upwards. Do not
damage cover, intake boot, or electrical harness.
3. Pull clutch cover backwards and align with bolt holes

on inner clutch cover.
4. Remove the outer clutch cover from the vehicle by

pulling out towards the drivers side.

PVT SYSTEM
4. Install and torque the outer clutch cover bolts q to

specification.
TORQUE
PVT Outer Cover Fasteners
35 in-lbs (4 Nm)

PVT SYSTEM
DRIVE CLUTCH REMOVAL / 6. Remove the clutch spacer q, washer q, bearing e,

INSTALLATION (NON-EBS) and washer r from the sheave assembly t.
REMOVAL IMPORTANT
1. Remove the PVT Outer Cover. Refer to PVT Outer Note the orientation of the spacer for installation.
Cover Removal / Installation page 6.13
2. Remove the Drive Belt. Refer to Belt Removal page
6.6
3. Using a permanent marker, mark the cover, spider,
and moveable sheave for reference.
IMPORTANT
Always mark the parts before disassembly. The X’s cast
in the parts should not be used for alignment purposes
as these may have not been aligned when originally
assembled.
4. Remove the Drive Clutch retaining bolt q using a

Torx T-60 internal driver.
7. Install the Drive Clutch Puller (PN PU-52422) to

remove the Stationary Sheave.
INSTALLATION
NOTICE
If the Drive Clutch was replaced as an assembly, install
the Drive Clutch Assembly and Drive Clutch bolt.
Proceed to step e to complete installation.
1. Install the Stationary Sheave assembly q if removed.

2. Install the clutch spacer q, washer w, bearing e,
and washer r on the sheave assembly t.
5. Remove the Movable Sheave assembly w. Use a
rocking motion while pulling on the movable sheave
by hand to slide the Spider and Movable Sheave off
the Stationary Sheave e.
NOTICE
The stationary sheave of the drive clutch can remain in
the vehicle if not being serviced.
IMPORTANT
In the event that the movable sheave can not be
removed by hand, remove the outer slip-fit post and
install the Drive Clutch Puller (PN PU-52422) to remove
the Movable and Stationary Sheave as an assembly.
Once removed refer to Clutch Disassembly page 6.26
for more information.

PVT SYSTEM
3. Install the movable sheave assembly w and drive DRIVE CLUTCH REMOVAL /
clutch bolt e. INSTALLATION (EBS)
IMPORTANT REMOVAL
Ensure proper orientation of washers. Orientation 1. Remove the PVT Outer Cover. Refer to PVT Outer
should be as follows: Clutch Spider, Yellow Washer, Cover Removal / Installation page 6.13
Silver Belleville Washer with dome side facing outwards
towards Outer Post, and Outer Post. 2. Remove the Drive Belt. Refer to Belt Removal page
6.6
and moveable sheave for reference.
IMPORTANT
Always mark the parts before disassembly. The X’s cast
in the parts should not be used for alignment purposes
as these may have not been aligned when originally
assembled.
4. Remove the Drive Clutch retaining bolt q using a

Torx T-60 internal driver.
4. Torque the drive clutch bolt. 6

TORQUE
Drive Clutch Retaining Bolt (Moveable sheave only
removed):
96 lb-ft (130 Nm)
TORQUE
completely removed or Drive Clutch Assembly
replaced): 5. Remove the Movable Sheave assembly w. Use a
Step 1: 110 ft-lbs (149 Nm) rocking motion while pulling on the movable sheave
by hand to slide the Spider and Movable Sheave off
Step 2: Loosen Fastener the Stationary Sheave e.
NOTICE
The stationary sheave of the drive clutch can remain in
5. Install the Drive Belt. Refer to Belt Installation page the vehicle if not being serviced.
6.8
6. Perform clutch alignment. Refer to IMPORTANT
7. Install the PVT Outer Cover. Refer to PVT Outer In the event that the movable sheave can not be
Cover Removal / Installation page 6.13 removed by hand, remove the outer slip-fit post and
install the Drive Clutch Puller (PN PU-52422) to remove
the Movable and Stationary Sheave as an assembly.
Once removed refer to Clutch Disassembly page 6.26
for more information.

PVT SYSTEM
6. Remove the clutch spacer q, spring w, washer e, 2. Install the EBS sleeve assembly ensuring the sleeve
EBS sleever, from the sheave assembly y. q is seated flush with the stationary sheave w.
IMPORTANT
Note the orientation of the spacer for installation.
IMPORTANT
During reassembly ensure the EBS cam remains fully
seated with the Stationary Sheave. If not properly
seated the EBS cam can be damaged and severe
7. Install the Drive Clutch Puller (PN PU-52422) to
creeping will occur.
remove the Stationary Sheave.
INSTALLATION
3. Install the thrust washer, EBS spring, and spacer.
NOTICE
If the Drive Clutch was replaced as an assembly, install
the Drive Clutch Assembly and Drive Clutch bolt.
Proceed to the torque procedure to complete
installation.
1. If removed, install a new o-ring q and helix w

ensuring it is fully seated and engaged with the drive
lugs of the stationary sheave.

PVT SYSTEM
4. Install the movable sheave assembly w and drive

clutch bolt e.
IMPORTANT
Ensure proper orientation of washers. Orientation
should be as follows: Clutch Spider, Yellow Washer,
Silver Belleville Washer with dome side facing outwards
towards Outer Post, and Outer Post.
5. Torque the drive clutch bolt. 6

TORQUE
Drive Clutch Retaining Bolt (Moveable sheave only
removed):
96 lb-ft (130 Nm)
TORQUE
completely removed or Drive Clutch Assembly
replaced):
6. Install the Drive Belt. Refer to Belt Installation page

6.8
7. Perform clutch alignment. Refer to
8. Install the PVT Outer Cover. Refer to PVT Outer

PVT SYSTEM
DRIVEN CLUTCH REMOVAL / 2. Install shims s (0–8) as required, washer d , and the
INSTALLATION Driven Clutch Bolt f.
REMOVAL
1. Remove the PVT Outer Cover. Refer to PVT Outer
6.6
3. Use a 3/8 inch 6 inch extension w as shown to hold
the driven clutch. Remove the driven clutch bolt e,
belleville washer r, and washers t.
3. Torque the Driven Clutch Bolt f using a 6 inch

extension g wedged between the movable sheave
and the upper A-arm.
4. Remove the Driven Clutch.

INSTALLATION
1. Install the Driven Clutch assembly. Ensure the Driven
Clutch assembly is nearly flush with the Transmission
Input shaft.
CAUTION
The Driven Clutch Bolt will engage the threads of the TORQUE
Input Shaft without the Driven Clutch being fully mated
to the Input Shaft. Damage can occur to the clutch and Driven Clutch Retaining Bolt:
Input Shaft if the Driven Clutch is not flush with the 20 ft-lbs (27 N·m)
Input Shaft.
6.8

PVT SYSTEM
PVT INNER COVER REMOVAL / INSTALLATION

INSTALLATION 1. Inspect the inner clutch cover. Replace if cracked or
REMOVAL damaged.
1. Remove the PVT Outer Cover. Refer to PVT Outer 2. Inspect the seal q on the transmission input shaft.
Cover Removal / Installation page 6.13 Replace if damaged.
6.6
3. Remove the Drive Clutch. Refer to Drive Clutch
Removal / Installation (EBS) page
4. Remove the Driven Clutch. Refer to Driven Clutch
Removal / Installation page
5. Remove Transmission Support fasteners q.
3. Inspect inner clutch cover seal (engine side). Replace

if cracked, torn or damaged.
6
6. Remove three bolts w that retain the inner clutch

cover to the engine. Remove bolts e and r that
secure the clutch cover to the transmission.
NOTICE
The transmission will need to be lowered until sufficient
clearance is gained to remove the lowest mounting bolt
o.
7. Remove the inner clutch cover from the vehicle.

PVT SYSTEM
4. Install Inner clutch cover and torque fasteners q to 7. Install the two fasteners r into the engine by hand.
specification.
8. Install the two fastening nuts t.

TORQUE
Clutch Cover Fasteners:
37 ft-lbs (50 Nm)
5. Install the two fasteners w. Do not torque.
9. Torque the two fasteners y.
6. Insert the two fasteners e through the transmission.
TORQUE
Clutch Cover Fasteners
50 ft-lbs (68 Nm)

PVT SYSTEM
10. Install the two fastening nuts u. 12. Torque the mounting fasteners o.
11. Torque the clutch cover fasteners i. TORQUE

Transmission Mount to Engine Fasteners
37 ft-lbs (50 Nm)
13. Secure fuel line clip a to inner clutch cover.
TORQUE
Clutch Cover Fasteners
50 ft-lbs (68 Nm)
14. Clean the inside of the drive clutch and the engine
crankshaft with alcohol. Allow parts to dry before
proceeding.
15. Install the Driven Clutch. Refer to Driven Clutch
Removal / Installation page
16. Install the Drive Clutch. Refer to Drive Clutch
Removal / Installation (EBS) page
6.8

PVT SYSTEM
DRIVE CLUTCH SERVICE

DRIVE CLUTCH ASSEMBLY VIEW (NON-EBS)
q Clutch Bolt
140 ft-lbs (190 Nm) g Washer
w Drive Clutch Cover Bolts h Needle Bearing
100 in-lbs (11 Nm)
e Drive Clutch Cover Bushing j Washer
r Drive Clutch Cover k Stationary Sheave
l Shift Weight Fastener
t Outer Clutch Post 20 in-lbs (2 N·m)
y O - Ring 1( Shift Weight
u Spring 2) Bushing
i Belleville Washer
Dome side facing outer post 2! Nut
o Washer 2@ Clutch Button
a Spider 2# Washer
s Movable Sheave Assembly 2$ Roller
d Bushing 2% Spider Pin
f Clutch Spacer

PVT SYSTEM
DRIVE CLUTCH ASSEMBLY VIEW (EBS)
q Clutch Bolt
140 ft-lbs (190 Nm) h Washer
w Drive Clutch Cover Bolts j EBS Sleeve / One-way Bearing
100 in-lbs (11 Nm)
e Drive Clutch Cover Bushing k O - Ring
r Drive Clutch Cover l EBS Helix
t Outer Clutch Post 1( Stationary Sheave
y O - Ring 2) Shift Weight Fastener
20 in-lbs (2 N·m)
u Spring 2! Shift Weight
i Belleville Washer 2@ Bushing
Dome side facing outer post
o Washer 2# Nut
a Spider 2$ Clutch Button
s Movable Sheave Assembly 2% Washer
d Bushing 2^ Roller
f Clutch Spacer 2& Spider Pin
g Spring

PVT SYSTEM
CLUTCH DISASSEMBLY 3. Remove cover bolts q evenly in a cross pattern and

remove cover plate w.
CAUTION
The clutch assembly is a precisely balanced unit. Never
replace parts with used parts from another clutch
assembly.
MOVABLE SHEAVE
and moveable sheave for reference, as the cast in X's
may not have been in alignment before disassembly.
4. Inspect area on shaft where bushing rides for wear,

galling, nicks, or scratches. Replace clutch assembly
if worn or damaged.
5. Remove and inspect the Clutch Spring r. Refer to
Drive Clutch Spring Inspection page 6.29
procedure.
2. Remove the clutch slip post.
6. Remove and inspect belleville washer t and washer

y. Replace if necessary.
IMPORTANT
Belleville washer must be installed with dome facing the
outer post.
MOVABLE AND STATIONARY

DISASSEMBLY
NOTICE
This procedure is used in the event that the Movable
Sheave did not separate from the Stationary Sheave
during Drive Clutch removal and the Drive Clutch was
removed as an assembly.

PVT SYSTEM
1. Using a permanent marker, mark the cover, spider, 4. Remove and inspect the Cover Plate w.
and moveable sheave for reference, as the cast in X's
may not have been in alignment before disassembly.
5. Remove and inspect the Clutch Spring e. Refer to

Drive Clutch Spring Inspection page 6.29.
2. Remove the clutch slip post.
6. Remove and inspect the Belleville Washer r and
washer t.
7. Using a 3 jaw puller remove the Spider y from the
Movable Sheave.
6
3. Remove cover bolts q evenly in a cross pattern.
8. With the Spider removed separate the sheaves as

shown.

PVT SYSTEM
9. Inspect area on shaft where bushing rides for wear, SPIDER REMOVAL
galling, nicks, or scratches. Replace clutch assembly
1. Remove the spider assembly. If the spider cannot be
if worn or damaged.
removed by hand, use a conventional 3 jaw puller as
shown to remove the spider from the clutch assembly.
BEARING INSPECTION IMPORTANT
• Verify there is no binding or rough spots. If problems Do not pull on the outer fingers of the spider or damage
are noted continue with disassembly. may occur. Position 3 jaw puller in the positions shown
q.
BUTTON TO TOWER CLEARANCE

INSPECTION ROLLER, PIN, AND THRUST WASHER
1. Inspect for any clearance between spider button to INSPECTION
tower. If clearance exceeds specification, replace all 1. Inspect all rollers e, roller pins r, roller washers w,
buttons and inspect surface of towers. Refer to and roller caps q by pulling a flat metal rod across
Spider Removal page procedure. the roller.
2. Turn roller with your finger. If you notice resistance,
galling, or flat spots, replace all the rollers.
Button to Tower Clearance:

0.000 - 0.020”
2. Inspect sheave surfaces. Replace the entire clutch if

worn, damaged or cracked.

PVT SYSTEM
SHIFT WEIGHT INSPECTION DRIVE CLUTCH SPRING INSPECTION

• Remove shift weight fasteners q and weights w. • Measure the Drive Clutch Spring height. Compare to
Inspect the contact surface of the weight w. The specification and replace if necessary.
surface should be smooth and free of dents or gall
marks. Inspect the weight pivot bore e and bolts for
wear or galling. Also inspect the shift weight bushing
for wear. Replace if necessary. If weights or bolts are
worn or broken, replace in sets of three with new bolts
and nuts.
CAUTION
The clutch assembly is a precisely balanced unit. Never
replace parts with used parts from another clutch
assembly.
MEASUREMENT
Drive Clutch Spring Height:
7044938: 3.76 in (95.43 mm)7045110: 4.60”
(116.74mm)7045326: 3.83” (97.26mm)
6
NOTICE
A damaged shift weight is usually caused by a
damaged or stuck roller in the spider assembly. Refer to
Roller, Pin, and Thrust Washer Inspection page 6.28
procedure.

PVT SYSTEM
CLUTCH INSPECTION (NON-EBS) 4. Inspect the moveable clutch bushing, towers, and
sheave face for damage or wear.
NOTICE
Remove PVT cover and moveable sheave, then
proceed as follows:
1. Rotate the clutch bearing in both clockwise and

counter-clockwise directions. The bearing should
rotate freely in both directions. Verify there are no
binding or rough spots. If problems are noted, replace
bearing assembly.
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.
2. Remove the clutch spacer q, washer q, bearing e,

and washer r from the sheave assembly t.
IMPORTANT
MEASUREMENT
Shaft Diameter:1.416” (35.975 mm)
Service Limit:1.413” (35.913 mm)
3. Inspect the clutch spacer q, washer q, bearing e,

and washer r for any visible damage or wear.
Replace any part that is found to have damage.

PVT SYSTEM
CLUTCH INSPECTION (EBS) 3. If helix require replacement, using a pick remove the
O-ring q from the retaining groove and remove the
NOTICE EBS helix from the clutch sheave e. Replace the
Remove PVT cover and moveable sheave, then EBS helix and O-ring.
proceed as follows:
1. Remove the clutch spacer q, spring w, washer e,

and EBS sleever from the sheave assembly t.
IMPORTANT
NOTICE
ONLY remove the EBS helix if it requires replacement.
The O-ring and EBS helix will be damaged upon
removal and require replacement.
6
4. Rotate the clutch bearing in both clockwise and
counter-clockwise directions. The bearing should
rotate clockwise and lock counter-clockwise.
2. Inspect the EBS helix q for wear, grooving, or
cracks. If any damage or wear is found, remove the o-
ring w retaining the ebs helix.
5. Verify there are no binding or rough spots. If problems

are noted, replace EBS sleeve / one-way bearing
assembly.

PVT SYSTEM
6. Inspect the EBS spring (plain silver painted). 8. Inspect surface of shaft for pitting, grooves or
Measure the free length of the spring and compare to damage. Measure the outside diameter and compare
specification. Replace if necessary. to specifications. Replace the drive clutch assembly if
shaft is worn or damaged.
MEASUREMENT
EBS Spring Free Length MEASUREMENT
0.76 in (17.78 mm) Shaft Diameter:1.416” (35.975 mm)
Service Limit:1.413” (35.913 mm)
7. Inspect the moveable clutch bushing, towers, and
sheave face for damage or wear.

PVT SYSTEM
DRIVE CLUTCH BUSHING INSPECTIONS EBS SLEEVE ASSEMBLY (ONE-WAY

1. Inspect the Teflon® coating on the Moveable Sheave BEARING) INSPECTION
bushing, Drive Clutch Cover Bushing, and the One- • As the vehicle is driven, the EBS sleeve bushing will
way Bearing Bushing. Inspect for signs of wear, begin to wear. Some gold coloration within the bushing
grooving or cracking. De-glaze sheave surfaces with is considered normal, but an excessive amount of gold
a 3M Scotch-Brite™ Pad if needed. coloration showing or “scarring” is a sign of excessive
NOTICE wear.
Replace the bushing(s) if more brass than Teflon® is • Normal bushing wear will exhibit a powder-like
visible on the bushing(s). Refer to Bushing Service residue, where excessive bushing wear will “flake” and
page 6.34 procedure. larger pieces of the bushing material will be visible.
• Examples of normal bushing wear and excessive
bushing wear are shown below. If excessive bushing
wear is found, the EBS sleeve bushing should be
replaced. The bushing can be replaced individually or
the EBS sleeve assembly can be replaced.
NORMAL BUSHING WEAR
EXCESSIVE BUSHING WEAR

PVT SYSTEM
BUSHING SERVICE DRIVE CLUTCH BUSHING INSTALLATION

MOVEABLE SHEAVE - BUSHING REMOVAL 1. Place adapter cup (PN 5020632) w on puller.
1. Remove clutch as outlined previously in this chapter.
2. Install handle end of the Piston Pin Puller
(PN2870386 ) q securely into bench vise and lightly
grease puller threads.
2. Apply Loctite® 620 evenly to bushing bore inside

moveable sheave.
3. Set bushing in place on sheave.
4. Insert installation puller tool (PN 5020634) e with “A”
3. Remove nut from puller rod and set aside. side down, into center of bushing.
4. Install adapter cup (PN 5020632) w onto puller. 5. With towers pointing upward, slide sheave, bushing
and tool onto puller rod.
6. Install nut on puller rod and hand tighten. Turn barrel
to apply additional tension if needed.
7. Turn sheave counterclockwise, making sure bushing
is drawn straight into bore. Continue until bushing is
seated.
8. Remove nut from puller rod and set aside.
9. Remove sheave from puller.
10. Remove installation tool.
5. With towers pointing toward the vise, slide sheave

onto puller rod.
6. Install puller tool (PN 5020629) e into center of
sheave with “A side" toward sheave.
7. Install nut 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.
8. Turn sheave counterclockwise on puller rod until it
comes free. Lift sheave off puller.
10. Pull bushing removal tool and adapter from puller rod.
Remove bushing from tool and discard.

PVT SYSTEM
COVER BUSHING REMOVAL 5. Turn clutch cover counterclockwise on puller rod until
bushing is seated.
1. Install adapter cup (PN 5020632) w on puller.
6. Remove nut from puller rod. Take installation tool and
clutch cover off rod.
IMPORTANT
When removing the bushing, the outside of the cover
should be facing the barrel of the Piston Pin Puller as
shown or damage to the cover may result.
2. From inside of clutch cover, insert adapter tool (PN 6

5020629) e into cover bushing.
3. With outside of cover toward the puller barrel, slide
cover onto puller.
4. Install nut onto puller rod and hand tighten. Turn
puller barrel to increase tension as needed.
5. Turn clutch cover counterclockwise on puller rod until
bushing is removed and cover comes free.
7. Remove bushing and bushing removal tool from
puller. Discard bushing.
COVER BUSHING INSTALLATION
1. Apply Loctite® 620 evenly to bushing bore in cover.
2. Install adapter cup (PN 5020632) on puller, insert
cover onto puller rod, placing inside of cover toward
vise.
IMPORTANT
When installing the bushing, the inside of the cover
should be facing the barrel of the Piston Pin Puller or
damage to the cover may result.
3. Working from outside of cover, insert new bushing

and adapter tool (PN 5020634) into center of clutch
cover.
4. Install nut on rod and hand tighten. Turn puller barrel
to apply more tension if needed.

PVT SYSTEM
CLUTCH ASSEMBLY (NON-EBS) MOVEABLE SHEAVE

NOTICE 1. Install clutch spider as shown.
The Teflon® bushings are self-lubricating. NOTICE
If necessary, once the splines are aligned properly, an
arbor press may be used to properly seat the clutch
CAUTION spider.
Do not apply oil or grease to the bushings.
Reassemble the drive clutch in the following sequence.

Be sure the “X”, or the marks that were made earlier are
aligned during each phase of assembly.
2. Install washer, belleville washer , and clutch spring.

IMPORTANT
outer post.
STATIONARY SHEAVE

PVT SYSTEM
3. Install the clutch cover and clutch cover bolts. Hand 5. Install the clutch slip post.
tighten bolts.
IMPORTANT
4. Install cover bolts and torque in a cross pattern Ensure that the slip post passes through both washers
evenly to specification. during installation. If the slip post is not seated, the
washers may fall out causing improper operation.
INSTALLATION
1. Install stationary sheave assembly q. 6
TORQUE
Drive Clutch Cover Bolts:
100 in-lbs (11 Nm)
2. Install moveable sheave assembly.

PVT SYSTEM
3. Install drive clutch bolt e. Using drive clutch holding

tool torque bolt to specification.
Drive Clutch Holding Fixture
PU-52430
TORQUE
Drive Clutch Bolt (Moveable sheave only removed):
96 ft-lbs (130 Nm)
TORQUE

PVT SYSTEM
CLUTCH ASSEMBLY (EBS) 2. Install the EBS sleeve assembly ensuring the sleeve
NOTICE
q is seated flush with the stationary sheave w.
The Teflon® bushings are self-lubricating.
CAUTION
Do not apply oil or grease to the bushings.
Reassemble the drive clutch in the following sequence.

Be sure the “X”, or the marks that were made earlier are
aligned during each phase of assembly.
IMPORTANT
During reassembly ensure the EBS cam remains fully
seated with the Stationary Sheave. If not properly
seated the EBS cam can be damaged and severe
creeping will occur.

6
STATIONARY SHEAVE
1. If removed, install a new o-ring q and helix w
ensuring it is fully seated and engaged with the drive
lugs of the stationary sheave.

PVT SYSTEM
MOVEABLE SHEAVE 3. Install the clutch cover and clutch cover bolts. Hand
tighten bolts.
1. Install clutch spider as shown.
NOTICE
If necessary, once the splines are aligned properly, an
arbor press may be used to properly seat the clutch
spider.
4. Install cover bolts and torque in a cross pattern

evenly to specification.
2. Install washer, belleville washer , and clutch spring.

IMPORTANT
outer post.
TORQUE
Drive Clutch Cover Bolts:
100 in-lbs (11 Nm)

PVT SYSTEM
5. Install the clutch slip post. 3. Install drive clutch bolt e. Using drive clutch holding
tool torque bolt to specification.
Drive Clutch Holding Fixture
PU-52430
IMPORTANT
Ensure that the slip post passes through both washers
during installation. If the slip post is not seated, the
washers may fall out causing improper operation.
TORQUE
INSTALLATION Drive Clutch Bolt (Moveable sheave only removed):
1. Install stationary sheave assembly q.
96 ft-lbs (130 Nm)
6
TORQUE
2. Install moveable sheave assembly w.

PVT SYSTEM
DRIVEN CLUTCH SERVICE

DRIVEN CLUTCH ASSEMBLY VIEW
q Driven Clutch Bolt d Spring Cup

20 ft-lbs (27 N·m)
f Circlip
w Washer Fully seat in groove
e Shim g Bushing
Clutch may use 0-8 shims
r h Moveable Sheave
t Bushing j Windage Plate
k Windage Plate Fastener
y 4 ft-lbs (6 N·m)
u Stationary Sheave l Washer
i Bushing 1( Helix Fasteners
44 ft-lbs (60 N·m)
o Circlip 2) Spring Pin / Roll Pin
Fully seat in groove Non - serviceable (Retains Roller Pin in Movable Sheave)
a Helix 2! Roller Pin

Non - serviceable
s Spring 2@ Roller
Snap - fit to Roller Pin

PVT SYSTEM
DRIVEN CLUTCH DISASSEMBLY 4. Disassemble the spring cap, clutch spring, and helix
from the stationary sheave.
1. Remove driven clutch from the transmission input
shaft.
IMPORTANT
It is important to mark the position of the helix cover,
sheaves and spider with a tape or grease marker
before disassembly. Some components will have X’s on
the components for alignment reference. This helps
with clutch assembly and maintains clutch balance.
2. Separate the sheaves and place the driven clutch

(helix side down) into the Universal Clutch
Compressor.
IMPORTANT
Mark Helix to Sheave hole orientation before removing
helix.
5. Inspect roller for play and wear or rough spots by

rotating it. If excessive wear, rough spots, or play
exists replace the roller. Rollers are “snap-fit” to the 6
roller pin and should be replaced if the roller does not
stay retained to the pin.
NOTICE
Roller pin is not serviceable.
Universal Clutch Compressor: PU-50518-A
3. Spin the compressor down until it just starts to

contact the helix cover. Remove the three fasteners
that secure the cam (helix) assembly. Remove the
universal clutch compressor.
6. Inspect the sheaves for excessive wear or damage.

Replace if necessary.
CAUTION
The helix cover is loaded by the spring. Not using a
proper compressor may result in personal injury or
damage to the clutch.

PVT SYSTEM
HELIX AND MOVABLE SHEAVE BUSHING SERVICE

BUSHING INSPECTION HELIX BUSHING REMOVAL
1. Inspect the Teflon® coating q on the moveable 1. Install the main adapter q on puller.
sheave bushing. Inspect Sheave for signs of wear,
grooving or cracking. De-glaze sheave surfaces with
a 3M Scotch-Brite™ Pad if needed. Replace if
needed.
Moveable Sheave Bushing Inspection:
Replace the movable sheave if more brass than
Teflon® is visible on the bushing.
2. From the inside of the Helix, insert bushing adapter

w (PN 5020636) into the bushing. Install spacer and
top nut to secure adapter on Helix.
3. Insert the piston pin puller in a vise.
4. Using a pry bar located between the fingers of the
helix, turn the helix counter clockwise to remove the
bushing.
2. Inspect the Teflon® coating w on the Helix bushing. 5. Remove the nut from the puller rod and set aside.
Inspect Helix for signs of wear, grooving or notching
on ramps. De-glaze surfaces with a 3M Scotch- 6. Remove the bushing and bushing removal tool from
Brite™ Pad if needed. Replace if needed. the puller. Discard the bushing.
Helix Bushing Inspection: HELIX BUSHING INSTALLATION

Replace the Helix bushing if more brass than Teflon® is 1. Apply Loctite 620R evenly to bushing bore in cover.
visible on the bushing. Refer to Bushing Service page
6.44procedure.
2. From the bottom of the Helix, insert the new bushing

and bushing adapter w (PN 5020636)
3. Install the main adapter q, spacer adapter, and
securing nut on top of the Helix.

PVT SYSTEM
4. Use a pry bar located between the fingers of the Helix 3. Loosely install the retaining fasteners attaching the
to turn the Helix counterclockwise. Turn until bushing helix to the stationary sheave using previous hole
bottoms out. orientation.
IMPORTANT
Only light force is needed to install the bushing. Do not
increase pressure after bushing bottoms out, or
damage may result to bushing.
5. Remove nut and spacer adapter from puller rod. Re-

move Helix and bushing adapter from puller rod.
DRIVEN CLUTCH ASSEMBLY

1. Install the roller. Rollers are “snap-fit” to the roller pin
and should be replaced if the roller does not stay
retained to the pin. Ensure the roller is fully seated
and roller rotates freely.
4. Using clutch compressor compress the driven clutch
assembly.
CAUTION
The helix cover is loaded by the spring. Not using a
proper compressor may result in personal injury or
damage to the clutch.
6
5. Torque the fasteners to specification.

TORQUE
Helix Fasteners:
44 ft-lbs (60 N·m)
2. Install the spring cap, clutch spring, and helix on the 6. Verify the alignment marks made during disassembly
stationary sheave. Ensure the clutch spring is fully are properly aligned.
seated. 7. Install the stationary and movable sheave on the
vehicle. See PVT Inner Cover Assembly page

PVT SYSTEM
PVT SYSTEM DIAGNOSTICS

PVT TROUBLESHOOTING
-Wrong or broken drive clutch -Replace with recommended spring.
spring.
-Install correct shift weight kit to match
Engine RPM below specified
-Drive clutch shift weight too heavy. engine application.
operating range, although engine
is properly tuned.
-Replace spring; refer to proper
-Driven clutch spring broken or installation location.
installed in wrong helix location.
-Drive clutch binding. A. Disassemble drive clutch; inspect
shift weights for wear and free
operation.
B. Clean and polish stationary shaft
hub; reassemble clutch without spring
to determine problem area.
Erratic engine operating RPM -Belt worn unevenly - thin / burnt
during acceleration or load spots. Replace belt.
variations.
-Driven clutch malfunction. A. Replace ramp buttons.
B. Inspect movable sheave for
excessive bushing clearance.
-Sheave face grooved. -Replace the clutch.

-Incorrect drive clutch spring (too -Install correct recommended spring.
high of rate).
-Install correct recommended shift
-Drive clutch shift weights incorrect weights.
for application (too light).
-Drive clutch binding. -Disassemble and clean clutch,

inspecting shift weights and rollers.
Reassemble without the spring and
Engine RPM above specified
move sheaves through entire range to
operating range.
further determine probable cause.
-Driven clutch binding.
-Disassemble, clean, and inspect
driven clutch, noting worn sheave
bushing and ramp buttons and helix
-Converter sheaves greasy; belt spring location.
slipage.
-Clean sheaves with denatured alcohol
or brake cleaner, install new belt.
-Drive belt worn too narrow. -Replace belt.
-Excessive belt / sheave clearance -Perform belt / sheave clearance

Harsh drive clutch engagement. with new belt. adjustment with shim washers beneath
-Worn spider rollers / worn spider spider.
roller washers -Replace spider rollers / spider roller
washers
Drive belt turns over -Wrong belt for application. -Replace with correct belt.
-Abuse (continued throttle -Caution operator to operate machine
Belt burnt, thin spots application when vehicle is within guidelines.
stationary, excess load)

PVT SYSTEM

-Inspect brake system.
-Dragging brake
-Slow, easy clutch engagement -Fast, effective use of throttle for
efficient engagement.
-Plugged air intake or outlet. -Clear obstruction
-Belt slippage due to water, oil, -Inspect system. Clean , repair or

grease, etc., rubbing on cover. replace as necessary.
-Clutches or weight being applied to Seal PVT system ducts.
cover while in operation. -Remove weight. Inform operator.
PVT cover overheating (melting)
-High vs. low range.
-Instruct operator on guidelines for
operation in proper driving range for
different terrain as outlined in Owner’s
Safety and Maintenance Manual.
-Cover seals or ducts leaking -Find leak and repair as necessary.
Water ingestion -Operator error -Instruct operator on guidelines for

operation in wet terrain as outlined in
Owner’s Safety and Maintenance
Manual.
-Belt worn out -Replace belt.
6
Belt slippage -Water ingestion -Inspect and seal PVT system.
-Belt contaminated with oil or grease -Inspect and clean.

-Belt worn or separated, thin spots, -Replace belt.
loose belt -Inspect and repair as necessary.
PVT noise -Broken or worn clutch components,
cover hitting clutches
-Replace belt. Refer to belt burnt
Engagement -Thin spots on belt, worn belt
troubleshooting and instruct operator.
erratic or stabby -Drive clutch bushings stick
-Inspect and repair clutches.
Groove on the side of the belt next
Interaction with Flange-Sleeve No action needed. This is a Function of
to the cogs up to approximately
System the EBS mechanism
0.10” (0.25 mm) deep
Inspect the Stationary Shaft and Flange
Grooving on the inner cogs of belt Sticking of the Flange Sleeve Sleeve Bushings, EBS Spring, and
next to Stationary Sheave. Assembly Drive Helix. Clean / Replace as
necessary

PVT SYSTEM

Verify flange sleeve is retracting to flush
with stationary sheave at idle
Shim and align clutches to ensure
proper alignment
Creeping, Hard Shifting, Clutches Drag on the one-way bearing or Inspect the one-way bearing for drag,
rotating at idle Flange Sleeve sticking Inspect the flange sleeve bushing, drive
helix, and stationary shaft for smoot
operation.
Verify EBS spring is in the proper
position.
Clunking noise on drive away Normal operation No action needed

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

Loading the vehicle into a tall trailer Shift transmission to Low during loading of the vehicle to prevent belt
when in high range. burning.
Starting out going up a steep incline When starting out on an incline, use Low gear. Shift transmission to Low
from a stopped position. during loading of the vehicle to prevent belt burning.
Driving at low RPM or low ground Drive at higher speed or use Low. The use of Low is highly recommended
speed (at approximately 3-7 MPH). for cooler PVT operating temperatures and longer component life.
Warm engine at least 5 min., then with transmission in neutral, advance
Insufficient engine warm-up when
throttle to approx. 1/8 throttle in short bursts, 5 to 7 times. The belt will
exposed to low ambient temperatures.
become more flexible and prevent belt burning.
Slow and easy clutch engagement. Fast, effective use of the throttle for efficient engagement.
Shift the transmission to Low, carefully use quick, firm throttle application
Stuck in mud or snow. and avoid excessive slipping of the PVT system. WARNING: Excessive
throttle may cause loss of control and vehicle overturn.
6
Shift the transmission to Low, carefully use quick, firm throttle application
Climbing over large objects from a
and avoid excessive slipping of the PVT system. WARNING: Excessive
stopped position.
throttle may cause loss of control and vehicle overturn.
Remove the PVT drain plug. Shift the transmission to neutral. Using the
throttle, vary the engine rpm from idle to full throttle. Repeat several times
Belt slippage from water or snow
as required. During this procedure, the throttle should not be held at the
ingestion into the PVT system.
full position for more than 10 seconds. Clutch seals should be inspected
for damage if repeated leaking occurs.
Clutch component inspection should be performed by a Polaris MSD
Clutch malfunction.
certified technician.
Fouled spark plugs, foreign material in fuel tank, restricted fuel lines, or
Poor engine performance.
faulty fuel pump may cause symptoms similar to clutching malfunction.
Low: Heavy pulling, basic operational speeds less than 7 MPH, riding
GENERAL RANGE OPERATION through rough terrain (swamps, mountains, ect.), low ground speeds.
GUIDELINES:
High: High ground speeds, or speeds above 7 MPH.
Operating in Low Gear

Low gear should be used when riding through rough terrain or when basic operational ground speeds are less than 7
MPH. Use High gear when basic operational ground speeds are more than 7 MPH.
NOTICE
Using High gear for heavy loads, hilly terrain, or in wet, muddy conditions will increase the chance of drive belt
burning.

PVT SYSTEM
VEHICLE CREEPING
Engine
calibration error
Start Vehicle in
Park or N. Is idle
speed 1250
→
No
or intake leak is
probable. Refer
to Engine
+/-100 RPM? Troubleshooting
or Fuel System
Troubleshooting.
Yes ↓
With the engine
idling on flat and
level ground in P
or N, shift through
all gears and note
shift effort.
→
No
Shift linkage/
cable issue.
Proceed to
diagnose shift
Repeat with
engine off. More cable issues.
difficult with
engine idling?
↓
Follow the proper
direction: q for Perform clutch
hard shifting/
creeping. w for
unconfirmed
→
q
alignment. Refer
to Driven Clutch
Alignment. Does → Yes
Replace the
idle bearing /
slide sleeve
customer the vehicle still assembly and
complaint of hard creep? helix.
shifting/creeping.
w ↓ Service
Accelerate to 5
→ Spider
→ →
Shift to Low.
MPH in Low; Rollers.
Does the vehicle How many
Release gas Less Refer to
rock or drive miles are on
No pedal; Does than Roller, Pin,
when you put it No vehicle?
vehicle come to a 800 and Thrust
into gear?
stop? Washer
Inspection.
Yes ↓ Yes ↓ ↓
Greater than
800

PVT SYSTEM
Probable
interference Inspect spider
between rollers -
movable Remove the
sheave towers drive clutch Service
Warm clutches and spider
Perform clutch cover by Spider
alignment. Refer
to Driven Clutch
Alignment. Does
up by driving at
moderate speeds
in high gear for 2
miles; Does
→
No
buttons.
Remove belt
and drive
spring.
referring to
Belt Removal.
Apply load on
→
No
Rollers.
Refer to
PVT Inner
the vehicle each roller Cover
Vehicle come to a Reinstall
creep? firmly with Disassem-
stop? cover and your finger bly.
operate clutch while rotating.
by hand. Is Do all three
there rotate freely?
resistance to
motion?
Yes ↓ Yes ↓ Yes ↓

Remove
Yes ↓
spider and
lightly sand
with a high grit 6
Replace idle sandpaper Replace
PVT System Inspect the
bearing/slide
sleeve assembly
and helix. Refer
to Clutch
operating
properly at this
time. No further
(220 or
higher).
Remove
material so
idle bearing
for free
rotation. Does
→
No
the idle
bearing/
slide
sleeve
action is it rotate
Inspection and button rides assembly
necessary. freely?
Bushing Service. smoothly in and helix
tower.
OR
Replace drive
clutch.
Yes ↓
If problem
persists,
replace the
drive clutch.

PVT SYSTEM
NOTES

TRANSMISSION
CHAPTER 7
TRANSMISSION
GENERAL INFORMATION - TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
SERVICE NOTES - TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
SPECIAL TOOLS - TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
SERVICE SPECIFICATIONS - TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
GEAR, SHAFT, BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
TRANSMISSION ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
TRANSMISSION SUBASSEMBLY VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
TRANSMISSION VENT LINE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
SHIFT CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
SHIFT CABLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
SHIFT LEVER REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.10
SHIFT CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.10
SHIFT CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.13
SHIFT CABLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.14
SHIFT CABLE SERVICE (HVAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.19
DIFFERENTIAL OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.25
TRANSMISSION SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.26
TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.26 7
TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.29
TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.32
GEAR CLUSTER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.35
SNORKEL TUBE REMOVAL / DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.36
BEVEL DIFFERENTIAL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.37
BEVEL DIFFERENTIAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.38
SNORKEL GEAR BACKLASH PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.40
TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.43
TRANSMISSION DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.49
TROUBLESHOOTING - TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.49

TRANSMISSION
GENERAL INFORMATION - TRANSMISSION

SERVICE NOTES - TRANSMISSION SERVICE SPECIFICATIONS -
TRANSMISSION
WARNING
FLUID CAPACITY
sure machine is secure before beginning any procedure Recommended Transmission Lubricant: AGL
that requires machine lifting. Always wear eye (PN: 2878068) (Quart)
protection. Capacity: 52 fl oz ( 1550 mL)
The transmission has two traction operational modes:

Differential Lock and Differential Unlock. Locking the rear
differential is beneficial in low traction and rough terrain GEAR, SHAFT, BEARING INSPECTION
conditions. Unlocking the rear differential makes During transmission disassembly and assembly, all of
maneuvering easier and minimizes damage to terrain. the gears, shafts, bushings, and bearings should be
inspected for any excessive wear or damage. If there is
unusual wear or damage found replace parts as
SPECIAL TOOLS - TRANSMISSION necessary.
PART
TOOL DESCRIPTION Failed parts may also cause damage to corresponding
NUMBER
PU-52547 Snorkel Tube Tool parts. This can apply to gears, bushings, bearings and
other internal parts. Reference Transmission
2871699 Rear Driveshaft Seal Guide Subassembly Views page 7.4 for gear and bearing
2871698 Rear Output Seal Driver locations.
2871282 Bearing Seal Driver (50 mm)
All parts should be inspected and replaced prior to
Bosch Automotive Service Solutions: 1-800-345-2233 transmission assembly.
or http://polaris.service-solutions.com
IMPORTANT
If gear replacement is required, also replace the
corresponding gear and/or gear shaft.

TRANSMISSION
TRANSMISSION ASSEMBLY VIEW
q Turf Solenoid i Bearing Cover Fastener (QTY 3)

25 ft-lbs (34 Nm) 9 ft-lbs (12 Nm) 7
w Bellcrank Nut o Bearing Cover Fastener
e Ring Gear Fastener (QTY 8) a Fork Retainer Fastener
r Park Plate Fastener (QTY 3) s Transmission Case Fastener (QTY 14)
t Sector Cover Fastener (QTY 5) d Fill Plug
y Speed Sensor Fastener f Rear Mount Bracket Fastener (QTY 2)
u Drain Plug, Magnetic
12 ft-lbs (16 Nm)

TRANSMISSION
TRANSMISSION SUBASSEMBLY VIEWS

GEAR CLUSTER ASSEMBLY
q Bearing s Snap Ring

w Shift Dog, Park / Low d Engagement Dog, High / Reverse
e Snap Ring f Snap Ring
r Thrust Washer g Thrust Washer
t Gear, Low h Needle Bearing
y Needle Bearing j Gear, High
u Shaft, Reverse k Thrust Washer
i Needle Bearing l Snap Ring
o Gear, Reverse 1( Bearing
a Thrust Washer

TRANSMISSION
INPUT SHAFT SUBASSEMBLY SHIFT FORK
q Shim t Gear, Low q Snap Ring a Spring

w Bearing y Input Shaft w Cup, Washer s Cup, Washer
e Snap Ring u Bearing e Spring d Snap Ring
r Washer r Shift Fork f Snap Ring
t Spring g Spacer
PINION SUBASSEMBLY
y Shift Collar h Spring, Torsion
u Shift Rail j Park Cam 7
i Spring k Shift Drum
o Shift Fork
q Bearing y Fastener M6 x 1.0 x 40

w Snap Ring u Cover, Bearing Center
Drive
e Thrust Washer i Snap Ring
r Gear, Stage 3 o Bearing
t Fastener M6 x 1.0 x 18 a Pinion Shaft

TRANSMISSION
IDLER ASSEMBLY SNORKEL / FRONT OUTPUT
q Bearing e Bearing q Seal u O-ring

w Gear Idler w Snap Ring i Gear, Snorkel
e Snap Ring o Bearing
r Bearing a Thrust Washer
t Shaft, Front Output s Snap Ring
y Tube, Snorkel
q Bearing r Thrust Washer

w Shaft, Idler t Snap Ring
e Gear, Stage 2 1( Bearing

TRANSMISSION
BELLCRANK / SHIFT SHAFT / TRANS-

MISSION RANGE SENSOR
q Nut i Snap Ring

w Bellcrank o Spring Washer
e O-ring a Thrust Washer
r Pawl Assembly s Transmission Range
Sensor
t Shift Shaft d O-ring
y Gear, Sector f Star, Detent 7
u Spring g Gear, Sector

TRANSMISSION
TRANSMISSION VENT LINE ROUTING

The transmission vent line runs along the rear passenger side frame. It is secured along the front frame by one
retention clip as shown. The vent line ends its routing secured into a vertical section of the frame with a vent line
termination fitting.

TRANSMISSION
SHIFT CABLE
SHIFT CABLE INSPECTION 4. Push shifter into Park while looking for dash
movement. If the plastic dash moves and the shifter
1. Place the vehicle on a flat surface in park, chock the
contacts the cut-out before a shift is complete, the
wheels, and turn the ignition key off.
shift cable is not adjusted correctly.
2. Remove rubber bezel surrounding the shifter.
5. If the shift cable is found to be out of adjustment,

3. Push shifter into High Gear while looking for dash proceed with Shift Cable Adjustment.
movement. If the plastic dash lifts and the shifter
contacts the cut-out before a shift is complete, the STOP!
shift cable is not adjusted correctly. If the shifter does not contact the dash in park or high
the shift cable requires no further adjustment, reinstall
the rubber bezel.
Shift cable adjustment may be necessary if symptoms

7
include:



TRANSMISSION
SHIFT LEVER REMOVAL / SHIFT CABLE ADJUSTMENT

INSTALLATION Shift cable adjustment may be necessary if symptoms
include:
1. Remove the shift knob cover q. Remove retaining
screw w and shift knob e from the shift lever r. • No gear position or incorrect gear position shown.

1. Shift to High Gear, release the shifter. Measure the
distance between shifter and top side of the dash
opening.
2. Remove the four push rivets retaining the upper dash

panel and remove the panel to access the shift lever.
3. Remove the rubber grommet t from the dash and
shift lever r.
2. Shift to Park, release the shifter. Measure the

distance between shifter and bottom side of the dash
opening.
4. Remove nut s retaining the shift cable i to the shift

lever r. Disconnect cable end from the lever.
5. Remove the retaining ring o and slide the shift lever
r off the mounting bracket and out from the frame.
6. Remove both bushings a from the shift lever and
service as needed.
7. Perform the previous steps in reverse order to
reinstall the shift lever (lever, cable, dash panel, shift
knob).
NOTICE
For optimal shift cable adjustment, the gap
measurements in High and Park should be equal. This
will ensure the shifter will not contact the dash.

TRANSMISSION
3. Locate the shift cable q through the right rear wheel 6. With the cable removed from the bracket, turn the
well area. upper jam nut y to adjust the cable. Moving the
upper jam nut y closer to the shift cable boot creates
a larger gap in high. Moving the upper jam nut y
away from the shift cable boot creates a larger gap in
park.
NOTICE
1 full turn of the adjustment nut y equals approximately
1 mm of dash gap.
CLOSER TO DASH IN HIGH GEAR
4. Inspect shift cable q, dust boot w, clevis pin and

pivot bushings e, and mount r. Verify there is no
wear or damage. Replace if wear or damage is found.
CLOSER TO DASH IN PARK 7
5. Loosen the lower jam nut t and pull the cable out of
the mount bracket to move the upper jam nut y.
7. Reinstall the cable in the bracket.

TRANSMISSION
8. While holding the upper jam nut y use a crows foot

to tighten the lower jam nut t. Torque to
specification.
IMPORTANT
When setting torque using a crows foot, the socket
must be at a 90° angle to the torque wrench as shown.
TORQUE
Lower Jam Nut:
13 ft-lbs (18 N·m)
9. After adjustment verify there is no contact with the

dash in both Park/High. If the shifter is still contacting
the dash, repeat the adjustment procedure until there
is no contact with the dash.
10. Reinstall the rubber bezel.
11. With the engine off, check the following:
• Shifter fully engages all gears.
• Dash is not moving when shifting into Park/High

TRANSMISSION
SHIFT CABLE ROUTING

NOTICE
Ensure the retention points q and the jam nuts w are secure.
TOP VIEW
7
SIDE VIEW

TRANSMISSION
SHIFT CABLE SERVICE 6. Remove the 10mm fastener w, two push rivets e,
and T40 Torx fastener r securing the left dash
NOTICE bracket.
On INTL models the parking brake may interfere with
the shift cable service. Refer to the Brake System
Chapter for more information.
REMOVAL
1. Remove the fresh intake line behind the bulkhead to
gain access to the shift cable routing. Refer to Intake
System Assembly View page 3.15.
NOTICE
This step is not applicable on High Lifter models.
2. If equipped, remove the Ride Command screen.

Refer to Ride Command Monitor Service page 13.39
3. Remove the upper dash panel. Refer to Dash Panels 7. Rotate the left dash bracket t to the left as shown
/ Glove Box Service page 11.34. and remove from the vehicle.
4. Remove the two push rivets q from the center dash
trim panel.
8. Remove the 10mm nut y from the shift cable u, and

remove the cable from the shift lever.
5. Rotate the center trim panel upwards, disconnect the

electrical connectors and release from the upper
retaining tabs. Remove from the vehicle.

TRANSMISSION
9. Loosen the locknut i behind the dash, and remove 14. Remove the shift cable from the retainer a near the
the shift lever from the retaining bracket vehicle battery.
10. Remove the fresh intake line behind the bulkhead to 15. Remove the 10mm fastener s securing the shift
gain access to the shift cable routing. Refer to Intake cable to the transmission.
System Assembly View page 3.15.
NOTICE
This step is not applicable to High Lifter models.
11. Remove the propshaft tunnel cover. Refer to Floor

Removal / Installation page 11.39.
12. Remove the shift cable from the two retainers o
under the propshaft tunnel cover. 7
13. Remove the storage bin above the battery.

TRANSMISSION
16. Loosen the fasteners d securing the shift cable INSTALLATION

brackets f to the transmission and remove the
1. Install the shift cable in the transmission bracket.
brackets.
Torque the locknut g to specification.
NOTICE
On INTL models the shift cable will be mounted to the
park brake caliper bracket. Remove the fasteners
securing the cable.
TORQUE
Shift Cable Locknut:
13 ft-lbs (18 Nm)
17. Remove the shift cable from the vehicle 2. Install the shift cable in the vehicle. Refer to Shift
Cable Routing page 7.13 for proper routing.
18. Loosen the locknut g securing the shift cable to the
transmission bracket. Retain bracket for reassembly. 3. Install fasteners d securing the shift cable brackets
f to the transmission and torque to specification.
NOTICE
On INTL models the shift cable will be mounted to the
park brake caliper bracket. Install the fasteners
securing the cable.
TORQUE
Shift Cable Brackets:
37 ft-lbs (50 Nm)

TRANSMISSION
4. Install the cable in the transmission shift bracket. 7. Secure the cable to the propshaft tunnel retainers o.
Install a new fastening nut s and torque to
specification.
8. Install the shift cable into the dash retainer, and

torque the locknut i to specification.
TORQUE
Shift Cable Fastening Nut:
13 ft-lbs (18 Nm)
5. Secure the cable to the chassis retainer a behind the

battery.
TORQUE
13 ft-lbs (18 Nm)
6. Reinstall the storage bin above the battery.

TRANSMISSION
9. Install the shift cable u into the shift lever assembly 11. Install the T40 Torx fastener r, two push rivets e,
and secure with a new fastening nut y. Torque to and 10mm fastener w. Torque fasteners w and r to
TORQUE TORQUE
Shift Cable Fastening Nut: 10mm Dash Bracket Fastener:
10. Install the left dash bracket t by rotating in as TORQUE

shown. T40 Dash Bracket Fastener:
42 in-lbs (5 Nm)
12. Install the center dash panel and connect all electrical
connectors.
IMPORTANT
Ensure the top retaining tabs are engaged in the dash.

TRANSMISSION
13. Install the two push rivets q into the bottom of the SHIFT CABLE SERVICE (HVAC)
center dash trim panel. REMOVAL
1. Remove the four T20 Torx fasteners q securing the
wiper motor trim panel to the windshield.
14. Install the fresh intake line behind the bulkhead. Refer
to Intake System Assembly View page 3.15.
NOTICE 2. Disconnect the wiper motor connectors w and set the
This step is not applicable on High Lifter models. trim panel with rear view mirror aside.
15. Install the propshaft tunnel cover. Refer to Floor

Removal / Installation page 11.39.
16. Install the upper dash panel. Refer to Dash Panels /
Glove Box Service page 11.34.
17. If equipped, install the Ride Command screen. Refer
7
to Ride Command Monitor Service page 13.39
3. Release the lock-and-ride connections e securing

the windshield to the ROPS.
4. With the aid of an assistant, remove the windshield

and set aside.

TRANSMISSION
5. If equipped, remove the Ride Command screen. 9. Remove the 10mm fastener y, two push rivets u,
Refer to Ride Command Monitor Service page 13.39 and T40 Torx fastener i securing the left dash
bracket.
NOTICE
Panduit straps connecting HVAC vent hoses to vents
will need to be cut and replaced. Refer to HVAC
Assembly View page for panduit strap locations.
7. Remove the two push rivets r from the center dash

trim panel.
10. Rotate the left dash bracket o to the left as shown

and remove from the vehicle.
8. Rotate the center trim panel t upwards, disconnect

the electrical connectors and release from the upper
retaining tabs. Remove from the vehicle.
11. Remove the 10mm nut a from the shift cable s, and
remove the cable from the shift lever.

TRANSMISSION
12. Loosen the locknut d behind the dash, and remove 17. Loosen the locknut h securing the shift cable to the
the shift lever from the retaining bracket. transmission bracket.
13. Remove the propshaft tunnel cover. Refer to Floor 18. Remove the 10mm fastener j securing the shift
Removal / Installation page 11.39. cable to the transmission.
14. Remove the shift cable from the two retainers f
under the propshaft tunnel cover.
19. Remove the shift cable from the vehicle.
15. Remove the storage bin above the battery.

16. Remove the shift cable from the retainer g near the
vehicle battery.

TRANSMISSION
INSTALLATION 4. Secure the cable to the chassis retainer g near the

vehicle battery.
1. Install the shift cable in the vehicle. Refer to Shift
Cable Routing page 7.13 for proper routing.
2. Install the cable in the transmission shift bracket.
Install a new fastening nut j and torque to
specification.
5. Reinstall the storage bin above the battery.

6. Secure the cable to the propshaft tunnel retainers f.
TORQUE
Shift Cable Fastening Nut:
13 ft-lbs (18 Nm)
3. Install the shift cable into the transmission retaining

bracket and torque the locknut h to specification.
7. Install the shift cable into the dash retainer, and

torque the locknut d to specification.
TORQUE
13 ft-lbs (18 Nm)
TORQUE
13 ft-lbs (18 Nm)

TRANSMISSION
8. Install the shift cable s into the shift lever assembly 10. Install the T40 Torx fastener i, two push rivets u,
and secure with a new fastening nut a. Torque to and 10mm fastener y. Torque fasteners y and i to
TORQUE TORQUE
Shift Cable Fastening Nut: 10mm Dash Bracket Fastener:
9. Install the left dash bracket o by rotating in as TORQUE

shown. T40 Dash Bracket Fastener:
42 in-lbs (5 Nm)
11. Install the center dash panel t, and connect all 7

electrical connectors.
IMPORTANT
Ensure the top retaining tabs are engaged in the dash.

TRANSMISSION
12. Install the two push rivets r into the bottom of the 18. Connect the wiper motor connectors w, and install
center dash trim panel. the trim panel with rear view mirror.
13. Install the propshaft tunnel cover. Refer to Floor 19. Install the four T20 Torx fasteners q to secure the
Removal / Installation page 11.39. wiper motor trim panel to the windshield. Torque to
specification.
Glove Box Service page 11.34.
15. If equipped, install the Ride Command screen. Refer
to Ride Command Monitor Service page 13.39
16. With the aid of an assistant, install the windshield.
17. Rotate the lock-and-ride connections e to secure the
windshield to the ROPS.
TORQUE
Windshield Wiper Motor Trim:

TRANSMISSION
DIFFERENTIAL OPERATION When “Differential-Lock” is selected in either 2WD or

Transmissions equipped with Turf Mode have three 4WD, power is removed from the electrical solenoid
traction operational modes: Differential Lock in 2WD & allowing the solenoid plunger to retract. Spring tension
4WD and Differential Unlock in Turf mode. Differential moves the shift fork back into place and mates the
lock is beneficial in low traction and rough terrain engagement dog to the side gear that is part of the
conditions. Differential unlock makes maneuvering planetary differential assembly. This locks the rear
easier and minimizes damage to terrain. differential as a solid rear axle, increasing traction.
When “Differential-Unlock” is selected, the rear

differential becomes unlocked for tighter turns. An
electrical solenoid mounted in the rear portion of the
gearcase actuates the shift fork. The solenoid plunger
extends out to move the fork and slides the engagement
dog away from the side gear that is part of the planetary 7
differential assembly. This unlocks the rear differential.
The rear drive shafts are now dependent on the
differential allowing for tighter turns.
IMPORTANT
TURF mode is only available in drive gears and when
the parking brake is released (INTL models).

TRANSMISSION
TRANSMISSION SERVICE
TRANSMISSION REMOVAL 8. Place a shop towel around the fuel line to catch any
dripping fuel. Disconnect the fuel supply w at the fuel
CAUTION rail. Refer to Fuel Line Quick Connect Removal page
Serious injury may result if machine tips or falls. Be 5.9.
sure machine is secure before beginning this
procedure. Always wear eye protection.
1. Disconnect the (-) negative battery cable from the

battery.
2. Remove Cargo Box. See Cargo Box Removal page
11.33
3. If internal transmission repair is required, drain the
transmission lubricant (see Transmission Fluid
4. Remove both rear drive shafts from the transmission.
Refer to Rear Drive Shaft Removal page 8.49
procedure
5. Remove the outer clutch cover and belt. Refer to Belt 9. Disconnect TMAP, CPS, Coolant Temp Sensor, Trans
Removal page 6.6 procedure. Switch, Speed Sensor, Injectors, ETC.
6. Remove drive and driven clutch and inner clutch
cover. Refer to PVT Inner Cover Disassembly page
procedure.
7. Remove the vent line from the transmission fitting q.

TRANSMISSION
10. With the transmission in neutral, remove two bolts 13. Remove the intake manifold assembly from the
securing the Rear Prop Shaft to the transmission. vehicle.
14. Disconnect the transmission shift cable by removing
the clip and sliding the washer and shift cable off the
bellcrank.
NOTICE
To aid in removal, rotate prop shaft to access bolts
15. Mark the location of the shift cable and upper jam nut
11. Loosen and remove intake clamps to TPS e and
retaining intake manifold r to engine.
y. Loosen the lower jam nut t and remove the shift
cable assembly from the bracket.
12. Remove lower manifold mounting fastener to 16. Support the engine. Remove the rear transmission
transmission mount bracket. isolator fasteners u.

TRANSMISSION
17. Remove the two fasteners i retaining the rear

isolator to the frame bracket.
18. Lift the transmission out the top of the vehicle

chassis.

TRANSMISSION
TRANSMISSION INSTALLATION 4. Inspect seal 5416417 prior to installing PVT inner

cover. Replace seal if damaged. Install seal to the
CAUTION groove in the clutch cover around crankshaft opening
Serious injury may result if machine tips or falls. Be and o-ring 5415647 to transmission in the groove
sure machine is secure before beginning this around the input shaft. L
procedure. Always wear eye protection. NOTICE
Make sure O-ring seal is in place in the transmission
1. Install transmission through the top of the vehicle gland around the input shaft prior to installing the cover.
chassis.
2. Install rear transmission mount to the frame bracket. 5. Install the PVT inner cover. Refer to PVT Inner Cover
Torque fasteners i to specification. Assembly page
6. Install the drive clutch, belt and driven clutch. Install
washer and shims on transmission input shaft before
installing driven clutch mounting bolt. Torque
TORQUE
Drive Clutch Bolt:
96 ft-lbs (130 Nm)
Driven Clutch Bolt:

43 ft-lbs (58 Nm)
7. Install PVT hoses and outer PVT cover. Torque

TORQUE TORQUE
Rear Transmission Mount Fasteners:
7
Hose Clamps:
22 ft-lbs (30 Nm) 35 in-lbs (4 Nm)
Outer PVT Cover Fasteners:

3. Install transmission isolator bolt u through the
transmission bracket and isolator. Torque fasteners to 35 in-lbs (4 Nm)
specification.
TORQUE
Rear Transmission Mount Bracket Fastener:
40 ft-lbs (54 Nm)

TRANSMISSION
8. Install throttle body / intake manifold assembly. 9. Install zip ties retaining the harnesses to intake
Tighten clamps e, r retaining intake manifold to manifold.
engine. Install lower intake plenum mounting fastener
(to trans mount bracket). Torque fasteners to
specification.
10. Connect harness going to TMAP sensors, CPS,

coolant temp sensor, Trans switch, speed sensor,
injectors, ETC.
11. Connect the fuel supply at the fuel rail. Refer to Fuel
12. Install shift cable assembly. Tighten the lower jam nut
w until the line meets with the upper shift cable jam
nut q.
TORQUE
Intake Duct Hose Clamps:
3 lb-ft (4 Nm)

18 ft-lbs (24 Nm)

TRANSMISSION
13. Connect the transmission shift cable to the bellcrank. 19. Connect the battery. Torque fasteners to
Install the clip and sliding the washer. specification.
TORQUE
Battery Fasteners:
40 in-lbs (5 Nm)
14. Install two bolts securing the Rear Prop Shaft to the
transmission. Torque to specification.
TORQUE
Rear Prop Shaft (to transmission) Fasteners:
22 ft-lbs (30 Nm)
15. Install cargo box. Torque fasteners to specification.

TORQUE
Cargo Box Bracket Fasteners:
5 ft-lbs (7 Nm)
16. Install both rear drive shafts.

17. Install the Cargo Box.
18. Check the transmission fluid level. See Transmission
Fluid Level Inspection page 2.50

TRANSMISSION
TRANSMISSION DISASSEMBLY 6. Remove the two sector gears.

1. Drain and properly dispose of transmission fluid.
2. Remove bell crank nut q and bell crank w.
NOTICE
Note the timing marks on the shift gears for reassembly
3. Remove E-clip e retaining the spring washer, washer purposes.
and gear selector switch r.
4. Remove sector cover bolts t and remove the cover. 7. Remove transmission case bolts y.
5. Remove detent spring , detent pawl and detent star.
Note the master spline on the detent star and the shift
shaft.
8. Using the three (indicated by arrows) designated pry

points shown in the image, separate the transmission
case halves.
CAUTION
Do not pry on the transmission case mating surfaces or
the transmission cases will be damaged and leak oil
after it is reassembled.

TRANSMISSION
9. Lift up on the shift shaft rail i and move the rail 13. Remove the reverse shaft / gear cluster assembly d,
assembly rearward to allow the shift fork pins to be and idler shaft assembly f.
removed from the shift drum u. Remove the shift
drum from the transmission housing.
14. Remove the fasteners retaining the pinion shaft plate

g h.
10. Remove the shift shaft and forks as an assembly.
11. Remove the differential assembly o by lifting
underneath the gear or by tapping the shaft from the
opposite side.
12. Remove the idler shaft assembly a and input shaft
assembly s
NOTICE
One screw is longer g and than the others and must be
put back in the correct location.
15. Remove the pinion shaft assembly j.

16. Inspect all gear and shaft assemblies for damage.
17. Check the bearings for damage and that they are
easy to turn. Replace any questionable bearings.

TRANSMISSION
18. To disassemble the shift shaft rail remove the snap

ring k from the end of the shift rail on either side.
CAUTION
Use caution when disassembling the shift rail. The
compressed springs on the shift rail may pop off
causing injury.
19. Remove all seals from the gearcase halves and clean
the cases in preparation for assembly.

TRANSMISSION
GEAR CLUSTER DISASSEMBLY

NOTICE
For additional exploded views, also refer to Transmission Subassembly Views page 7.4.
1. Remove the bearing from the reverse shaft using a bearing puller. Remove the retaining ring and slide the washers,
high gear and needle bearing off the reverse shaft.
q Bearing s Snap Ring

w Shift Dog, Park / Low d Engagement Dog, High / Reverse
e Snap Ring f Snap Ring
r Thrust Washer g Thrust Washer
t Gear, Low h Needle Bearing
y Needle Bearing j Gear, High
u Shaft, Reverse k Thrust Washer
i Needle Bearing l Snap Ring
o Gear, Reverse 1( Bearing
a Thrust Washer
2. Remove the Reverse/High shift dog.

3. Remove the snap ring, washer, needle bearing, and reverse gear from the reverse shaft.
4. If necessary, disassemble the other end of the reverse shaft. Remove the bearing , Park/Low shift dog, retaining
ring, washer, low gear and needle bearing from the reverse shaft.

TRANSMISSION
SNORKEL TUBE REMOVAL / 2. Extract the snorkel shaft seal g from the snorkel tube
DISASSEMBLY o by drilling a small pilot hole and threading a screw
in to slowly pull the seal out.
CAUTION
The pinion shaft must be removed prior to removing the
snorkel tube assembly. Failure to remove pinion shaft
will result in damage to the snorkel tube or LH
gearcase.
NOTICE
For additional exploded views, also refer to
Transmission Subassembly Views page 7.4.
1. Use the snorkel tube tool to remove the snorkel tube

and front output shaft as an assembly.
e Snap Ring o Snorkel Tube

r Thrust Washer a Bearing
t Bearing s Snap Ring
y Ring Gear d Thrust Washer
u Front Output Shaft f Snap Ring
i O-Ring g Seal
3. Once the three snap rings e, s, & f are removed,

use an arbor press to remove the snorkel tube and
other components from the shaft.
Snorkel Tube Tool: CAUTION

PU-52547 Support the end face of the gear teeth when pushing
the shaft through or damage to the gear teeth may
occur.

TRANSMISSION
BEVEL DIFFERENTIAL DISASSEMBLY 4. Remove dowel pin from the differential pin.
1. Use a scribe or marker to mark the differential carrier
and ring gear q prior to disassembly.
5. Slide the differential pin y out of the carrier and

remove the pinion gears u.
2. Remove eight fasteners w retaining the ring gear.
6. Remove output gear i and Thrust washer o.

3. Remove ring gear e, thrust washer r, and output
gear t.

TRANSMISSION
BEVEL DIFFERENTIAL ASSEMBLY 4. Insert the dowel pin through the carrier into the
differential pin.
1. Thoroughly clean the differential components.
2. Install the thrust washer q and output gear w into
the carrier.
5. Install the output gear t, thrust washer y, and ring

gear u.
3. Place the pinion gears e into the carrier and slide the
differential pin r into the carrier.
NOTICE
When installing the ring gear, align with the mark made
of the carrier during disassembly.
NOTICE
Align the hole of the differential pin with the dowel pin
hole in the carrier.

TRANSMISSION
6. Install eight fasteners i securing ring gear.
TORQUE
Ring Gear Fasteners:
28 ft-lbs (38 Nm)

TRANSMISSION
SNORKEL GEAR BACKLASH 4. Apply a small amount of white lithium grease or Anti-
PROCEDURE Seize on the threads h of the snorkel tube.
1. Reassemble the snorkel tube and snorkel shaft

assembly by reversing the disassembly procedure.
5. Install the snorkel shaft into the gearcase. Using the

Snorkel Tool (PU-52547), tighten the snorkel tube
until it is lightly seated in the transmission housing.
q Snap Ring u Front Output Shaft
w Thrust Washer i Bearing
e Bearing o Snap Ring
r Gear, Snorkel a Snap Ring
t O-Ring s Seal
y Snorkel Tube
2. After the 13T gear and bearing are pressed onto the
snorkel shaft (flush to the shoulder), install the
washer and new retaining ring.
3. Press the gear back towards the retaining ring. Avoid
excessive force so the retaining ring is not damaged
or pre-stressed significantly.
NOTICE
Failure to press the gear back against the washer and
retaining ring will lead to a gear backlash change after
vehicle is placed into service.

TRANSMISSION
6. Inspect the pinion shaft assembly. Replace bearings 9. Install only the three screws that secure the pinion
if needed. Inspect each gear for damage, chips or shaft assembly as shown below. Leave the longer
abnormally worn teeth. locking screw k out at this point.
NOTICE
Item i is directional and must have the beveled edge
face outward upon assembly.
NOTICE
DO NOT install the longer screw k. Installing the
longer screw will lock the snorkel tube and not allow for
backlash setting adjustment.
DESCRIPTION TORQUE
10. Torque the bearing cover retaining screws to
q Bearing — specification.
w Retaining Ring — TORQUE
e Washer — Bearing Cover Retaining Screws: 7

9 ft-lbs (12 Nm)
r Gear (46T) —
t Bearing Cover Retaining 9 ft-lbs (12 Nm)

11. Temporarily install the RH case with a couple
Screws (qty. 3) fasteners to hold the pinion shaft square to establish
a zero backlash starting point. Remove the RH case
y Snorkel Locking Screw 9 ft-lbs (12 Nm) half once zero backlash starting point is established.
12. Rotate the snorkel tube counterclockwise using the
u Bearing Cover —
snorkel tool (PU-52547) until the snorkel gear and
i Retaining Ring — pinion gear have ‘zero’ backlash.
NOTICE
o Bearing —
DO NOT overtighten the snorkel tube when backing it
a Pinion Shaft — out. At the 'zero' backlash position, you should still be
able to turn the snorkel shaft using your fingers, but it
NOTICE will feel rough and may have some tight spots.
If pinion shaft was disassembled, the bearing cover
must be installed on the shaft before installing the 46T 13. Look down into the transmission housing to see the
gear. snorkel locking screw hole opening to reference your
starting point.
7. Install the pinion shaft assembly. Be sure to properly NOTICE
mesh the snorkel shaft bevel gear with the pinion
If you have a hard time seeing into the hole, insert a
shaft bevel gear.
small Allen wrench, punch or screwdriver into the hole
8. Apply Loctite® 242 to the threads of the bearing to feel when the notch is aligned with the hole.
cover retaining screws.

TRANSMISSION
14. Slowly rotate the snorkel tube clockwise while

counting the number of notches passing through the
hole opening as you rotate the tube. Rotate the
snorkel tube to the 3rd notch from the ‘zero’ backlash
position obtained in step 11.
15. Check the pinion shaft gear backlash again by feel. If
the pinion shaft gear lash appears to be too tight,
rotate the snorkel shaft clockwise to the next notch
(4th notch).
16. Once the backlash is set, apply Loctite® 242 to the
threads and install the locking screw k to secure the
snorkel tube.
17. Torque the locking screw to specification.

TORQUE
Snorkel Locking Screw:
9 ft-lbs (12 Nm)

TRANSMISSION
TRANSMISSION ASSEMBLY 4. Assemble the reverse shaft / gear cluster assembly

and input shaft assembly if previously disassembled.
NOTICE
The snorkel shaft and pinion shaft must be installed NOTICE
prior to transmission assembly. The snorkel shaft Subassemblies can also be viewed in Transmission
cannot be installed after assembling the transmission. Subassembly Views page 7.4.
IMPORTANT
REVERSE SHAFT / GEAR CLUSTER ASSEMBLY
Thoroughly clean the mating surfaces of the
transmission case halves so they are free of 3 Bond
sealant. Failure to properly clean the surfaces may lead
to transmission case leaks.
1. Install shift fork q and torsion spring into

transmission housing as an assembly. Load spring as
shown in image below
2. Apply Loctite® 242 to two screws w and install with
retaining plates over shift fork. Torque to
specification.
NOTICE
Verify the shift fork q pivots back and forth freely and q Bearing
the torsion spring if biasing the shift fork away from the
bearing. w Shift Dog, Park / Low
e Snap Ring
r Thrust Washer 7
t Gear, Low
y Needle Bearing
u Shaft, Reverse
i Needle Bearing
o Gear, Reverse
a Thrust Washer
s Snap Ring
TORQUE d Engagement Dog, High / Reverse
Shift Fork Screws:
9 ft-lbs (12 Nm) f Snap Ring
g Thrust Washer
3. Slide engagement dog e onto retaining pins of shift h Needle Bearing
fork.
j Gear, High
k Thrust Washer
l Snap Ring
1( Bearing

TRANSMISSION
INPUT SHAFT ASSEMBLY 6. Install the idler gear shaft assembly r and gear
cluster assembly t together in the case.
q Shim
w Bearing 7. Install the transmission input shaft assembly y into
the case.
e Snap Ring
r Washer
t Gear, Low
y Input Shaft
u Bearing
5. Assemble shift shaft rail if previously disassembled.
8. Install the idler shaft assembly u.
NOTICE
Both shift forks need to be orientated the same way, so
that the shift fork pins are both offset to the same side
of the rail.

TRANSMISSION
9. Install the bevel differential assembly i. Rotate 11. Inspect the shift drum for any damage or wear.
output shaft assembly to align slots with engagement Inspect the splines of the shift drum.
dog. Ensure bearing is fully seated upon assembly.
12. Install the shift drum o into the transmission housing.

10. Assemble the shift rail if disassembled. Refer to Lift up on the shift shaft rail a and move the rail
Transmission Subassembly Views page 7.4. Install assembly towards the shift drum to allow the shift fork
the shift forks / rail assembly into the transmission ends to be installed into the shift drum o.
case. Ensure that the shift forks are fully seated in the
engagement dogs.
NOTICE
Shift fork pins should be offset towards the input shaft
as shown above.

TRANSMISSION
13. The shift drum has several components. The 15. Install the transmission case cover and retaining bolts
orientation of the torsion spring s is important when j. Torque bolts to specification.
rebuilding the shift drum. After assembly of cam f,
torsion spring g, washer d, and retaining ring s,
while holding the drum, the cam should be twisted by
hand to load the torsion spring and ensure it moves
freely. Twist the cam away from it’s free state position
and make sure it snaps back into it’s free state.
TORQUE
Transmission Case Bolts:
20 ft-lbs (27 Nm)
NOTICE
s Retaining Clip g Cam
If using NEW left hand gearcase, holes are "not
d Washer h Drum threaded" for self tapping screws to form threads.
f Torsion Spring
16. Install new seals into the transmission case halves.
• The snorkel shaft seal k, should be pressed in
CAUTION until it seats against the housing counter-bore.
• The input shaft seal l, should be pressed in until it
seats flush with the housing.
• The rear output shaft seals 1(, can be installed
using a standard bushing installation tool. Seals
should be installed just past the case lead-in
chamfer (.082" or 2.1 mm from outer face of bore).
Make sure torsion spring is installed correctly and the

cam snaps back into it’s free state. If the torsion spring
is left out, or installed incorrectly, the shift into PARK
may not engage completely.
14. Apply a continuous bead of Loctite® 680 Sealant to

the left hand transmission mating surface.

TRANSMISSION
17. Thoroughly clean the shift shaft housing. 20. Install the detent pawl 2! onto the shift shaft and
carefully install the compression spring 2@.
IMPORTANT
Make sure the transmission is in HIGH gear prior to 21. Install a new O-ring 2# on each shift shaft. Apply a
reassembly small amount of white lithium grease on the O-rings,
shift shafts and component contact surfaces prior to
installing the sector cover.
18. Install the sector gear (16T) onto the shift drum shaft.
Install the shift shaft assembly and sector gear (11T)
into the bushing pocket on the left side. Align the
timing marks on the gears as shown.
22. Clean the transmission and gear sector cover mating

surfaces thoroughly.
23. Apply Loctite® 680 Sealant (Commercially available)
onto the cover and transmission case mating surface.
NOTICE
24. Install the sector cover and align the transmission
HIGH gear shown in image
case dowel 2$ with the alignment hole. Install and
torque the bolts to specification.
19. Install the detent star 2) onto the shift drum shaft. Be
TORQUE
sure to install the detent star with the with shorter hub
facing outward and skip-tooth aligned. Sector Cover Bolts:
10 ft-lbs (14 Nm)
25. Install the transmission range sensor.

TRANSMISSION
26. Install the bellcrank onto the shift shaft. Install the nut
IMPORTANT
The bell crank is keyed to the shift shaft. Note the spline
location for correct installation
TORQUE
Bell Crank Nut:
14 ft-lbs (19 Nm)
27. Install the transmission drain plug and torque to

specification.
TORQUE
Fill / Drain Plug:
12 ft-lbs (16 Nm)
28. Refer to Transmission Installation page 7.29 to

complete the repair.

TRANSMISSION
TRANSMISSION DIAGNOSTICS
TROUBLESHOOTING - TRANSMISSION
Check the following items when shifting difficulty is
encountered.
• Shift cable adjustment/condition

• PVT alignment (properly shimmed)
• Transmission lubricant type/quality
• Loose fasteners on sector gear cover
• Worn rod ends, clevis pins, or pivot arm bushings
• Shift selector rail travel
• Belt drag - place vehicle in neutral and check clutch to
make sure the belt moves freely
• Worn, broken or damaged internal transmission
components
NOTICE
To determine if shifting difficulty or problem is caused
by an internal transmission problem, isolate the
transmission by disconnecting the shift cable end from
the transmission bellcrank. Manually select each gear
range at the transmission bellcrank, and test ride
vehicle. If it functions properly, the problem is outside
the transmission.
If transmission problem remains, disassemble 7

transmission and inspect all gear dogs for wear
(rounding) or damage. Inspect all bearings, circlips,
thrust washers and shafts for wear.

TRANSMISSION
NOTES

FINAL DRIVE
CHAPTER 8
FINAL DRIVE
FRONT BEARING CARRIER SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
BEARING CARRIER REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
BEARING CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
PROP SHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
FRONT PROP SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
FRONT PROP SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
REAR PROP SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.14
REAR PROP SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.14
PROPSHAFT U-JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.15
PROPSHAFT U-JOINT DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.15
PROPSHAFT U-JOINT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.16
FRONT GEARCASE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.18
FRONT GEARCASE ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.18
FRONT GEARCASE ASSEMBLY VIEW (ADC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.19
FRONT GEARCASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.20
FRONT GEARCASE DISASSEMBLY (NON-ADC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.22
FRONT GEARCASE DISASSEMBLY (ADC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.24
FRONT GEARCASE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.27
FRONT GEARCASE ASSEMBLY (NON-ADC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.29
FRONT GEARCASE ASSEMBLY (ADC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.32
FRONT GEARCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.36 8
FRONT GEARCASE VENT LINE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.39
FRONT DRIVE OPERATION / TROUBLEHSOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.40
ALL WHEEL DRIVE (AWD) OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.40
ALL WHEEL DRIVE (AWD) DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.41
FRONT GEARCASE (ADC) OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.42
FRONT GEARCASE TROUBLESHOOTING (ADC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.43
REAR BEARING CARRIER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.45
REAR BEARING CARRIER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.45
REAR BEARING CARRIER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.45
REAR BEARING CARRIER BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.46
REAR BEARING CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.47
REAR DRIVE SHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.49
REAR DRIVE SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.49
REAR DRIVE SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.50
DRIVE SHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.52
DRIVE SHAFT / CV JOINT HANDLING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.52
OUTER CV JOINT / BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.52
INNER PLUNGING JOINT / BOOT REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.55

FINAL DRIVE
FRONT BEARING CARRIER SERVICE

BEARING CARRIER REMOVAL / 4. Remove the cotter pin.
INSPECTION
INSPECTION
1. Elevate vehicle and safely support machine under the
frame area.
CAUTION
sure machine is secure before beginning this service
procedure. Wear eye protection when removing
bearings and seals.
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. 5. Remove the front wheel hub castle nut.
NOTICE
Side to side play could also indicate tie rod end wear
and top to bottom play could also indicate upper or
lower ball joint wear. Be sure to closely inspect these
components if play is found.
REMOVAL
1. Remove the wheel nuts and wheel of the affected
bearing carrier.
2. Remove the rubber dust cap if equipped.
3. Remove the two brake caliper mounting bolts and
remove caliper assembly.
6. Remove the washer(s) from the front wheel hub
assembly.
CAUTION
Do not hang caliper by the brake line. Use wire to hang
caliper to prevent damage to brake line.

FINAL DRIVE
7. Remove the wheel hub and brake disc assembly. 9. Remove the upper ball joint pinch bolt.
10. Remove the lower ball joint fastener.
8. Remove the fastener retaining the tie rod end to the

bearing carrier.
11. Using a soft faced hammer, lightly tap the bearing 8
carrier while removing the upper and lower ball joints
ends from the bearing carrier.
12. Pull the bearing carrier out to remove it from the
driveshaft.

FINAL DRIVE
13. Rotate bearing by hand and check for rough spots. 2. Support the bottom of the bearing carrier housing.
The bearing should rotate quietly and smoothly with
no detectable up and down movement and minimal CAUTION
movement sideways between the inner and outer
races. Visually inspect for moisture, dirt or corrosion. Use an arbor and press only on the outer race,
otherwise bearing damage may occur.
BEARING REPLACEMENT 3. Apply Loctite® 603 retaining compound to the outer

REMOVAL circumference of the new bearing race and carefully
press the new bearing into the bearing carrier
1. Remove outer snap ring. housing.
2. From back side of the bearing carrier, using a press, NOTICE

push on the outer bearing race as shown.
Use care to not allow any of the Loctite® compound to
3. get in the bearing.
4. Wipe the housing clean of any excess compound and

install the snap ring.
4. Push bearing out evenly by pushing on outer race

only. Once bearing is at bottom of casting, support
casting on outer edges so bearing can be removed.
5. Inspect bearing carrier housing for scratches, wear or
damage. Replace front bearing carrier if damaged.
INSTALLATION
1. 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.

FINAL DRIVE
BEARING CARRIER INSTALLATION 4. Install upper ball joint pinch bolt. Torque to
specification.
CAUTION
New bolts have a pre-applied locking agent which is
destroyed upon removal. Always use new brake caliper
mounting bolts upon assembly.
1. Install the end of the drive shaft through the backside

of the bearing carrier.
TORQUE
Upper Ball Joint fastener:
42 lb-ft (57 Nm)
5. Install the steering tie rod end onto the front bearing
carrier. Install the nut and torque to specification.
2. Install the upper and lower ball joint ends into the
front bearing carrier.
3. Install the lower ball joint fastener. Torque to
specification.
TORQUE
Tie Rod End Fastener:
40 lb-ft (54 Nm)
TORQUE 6. Apply grease to the drive shaft splines.

Lower Ball Joint fastener:
42 lb-ft (57 Nm)

FINAL DRIVE
7. Install front wheel hub assembly. 9. Install the castle nut. Torque to specification.
8. Install washer(s). TORQUE

Front Hub Castle Nut:
80 lb-ft (108 Nm)
10. Install new cotter pin. If the cotter pin does not align
with the holes, tighten nut slightly to align holes for
the cotter pin.
NOTICE
If cone washers are used, ensure that the washer is
installed with the domed side facing out.

FINAL DRIVE
11. Install the front brake caliper. Install the mounting

bolts. Torque to specification.
TORQUE
Front Caliper Mounting Bolts:
28 ft-lbs (38 Nm)
12. Install wheel and four wheel nuts. Torque wheel nuts
to specification.
TORQUE
Wheel Nuts (Steel): 60 lb-ft (81 Nm)
Wheel Nuts (Cast Alum): 120 lb-ft (163 Nm)
13. Rotate wheel and check for smooth operation. Bend

both ends of cotter pin around the end of the shaft.
Install the center cap and/or rubber dust cap.
8

FINAL DRIVE
PROP SHAFT SERVICE

FRONT PROP SHAFT REMOVAL • Slide seat rearward to remove.

2. Remove Driver Seat.
• Lift up on Release Lever q.
4. Disconnect Positive and Negative battery cables.
• Tilt seat forward.

FINAL DRIVE
5. Remove Battery Bracket Fastener w and Bracket e. 8. Remove two push rivets from hard intake.
Remove Battery.
9. Lift the Electrical Harness u out of the center of the

6. Remove Battery Box Fasteners r and remove hard plastic intake and slide to the side.
Battery Box.
8
10. Loosen four Worm Clamps i retaining the hard
7. Remove eight push rivets t and remove center intake line from the rubber lines.
console.
11. Slide the plastic intake rearward & then frontward to

angle out driverside of vehicle.

FINAL DRIVE
12. Remove two carrier bolts o.
13. Remove front propshaft bolts.
14. Slide prop shaft forward enough to allow clearance to

lift back of prop shaft up and out the opening in the
footwell.

FINAL DRIVE
FRONT PROP SHAFT INSTALLATION 5. Install the plastic intake. Engage the rear rubber lines
to the plastic intake. Engage the front rubber boots
1. Install front of prop shaft first. Slide prop shaft forward
over the plastic intake.
enough to allow rear of prop shaft enough clearance
to fit through the opening in the floor. NOTICE
2. Engage the rear of the prop shaft first, then the front. Use a small pic to help aid in getting the rubber lines to
engage of all sides of the plastic intake.
3. Install prop shaft bolts. Torque to specification.
6. Tighten four Hose Clamps i retaining the hard

intake line from the rubber lines. Torque Worm
Clamps to specification
TORQUE
Front Prop Shaft Fasteners:
22 ft-lbs (30 Nm)
TORQUE
4. Install two Carrier Bolts o. Torque Carrier Bolts to Hose Clamp:
specification
35 in-lbs (4 Nm)
7. Route the Electrical Harness u back into the center

of the hard plastic intake. 8
TORQUE
Carrier Bolts:
40 ft-lbs (54 Nm)

FINAL DRIVE
8. Install two push rivets to the hard intake line. 11. Install Battery. Install Battery Bracket e and Battery
Bracket Fastener w. Torque Fastener to
specification.
9. Install the center console and eight push rivets t.
TORQUE
Battery Bracket Fastener:
42 in-lbs (5 Nm)
12. Connect Positive and Negative battery cables.
10. Install Battery Box and two Battery Box Fasteners r.
13. Install battery cover.
TORQUE
Battery Box Fasteners:
42 in-lbs (5 Nm)

FINAL DRIVE
14. Install Driver Seat.

• Engage front seat base tabs.
• Push seat down until properly seated.
8
15. Fold down passenger seat.

FINAL DRIVE
REAR PROP SHAFT REMOVAL REAR PROP SHAFT INSTALLATION

1. Perform Front Prop Shaft Removal. 1. Install the Rear Prop Shaft through the opening in the
floor.
2. Remove two fasteners securing the Rear Prop Shaft
to the transmission.
2. Install two fasteners securing the Rear Prop Shaft to

the transmission.
NOTICE
Access the Rear Prop Shaft from the rear driver side of
the vehicle.
3. Disengage the Rear Prop Shaft from the

transmission. Remove the Rear Prop Shaft through
the opening in the floor.
NOTICE
Access the Rear Prop Shaft from the rear driver side of
the vehicle.
TORQUE
Rear Prop Shaft Fasteners:
22 ft-lbs (30 Nm)
3. Perform Front Prop Shaft Installation.

FINAL DRIVE
PROPSHAFT U-JOINT SERVICE

PROPSHAFT U-JOINT DISASSEMBLY 3. Place a remover adapter e on other end of U-joint
with a smaller OD than the U-joint cap.
NOTICE
Before servicing the prop shaft U-joint, be sure the joint
is clean to ensure no debris damages the yoke.
1. With the prop shaft removed and marked for

alignment orientation, remove the retaining rings q
from both sides of the yoke.
4. Position clamp r over receiving cup adapter and

remover adapter.
2. Using a commercially available Ball Joint / U-Joint

Press Set, place a receiving cup adapter w with a
larger ID than the U-joint cap OD on one end.
8
5. Tighten clamp with hand tools to force U-joint cups
out of yoke.
6. Discard and replace all U-joint parts that were

removed from the yoke.

FINAL DRIVE
PROPSHAFT U-JOINT ASSEMBLY 5. Place clamp and installer adapters r with smaller
OD than caps over each cap.
1. With NEW U-joint, remove two opposing caps q from
end of joint to go into yoke and secure other two so
they do not fall off during installation.
6. Tighten clamp to install caps simultaneously into yoke

bores.
2. Ensure yoke bores and ring grooves are clean before
installing new U-joint.
3. Place U-joint ends w without caps into yoke bores.
7. Push U-joint side to side during clamping to seat into

caps properly.
8. Tighten clamp until both caps are flush with yoke and
one cap is past retaining ring groove t.
4. Place caps e into yoke bores and align with U-joint
ends by hand.

FINAL DRIVE
9. Install retaining ring y with sharp, square edge facing

away from U-joint into exposed groove.
10. Place larger adapter u with ID larger than yoke bore

on side with retaining ring.
11. Tighten clamp until other cap is below retaining ring 8

groove.
12. Install second retaining ring i with sharp, square
edge facing away from U-joint.
13. Verify the U-joint moves freely and does not bind.

FINAL DRIVE
FRONT GEARCASE SERVICE

FRONT GEARCASE ASSEMBLY VIEW
q Oil Seal f Roller 2% Gearcase

w Cover Screws, M6 g Spring Retainer Assy. 2^ Plug (Fill)
9 ft-lbs (12 N·m) 10 ft-lbs (14 Nm)
e Cover h Torsion Spring 2& Oil Seal

r O-Ring j Stud / Dowel Pin 2* Isolation Bushing
t Coil k Ring Gear 2( Gearcase Vent (Hose Fitting)
y Backlash Spacer l Spacer 3) Bushing
u Bearing 1( Bushing (Outer) 3! Pinion Gear
i Hub Assembly 2) Hub Assembly 3@ Shim
o Bushing (Inner) 2! Cage Spacer 3# Bearing
a Armature Plate 2@ Bearing 3$ Snap Ring (Inner)
s Roller Cage Assy. 2# Bushing 3% Snap Ring (Outer)
d H-Clip 2$ Magnetic Plug (Drain) 3^ Pinion Seal
10 ft-lbs (14 Nm)

FINAL DRIVE
FRONT GEARCASE ASSEMBLY VIEW (ADC)
q Cover Screws, M6 g H-Clip 2& Magnetic Plug (Drain)

9 ft-lbs (12 N·m) 10 ft-lbs (14 Nm)
w Oil Seal h Roller Cage Assy. 2* Gearcase

e Cover j Roller 2( Plug (Fill)
10 ft-lbs (14 Nm)
8
r O-Ring k Spring Retainer Assy. 3) Oil Seal
t Coil (Outer) l Torsion Spring 3! Isolation Bushing
y Coil (Inner) 1( Stud / Dowel Pin 3@ Gearcase Vent (Hose Fitting)
u Backlash Spacer 2) Ring Gear 3# Bushing
i Bearing 2! Spacer 3$ Pinion Gear
o Armature Plate (Hub) 2@ Bushing (Outer) 3% Shim
a Hub Assembly 2# Hub Assembly 3^ Bearing
s Bushing (Inner) 2$ Cage Spacer 3* Snap Ring (Inner)
d Armature Plate (Inner) 2% Bearing 3& Snap Ring (Outer)
f Armature Plate (Outer) 2^ Bushing 3( Pinion Seal

FINAL DRIVE
FRONT GEARCASE REMOVAL 6. Remove both front upper ball joint fasteners.
1. Place the transmission in Park. Elevate front of
vehicle and safely support machine under the frame.
CAUTION
Serious injury may result if machine tips or falls.Be sure
machine is secure before beginning this service
procedure.
2. Remove the front bumper.

3. Remove both front wheels.
4. Remove both front brake caliper assemblies.
7. Remove both front upper control arm from the

bearing carrier. This will allow the lower control arms
to be lowered creating clearance to remove the axles
from the front gearcase.
5. Remove both tie rod ends from the bearing carriers.
8. Remove both front axles from the front gearcase.

FINAL DRIVE
9. Remove the prop shaft pinch bolts. 15. Remove the front gearcase through the opening in
the front of the chassis.
10. Detach the front gearcase vent hose.

11. Disconnect the AWD wire harness.
12. Remove the upper front gearcase nut and bolt.
13. Remove the lower front gearcase nut and bolt.
14. Slide the propshaft off the splines of the front

gearcase.

FINAL DRIVE
FRONT GEARCASE DISASSEMBLY 3. Remove the LH output hub assembly from the clutch
(NON-ADC) housing or outer cover plate assembly.
All internal gearcase parts should be inspected prior to
assembly of the front gearcase. For any items not
covered in the following information, please refer to Front
Gearcase Assembly View page 8.18 for an exploded
view of all internal parts. Check each item for excessive
wear or damage, replace if necessary.
NOTICE
Refer to the “Electronic Parts Catalog” for individual
part availability. Most parts are to be replaced as an
assembly or as a kit.
1. Drain and properly dispose of gearcase fluid.

Remove any metal particles from the drain plug
magnet.
NOTICE
2. Remove cover fasteners and remove the cover plate
assembly. Nylon spacer is non-serviceable and should not be
removed.
4. Remove and inspect the armature plate. Refer to

AWD DIAGNOSIS for detailed inspection process.

FINAL DRIVE
5. Remove the spring retainer and torsion spring from 7. Remove inner and outer bushing / spacer.
the top of the ring gear.
8. Remove the RH output hub assembly from the

gearcase housing.
6. Remove the ring gear and roll cage assembly from

the gearcase housing. With the ring gear removed
8
inspect the ring gear dowel pin and ensure that it is 9. Remove pinion seal.
seated correctly.

FINAL DRIVE
10. Remove the internal retaining ring / snap ring. FRONT GEARCASE DISASSEMBLY
(ADC)
Gearcase Assembly View page 8.18 for an exploded
view of all internal parts. Check each item for excessive
wear or damage, replace if necessary.
NOTICE
1. Drain and properly dispose of gearcase fluid.

Remove any metal particles from the drain plug
11. Remove the pinion gear assembly from the gearcase magnet.
housing.
2. Remove cover fasteners and remove the cover plate
assembly.
12. Inspect and clean the gearcase housing and replace

any oil seals and O-rings upon assembly.

FINAL DRIVE
3. Remove the LH output hub assembly from the clutch 5. Remove the spring retainer and torsion spring from
housing or outer cover plate assembly. the top of the ring gear.
4. Remove and inspect the armature plates. Refer to

AWD DIAGNOSIS for detailed inspection process.
6. Remove the ring gear and roll cage assembly from

the gearcase housing. With the ring gear removed
8
inspect the ring gear dowel pin and ensure that it is
seated correctly.

FINAL DRIVE
7. Remove inner and outer bushing / spacer. 10. Remove the internal retaining ring / snap ring.
8. Remove the RH output hub assembly from the 11. Remove the pinion gear assembly from the gearcase
gearcase housing. housing.
9. Remove pinion seal. 12. Inspect and clean the gearcase housing and replace
any oil seals and O-rings upon assembly.

FINAL DRIVE
FRONT GEARCASE INSPECTION 2. Inspect the pinion bearing for signs of wear and the
All internal gearcase parts should be inspected prior to pinion shaft seal surface for pitting.
assembly of the front gearcase. For any items not AWD COIL INSPECTION
Gearcase Assembly View page 8.18 for an exploded 1. Inspect the AWD coil q located in the outer cover
view of all internal parts. Check each item for excessive plate assembly. Refer to AWD DIAGNOSIS for
wear or damage, replace if necessary. detailed inspection process. Replace the cover plate
seal w and oil seal e.
NOTICE
PINION GEAR BEARING REMOVAL /

INSTALLATION
1. Remove the snap ring.
2. Press off the bearing assembly.
RING GEAR / ROLLER CAGE INSPECTION

1. 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.
NOTICE
Rollers are spring loaded. Take care not to allow them
to fall out or lose them upon removal of the roll cage.
2. Thoroughly clean all parts and inspect the rollers q

8
3. Replace bearing and press on pinion shaft. for nicks and scratches. The rollers must slide up and
down and in and out freely within the H-springs w
4. Install new snap ring. and roll cage e sliding surfaces.
PINION INSPECTION
1. Inspect the pinion gear for chipped, broken or missing
teeth.
NOTICE
assembly or as a complete kit.

FINAL DRIVE
3. Inspect the inner ring gear / roller cage housing for a

consistent wear pattern. Inspect the ring gear for
chipped, broken, or missing teeth.
4. Inspect the roll cage assembly t sliding surfaces and
H-springs y. The sliding surfaces must be clean and
free of nicks, burrs or scratches. If damaged, replace
the roll cage assembly.
OUTPUT HUB / BEARING INSPECTION

1. Inspect both output hub assemblies. Inspect the
bearings and replace if needed.
q Bearing e Inner Bushing / Spacer

w Hub Assembly e Outer Bushing / Spacer

FINAL DRIVE
FRONT GEARCASE ASSEMBLY (NON- 3. Install a new pinion shaft seal into the pinion gear
ADC) housing. Using a universal seal installer, press the
new seal into the housing until the seal is just below
All internal gearcase parts should be inspected prior to the housing chamfer.
covered in Front Gearcase Disassembly (Non-ADC)
page 8.22, please refer to Front Gearcase Assembly
View page 8.18 for an exploded view of all internal parts.
Check each item for excessive wear or damage, replace
if necessary.
NOTICE
1. Replace all O-rings, seals and worn components.

2. Install pinion shaft assembly and install internal snap
ring.
4. Install the RH output hub into the gearcase housing.
8
NOTICE
If bearing replacement was required, press new bearing 5. Install inner and outer bushing / spacer.
onto the pinion shaft and install a new snap ring.

FINAL DRIVE
6. If disassembled install the H-springs in the roller cage 9. Install the torsion spring r by wrapping each leg of
assembly. the spring around the dowel pin on the ring gear.
7. Place the cage in the housing and carefully install 10. Align spring retainer dowel pin with ring gear dowel
each rollerq. pin and install the retainer on top of the torsion spring.
8. Lower the roll cage assembly into the inner ring gear / 11. Check the action of the torsion spring by rotating in
roller cage housing while installing the rollers to both directions to ensure the spring and retainer are
prevent them from falling out of the roller cage. installed properly.
NOTICE
Install roll cage so that the ring gear grooves line up
with the roll cage windows.

FINAL DRIVE
12. Install armature plate. 15. Install the LH output hub assembly.
IMPORTANT 16. Install the output cover assembly onto the gearcase
Verify the armature plate is resting within the tabs on housing. Take care not to damage the new cover
the spring retainer q and that the armature plate tabs plate seal while installing the output hub.
fully engage in the roller cage notch w.
13. Carefully install the ring gear and roll cage assembly
into the gearcase housing.
8
17. Install the seven cover plate screws and torque to
specification.
14. Install a new O-ring on the cover plate assembly.

NOTICE
Be sure the square O-ring is placed flat on the cover
surface. If the O-ring is twisted fluid leakage may occur.
TORQUE
Front Gearcase Cover Plate Screws:
9 ft-lbs (12 N·m)

FINAL DRIVE
18. If removed, install the drain plug. Add the proper 3. Install a new pinion shaft seal into the pinion gear
lubricant to the front gearcase. Check drain plug for housing. Using a universal seal installer, press the
proper torque. Refer to Maintenance Chapter for fluid new seal into the housing until the seal is just below
fill and change information. the housing chamfer.
TORQUE
Front Gearcase Drain Plug:
10 ft-lbs (14 Nm)
19. Install the fill plug. Torque to specification. Inspect for

any leaks, prior to installation in vehicle.
TORQUE
Front Gearcase Fill Plug:
10 ft-lbs (14 Nm)
FRONT GEARCASE ASSEMBLY (ADC)

4. Install the RH output hub into the gearcase housing.
covered in Front Gearcase Disassembly (Non-ADC)
page 8.22, please refer to Front Gearcase Assembly
View page 8.18 for an exploded view of all internal parts.
Check each item for excessive wear or damage, replace
if necessary.
NOTICE
1. Replace all O-rings, seals and worn components.

2. Install pinion shaft assembly and install internal snap
ring. 5. Install inner and outer bushing / spacer.
NOTICE
If bearing replacement was required, press new bearing
onto the pinion shaft and install a new snap ring.

FINAL DRIVE
6. If disassembled install the H-springs in the roller cage 9. Install the torsion spring r by wrapping each leg of
assembly. the spring around the dowel pin on the ring gear.
7. Place the cage in the housing and carefully install 10. Align spring retainer dowel pin with ring gear dowel
each rollerq. pin and install the retainer on top of the torsion spring.
8
8. Lower the roll cage assembly into the inner ring gear / 11. Check the action of the torsion spring by rotating in
roller cage housing while installing the rollers to both directions to ensure the spring and retainer are
prevent them from falling out of the roller cage. installed properly.
NOTICE
Install roll cage so that the ring gear grooves line up
with the roll cage windows.

FINAL DRIVE
12. Install outer armature plate. 13. Install inner armature plate.
IMPORTANT IMPORTANT
Verify the armature plate is resting within the tabs on Verify the inner armature plate e is resting within the
the spring retainer q and that the armature plate tabs tabs on the outer r armature plate. Ensure that it is
fully engage in the roller cage notch w. fully seated prior to output hub installation.
14. Carefully install the ring gear and roll cage assembly
into the gearcase housing.

FINAL DRIVE
15. Install a new O-ring on the cover plate assembly. 18. Install the seven cover plate screws and torque to
specification.
NOTICE
Be sure the square O-ring is placed flat on the cover
surface. If the O-ring is twisted fluid leakage may occur.
16. Install the LH output hub assembly.
TORQUE
Front Gearcase Cover Plate Screws:
9 ft-lbs (12 N·m)
19. If removed, install the drain plug. Add the proper

17. Install the output cover assembly onto the gearcase lubricant to the front gearcase. Check drain plug for
housing. Take care not to damage the new cover proper torque. Refer to Maintenance Chapter for fluid
plate seal while installing the output hub. fill and change information.
TORQUE
Front Gearcase Drain Plug:
10 ft-lbs (14 Nm)
20. Install the fill plug. Torque to specification. Inspect for

any leaks, prior to installation in vehicle. 8
TORQUE
Front Gearcase Fill Plug:
10 ft-lbs (14 Nm)

FINAL DRIVE
FRONT GEARCASE INSTALLATION 4. Torque the front gearcase mounting bolts to

specification.
1. Install the front gearcase through the opening in the
front of the chassis. Line up the propshaft with the TORQUE
splines on the front gearcase during installation.
Front Gearcase Mounting Bolt:
44 + 90° ft-lbs (60 + 90° N·m)
5. Install the prop shaft on the front gearcase and install

the front prop shaft pinch bolts.
2. Loosely install the upper front gearcase nut and bolt.
TORQUE
Prop Shaft Pinch Bolt Fastener:
22 ft-lbs (30 N·m)
6. Install the vent line on the gearcase and ensure it’s

routed properly.
7. Connect the AWD harness.
8. Install both front axles from the front gearcase.
Ensure the axles are fully seated.
3. Loosely install the lower front gearcase nut and bolt.

FINAL DRIVE
9. Install both front upper control arm from the bearing 11. Install both tie rod ends from the bearing carriers.
carrier. This will allow the lower control arms to be Torque to specification.
lowered creating clearance to remove the axles from
the front gearcase.
TORQUE
Tie Rod Retaining Nut:
10. Install both front upper ball joint fasteners. Torque to
Step 1: 30 ft-lbs (41 Nm)Step 2: Tighten additional
specification.
90°
12. Install both front brake caliper assemblies. Torque to

specification.
TORQUE
Front Upper Ball Joint Pinch Fastener:
42 ft-lbs (57 N·m)
TORQUE
Front Caliper Mounting Fastener:
28 ft-lbs (38 Nm)
13. Install the front bumper.

14. Install both front wheels. Torque to specification.
TORQUE
Wheel Lug Nuts:
120 ft-lbs (163 Nm)

FINAL DRIVE
15. Add the proper lubricant to the front gearcase. Check

drain / fill plug for proper torque. Refer to
Maintenance Chapter for fluid fill and change
information.
TORQUE
10 ft-lbs (14 Nm)

FINAL DRIVE
FRONT GEARCASE VENT LINE ROUTING

The front gearcase vent line runs along the front passenger side frame. It is secured along the front frame by four
retention clips, two horizontal and two vertical as shown. The vent line ends its routing secured into a horizontal section
of the frame with a vent line termination fitting.

FINAL DRIVE
FRONT DRIVE OPERATION / TROUBLEHSOOTING

ALL WHEEL DRIVE (AWD) OPERATION AWD Engagement: When the AWD switch is activated,
The AWD switch may be turned on or off while the the AWD coil is powered by a 12 volt DC input which
vehicle is moving, however, AWD will not enable until the creates a magnetic field. This magnetic field attracts an
engine RPM drops below 3100. Once the AWD is armature plate that is keyed to the roll cage w. When the
enabled, it remains enabled until the switch is turned off. ring gear q and roll cage w are spinning (vehicle is
moving), the energized coil and armature plate will apply
Engage the AWD switch before getting into conditions drag to the roll cage w that indexes the rollers e inside
where the front wheel drive may be needed. If the rear the ring gear q to an engagement position. While in the
wheels are spinning, release the throttle before switching engagement position, the front drive will be in an “over-
to AWD. running” condition (not engaged), until the rear wheels
lose traction. Once the rear wheels begin to lose traction,
CAUTION the front drive will engage by coupling the output hubs r
to the ring gear q via the rollers e. The front drive will
Switching to AWD while the rear wheels are spinning
remain engaged until the torque requirement goes away
may cause severe drive shaft and gearcase damage.
(i.e. rear wheels regain traction).
Always switch to AWD while the rear wheels have
traction or are at rest.
With the AWD switch off, the vehicle drives through the
rear wheels only (2 wheel drive). When the AWD is
enabled, the front drive acts as an on-demand AWD
system. This means, the front drive will engage once the
rear wheels have lost traction, and will remain engaged
until the torque requirement goes away (i.e. rear wheels
regain traction).
CAUTION
If the rear wheels are spinning, release the throttle
before turning the AWD switch on.If AWD is engaged
while the wheels are spinning, severe drive shaft and AWD Disengagement: Once the rear wheels regain
front gearcase damage could result. traction, the front wheels will return to the “over-running”
condition. The vehicle is now back to rear wheel drive
until the next loss of rear wheel traction occurs.
Torsion Spring Operation: The torsion spring q acts
as a return mechanism to help disengage the coupling of
the output hubs w and ring gear e by creating an “over-
running” condition for the rollers r upon disengagement.

FINAL DRIVE
ALL WHEEL DRIVE (AWD) DIAGNOSIS 5. Check to make sure the coil t is seated in the U-
AWD WILL NOT ENGAGE shaped y insert that is pressed into the gearcase
cover u. The top of the coil should be seated below
1. Check the gearcase coil resistance. To test the coil the U-shaped insert. The U-shaped insert controls the
resistance, measure between the power wire q (GY) pole gap. If the top of the coil is above the surface of
and ground wire w (BN/WH). Measurement should the U-shaped insert it raises the armature plate,
be within specification. thereby increasing pole gap. If the pole gap increases
the coil will not be strong enough to engage the AWD
system. If this is found, replace the cover plate
assembly.
Front Gearcase Coil Resistance:

21.6 - 26.4 ΩADC Models: 8.49 - 16.49 Ω
6. Inspect the roller surface on the inside of the ring gear

2. Turn the ignition and AWD switches on and place for gouging/rough spots.
gear selector in High or Low gear. Check for minimum
battery voltage at the Gray and Brown/White chassis
wires that power the coil. A minimum of 11 volts DC
should be present.
3. If electrical tests are within specification, remove
gearcase (see FRONT GEARCASE REMOVAL) and
inspect components. 8
4. Inspect armature plate e for a consistent wear
pattern. There should be two distinct wear bands r.
If only one band of wear is present (or if there is wear
between the two bands), inspect the coil area as
indicated in Step 5. A wear band with an interrupted
wear mark may indicate a warped plate, which may
cause intermittent operation.
7. Inspect the roll cage o assembly for cracks or

excessive wear. If damaged, replace the roll cage
assembly.
8. Inspect the rollersa for nicks and scratches. The
rollers must slide up, down, in and out freely within
the roll cage sliding surfaces and H-springs.

FINAL DRIVE
FRONT GEARCASE (ADC) OPERATION

The active descent control front gearcase is designed to
allow the vehicle to operate in 2x4, 4x4, or utilize the
vehicles EBS to allow 4x4 ADC (active descent control)
in the forward and reverse direction.
IMPORTANT
All-wheel drive ADC MUST be selected on the all-wheel
drive / ADC switch to activate the ADC system.
When the vehicle is in 2x4, all coils within the gearcase

are off. This allows the pinion and ring gear to spin
without engaging the front gearcase output hubs.
When the vehicle is in 4x4, the 4 wheel drive coil is

turned on but the ADC coil remains off. Turning on the 4
wheel drive coil applies drag to the outer armature plate.
The outer armature plate is connected to the roller cage,
which engages the rollers in the cage with the forward /
reverse ramp in the bi-directional clutch. In the event that
the vehicle wheels roll down a hill faster than it is being
driven, ADC will not slow the vehicle.
When the vehicle is in 4x4 ADC, the AWD coil is turned

on and the ADC coil remains off until necessary. When
descending a hill, the EBS slows the driveline and rear
wheels. The ADC coil detects the speed difference and
locks the front wheels to the driveline. The front wheels
can now assist in controlling the descent. Turning on the
ADC Coil applies drag to 2 inner armature plates. One
armature plate is connected to an output hub and the
other is connected to the roller cage. The frictional drag
between the two armature plates causes the output hub
to rotate the roller cage, which engages the rollers in the
cage with the forward / reverse ramp in the bi-directional
clutch. Because the hubs rotate faster than the driveline
in an engine breaking situation this combination of
events slows the vehicle when the clutch engine brake
system is active allowing true four wheel engine braking
in forward / reverse gears.
During engine braking the front drive can also speed

differentiate across the axle when turning. Also, if the
outer wheel slips or loses traction the inner wheel will
then begin to slow the vehicle as well.

FINAL DRIVE
FRONT GEARCASE TROUBLESHOOTING (ADC)

ADC NOT FUNCTIONING
Verification of complaint: Drive vehicle with ADC switched on and off down a grade if possible to determine if ADC
(Auto-lock is working correctly). May need to be in low range to tell in high traction areas. Make sure switch is on ADC
mode. Make sure ADC light is lit on gage pod. Vehicle must be in hi, low, or reverse. Also, vehicle throttle lever must be
off. If complaint is warranted, move onto component check list. If no, move onto other vehicle components
(suspension, driveline, engine, etc.) Vehicle may also be tested in air. All 4 wheels need to be off ground, put into ADC
mode and roll back wheels if possible. Rotate cover side front wheel forward and back, should feel roll cage in front
drive index and lock the front wheel to the drive line. This can only be done on the cover side wheel. It is also best to
make sure 4x4 is not engaged any more. This way is possible to test but best way is to ride vehicle down steep hill as
stated above.
DIAGNOSIS PROBLEM DIAGNOSIS REPAIR PROCEDURE REPAIR VERIFICATION

POTENTIAL PROBLEM
PROCEDURE
Check to see if ADC light No ADC light on gage Problem might not be front N/A
is lit on gage pod. pod. differential related. Check
electrical system in
vehicle.
Check wires to see if there Cut wire. Replace output cover (Unit Drive vehicle with ADC
are any visible cuts or will need to be removed mode on to determine if
Unplugged / damaged nicks. from vehicle to do repair.) problem has been fixed. If
wire connector. not, continue onto
additional problems listed.
Check to see if front Unplugged Plug wire harness into Drive vehicle with ADC
differential is plugged into front drive connector. mode on to determine if
wire harness. problem has been fixed. If
not, continue onto
Differential installed in vehicle

No power from vehicle to Unhook wire connector to No power to front Problem might not be front N/A
front differential (blown front differential. Using differential wire harness. differential related. Check
fuse) multimeter determine if electrical system in
vehicle wire connector is vehicle.
getting power to the front
drive on two outer most
pins.
ADC Coil Short Check resistance of coil Coil to be +/- 4 ohms to Replace output cover (Unit Drive vehicle with ADC
nominal will need to be removed mode on to determine if
from vehicle to do repair.) problem has been fixed. If
8
not, continue onto
Check continuity to both Continuity should be Replace output cover (Unit Drive vehicle with ADC
leads present between leads. will need to be removed mode on to determine if
not, continue onto
Check continuity to case No continuity between Replace output cover (Unit Drive vehicle with ADC
Check continuity to case either lead and the case. will need to be removed mode on to determine if
not, continue onto
4x4 Not turning off Lift Vehicle off ground. Power to 4x4 is not Problem might not be front N/A
Rotate cover side wheel in turning off when ADC is differential related. Check
both the forward and turning on. electrical system in
reverse direction. If it locks vehicle.
to the drive train in only
one direction, ADC is not
indexing cage in both
directions

FINAL DRIVE
DIAGNOSIS PROBLEM DIAGNOSIS REPAIR PROCEDURE REPAIR VERIFICATION

POTENTIAL PROBLEM
PROCEDURE
Hub Plate Hub Plate will be attached Plate should be flat. Plate Replace hub plate or hub Drive vehicle with ADC
to output hub. Initially look should have even wear assembly with hub plate. mode on to determine if
at plate and see if any on both sides and no May need to replace Hub problem has been fixed. If
excessive wear is present. significant gauging plate and Armature plate not, continue onto
Look and see if plate is should be present. at the same time. additional problems listed.
bent or warped. Look to
see if any debris is on
plate or debris is causing
uneven wear. To do further
evaluation plate would
need to be removed from
hub, by removing bearing.
Plate then can be placed
on a flat surface to
determine if plate is flat.
ADC Armature Plate Place Plate on flat surfacePlate should not have Replace Armature plate. Drive vehicle with ADC
with tangs up to check for significant rock when May need to replace both mode on to determine if
flatness. Also look for pushing on one side of Armature plate and hub problem has been fixed. If
even wear on surface the plate. Plate should plate at the same time. not, continue onto
Differential removed from vehicle
towards Hub plate also have even consistent additional problems listed.
wear on the surface.
Roll Cage Check to see if cage is Roll cage should have no Replace roll cage Drive vehicle with ADC
broken or cracked. Look to cracks or breaks. Springs assembly (cage and mode on to determine if
see if any springs are should have no cracks spring). Always replace problem has been fixed. If
broken or stuck in place. and fully intact. Clutch both. (do not take springs not, continue onto
Look to see if cage can should be able to off old cage and put onto additional problems listed.
index properly in both advance down the new cage).
directions engagement ramp
smoothly.
Torsion Spring Make sure Spring is Plastic retainer should If torsion spring is not Drive vehicle with ADC
installed properly. Make index with some force installed correctly, install mode on to determine if
sure Spring is able to from spring. Retainer correctly and retest. If problem has been fixed. If
index properly in both should also index far other issue with retainer or not, continue onto
directions enough to allow clutch to spring, replace one or both additional problems listed.
engage. and retest.
Cover Side Hub Check to see if Hub plate If Hub plate can not slide Replace with new hub Drive vehicle with ADC
can slide on hub spline. it may not engage coil assembly and Hub Plate. mode on to determine if
correctly. problem has been fixed. If
not, continue onto
ADC Coil/Coil Pocket Check Pole Faces for Pole faces should be Clean off pole faces if no Drive vehicle with ADC
(Output Cover) debris smooth and even wear significant wear is noticed. mode on to determine if
should be present. If pole faces are severely problem has been fixed. If
worn and damaged, not, continue onto
replace output cover. additional problems listed.
Check for Coil raised Coil should be well below Replace output cover. Drive vehicle with ADC
above pole faces the pole faces. If coil is mode on to determine if
outside pole faces it problem has been fixed. If
would cause the plates not, continue onto
not to touch the pole additional problems listed.
faces.
Check Wear on Pole faces Pole faces should be Clean off pole faces if no Drive vehicle with ADC
smooth and even wear significant wear is noticed. mode on to determine if
should be present. If pole faces are severely problem has been fixed. If
worn and damaged, not, continue onto
replace output cover. additional problems listed.

FINAL DRIVE
REAR BEARING CARRIER SERVICE

REAR BEARING CARRIER INSPECTION 5. Remove the castle nut.
1. Elevate the rear of vehicle and safely support
machine under the frame area.
CAUTION
sure machine is secure before beginning this service
procedure. Wear eye protection when removing
bearings and seals.
2. Check bearings for side play by grasping the top and

bottom of the tire firmly and checking for movement.
3. If movement is detected, inspect wheel hub, castle
nut torque, bearing condition and upper and lower
ball joint wear.
6. Remove the washer.
REAR BEARING CARRIER REMOVAL

1. Place the transmission in PARK.
2. Elevate the rear of the vehicle and safely support the
vehicle under the main frame area.
3. Remove wheel nuts, and wheel.
4. Remove the cotter pin.
8
7. Remove the two rear brake caliper mounting bolts
and remove the caliper from the bearing carrier.
CAUTION
Do not hang the caliper by the brake line. Use
mechanics wire to hang the caliper to prevent possible
damage to the brake line.

FINAL DRIVE
8. Slide the wheel hub out from the bearing carrier and REAR BEARING CARRIER BEARING
drive shaft. REPLACEMENT
1. Remove the retaining ring from the bearing carrier.
9. Remove the upper and lower A-arm fasteners from

the bearing carrier.
2. From the back side, using a press, push on the outer
bearing race as shown.
10. Remove the bearing carrier. Inspect the bearing for

smoothness and side to side movement, replace as
needed. NOTICE
Once bearing is at bottom of casting, support casting on
outer edges so bearing can be removed.
3. Inspect bearing carrier housing for scratches, wear or

damage. Replace rear bearing carrier if damaged.

FINAL DRIVE
4. Inspect the bearing carrier bushings and replace if REAR BEARING CARRIER
worn or damaged. INSTALLATION
1. Place the bearing carrier over the drive shaft.
2. Align the bottom of the bearing carrier with the lower
A-arm. Install the lower bearing carrier fastener.
3. Align the top of the bearing carrier with the upper A-
arm. Install the upper bearing carrier fastener.
5. Thoroughly clean the rear 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
Use an arbor and press only on the outer race, NOTICE
otherwise bearing damage may occur. The lower shock bolt may need to be removed to allow
the upper A-arm to move freely.
7. Apply Loctite® 603 retaining compound to the outer
circumference of the new bearing race and carefully 4. Torque the upper and lower bearing carrier fasteners
press the new bearing into the bearing carrier to specification.
housing.
TORQUE
Bearing Carrier Fasteners: 8
40 lb-ft (54 Nm)
5. Install the wheel hub assembly onto the drive shaft.

6. Install the washer(s).
NOTICE
Use care to not allow any of the Loctite® compound to
get in the bearing.
8. Wipe the housing clean of any excess compound and

install the snap ring.

FINAL DRIVE
7. Install the castle nut. 9. Install the rear brake caliper and torque the mounting
bolts to specification.
TORQUE
Rear Wheel Hub Castle Nut : TORQUE
180 ft-lbs (245 N·m) Rear Caliper Mounting Bolts:
46 lb-ft (62 Nm)
8. Install the cotter pin.
10. Install the wheel, washers and wheel nuts. Torque
wheel nuts to specification.
TORQUE
Wheel Nuts (Alum): 120 lb-ft (163 Nm)

FINAL DRIVE
REAR DRIVE SHAFT SERVICE

REAR DRIVE SHAFT REMOVAL 6. Remove the washer(s).
1. Place the transmission in PARK.
2. Elevate the rear of the vehicle and safely support the
vehicle under the main frame area.
3. Remove wheel nuts, and wheel.
4. Remove the cotter pin.
NOTICE
Image for reference only. Each hub requires a different
number of washers. Refer to Rear Hub Identification
page to make sure that the correct washer and
washer quantity is used.
5. Remove the castle nut. 7. Remove the two rear brake caliper mounting bolts
and remove the caliper from the bearing carrier.
CAUTION
Do not hang the caliper by the brake line. Use
mechanics wire to hang the caliper to prevent possible
damage to the brake line.

FINAL DRIVE
8. Slide the wheel hub out from the bearing carrier and 11. With a short, sharp jerk, remove drive shaft from the
drive shaft. transmission.
9. Remove the upper A-arm fastener.

REAR DRIVE SHAFT INSTALLATION
1. Install a new spring ring q and o-ring w on the end of
the drive shaft e if not replacing the drive shaft
assembly. Apply an anti-seize compound to the
splines of both ends of the shaft.
10. Tilt the carrier down while removing the end of the
driveshaft.

FINAL DRIVE
2. Align splines of the drive shaft with the transmission 6. Refer toRear Bearing Carrier Installation page
and reinstall the drive shaft. Use a rubber mallet to procedure to reassemble the vehicle.
tap on the outboard end of the drive shaft if
necessary.
3. Perform push / pull test on the axle ensure the

retaining ring is locked into the rear gearcase.
4. Rotate the bearing carrier onto the drive axle and
rotate into upper A-arm.
5. Install the upper bearing carrier fastener.

FINAL DRIVE
DRIVE SHAFT SERVICE

DRIVE SHAFT / CV JOINT HANDLING OUTER CV JOINT / BOOT
TIPS REPLACEMENT
Care should be exercised during drive shaft removal or 1. Use a side cutters to cut and discard the boot clamps
when servicing CV joints. Drive shaft components are
precision parts. q.
Cleanliness and following these instructions is very
important to ensure proper shaft function and a normal
service life.
• The complete drive shaft and joint should be handled

by getting hold of the interconnecting shaft to avoid
disassembly or potential damage to the drive shaft
joints.
• Over-angling of joints beyond their capacity could
result in boot or joint damage.
• Make sure surface-ground areas and splines of shaft
are protected during handling to avoid damage.
• Do not allow boots to come into contact with sharp
edges or hot engine and exhaust components.
2. Remove the large end of the boot from the CV joint
• The drive shaft is not to be used as a lever arm to and slide the boot down the shaft.
position other suspension components.
• Never use a hammer or sharp tools to remove or to
install boot clamps.
• Be sure joints are thoroughly clean and that the proper
amount and type of grease is used to refill when joint
boots are replaced and when joints are cleaned. Refer
to text for grease capacity of CV joints and CV joint
boots.
3. Clean the grease from the face of the joint.

FINAL DRIVE
4. Place the drive shaft in a soft-jawed vise. Using a 7. Thoroughly clean the joint with an appropriate solvent
soft-faced hammer, or brass drift, strike the inner race and dry the joint to prevent any residual solvent from
of the joint to drive the joint off the drive shaft. Be sure being left in the joint upon reassembly.
to tap evenly around the joint to avoid binding.
8. Visually inspect the joint by tilting the inner race to

IMPORTANT one side to expose each ball. Severe pitting, galling,
play between the ball and its cage window, any
Tap on inner race only!
cracking or damage to the cage, pitting or galling or
chips in raceways call for joint replacement.
5. Make sure circlip w is on the shaft and not left in the
NOTICE
joint.
Shiny areas in ball tracks and on the cage spheres are
normal. Do not replace CV joints because parts have
polished surfaces. Replace CV joint only if components
are cracked, broken, worn or otherwise unserviceable.
9. Clean the splines on the end of the shaft and apply a

light coat of grease prior to reassembly.
10. Slide the small boot clamp and boot (small end first) 8
onto the drive shaft and position the boot in it’s
groove machined in the shaft.
11. Install a new circlip on the end of the shaft.
12. Grease the joint with the special CV joint grease
provided in the boot replacement kit. Fill the cavity
behind the balls and the splined hole in the joint’s
6. Remove the CV boot from the shaft. inner race. Pack the ball tracks and outer face flush
with grease. Place any remaining grease into the
IMPORTANT boot.
Complete disassembly of the CV joint is NOT IMPORTANT
recommended. The internal components are precision
fit and develop their own characteristic wear patterns. The grease provided in the replacement kit is specially
Intermixing the internal components could result in formulated for wear resistance and durability. DO NOT
looseness, binding, and/or premature failure of the joint. use substitutes or mix with other lubricants.
IMPORTANT IMPORTANT
If the grease in the joint is obviously contaminated with The amount of grease provided in the boot kit is pre-
water and/or dirt, the joint should be replaced. measured. Use entire contents of package.

FINAL DRIVE
13. Slide the joint onto the drive shaft splines and align 19. While pulling out on the CV shaft, fully extend the CV
the circlip with the lead-in chamfer on the inner race joint and slide a straight O-ring pick or a small slotted
of the joint. screw driver between the small end of the boot and
the shaft. This will allow the air pressure to equalize in
the CV boot in the position that the joint will spend
most of its life. Before you remove your instrument,
be sure the small end of the boot is in its correct
location on the shaft.
20. Install and tighten the small clamp r on the boot
using the appropriate clamp tool.
14. Use a soft-faced hammer to tap the joint onto the

drive shaft until it locks into place.
15. Pull on the joint to make sure it is securely locked in
place.
16. Remove excess grease from the CV joint's external
surfaces and place the excess grease in the boot.
17. Pull the boot over the joint and position the boot lips Axle Boot Clamp Tool: PU-48951
into the grooves on the joint housing and shaft. Make or
sure the boot is not dimpled or collapsed. CV Boot Clamp Pliers: 8700226
18. Install and tighten the large clamp e using the
appropriate clamp tool.
Axle Boot Clamp Tool: PU-48951

or
CV Boot Clamp Pliers: 8700226

FINAL DRIVE
INNER PLUNGING JOINT / BOOT 4. Using a soft-faced hammer, or brass drift, strike the
REPLACEMENT inner race of the joint to drive the joint off the shaft. Be
sure to tap evenly around the joint to avoid binding.
1. Use a side cutters to cut and discard the boot clamps
q.
IMPORTANT
2. Remove the large end of the boot from the plunging Tap on inner race only!
joint and slide the boot down the shaft.
5. Make sure the circlip w is on the shaft and not left in
the joint.
3. Clean the grease from the face of the joint and place
the drive shaft in a soft-jawed vise.

FINAL DRIVE
6. Remove the boot from the shaft. 13. Fully compress the joint and push the drive shaft
firmly into the inner race.
IMPORTANT
14. Align the circlip with the lead-in chamfer.
Complete disassembly of the plunging joint is NOT
recommended. The internal components are precision
fit and develop their own characteristic wear patterns.
Intermixing the internal components could result in
looseness, binding, and/or premature failure of the joint.
15. Use a soft-faced hammer to tap the joint onto the

drive shaft until you reach the end of the splines and
the joint locks in place.
16. Pull on the joint to test that the circlip is seated and
that the joint is securely fastened to the shaft.
IMPORTANT
17. Remove excess grease from the plunging joint’s
If the grease in the joint is obviously contaminated with external surfaces and place the excess grease in the
water and/or dirt, the joint should be replaced. boot.
18. Pull the boot over the joint and position the boot lips
7. Thoroughly clean the joint with an appropriate solvent into the grooves on the joint housing and shaft. Make
and dry the joint to prevent any residual solvent from sure the boot is not dimpled or collapsed.
being left in the joint upon reassembly. 19. Install and tighten the small clamp e using the
8. Visually inspect the joint for damage. Replace if appropriate clamp tool.
needed.
9. Clean the splines on the end of the shaft and apply a
light coat of grease prior to reassembly.
10. Slide the small boot clamp and boot (small end first)
onto the drive shaft and position the boot in its groove
machined in the shaft.
11. Install a new circlip on the end of the shaft.
12. Grease the joint with the special joint grease provided
in the boot replacement kit. Fill the cavity behind the
balls and the splined hole in the joint’s inner race.
Pack the ball tracks and outer face flush with grease.
Place any remaining grease into the boot.
IMPORTANT
The grease provided in the replacement kit is specially Axle Boot Clamp Tool: PU-48951
formulated for wear resistance and durability. DO NOT or
use substitutes or mix with other lubricants. CV Boot Clamp Pliers: 8700226
NOTICE
The amount of grease provided in the boot kit is pre-
measured. Use entire contents of package.

FINAL DRIVE
20. Pull out on the drive shaft to center the joint in the
housing. Slide a straight O-ring pick or a small slotted
screw driver between the large end of the boot and
the joint housing and lift up to equalize the air
pressure in the boot.
21. Position the boot lip in its groove. Install and tighten
the large clamp r using the appropriate clamp tool.
Axle Boot Clamp Tool: PU-48951

or
CV Boot Clamp Pliers: 8700226

FINAL DRIVE
NOTES

CHAPTER 9
GENERAL INFORMATION - STEERING / SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
SERVICE NOTES - STEERING / SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
SPECIAL TOOLS - STEERING / SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
SERVICE SPECIFICATIONS - STEERING / SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
ELECTRONIC POWER STEERING (EPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
EPS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
EPS SYSTEM BREAKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
STEERING ASSEMBLY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
STEERING ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
TIE ROD END / WHEEL HUB INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
WHEEL TOE MEASUREMENT / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
STEERING WHEEL / UPPER STEERING SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
STEERING RACK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
STEERING RACK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.10
POWER STEERING UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
STEERING SHAFT BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.12
FRONT A-ARM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.13
FRONT LOWER A-ARM REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.13
A-ARM BUSHING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.14
FRONT UPPER A-ARM REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.14
BALL JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.16
BALL JOINT SERVICE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.16
BALL JOINT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.17
REAR A-ARM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.19 9
REAR UPPER A-ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.19
REAR UPPER A-ARM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.20
A-ARM BUSHING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.20
REAR LOWER A-ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.21
REAR LOWER A-ARM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.21
STABILIZER BAR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.22
REAR STABILIZER BAR REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.22
SHOCK / SPRING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.23
SHOCK ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.23
SHOCK SPRING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.24

GENERAL INFORMATION - STEERING / SUSPENSION

SERVICE NOTES - STEERING /
SUSPENSION
WARNING
sure machine is secure before beginning any procedure
that requires machine lifting. Always wear eye
protection.
DANGER
The locking agent on the existing a-arm bolts was
destroyed during removal. DO NOT reuse old
hardware. Serious injury or death could result if
fasteners come loose during operation.
IMPORTANT
New ball joint bolts have a pre-applied locking agent
which is destroyed upon removal. Always use new
brake caliper mounting bolts upon assembly.
SPECIAL TOOLS - STEERING /

SUSPENSION
TOOL DESCRIPTION PART NUMBER
Ball Joint Tool PU-50506
Spring Compressor Tool 2870623
Shock Spanner Wrench 2871095
Bosch Automotive Service Solutions:

1-800-345-2233 or http://polaris.service-solutions.com
SERVICE SPECIFICATIONS - STEERING

/ SUSPENSION
SERVICE
PART DESCRIPTION
SPECIFICATION
Wheel Toe Out 1/8-1/4 in (3.2-6.4 mm)

ELECTRONIC POWER STEERING (EPS)

EPS OPERATION • If the fuse fails, the Power Steering Malfunction
The EPS module is an intelligent electronic power Indicator Light (MIL) on the instrument cluster will
steering system that operates off of the vehicle’s 12V illuminate. During this time, the vehicle will have no
electrical system. It calculates steering assist by sensing power steering operation. You will be able to connect
the difference between the input torque of the steering and communicate with the vehicle’s Engine Controller,
post and the output torque required to turn the wheels, but not the Power Steering Controller, while using
and then provides assist by energizing an electric motor. Digital Wrench®.
The process provides a smooth, seamless assist.
NOTICE
The system is continuously running diagnostic checks DO NOT SPLICE OR CUT INTO THE CAN CIRCUITS.
and monitoring factors such as battery voltage, ground
speed and engine speed. In the event an internal or
external issue that affects the EPS system is detected, WARNING
the system will illuminate a fault indicator and transition
to a normal mechanically coupled steering system. The Electronic Power Steering (EPS) units are not
system is Polaris Digital Wrench® compatible for interchangeable between ATV and RANGER product
simplified diagnostics and system troubleshooting lines.
through the vehicle’s diagnostic port.
With the engine off and the key on, the power steering NOTICE
unit will operate for up to five minutes. After the five Refer to Steering / Suspension chapter for power
minutes, you will need to cycle the key switch and restart steering unit removal and installation procedures.
the engine to regain power steering operation.
NOTICE
WIRE COLOR FUNCTION
To conserve battery power, the EPS unit will shut down
5 minutes after the engine has stopped if the key ORANGE (2-Pin) Main Power (30A Protected)
remains in the ON position. At this point, the EPS BROWN (2-Pin) Ground
Malfunction Indicator Light will illuminate to indicate the ORANGE (8-Pin) Key-On Battery Voltage
EPS has shut down and will set a fault code in Digital
Wrench®. YELLOW (8-Pin) CAN High Signal
GREEN (8-Pin) CAN Low Signal
The Power Steering 30A Fuse.

EPS SYSTEM BREAKOUT

STEERING ASSEMBLY SERVICE

STEERING ASSEMBLY VIEW
ITEM DESCRIPTION TORQUE ITEM DESCRIPTION TORQUE

Power Steering Mount Lower Steering Shaft Pinch 25 ft-lbs (34 Nm)
q NA f Bolt
Steering Wheel Tilt
w Steering Wheel NA g NA
Assembly Bolt
Steering Shaft, Lower Upper Steering Shaft Pinch 25 ft-lbs (34 Nm)
e NA h Bolt
Steering Adjustment Shock
r Steering Shaft , Upper NA j Assembly Bolt NA 9
Steering Adjustment Shock
t Steering Gear Box Asm. NA k 7 ft-lbs (10 Nm)
Assembly Nut
y Tilt Steering Asm. NA l Steering Rack Mount Nuts 40 ft-lbs (54 Nm)
Steering Wheel Tilt
u Power Steering Asm. NA 1( 40 ft-lbs (54 Nm)
Assembly Fasteners
i Steering Wheel Cap NA 2) Lower Steering Shaft Nut NA
o Tilt Assembly NA 2! Nut 65 ft-lbs (88 Nm)
a Tie Rod Jam Nut 13 ft-lbs (18 Nm) 2@ Steering Bushing NA
Step 1: 30 ft-lbs
Power Steering Unit Frame Tie Rod Retaining Nut (41 Nm)
s Nut
NA 2# Step 2: Tighten
additional 90°
Power Steering Unit Frame 14 ft-lbs (19 Nm)
d Fasteners

STEERING INSPECTION TIE ROD END / WHEEL HUB

Steering system components should be checked INSPECTION
periodically for loose fasteners q, worn tie rod ends w,
loose steering shaft U-joints e, worn A-arm ball joints • To check for play in the tie rod end q, grasp the
and general damage. Also check to make sure all cotter steering tie rod, pull in all directions feeling for
pins r are in place. If cotter pins are removed, they must movement.
be replaced.
Replace any worn or damaged steering components.
Steering should move freely through the entire range of
travel without binding. Check routing of all cables, hoses,
and wiring to be sure the steering mechanism is not
restricted or limited.
• Replace any worn steering components. Steering

should move freely through entire range of travel
without binding.
• Elevate front end of machine so front wheels are off
the ground. Check for any looseness in front wheel/
hub assembly by grasping the tire firmly at top and
bottom first, and then at front and rear. Try to move the
NOTICE wheel and hub by pushing inward and pulling outward.
Check front end alignment whenever steering
components are replaced.
WARNING
Due to the critical nature of the procedures outlined in
this chapter, Polaris recommends steering component
repair and adjustment be performed by an authorized
Polaris MSD certified technician.
• If abnormal movement is detected, inspect the hub and

wheel assembly to determine the cause (loose wheel
nuts or loose front hub nut).

WHEEL TOE MEASUREMENT / 5. Measure the distance between the marks and record.
ADJUSTMENT Call this measurement e. Subtract measurement e
from measurement w, this is the vehicle toe. The
MEASUREMENT recommended vehicle toe tolerance is 1/8-1/4 in (3.2-
IMPORTANT 6.4 mm) toe out. This means the front of the tire w is
wider than the measurement at the rear e.
Make sure tire pressures are set the same on the right
and left tires. MEASUREMENT
Wheel Toe-Out:
1. Place machine on a smooth level surface and set 1/8-1/4 in (3.2-6.4 mm)
steering wheel in a straight ahead position. Secure
the steering wheel in this position.
ADJUSTMENT
2. Place a chalk mark on the center line of the front tires
approximately 10 in (25.4 cm) from the floor or as 1. Hold tie rod end to keep it from rotating.
close to the hub/axle center line as possible q. 2. Loosen jam nuts at both end of the tie rod.
3. Adjust the tie rod as needed to achieve the proper toe
setting.
IMPORTANT
When tightening the tie rod end jam nuts, the rod ends
must be held parallel to prevent rod end damage and
premature wear. Damage may not be immediately
apparent if done incorrectly.
4. After alignment is complete, torque jam nuts to

specification.
TORQUE
Tie Rod Jam Nut:
13 ft-lbs (18 Nm)
NOTICE
It is important the height of both marks be equally
positioned to get an accurate measurement.
3. Measure the distance between the marks and record

the measurement. Call this measurement w.
9
4. Rotate the tires 180° by moving the vehicle forward.

Position chalk marks facing rearward, even with the
hub/axle center line.

STEERING WHEEL / UPPER STEERING 6. Remove the steering wheel cap.

SHAFT REMOVAL
1. Remove upper and lower dash panels. Refer to Dash
Panels / Glove Box Service page 11.34 procedure.
CAUTION
Striking the steering wheel or steering shaft while
installed in the vehicle can permanently damage the
EPS unit and cause a Power Steering Fault.
2. Remove the pinch bolt q retaining the upper steering

shaft w to the power steering unit.
7. Loosen the nut and back it half way off the steering
shaft.
8. Place the assembly in a vise.
9. Using a large bronze drift and hammer, strike steering
shaft nut to pop the steering wheel off the tapered
shaft.
10. Once the steering wheel pops loose, completely
remove the nut and lift the steering wheel off the
shaft.
3. Remove the steering tilt assembly fasteners.
4. Remove the fastener retaining the upper steering

shaft to the power steering unit.
5. Remove the steering wheel, upper steering shaft and
pivot out as an assembly.

STEERING RACK REMOVAL

1. Remove the pinch bolt w retaining the lower portion
of the steering shaft e to the steering rack assembly
q.
2. Remove the nuts r retaining the both tie rod ends to

the steering knuckle.
3. Remove the three fasteners t retaining the steering 9

rack to the frame.
4. Remove Steering Rack from vehicle.

STEERING RACK INSTALLATION 3. Install the steering shaft e to the steering rack
assembly q. Install the pinch bolt w and nut. Torque
1. Lay the old and new steering racks next to each other
to specification
on a clean surface. Measure the old steering rack
length from tie rod end to tie rod end. Turn the tie rod
ends in or out to adjust the new steering rack to this
measurement.
TORQUE
Lower Steering Shaft to Rack Pinch Bolt:
25 ft-lbs (34 Nm)
2. Install the new steering rack into the vehicle. Install
three nuts t retaining the steering rack to the frame.
Torque to specification. 4. Install the tie rod ends into the steering knuckle as
shown. Install the Tie Rod Retaining Nut r and
TORQUE
Steering Rack Mounting Nuts:
TORQUE
40 ft-lbs (54 Nm)
Tie Rod Retaining Nut:
Step 1: 30 ft-lbs (41 Nm)Step 2: Tighten additional
90°
5. Perform Wheel Toe Adjustment.

POWER STEERING UNIT INSTALLATION 7. Loosely install the steering tilt assembly bolts and
nuts.
1. Install the power steering unit onto the mount bracket
and torque power steering mounting fasteners to CAUTION
specification.
Striking the steering wheel or steering shaft can
TORQUE permanently damage the EPS unit and cause a Power
Power Steering Mount Fasteners: Steering Fault.
30 ft-lbs (41 Nm)
2. Align the skip-tooth spline on the power steering

output shaft with the opening in the lower power
steering shaft.
3. Install power steering and mount assembly to the
frame and torque fasteners to specification.
TORQUE
Power Steering Unit Frame Fasteners:
14 ft-lbs (19 Nm)
4. Install the pinch bolt retaining the lower power

steering shaft to the power steering unit. Torque to 8. Install the upper steering shaft pinch bolt and torque
specification. to specification.
TORQUE TORQUE
Lower Steering Shaft Pinch Bolt: Upper Steering Shaft Pinch Bolt:
5. Position the steering wheel, pivot tube and upper 9. Install the fastener retaining the steering wheel tilt
steering shaft assembly to the proper mounting assembly to the frame. Torque fastener to
location. specification.
6. Be sure the front wheels are pointing straight ahead
and that the steering wheel is straight. Align the skip- TORQUE
tooth spline on the power steering input shaft with the Steering Wheel Tilt Assembly Fasteners:
opening in the upper steering shaft and install the 40 ft-lbs (54 Nm)
upper shaft onto the power steering input shaft. 9
10. Reconnect both electrical harnesses onto the power
steering unit. Be sure the connectors snap into place
and the wires are routed correctly.
11. Reinstall the upper and lower dash panels making
sure to reconnect the instrument cluster, both 12V
outlets and all the switches.
12. Turn the key switch on and test EPS operation.

STEERING SHAFT BEARING 8. Apply Loctite® 271 (Red) to the outer circumference
REPLACEMENT of the new upper bearing race. Slide the new upper
bearing onto the steering shaft and press it into the
NOTICE pivot tube by hand.
Replacement pivot tube assembly comes with new NOTICE
upper and lower bearings installed. Use this procedure
if replacing just the bearings only. Use care not to allow any of the Loctite® to get in the
bearing.
Bearings will be seated in the pivot housing upon
1. Perform the Steering Rack Removal page 9.9 tightening the steering wheel nut in step 14.
procedure.
2. Remove the steering wheel cap and retaining nut. 9. Install the steering wheel and hand tighten the nut.
3. Press steering shaft out of the steering wheel and 10. Reinstall the steering shaft assembly in the vehicle.
pivot tube. Install the lower portion of the steering shaft onto the
4. Note the order and location of the spacers between steering gear box assembly. Torque the lower pinch
the pivot tube and steering shaft. bolt to specification.
5. Drive the bearings out of the pivot tube using a drift TORQUE
punch.
Lower Steering Shaft Pinch Bolt:
6. Inspect the pivot tube bearing surfaces for signs of 25 ft-lbs (34 Nm)
excessive wear or damage.
7. Apply Loctite® 271 (Red) to the outer circumference 11. Install the fastener retaining the steering wheel tilt
of the new lower bearing race. Slide the new lower assembly to the frame. Torque fastener to
bearing onto the steering shaft and install the steering specification.
shaft through the pivot tube.
TORQUE
NOTICE
Steering Wheel Tilt Assembly Fasteners:
Use care not to allow any of the Loctite® to get in the
40 ft-lbs (54 Nm)
bearing.
Be sure the lower spacers are still on the steering shaft.
12. Be sure the front wheels are facing straight forward.
Remove the steering wheel and align as needed.
Torque the steering wheel nut to specification.
TORQUE
Steering Wheel Nut:
65 ft-lbs (88 Nm)
13. Wipe the pivot tube clean of any excess Loctite®.

14. Install steering wheel cap and field test steering
operation.
I- DESCRIPTION TORQUE
T-
q Steering Wheel Cap NA

w Nut 65 ft-lbs (88 Nm)
e Steering Wheel NA
r Hub Insert NA
t Bushing NA
y Steering Shaft, Upper NA
u Tilt Assembly NA

FRONT A-ARM SERVICE

FRONT LOWER A-ARM REMOVAL / 4. Loosen and remove the lower A-arm front through-
INSTALLATION bolt fastener w and rear through-bolt fastener e.
Remove the lower A-arm from the vehicle.
1. Remove A-Arm shield from A-Arm.
5. Examine A-arm bushings and pivot tube. Replace if

2. Loosen lower ball joint nut q from bearing carrier as worn. Discard hardware.
shown.
6. If not replacing the A-arm, thoroughly clean the A-arm
and pivot tube.
7. Install new ball joint into A-arm. Refer to “Ball Joint
Service” section.
8. Install new lower A-arm assembly onto vehicle frame.
Torque new bolt to specification.
9. Insert lower A-arm ball joint end into the bearing
carrier. Install lower ball joint pinch bolt into the
bearing carrier and torque bolt to specification.
WARNING
Upon A-arm installation, test vehicle at low speeds
before putting into service.
3. Using a soft face hammer, tap on the nut to loosen

9
TORQUE
the ball joint end while pushing up on the lower A-
arm. Completely remove the ball joint nut and end Lower A-arm Bolts:
from the bearing carrier. 30 ft-lbs (40 N·m) + 180°
Front Ball Joint Nut:

45 ft-lbs (61 Nm)
10.
WARNING
Upon A-arm installation completion, test vehicle at low
speeds before putting into service.

A-ARM BUSHING REPLACEMENT FRONT UPPER A-ARM REMOVAL /

1. Place a small punch in the opening of one Pivot Cap INSTALLATION
and drive the opposite Pivot Cap out. 1. Elevate and safely support the front of the vehicle and
remove the front wheel.
2. Remove lower shock fastener q and stabilizer bar
link w from upper A-arm.
IMPORTANT
Be careful not to damage the A-Arm while using the
punch and hammer.
3. Carefully drill out brake line retention grommets.
2. Install new Pivot Cap q, Bushings w, and Pivot Shaft
e into new A-arm. A light press force may be
needed..
CAUTION
Do not damage brake line during this process

4. Remove upper ball joint pinch bolt r from bearing 11. Install new upper A-arm assembly onto vehicle frame.
carrier. Torque new bolt to specification.
TORQUE
Front Upper A-arm Bolts:
44 ft-lbs (60 N·m)
12. Install brake line routing clips and grommets in the A-

arm.
13. Insert upper A-arm ball joint end into the bearing
carrier. Install upper ball joint pinch bolt and nut into
the bearing carrier and torque nut to specification.
TORQUE
Front Ball Joint Pinch Nut:
42 ft-lbs (57 Nm)
5. Using a soft face hammer, tap on bearing carrier to
loosen the upper A-arm ball joint end while lifting 14. Install the fasteners retaining the front stabilizer bar
upward on the upper A-arm. Completely remove the link to the upper A-arm.. Torque nut to specification.
ball joint end from the bearing carrier.
TORQUE
6. Loosen and remove the upper A-arm front through-
bolt fastener t and rear though-bolt fastener y. Stabilizer Bar Link Nut:
Remove the upper A-arm from the vehicle. 40 ft-lbs (54 Nm)
15. Attach shock to A-arm with fasteners. Torque lower

shock nut to specification.
TORQUE
Front Shock Mounting Nut:
44 ft-lbs (60 N·m)
9
7. Examine A-arm bushings and pivot tube. Replace if
worn. Discard hardware.
WARNING
The locking agent on the existing bolts was destroyed
during removal. DO NOT reuse old hardware. Serious
injury or death could result if fasteners come loose
during operation.
8. If not replacing the A-arm, thoroughly clean the A-arm

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

BALL JOINT SERVICE

BALL JOINT SERVICE PREPARATION 7. If necessary, remove the lower front shock fastener
from the A-arm to gain enough clearance to install
NOTICE ball joint tool (PU-50506) on the lower ball joint.
Do not reuse a ball joint if it has been removed. If
removed, it must be replaced. Use this removal
procedure only when replacing the ball joint. BALL JOINT REMOVAL
If the ball joint is removed, the bearing carrier MUST be 1. Remove the retaining ring from the ball joint.
replaced. Refer to FRONT BEARING CARRIER
REMOVAL / INSTALLATION and REAR BEARING
CARRIER REMOVAL procedures.
Ball joint tool PU-50506 will allow the upper and lower
ball joints to be replaced with the A-arm installed on the
vehicle.
NOTICE
Image for reference only.
2. Install Spacer q over the top of the ball joint face.
q Press Asm. e Spacer

w Removal Adapter r Installation Adapter
NOTICE
The A-arm does not need to be removed to perform this
procedure if ball joint tool PU-50506 is used.
1. Properly lift and support the vehicle by the frame.

2. Remove the appropriate front wheel.
To service the upper ball joint: 3. Place Removal Adaptor w over the ball joint shaft.
3. Remove and discard the two front brake caliper 4. Install the Press Asm. e onto the A-arm to engage
mounting bolts and remove the caliper from the brake the ball joint Removal Adapter.
disc. Refer to FRONT BRAKE CALIPER REMOVAL
procedure. IMPORTANT
4. Remove and discard the upper ball joint pinch bolt. Be sure the Press Asm. opening is only contacting the
Spacer q and not the ball joint face.
5. If necessary, remove the lower front shock fastener
from the A-arm to gain enough clearance to install
ball joint tool (PU-50506) on the upper ball joint.
To service the lower ball joint:

6. Remove and discard the lower ball joint pinch bolt.

5. Tighten the Press Asm. screw and fully remove the 5. Tighten the Press Asm. screw and fully install the ball
ball joint from the A-arm. joint into the arm.
6. After the new ball joint is fully installed into the A-arm,
BALL JOINT INSTALLATION install a new retaining ring.
1. By hand, install the NEW ball joint into the A-arm.

2. Position the Installation Adapter w over the face of
the ball joint.
NOTICE
9
NOTICE 7. Repeat the ball joint service procedure for any
additional A-arm ball joint replacements.
8. Insert upper / lower A-arm ball joint end into the
bearing carrier. Install new fasteners. Torque to
3. Position the Spacer q over the shaft of the ball joint specification.
so it is against the A-arm.
TORQUE
4. Install the Press Asm. e onto the A-arm to engage
the Installation Adapter and Spacer. Ball Joint Pinch Bolts:
42 ft-lbs (57 N·m)
Front Lower Ball Joint Nut:
45 ft-lbs (61 Nm)

9. If removed reinstall the shock in the mount and install

fasteners. Torque to specification.
TORQUE
Front Shock Mounting Bolts:
44 ft-lbs (60 N·m)
10. If needed, install new brake caliper mounting bolts

IMPORTANT
New bolts have a pre-applied locking agent which is
destroyed upon removal. Always use new brake caliper
mounting bolts upon assembly.
TORQUE
Front Caliper Mounting Bolts: 28 ft-lbs (38 Nm)
11. Install wheel and four wheel nuts. Torque wheel nuts
to specification.
TORQUE
Wheel Nuts (Aluminum): 120 lb-ft (163 Nm)

REAR A-ARM SERVICE

REAR UPPER A-ARM REMOVAL 6. Remove the fastener e and nut retaining the upper
A-arm to the bearing carrier.
1. Properly lift and support the vehicle by the frame.
2. Using a 13 mm socket, remove the four nuts retaining
the rear stabilizer bar to the frame.
3. Remove the nut q from the lower portion of the
stabilizer bar link.
7. Drill out the rivet r retaining the brake line clamp to

the upper A-arm.
4. Remove the four wheel nuts and remove the wheel.

5. Remove the fastener w retaining the lower portion of
the rear shock to the lower A-arm.
8. Using a 15 mm socket and open-end wrench, remove

the two fasteners t retaining the upper A-arm to the 9
frame.

9. Allow the lower A-arm to drop and remove the upper 6. Install wheel and torque wheel nuts to specification.
A-arm by maneuvering the rear shock and stabilizer
link out. TORQUE
Wheel Nuts (Aluminum): 120 lb-ft (163 Nm)
REAR UPPER A-ARM INSTALLATION
WARNING WARNING
The locking agent on the existing bolts was destroyed Upon A-arm installation completion, test vehicle at low
during removal. DO NOT reuse old hardware. Serious speeds before putting into service.
injury or death could result if fasteners come loose
during operation.
1. Install the upper A-arm onto the frame by A-ARM BUSHING REPLACEMENT
maneuvering the shock and stabilizer link into the A-
1. Place a small punch in the opening of one Pivot Cap
arm. Torque new fasteners to specification.
and drive the opposite Pivot Cap out.
TORQUE
Rear A-Arm to Frame Fastener:
81 ft-lbs (110 N·m)
2. Attach the upper A-arm to the bearing carrier. Torque

new fastener to specification.
TORQUE
Rear Upper A-Arm to Bearing Carrier Fastener:
44 ft-lbs (60 N·m)
3. Attach the lower portion of the rear shock to the rear

lower A-arm. Torque new fastener to specification.
TORQUE IMPORTANT
Shock Mounting Bolts: Be careful not to damage the A-Arm while using the
44 ft-lbs (60 N·m) punch and hammer.
4. Attach the lower stabilizer bar link to the lower A-arm. 2. Install new Pivot Cap q, Bushings w, and Pivot Shaft
Torque new fastener to specification. e into new A-arm. A light press force may be
5. Attach the stabilizer bar to the frame. Torque needed..
TORQUE
Stabilizer Bar Fasteners:
17 lb-ft (23 Nm)

REAR LOWER A-ARM REMOVAL REAR LOWER A-ARM INSTALLATION

1. Properly lift and support the vehicle by the frame. WARNING
2. Remove the four nuts retaining the rear stabilizer bar The locking agent on the existing bolts was destroyed
to the frame. during removal. DO NOT reuse old hardware. Serious
3. Remove the nut q from the lower portion of the injury or death could result if fasteners come loose
stabilizer bar link. during operation.
1. Install the lower A-arm on the frame. Torque new

TORQUE
Rear A-Arm to Frame Fastener:
81 ft-lbs (110 N·m)
2. Attach the lower A-arm to the bearing carrier. Torque

new fastener to specification.
TORQUE
Rear Lower A-Arm to Bearing Carrier Fastener:
4. Remove the four wheel nuts and remove the wheel. 30 ft-lbs (40 N·m) + 180°
5. Remove the fastener w retaining the lower portion of
the rear shock to the lower A-arm. 3. Attach the lower portion of the rear shock to the lower
A-arm. Torque new fastener to specification.
TORQUE
44 ft-lbs (60 N·m)
4. Attach the lower stabilizer bar link to the lower A-arm.

Torque new fastener to specification.
5. Attach the stabilizer bar to the frame. Torque
TORQUE
Stabilizer Bar Fasteners:
9
6. Remove the fastener retaining the lower A-arm to the 17 lb-ft (23 Nm)
bearing carrier and frame.
6. Install wheel and torque wheel nuts to specification.
TORQUE
Wheel Lug Nuts:
120 ft-lbs (163 Nm)
WARNING
Upon A-arm installation completion, test vehicle at low
speeds before putting into service.
7. Remove the lower A-arm from the vehicle.

STABILIZER BAR SERVICE

REAR STABILIZER BAR REMOVAL /
INSTALLATION
REMOVAL
1. Elevate and safely support the vehicle with weight
removed from the rear wheel(s).
2. Identify / mark top side of the stabilizer bar to
reference during installation.
3. Remove the four fasteners w retaining the stabilizer
bar to the vehicle frame.
4. Remove the fasteners retaining the stabilizer bar to
the linkage q on each side of the vehicle.
5. Remove the stabilizer bar from the frame and inspect

the stabilizer bar for straightness.
INSTALLATION
1. Fully install stabilizer bar and stabilizer links. Center

stabilizer bar in the frame.
2. Torque the stabilizer bar mounting nuts and upper
rubber linkage bushing nuts to specification.
TORQUE
Stabilizer Bar Mount Fasteners:
31 ft-lbs (42 Nm)
Stabilizer Bar Link Fasteners:

17 ft-lbs (23 Nm)

SHOCK / SPRING SERVICE

SHOCK ANALYSIS
Shock “misting” q or “weepage” w is common and should be present during normal vehicle operation. All Shock
Absorber Seals are designed to allow a thin film of oil to pass into and out of the shock. This thin film of oil lubricates
the Seal to ensure low friction and reduces the corrosion rate of the Piston Rod.
Vehicle operating conditions have a high impact on how much shock oil might be present on the seal and shock body
(i.e. road conditions and operating temperature). It is important to properly identify the difference between normal
operation (weepage or misting) and a shock that has a leak. Below are some images to help determine what is normal
and what could be identified as a bad shock.
MISTING OR WEEPAGE LEAKAGE

SHOCK REMOVAL / INSTALLATION SHOCK SPRING REPLACEMENT

1. Elevate the vehicle far enough off the ground to
1. Remove the shock and note the spring preload cam
relieve the suspension load and support the A-arm.
setting.
2. Remove the upper and lower fasteners retaining the
2. Using spring compressor, compress the shock spring
shock and remove the shock from the vehicle.
Discard nuts and replace with new upon installation. far enough to remove spring retainer.
3. Reverse the procedure to reinstall the shock. Torque

new shock mounting fasteners to specification.
TORQUE
40 lb-ft (54 Nm)
Spring Compressor:
2870623
3. Remove the spring and adjusting cam from the

existing shock and install components onto the new
shock.
4. Install the spring retainer. If needed, use the spring
compressor to compress the spring far enough to
install the retainer.
NOTICE
The spring retainer gap should be 180° from the end of
the spring upon installation.
5. Turn adjustment cam to set preload distance noted in

Step 1.
6. Reinstall shock onto vehicle and torque new

BRAKE SYSTEM
CHAPTER 10
BRAKE SYSTEM
GENERAL INFORMATION - BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3
SPECIAL TOOLS - BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3
SERVICE NOTES - BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3
SERVICE SPECIFICATIONS - BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.4
BRAKE SYSTEM OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.5
BRAKE SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.6
BRAKE SYSTEM ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.6
BRAKE LINE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.7
BRAKE LINE CLOCKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
BRAKE SYSTEM CLOCKING (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
BRAKE FLUID REPLACEMENT / BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
BRAKE PRESSURE SWITCH REPLACEMENT (INTL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
MASTER CYLINDER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
MASTER CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
MASTER CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
BRAKE PEDAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
BRAKE PEDAL REMOVAL (INTL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
BRAKE PEDAL INSTALLATION (INTL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
FRONT BRAKE PAD SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
FRONT BRAKE PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
FRONT BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
FRONT BRAKE PAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
FRONT CALIPER SERVICE - 3 SEAT / CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27
FRONT CALIPER ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27
FRONT CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
FRONT CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
FRONT CALIPER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29 10
FRONT CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
FRONT CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
REAR BRAKE PAD SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
REAR BRAKE PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
REAR BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
REAR BRAKE PAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
REAR CALIPER SERVICE - 3 SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34
REAR CALIPER ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34
REAR CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
REAR CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
REAR CALIPER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36

BRAKE SYSTEM
REAR CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37

REAR CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37
REAR CALIPER SERVICE - CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
REAR CALIPER ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
REAR CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.40
REAR CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.41
REAR CALIPER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.41
REAR CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.42
REAR CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.42
BRAKE DISC SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.44
BRAKE DISK INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.44
BRAKE DISC REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.45
PARKING BRAKE (INTL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.46
PARKING BRAKE CABLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.46
PARKING BRAKE CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.47
PARKING BRAKE CABLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.48
PARKING BRAKE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.50
PARKING BRAKE LEVER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.51
PARKING BRAKE CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.54
PARKING BRAKE DISC SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.56
ABS SERVICE (INTL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.57
ANTILOCK BRAKING SYSTEM (ABS) OVERVIEW (INTL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.57
ABS BRAKE SYSTEM ASSEMBLY VIEW (INTL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.58
BRAKE WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.59
BRAKE PEDAL SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.59
BRAKE WARNING SYSTEM (INTL MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.59
BRAKE WARNING SYSTEM INSPECTION (INTL MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.60

BRAKE SYSTEM
GENERAL INFORMATION - BRAKE SYSTEM

SPECIAL TOOLS - BRAKE SYSTEM The Polaris brake system consists of the following
components or assemblies: brake pedal, master cylinder,
TOOL DESCRIPTION PART NUMBER hydraulic brake lines, brake calipers, brake pads, and
Mity Vac™ Pressure Test Tool 2870975 brake discs, which are secured to the drive line.
When the foot activated brake lever is applied it applies
Bosch Automotive Service Solutions: pressure on the piston within the master cylinder. As the
1-800-328-6657 or http://polaris.service-solutions.com/ master cylinder piston moves inward it closes a small
opening (compensating port) within the cylinder and
starts to build pressure within the brake system. As the
SERVICE NOTES - BRAKE SYSTEM pressure within the system is increased, the pistons
located in the brake calipers move outward and apply
CAUTION pressure to the moveable brake pads. These pads
contact the brake discs and move the calipers in their
Always wear safety glasses. floating bracket, pulling the stationary side pads into the
brake discs. The resulting friction reduces brake disc and
vehicle speed.
CAUTION
The friction applied to the brake pads will cause the pads
Brake fluid will damage finished surfaces. to wear. As these pads wear, the piston within the caliper
Do not allow brake fluid to come in contact with finished moves further outward and becomes self adjusting. Fluid
surfaces. from the reservoir fills the additional area created when
the caliper piston moves outward.
Disc brake systems are light weight, low maintenance, Brake fluid level is critical to proper system operation.
and perform well in the conditions this vehicle will Too little fluid will allow air to enter the system and cause
routinely encounter. There are a few things to remember the brakes to feel spongy. Too much fluid could cause
when replacing disc brake pads or performing brake brakes to drag due to fluid expansion.
system service to ensure proper system function and
maximum pad service life. Located within the master cylinder is the compensating
port which is opened and closed by the master cylinder
• DO NOT over-fill the master cylinder fluid reservoir. piston assembly. As the temperature within the hydraulic
system changes, this port compensates for fluid
• Make sure the brake pedal returns freely and
expansion or contraction. Due to the high temperatures
completely.
created within the system during heavy braking, it is very
• Adjust the caliper stop pin after pad service. important that the master cylinder reservoir have
adequate space to allow for fluid expansion. Never
• Check and adjust master cylinder reservoir fluid level overfill the reservoir! Do not fill the reservoir beyond
after pad service. the MAX LEVEL line!
• Make sure atmospheric vent on reservoir is When servicing Polaris brake systems use only Polaris
unobstructed. DOT 4 Brake Fluid (PN 2872189).
• Test for brake drag after any brake system service and
investigate cause if brake drag is evident. WARNING
• Make sure caliper moves freely on guide pins (where
applicable).
Once a bottle of brake fluid is opened, use what is 10
necessary and discard the rest in accordance with
• Inspect caliper piston seals for foreign material that local laws. Do not store or use a partial bottle of
could prevent caliper pistons from returning freely. brake fluid. Brake fluid is hygroscopic, meaning it
rapidly absorbs moisture. This causes the boiling
• Perform a brake burnishing procedure after installing temperature of the brake fluid to drop, which can
new pads to maximize service life. lead to early brake fade and the possibility of
• DO NOT lubricate or clean the brake components with serious injury.
aerosol or petroleum products. Use only approved
brake cleaning products.

BRAKE SYSTEM
SERVICE SPECIFICATIONS - BRAKE SYSTEM

FRONT BRAKE SYSTEM
Front Brake Pad Thickness 0.297 ± .007" (7.54 ± .178 mm) 0.150" (3.8 mm)
Front Brake Disc Thickness 0.188" ( 4.78 mm) 0.170" (4.32 mm)
Front Brake Disc Thickness Variance - 0.002” (0.051 mm)
Front Brake Disc Runout - 0.010" (0.254 mm)
Front Caliper Piston Bore I.D. 1.373" (34.87 mm) 1.375" (34.93 mm)
Front Caliper Piston O.D. 1.370" (34.80 mm) 1.368" (34.75 mm)
REAR BRAKE SYSTEM

Rear Brake Pad Thickness 0.298 ± .007" (7.56 ± .178 mm) 0.150" (3.8 mm)
Rear Brake Disc Thickness 0.188" (4.78 mm) 0.170" (4.32 mm)
Rear Brake Disc Thickness Variance - 0.002” (0.051 mm)
Rear Brake Disc Runout - 0.010" (0.254 mm)
Rear Caliper Piston Bore I.D. 1.505" (38.23 mm) 1.507" (38.28 mm)
Rear Caliper Piston O.D. 1.500" (38.10 mm) 1.498" (38.05 mm)
PARKING BRAKE SYSTEM (INTL MODELS - IF EQUIPPED)

Parking Brake Disc Thickness 0.19” (4.76 mm) 0.18” (4.63 mm)

BRAKE SYSTEM
BRAKE SYSTEM OPERATION

OVERVIEW
The Polaris brake system consists of the following
components or assemblies: brake pedal, master cylinder,
hydraulic brake lines, brake calipers, brake pads, and
brake discs, which are secured to the drive line.
When the foot activated brake lever is applied it applies
pressure on the piston within the master cylinder. As the
master cylinder piston moves inward it closes a small
opening (compensating port) within the cylinder and
starts to build pressure within the brake system. As the
pressure within the system is increased, the pistons
located in the brake calipers move outward and apply
pressure to the moveable brake pads. These pads
contact the brake discs and move the calipers in their
floating bracket, pulling the stationary side pads into the
brake discs. The resulting friction reduces brake disc and
vehicle speed.
The friction applied to the brake pads will cause the pads
to wear. As these pads wear, the piston within the caliper
moves further outward and becomes self adjusting. Fluid
from the reservoir fills the additional area created when
the caliper piston moves outward.
Brake fluid level is critical to proper system operation.
Too little fluid will allow air to enter the system and cause
the brakes to feel spongy. Too much fluid could cause
brakes to drag due to fluid expansion.
Located within the master cylinder is the compensating
port which is opened and closed by the master cylinder
piston assembly. As the temperature within the hydraulic
system changes, this port compensates for fluid
expansion or contraction. Due to the high temperatures
created within the system during heavy braking, it is very
important that the master cylinder reservoir have
adequate space to allow for fluid expansion. Never
overfill the reservoir! Do not fill the reservoir beyond
the MAX LEVEL line!
When servicing Polaris brake systems use only Polaris
DOT 4 Brake Fluid (PN 2872189).
WARNING 10
Once a bottle is opened, use what is necessary and
discard the rest in accordance with local laws. Do
not store or use a partial bottle of brake fluid. Brake
fluid is hygroscopic, meaning it rapidly absorbs
moisture. This causes the boiling temperature of
the brake fluid to drop, which can lead to early
brake fade and the possibility of serious injury.

BRAKE SYSTEM
BRAKE SYSTEM SERVICE

BRAKE SYSTEM ASSEMBLY VIEW
q Brake Caliper - Front RH i Cross Over Fitting / Rear Brake Junction

w Brake Line - Front RH o Brake Master Cylinder
e Brake Line - Rear Middle a Brake Line - Front LH
r Brake Line - Rear RH s Brake Caliper - Front LH
t Brake Caliper - Rear RH d Brake Disc
y Brake Caliper - Rear LH f Brake Disc Fastener
18 ft-lbs (24 Nm)
u Brake Line - Rear LH g Scraper Assy.

BRAKE SYSTEM
BRAKE LINE ROUTING

BRAKE ROUTING OVERVIEW
NOTICE
Arrow facing front of vehicle.
10

BRAKE SYSTEM
FRONT BRAKE LINES FROM CALIPERS TO MASTER CYLINDER
FRONT BRAKE LINES FROM CALIPERS TO MASTER CYLINDER (ABS MODELS ONLY)

BRAKE SYSTEM
REAR BRAKE LINE FROM MASTER CYLINDER TO JUNCTION BLOCK

SIDE VIEW
TOP VIEW
10

BRAKE SYSTEM
REAR BRAKE LINES FROM JUNCTION BLOCK TO REAR CALIPERS

BRAKE SYSTEM
BRAKE LINE CLOCKING

MASTER CYLINDER
ITEM DESCRIPTION ANGLE

q To Tee Block 30° +/- 2.5°
w To Right Front Caliper 25° +/- 2.5°
e To Left Front Caliper 15° +/- 2.5°
10

BRAKE SYSTEM
FRONT BRAKE CALIPER
MEASUREMENT
Front Brake Line Clocking:
42.5° +/- 2.5°
REAR BRAKE CALIPER
MEASUREMENT
Rear Brake Line Clocking:
20.0° +/- 2.5°

BRAKE SYSTEM
BRAKE SYSTEM CLOCKING (ABS)

MASTER CYLINDER (ABS MODELS)
REF CONNECTION ANGLE

q ABS Unit Front Port 80.0° +/- 2.5°
w ABS Unit Rear Port 60.0° +/- 2.5°
10

BRAKE SYSTEM
ABS UNIT (TOP OF ABS UNIT)
q Junction Block, Right Rear 42.5° +/- 2.5°
w Cross Fitting, Left Input Port 40.0° +/- 2.5°
e Cross Fitting, Right Input Port 60.0° +/- 2.5°
r Front Left Caliper 20.0° +/- 2.5°

BRAKE SYSTEM
ABS UNIT (CONNECTOR SIDE)
q Master Cylinder Rear Port 55.0° +/- 2.5°
w Master Cylinder Front Port 45.0° +/- 2.5°
10

BRAKE SYSTEM
BRAKE FLUID REPLACEMENT / BRAKE 2. Remove cover from reservoir.

BLEEDING NOTICE
Inspect the bellows in the cap and reset to fully
collapsed if necessary. If any holes are found in the
bellows, replace the reservoir cap.
3. If changing fluid, remove old fluid from reservoir with

a Mity Vac™ pump or similar tool.
4. Add brake fluid to the indicated MAX level of
reservoir.
NOTICE
When bleeding the brakes or replacing the fluid always
start with the furthest caliper from the master cylinder.
This procedure should be used to change fluid or bleed
brakes during regular maintenance.
CAUTION
Always wear safety glasses.
Polaris DOT 4 Brake Fluid P/N:
2872189
CAUTION
Brake fluid will damage finished surfaces. 5. Begin bleeding procedure with caliper furthest from
Do not allow brake fluid to come in contact with finished master cylinder.
surfaces. 6. Install a box-end wrench on caliper bleeder screw.
7. Attach a tight-fitting, clear hose to the bleeder fitting.
1. Locate master cylinder reservoir q in the front left- Place the other end of bleeder hose into a clear
hand wheel well area. Clean reservoir cover container.
thoroughly.
8. Have an assistant slowly pump the brake pedal until

pressure builds and then hold.

BRAKE SYSTEM
9. Open the bleed screw while an assistant continues

holding pressure on the brake pedal. When the brake
pedal reached full travel or fluid stops flowing through
the hose close the bleed screw.
NOTICE
Do not release brake pedal before bleeder screw is
tight or air may be drawn into master cylinder.
10. Release brake pedal pressure. Check level of fluid in

reservoir and add if necessary.
11. Repeat Steps 9 - 11 until brake pedal is firm and no
air can be seen moving through the clear hose. Add
fluid as necessary to maintain level in reservoir.
Master Cylinder Fluid Level:
Between the MIN and MAX line.
CAUTION
During the procedure, maintain at least 1/2"(1.27 cm) of
brake fluid in the reservoir to prevent air from entering
the master cylinder.
12. Tighten bleeder screw and remove bleeder hose.

Torque bleed screw to specification.
TORQUE
Caliper Bleed Screws:
4 ft-lbs (5.4 Nm)
13. Repeat Steps 9 - 13 for the remaining brake calipers

in the sequence shown at the beginning of the
procedure.
14. Fill the fluid reservoir to the correct level and install
master cylinder reservoir cover.
15. Field test machine at low speed before putting into
service. Check for proper braking action and pedal
reserve. With pedal firmly applied, pedal reserve
should be no less than 1/2" (1.3 cm). 10
16. Check brake system for fluid leaks.
17. Verify fluid level is filled between “MIN” and “MAX”
level after procedure is completed.

BRAKE SYSTEM
BRAKE PRESSURE SWITCH 9. Add DOT 4 brake fluid to the reservoir to the max line.
REPLACEMENT (INTL)
1. Apply brake pedal with a light force so that pedal is
pressed in 1–1.5”. Do not allow pedal to return back.
2. Put an appropriate pan under the brake pressure
switch to catch any brake fluid that spills.
3. Unplug the brake pressure switch electrical
connection.
4. Remove the brake pressure switch q and two stat-O-
seals w and brake line e.
10. Reinstall reservoir cap.

11. Clean any brake fluid spills with isopropyl alcohol
based cleaner.
NOTICE
Pay attention to brake line orientation for reassembly.
NOTICE
Some models may have 2 pressure switches. Pressure
switches will use the same replacement procedure, but
may utilize a spacer between the switch and master
cylinder. If a spacer is used note the location of the
spacer and seals for installation.
5. Install new brake pressure switch with two new stat-

O-seals (5423212) and the brake line. Torque to
specification.
TORQUE
Brake Line Fasteners:
15 lb-ft (20 Nm)
6. Release brake pedal.

7. Open the reservoir cap.
8. Pump the brake pedal several times until no air
bubbles appear and the brake pedal feels firm.

BRAKE SYSTEM
MASTER CYLINDER SERVICE

MASTER CYLINDER REMOVAL 4. Loosen the brake line banjo bolt r and brake switch
1. Remove retaining clip q from the clevis pin w that t allowing the fluid to drain.
attaches the master cylinder to the brake pedal lever. NOTICE
Tractor models will have two pressure switches, and
ABS models will have no pressure switches located on
the master cylinder.
2. Remove the two mounting bolts e that secure the

master cylinder to the frame.
5. Discard seals and replace upon assembly.

NOTICE
Make note of front and rear brake line orientation on the
master cylinder.
6. Dispose of brake fluid properly and DO NOT re-use.
3. Remove master cylinder and place a fluid catch

container under the master cylinder brake lines.
CAUTION
Brake fluid will damage finished surfaces.
10
Do not allow brake fluid to come in contact with finished
surfaces.

BRAKE SYSTEM
MASTER CYLINDER INSTALLATION

1. Install brake lines on master cylinder with new seals.
2. Align Brake lines. See Brake Line Clocking.
3. Torque Master Cylinder Banjo Bolt and Brake Switch.
TORQUE
Master Cylinder Banjo Bolt:
15 ft-lbs (20 Nm)
TORQUE
Brake Switch:
15 ft-lbs (20 Nm)
4. Attach the master cylinder to the frame and torque

mounting fasteners to specification.
TORQUE
Master Cylinder Mounting Fasteners:
20 ft-lbs (27 Nm)
5. Attach the master cylinder to the brake pedal lever by

installing the clevis pin and retaining clip.
6. Follow the Brake Fluid Replacement / Brake Bleeding
page 10.16 procedure.
7. Field test unit for proper braking action before putting
into service. Inspect for fluid leaks and firm brakes.

BRAKE SYSTEM
BRAKE PEDAL
BRAKE PEDAL REPLACEMENT
REMOVAL
1. Remove the clip e from the end of the pedal mount bracket.
2. Remove the retaining clip q and clevis pin w from the master cylinder arm to free it from the brake pedal.
3. Slide the brake pedal and bushings off the pedal mount bracket.
INSTALLATION
1. If the pedal mount bracket was removed, torque retaining nuts to specification.
10
TORQUE
Brake Pedal Mount Bracket Nuts:
18 lb-ft (24 Nm)
2. Install brake pedal to the pedal mount bracket and secure with pin and clip.
3. Install the clevis pin and retaining clip securing the brake pedal to the master cylinder arm.

BRAKE SYSTEM
BRAKE PEDAL REMOVAL (INTL)

1. Remove the nut q and washer w from the shoulder bolt e that attaches the master cylinder to the brake pedal
lever. Remove shoulder bolt.
2. Remove the E-clip r from the pedal mount and remove the brake pedal lever from the vehicle with its bushings t.

BRAKE SYSTEM
BRAKE PEDAL INSTALLATION (INTL)

1. Install the brake pedal onto pedal pivot shaft.
2. Insert E-Clip q into end of pivot shaft
3. Install the shoulder bolt, washer and nut w connecting the master cylinder to the brake pedal. Torque to
specification.
TORQUE
Brake Pedal Shoulder Bolt:
13 lb-ft (18 Nm)
4. Ensure brake pedal freeplay is within specification.

10
Brake Pedal Free-play:
0.090 in (2.28 mm)

BRAKE SYSTEM
FRONT BRAKE PAD SERVICE

FRONT BRAKE PAD REMOVAL 4. Push caliper piston into caliper bore slowly using a C-
clamp or locking pliers with pads installed.
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 wheel nuts, washers and front wheel.

Loosen pad adjuster screw.
NOTICE
Brake fluid will be forced through compensating port
into master cylinder fluid reservoir when piston is
pushed back into caliper. Remove excess fluid from
reservoir as required.
5. Push the mounting bracket inward and slip outer

brake pad out between the bracket and caliper body.
3. Remove the upper and lower caliper mounting bolts
and remove the caliper from the front hub.
6. Remove the inner pad from the bracket and caliper.

NOTICE
When removing caliper, use care not to damage brake
line. Support caliper to avoid kinking or bending brake
line.

BRAKE SYSTEM
FRONT BRAKE PAD INSPECTION FRONT BRAKE PAD INSTALLATION

Measure the thickness of the pad material. Replace pads 1. Lubricate mounting bracket pins q with a light film of
if worn beyond the service limit. silicone grease and install rubber dust boots w.
MEASUREMENT 2. Compress mounting bracket and make sure dust

boots are fully seated. Install pads with friction
Front Brake Pad Thickness
material facing each other.
Std: 0.297 ± .007" (7.54 ± .178 mm)
Service Limit: 0.150" (3.8 mm)
WARNING
If brake pads are contaminated with grease, oil, or
liquid soaked do not use the pads. Use only new, clean
pads.
3. Install caliper w onto front hub and torque mounting

bolts q to specification.
10
TORQUE
Front Caliper Mounting Bolts:
28 ft-lbs (38 Nm)
4. Slowly pump brake pedal until pressure has been

built up. Maintain at least 1/2, (12.7 mm) of brake fluid
in reservoir to prevent air from entering brake system.

BRAKE SYSTEM
5. Install the pad adjuster set screw and turn clockwise

until stationary pad contacts disc, then back off 1/2
turn (counterclockwise).
6. Verify fluid level in reservoir is up to MAX line inside

reservoir and install reservoir cap.
Master Cylinder Fluid
Up to MAX line inside reservoir

TORQUE
Wheel Lug Nuts:
120 ft-lbs (163 Nm)
BRAKE BURNISHING PROCEDURE

It is required that a burnishing procedure be performed
after installation of new brake pads to extend service life
and reduce noise.
Start machine and slowly increase speed to 30 mph.
Gradually apply brakes to stop machine. Allow pads and
disc to cool sufficiently during the procedure. Do not
allow pads or disc to become hot or warping may result.
Repeat this procedure 10 times. Do not make more
than 3 stops per 1 mile (1.6 km).

BRAKE SYSTEM
FRONT CALIPER SERVICE - 3 SEAT / CREW

FRONT CALIPER ASSEMBLY VIEW
REF PART DESCRIPTION REF PART DESCRIPTION

q Brake Pad Assembly y Brake Piston
w Caliper Mount Assembly u Ring
e Brake Caliper i Bolt
r Pin Seal Boot o Bleeder Screw
t Pin Bushing Boot a Plug Cap
10

BRAKE SYSTEM
FRONT CALIPER REMOVAL 6. Remove the two caliper mounting bolts and caliper
1. Elevate and safely support the front of the vehicle. e.
2. Remove the four wheel nuts and the front wheel.
CAUTION
or fall. Severe injury may occur.
3. Clean caliper area before removal.

4. Place a container below the caliper to catch brake
fluid when removing line. Remove brake line q from
caliper.
FRONT CALIPER DISASSEMBLY

1. Remove both brake pads from the caliper. Refer to
FRONT BRAKE PAD REMOVAL procedure.
2. Remove the mount bracket assembly q and dust
boots w from caliper. Thoroughly clean caliper before
disassembly and prepare a clean work area.
5. Loosen brake pad adjustment set screw w to allow

brake pad removal after the caliper is removed.

BRAKE SYSTEM
3. Use a commercially available caliper piston pliers to 5. Clean the caliper body, piston, and retaining bracket
extract the pistons from the caliper. r with brake cleaner or alcohol.
CAUTION
Do not remove the caliper pistons with a standard
pliers. The piston sealing surfaces will become
damaged if a standard pliers is used.
NOTICE
Be sure to clean the seal grooves in caliper body.
FRONT CALIPER INSPECTION

4. Once the pistons are removed, use a pick to carefully
remove the square O-rings e from the caliper. O- 1. Inspect caliper body for nicks, scratches, pitting or
rings should be replaced during caliper service. wear. Measure bore size and compare to
specifications. Replace if damaged or worn beyond
service limit.
10
MEASUREMENT
Front Caliper Piston Bore I.D.:
Standard: 1.373" (34.87 mm)

BRAKE SYSTEM
2. Inspect piston for nicks, scratches, pitting or wear. 3. Lubricate the mounting bracket pins q with silicone
Measure piston diameter and replace if damaged or grease and install the rubber dust seal boots w.
worn beyond service limit.
MEASUREMENT 4. Compress the mounting bracket and make sure the

Front Caliper Piston O.D.: dust seal boots are fully seated. Install the brake
Standard: 1.370" (34.80 mm) pads. Clean the disc and pads with brake parts
Service Limit: 1.368" (34.75 mm) cleaner or denatured alcohol to remove any dirt, oil or
grease.
3. Inspect brake disc and pads as outlined in this

chapter. FRONT CALIPER INSTALLATION
1. Install caliper w and torque mounting bolts q to
specification.
FRONT CALIPER ASSEMBLY
1. Install new O-rings in the caliper body. Be sure the
grooves are clean and free of residue or brakes may
drag upon assembly.
NOTICE
If brake disc scraper was removed, be sure to reinstall it
upon caliper installation.
2. Coat pistons with clean Polaris DOT 4 Brake Fluid.
Install pistons with a twisting motion while pushing TORQUE
inward. Piston should slide in and out of bore
smoothly, with light resistance. Front Caliper Mounting Bolts:
28 ft-lbs (38 Nm)

BRAKE SYSTEM
2. Install brake line and torque the banjo bolt e to the 6. Field test unit for proper braking action before putting
proper torque specification. into service. Inspect for fluid leaks and firm brakes.
Make sure the brake is not dragging when pedal is
IMPORTANT released. If the brake drags, re-check assembly and
Ensure the brake line is clocked properly. Refer to installation.
Brake Line Clocking page 10.11. NOTICE
If new brake pads are installed, brake burnishing is
recommended.
TORQUE
Brake Line Banjo Bolts:
15 ft-lbs (20 Nm)
3. Install the pad adjustment screw and turn until

stationary pad contacts disc, then back off 1/2 turn.
10
4. Follow the “Brake Bleeding / Fluid Change”
procedure as outlined earlier in this chapter.
TORQUE
Wheel Lug Nuts:
120 ft-lbs (163 Nm)

BRAKE SYSTEM
REAR BRAKE PAD SERVICE

REAR BRAKE PAD REMOVAL 5. Push caliper piston into caliper bore slowly with pads
installed.
1. Elevate and support rear of machine.
CAUTION
or fall. Severe injury may occur if machine tips or falls.
2. Remove the rear wheel. Loosen the pad adjuster

screw 2-3 turns.
NOTICE
Brake fluid will be forced through compensating port
into master cylinder fluid reservoir when piston is
pushed back into caliper. Remove excess fluid from
reservoir as required.
6. Remove the brake pads from the caliper.

4. Remove caliper mounting bolts and lift caliper off of
disc.
NOTICE
When removing caliper, be careful not to damage brake
line. Support caliper so as not to kink or bend brake
line.

BRAKE SYSTEM
REAR BRAKE PAD INSPECTION 3. Install caliper and torque bolts to specification.
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.
TORQUE
Rear Caliper Mounting Bolts:
46 lb-ft (62 Nm)
MEASUREMENT 4. Install the pad adjustment screw and turn until

Rear Brake Pad Thickness stationary pad contacts disc, then back off 1/2 turn.
Standard: 0.298 ± .007" (7.56 ± .178 mm) 5. Slowly pump brake pedal until pressure has been
Service Limit: 0.150" (3.8 mm) built up. Maintain at least 1/2" (12.7 mm) of brake
fluid in reservoir to prevent air from entering master
cylinder.
REAR BRAKE PAD INSTALLATION

BRAKE BURNISHING PROCEDURE
1. Lubricate mounting bracket pins q with a light film of
silicone grease and install rubber dust boots w. It is required that a burnishing procedure be performed
after installation of new brake pads to extend service life
and reduce noise.
Start machine and slowly increase speed to 30 mph.
Gradually apply brakes to stop machine. Allow pads and
disc to cool sufficiently during the procedure. Do not
allow pads or disc to become hot or warping may result.
Repeat this procedure 10 times. Do not make more
than 3 stops per 1 mile (1.6 km).
10
2. Compress mounting bracket and make sure dust

boots are fully seated. Install pads with friction
material facing each other.
WARNING
If brake pads are contaminated with grease, oil, or
liquid soaked do not use the pads. Use only new clean
pads.

BRAKE SYSTEM
REAR CALIPER SERVICE - 3 SEAT

REAR CALIPER ASSEMBLY VIEW
q Socket Set Screw t Pistons

w Bleeder Screw y Boots
e Caliper Assembly u Caliper Mount
r Square O-Rings i Brake Pad

BRAKE SYSTEM
REAR CALIPER REMOVAL 6. After the fluid has drained into the container, remove
the two caliper mounting bolts e and brake caliper.
1. Elevate and safely support the rear of the vehicle.
CAUTION
2. Remove the four wheel nuts and the rear wheel.

fluid when removing the brake line. Use a wrench to
remove the brake line banjo bolt q.
7. Clean the brake disc, caliper body and caliper pistons

with brake cleaner or alcohol.
REAR CALIPER DISASSEMBLY

1. Remove brake pad adjustment set screw q.
5. If necessary, loosen brake pad adjustment set screw

w 2-3 turns to allow brake pad removal after the
caliper is removed.
2. Push upper pad retainer pin inward and slip brake

pads i past the edge and remove from the caliper.
3. Remove mount bracket u and dust boots y . 10

BRAKE SYSTEM
4. Using a commercially available caliper piston pliers, REAR CALIPER INSPECTION

extract the piston t from the caliper body e.
1. Inspect caliper body for nicks, scratches or wear.
Remove the square O-rings r from the caliper body
Measure bore size and compare to specifications.
e. Replace if damage is evident or if worn beyond
IMPORTANT service limit.
Do not remove the caliper pistons with a standard
pliers. The piston sealing surfaces will become
MEASUREMENT
Rear Caliper Piston Bore I.D.:
Standard: 1.505" (38.23 mm)
5. Clean the caliper body, piston, and retaining bracket
2. Inspect piston for nicks, scratches, wear or damage.
NOTICE Measure diameter and replace if damaged or worn
beyond service limit.
Be sure to clean caliper body seal grooves.
MEASUREMENT
Rear Caliper Piston O.D.:
Standard: 1.500" (38.10 mm)
3. Inspect the brake disc and pads as outlined in this

chapter.

BRAKE SYSTEM
REAR CALIPER ASSEMBLY REAR CALIPER INSTALLATION

1. Install new caliper seals q in the caliper body w. Be 1. Install the rear caliper and torque the mounting bolts
sure groove is clean and free of residue or brakes q to specification.
may drag upon assembly.
TORQUE
2. Coat piston with clean DOT 4 Brake Fluid. Install
piston e with a twisting motion while pushing inward. Rear Caliper Mounting Bolts:
Piston should slide in and out of bore smoothly with 46 lb-ft (62 Nm)
light resistance.
3. Lubricate the mounting bracket pins r with silicone 2. Install the brake line and torque the banjo bolt w to
grease and install the rubber dust seal boots t. specification.
IMPORTANT
Ensure the brake line is clocked properly. Refer to
Brake Line Clocking page 10.11.
4. Compress the mounting bracket and make sure the 10

dust seals are fully seated. Install the brake pads.
Clean the disc and pads with brake parts cleaner or
denatured alcohol to remove any dirt, oil or grease.
TORQUE
15 lb-ft (20 Nm)

4. Follow the BRAKE BLEEDING / FLUID CHANGE

BRAKE SYSTEM

TORQUE
Wheel Lug Nuts:
120 ft-lbs (163 Nm)

released. If the brake drags, re-check assembly and
installation.
NOTICE
recommended. Refer to “Brake Burnishing
Procedure” page 10.33.

BRAKE SYSTEM
REAR CALIPER SERVICE - CREW

REAR CALIPER ASSEMBLY VIEW
REF PART DESCRIPTION REF PART DESCRIPTION

q Brake Pad Assembly y Brake Piston
w Caliper Mount Assembly u Ring
e Brake Caliper i Bolt
r Pin Seal Boot o Bleeder Screw
t Pin Bushing Boot a Plug Cap
10

BRAKE SYSTEM
REAR CALIPER REMOVAL 6. After the fluid has drained into the container, remove
the two caliper mounting bolts e and brake caliper.
1. Elevate and safely support the rear of the vehicle.
CAUTION
2. Remove the four wheel nuts and the rear wheel.

fluid when removing the brake line. Use a wrench to
remove the brake line banjo bolt q.
7. Clean the brake disc, caliper body and caliper pistons

5. If necessary, loosen brake pad adjustment set screw

w 2-3 turns to allow brake pad removal after the
caliper is removed.

BRAKE SYSTEM
REAR CALIPER DISASSEMBLY REAR CALIPER INSPECTION

1. Remove brake pad adjustment set screw o. 1. Inspect caliper body for nicks, scratches or wear.
Measure bore size and compare to specifications.
Replace if damage is evident or if worn beyond
service limit.
2. Push upper pad retainer pin inward and slip brake

pads q past the edge and remove from the caliper.
3. Remove mount bracket w and dust boots r & t.
MEASUREMENT
4. Using a commercially available caliper piston pliers, Rear Caliper Piston Bore I.D.:
extract the piston y from the caliper body e.
Standard: 1.505″ (38.23 mm)
Remove the square O-rings u from the caliper body
Service Limit: 1.507″ (38.28 mm)
e.
CAUTION 2. Inspect piston for nicks, scratches, wear or damage.
Do not remove the caliper pistons with a standard Measure diameter and replace if damaged or worn
pliers. The piston sealing surfaces will become beyond service limit.
10
MEASUREMENT
Rear Caliper Piston O.D.:
5. Clean the caliper body, piston, and retaining bracket Standard: 1.500″ (38.10 mm)
with brake cleaner or alcohol. Service Limit: 1.498″ (38.05 mm)
NOTICE
Be sure to clean caliper body seal grooves. 3. Inspect the brake disc and pads as outlined in this
chapter.

BRAKE SYSTEM
REAR CALIPER ASSEMBLY REAR CALIPER INSTALLATION

1. Install new caliper seals q in the caliper body w. Be 1. Install the rear caliper and torque the mounting bolts
sure groove is clean and free of residue or brakes q to specification.
may drag upon assembly.
TORQUE
2. Coat piston with clean Polaris DOT 4 Brake Fluid. In-
stall piston e with a twisting motion while pushing in- Rear Caliper Mounting Bolts:
ward. Piston should slide in and out of bore smoothly 46 lb-ft (62 Nm)
with light resistance.
3. Lubricate the mounting bracket pins r with silicone 2. Install the brake line and torque the banjo bolt w to
grease and install the rubber dust seal boots t. specification.
IMPORTANT
Ensure the brake line is clocked properly. Refer to
Brake Line Clocking page 10.11.
4. Compress the mounting bracket and make sure the

dust seals are fully seated. Install the brake pads.
Clean the disc and pads with brake parts cleaner or
alcohol to remove any dirt, oil, or grease.
TORQUE
15 lb-ft (20 Nm)

4. Follow the BRAKE BLEEDING / FLUID CHANGE

BRAKE SYSTEM

TORQUE
Wheel Lug Nuts:
120 ft-lbs (163 Nm)

installation.
NOTICE
recommended. Refer to “Brake Burnishing
Procedure” page 10.33.
10

BRAKE SYSTEM
BRAKE DISC SERVICE DISC RUNOUT

1. Mount dial indicator as shown. Slowly rotate the disc
BRAKE DISK INSPECTION and read total runout on the dial indicator. Replace
1. Visually inspect disc for scoring, scratches or gouges. disc if runout exceeds specification.
Replace the disc if any deep scratches are evident.
2. Use a 0-1” micrometer and measure disc thickness at
eight different points around the pad contact surface.
Replace disc if worn beyond service limit.
MEASUREMENT
Brake Disc Thickness
Standard: 0.188" ( 4.78 mm)
Service Limit: 0.170" (4.32 mm) MEASUREMENT
Brake Disc Runout:
MEASUREMENT Service Limit:
0.010" (0.254 mm)
Brake Disc Thickness Variance
Service Limit: 0.002” (0.051 mm)
difference between measurements

BRAKE SYSTEM
BRAKE DISC REPLACEMENT 5. Reinstall the applicable wheel hub assembly. Refer to
applicable installation procedure.
1. Remove the applicable brake caliper. Refer to the
applicable caliper removal procedure. NOTICE
2. Remove wheel hub cotter pin q, castle nut w and Each hub can require different numbers of washers and
washer(s) e and r. torque values. This is based on the location on the
vehicle, and material of the hub. Make sure to use the
NOTICE correct installation procedure for the hub being
Image for reference only. Each hub can require different serviced.
numbers of washers. This is based on the location on
the vehicle, and material of the hub. Record the number
NOTICE
of washers and hub material during removal to make
sure that the correct installation procedure is used. If replacing a rear brake disc, refer to Rear Hub
Identification page to make sure that the correct
washer and washer quantity is used.
NOTICE
If replacing a rear brake disc, refer to Rear Hub
6. Reinstall the applicable brake caliper. Refer to
Identification page to make sure that the correct
applicable caliper installation procedure.
washer and washer quantity is used.
7. Bleed brakes if needed. Follow the bleeding
procedure outlined earlier in this chapter.
installation.
3. Remove the wheel hub assembly from the vehicle

and remove the four bolts u retaining the disc to the
hub and discard.
4. Clean the wheel hub mating surface and install the
new disc on the wheel hub. Install new disc mounting
bolts u and torque to specification.
CAUTION 10
Always use new brake disc mounting bolts. The bolts
have a pre-applied locking agent which is destroyed
upon removal.
TORQUE
Front Brake Disc Mounting Bolts:
18 ft-lbs (24 Nm)
Rear Brake Disc Mounting Bolts:
28 lb-ft (38 Nm)

BRAKE SYSTEM
PARKING BRAKE (INTL)

PARKING BRAKE CABLE ASSEMBLY
q Front Parking Brake Assembly Fastener: M6 x 1.0 x 20 7 ft-lbs (9.5 Nm)
w Parking Brake Handle NA
e Clip-Hitch Pin NA
r Parking Brake Cable Locknut 13 ft-lbs (17.6 Nm)
t Washer: 0.312 / 0.325 x 0.88 x 0.075 NA
y Clevis Pin NA
u Parking Brake Caliper Fastener 37 ft-lbs (50 Nm)
i Parking Brake Caliper NA
o Parking Brake Bracket NA
a Parking Brake Cable NA
s Nyloc Nut: M6 x 1.0 15 ft-lbs (20 Nm)
d Front Parking Brake Bracket Fastener: M6 x 1.0 x 14 15 ft-lbs (20 Nm)
f Front Parking Brake Bracket Fastener: M8 x 1.25 x 16 22 ft-lbs (30 Nm)
g Nyloc Nut: M8 x 1.25 22 ft-lbs (30 Nm)

BRAKE SYSTEM
PARKING BRAKE CABLE ROUTING
10

BRAKE SYSTEM
PARKING BRAKE CABLE SERVICE 5. Remove the cotter pin t and stud y securing the
REMOVAL cable end to the caliper.

2. Remove the cotter pin q securing the parking brake
cable w.
6. Remove the cable from the vehicle.
3. Loosen the locknuts e securing the cable to the

bracket.
4. Loosen the locknuts r securing the cable to the

caliper.

BRAKE SYSTEM
INSTALLATION 4. Install the cable in the dash bracket and tighten the
locknuts e.
1. Install the cable in the vehicle. Refer to Parking Brake
Cable Routing page 10.47.
2. Install the stud y and cotter pin t to secure the
cable end to the caliper.
TORQUE
Parking Brake Cable Locknuts:
13 ft-lbs (17.6 Nm)
3. Install the cable in the caliper and tighten the locknuts
r to secure the cable to the caliper. 5. Install the cotter pin q to secure the parking brake
cable w.
TORQUE
Parking Brake Cable Locknuts: Glove Box Service page 11.34.
13 ft-lbs (17.6 Nm) 10

BRAKE SYSTEM
PARKING BRAKE CABLE ADJUSTMENT 4. Hold the outer jam nut and turn in the inner jam nut e
When the parking brake is fully engaged and “BRAKE” is clockwise, until the jam nut is tight against the
displayed on the instrument cluster, engine speed is bracket.
limited to 1600 RPM while in gear. If throttle is applied,
this limiting feature prevents operation, which protects
the parking brake pads from excessive wear.
CAUTION
If the parking brake is adjusted too tight, it may result in
excess heat in the parking brake system that can lead
to premature pad and rotor wear along with driveability
issues while in operation.
INSPECTION
• Pull back on parking brake lever (located on the center
dash panel).
IMPORTANT 5. Repeat Steps 3 and 4 until the proper adjustment is
After 4 clicks, “BRAKE” should display on the obtained for the parking brake.
instrument cluster and the wheels should not rotate 6. If additional adjustment is needed, the cable can be
when turning by hand. After 8 full clicks of travel, the adjust on the parking brake handle side jam nut r
vehicle should not roll while parked. Perform
adjustment if needed.
ADJUSTMENT
1. Place the vehicle in neutral on a flat level surface.
2. Locate the parking brake cable adjustment area
where the cable attaches to the caliper mount bracket
q
3. Use two open-end wrenches and loosen the outer

jam nut w. Back out the outer jam nut 1 1/2 turns.

BRAKE SYSTEM
PARKING BRAKE LEVER SERVICE 5. Unplug the brake switch.

REMOVAL 6. Remove the M6 fasteners y and M8 fasteners u
1. Remove the fastener q securing the parking brake securing the front parking brake assembly to the
handle w and remove the handle. chassis.
2. Remove the upper and center dash panels. Refer to 7. Remove the 10mm fasteners i securing the parking
Dash Panels / Glove Box Service page 11.34. brake assembly to the vehicle and remove the
parking brake assembly.
3. Remove the cotter pin e securing the parking brake
cable r.
4. Loosen the locknuts t securing the cable to the

bracket and remove the cable.
10

BRAKE SYSTEM
INSTALLATION 4. Install the parking brake cable and tighten the

locknuts t to secure the cable to the bracket.
1. Install the front brake assembly and install the 10mm
fasteners i to secure the parking brake assembly to
the vehicle. Torque the fasteners to specification.
5. Install the cotter pin e to secure the parking brake

cable r.
TORQUE
Parking Brake Assembly Fasteners:
7 ft-lbs (9.5 Nm)
2. Install the M8 fasteners u and M6 fasteners y to

secure the front parking brake assembly to the
chassis. Torque fasteners to specification.
6. Install the upper and center dash panels. Refer to

Dash Panels / Glove Box Service page 11.34.
TORQUE
M6 Parking Brake Assembly Fasteners:
15 ft-lbs (20 Nm)
M8 Parking Brake Assembly Fasteners:

22 ft-lbs (30 Nm)
3. Plug in the brake switch.

BRAKE SYSTEM
7. Install parking brake handle w and fastener q to

secure the parking brake handle w. Torque to
specification.
TORQUE
Parking Brake Handle Fastener:
22 in-lbs (2.5 Nm)
10

BRAKE SYSTEM
PARKING BRAKE CALIPER SERVICE INSTALLATION

REMOVAL 1. Install the caliper in the bracket and align with
1. Remove the pin clip q and clevis pin w securing the mounting holes.
parking brake cable to the caliper.
2. Install the two caliper fasteners e to secure the

2. Remove the two fasteners e securing the caliper to caliper to the bracket. Torque to specification.
the bracket.
TORQUE
3. Slide the caliper out to remove. Parking Brake Caliper Fasteners:
37 ft-lbs (50 Nm)

BRAKE SYSTEM
3. Install the parking brake cable into the caliper, and

install the clevis pin w and pin clip q to secure the
parking brake cable to the caliper.
10

BRAKE SYSTEM
PARKING BRAKE DISC SERVICE

INSPECTION
1. Measure the brake disc with a micrometer. Replace if
necessary.
MEASUREMENT
Parking Brake Disc Minimum Thickness:
0.18” (4.63 mm)
REPLACEMENT
1. Remove the parking brake caliper. Refer to Parking
Brake Caliper Service page 10.54.
2. Remove the brake disc mounting bolt q and flat
washer w to remove the brake disc.
TORQUE
Parking Brake Disc Mounting Fastener:
20 ft-lbs (27 Nm)

BRAKE SYSTEM
ABS SERVICE (INTL)

ANTILOCK BRAKING SYSTEM (ABS) OVERVIEW (INTL)
ABS is used to enhance vehicle braking performance by preventing the wheels from locking up during heavy braking
situations. The system monitors the vehicle wheel speed at via a tone ring that is fixed to the half shafts on both the
front and rear gearcase. The sensor outputs an analog signal while the tone ring spins with the wheel to generate a
speed signal for each wheel. When the brakes are applied the ABS HECU is able to control the brake pressure going
to each wheel to aid in deceleration.
The ABS feature can be enabled and disabled by the rider. Reference the owners manual for ABS settings.
q Speed Sensor
w Tone Ring
10

BRAKE SYSTEM
ABS BRAKE SYSTEM ASSEMBLY VIEW (INTL)
REF DESCRIPTION
q CYLINDER, BRAKE MASTER
w CALIPER, BRAKE - FRONT LH
e LINE, BRAKE - FRONT LH
r LINE, BRAKE - FRONT RH
t CALIPER, BRAKE - FRONT RH
y LINE, BRAKE - RPM
u LINE, BRAKE - LIP
i FITTING - TEE, BRAKE
o LINE, BRAKE - REAR LH
a CALIPER, BRAKE - REAR LH
s LINE, BRAKE - REAR RH
d CALIPER, BRAKE - REAR RH
f LINE, BRAKE - FRM
g ABS HECU
h FITTER - TEE, BRAKE
j LINE, BRAKE - RLM
k LINE, BRAKE - M1
l LINE, BRAKE - M2

BRAKE SYSTEM
BRAKE WARNING SYSTEM BRAKE WARNING SYSTEM (INTL

BRAKE PEDAL SWITCH INSPECTION MODELS)
The Brake Pedal Switch is mounted near the Brake • This vehicle uses a brake monitoring system with half
Pedal Assembly. When the brake pedal is depressed this plausibility check. This system uses a brake pedal
switch will turn from active to inactive. This can be switch mounted to the pedal, and two brake pressure
monitored using Digital Wrench ®. If the status does not switches mounted on the master cylinder or after the
switch when depressed, proceed with further testing. ABS module.
• For this system to operate correctly. The Brake
1. Disconnect electrical connector from sensor.
Pressure Switch has to be activated before the Brake
2. Inspect sensor and connector for moisture or Pedal Switch.
corrosion. If moisture or corrosion is found, clean first
• These inputs can be monitored on Digital Wrench®. If
and re check.
the brake pedal is depressed slowly, you will be able to
3. With connector disconnected, check resistance monitor the change in the Brake Pressure Switch
across pins on the sensor. When switch is closed before the Brake Pedal Switch if the system is
(brake pedal not depressed) resistance should be operating correctly.
less than 0.5 ohms. With switch open (brake pedal
• If the Brake Pedal Switch becomes active and stays
depressed) resistance should show an open (OL).
active for more than 3 seconds before the Brake
4. If the sensor test fails, resistance is not within Pressure Switch changes status, the Brake Warning
specification; the sensor should be replaced. Light will be illuminated indicating a concern with the
system.
5. If the sensor test passes, resistance is within
specification, inspect the circuit for correct operation. IMPORTANT
If there is a concern found with the circuit repair and
recheck operation. The Brake Warning Light may be illuminated giving a
false warning if the Brake Pedal Switch becomes active
6. If the concern is still present, it is possible that there but the system never builds pressure. This can be
may be a concern with the ECU. caused by a very light brake apply or if the pedal is
depressed and the system never builds pressure.
• If the Brake warning light is active, refer toBrake

Warning System (INTL Models) page 10.59 for testing
procedures.
10

BRAKE SYSTEM
BRAKE WARNING SYSTEM

INSPECTION (INTL MODELS)
1. Inspect the brake hydraulic system for any concerns.
If any leaks or mechanical failures are found with the
hydraulic system, concerns need to be repaired
before proceeding.
2. Connect the vehicle to Digital Wrench® and select
the Data Item Menu.
3. Add the Brake Switch and Foot Brake Switch inputs
to the main table.
4. Slowly depress the brake pedal, and observe the
switching point of the Brake Pressure Switch and the
Brake Pedal Switch.
5. When the brake pedal is depressed the Brake
Pressure Switches will become active before the
Brake Pedal Switch.
6. If all the switches are not changing status, check the
brake pedal (pay close attention to were the lever
triggers brake pedal switch), inspect the pedal mount
for mechanical damage, and check for free play.
NOTICE
A sticking brake pedal may also cause false brake
warning alarms.
7. The Brake Warning message could also be caused

by a failed sensor. If any of the three switches do not
change status when monitoring on Digital Wrench®.
Refer toBrake Light Switch page for Brake
Pressure Switch testing. Refer toBrake Pedal Switch
Inspection page 10.59 for Brake Pedal Switch testing.
8. If any of the three switches fail the testing procedure,
check the electrical circuit for the sensor that has
failed. It is possible that there could be a concern with
the circuit. If a circuit concern is found, repair or
replace as necessary.
9. If the electrical circuit passes testing the failed switch
will require replacement.
10. If the concern is still present after previous testing has
passed, suspect there is a fault within the ECU.

BODY / FRAME
CHAPTER 11
BODY / FRAME
GENERAL INFORMATION - BODY / FRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
SERVICE NOTES - BODY / FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
SPECIAL TOOLS - BODY / FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
BODY COMPONENTS ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
CHASSIS ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
CHASSIS ASSEMBLY VIEW (CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4
ROPS ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
ROPS ASSEMBLY VIEW (CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7
DASH PANEL / GLOVE BOX ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9
FRONT BODY ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.11
FLOORS / FENDER ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.12
SEAT COMPONENTS ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.14
ROOF ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.16
ROOF ASSEMBLY VIEW (CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.17
REAR PANEL ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.18
CARGO BOX ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.19
EXTERIOR BODY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.22
FRONT BUMPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.22
FRONT FENDER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.23
FRONT FASCIA SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.25
ROCKER PANEL SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.27
REAR CLOSE-OFF PANEL SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.28
DECAL REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.29
REAR CARGO BOX SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.33
CARGO BOX REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.33
CARGO BOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.33
INTERIOR BODY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.34
DASH PANELS / GLOVE BOX SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.34
DRIVER’S SEAT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.36
PASSENGER SEAT BACK SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.39
FLOOR REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.39
SEAT BELT SERVICE (3-SEAT MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.42
11

BODY / FRAME
GENERAL INFORMATION - BODY / FRAME

SERVICE NOTES - BODY / FRAME DECAL REPLACEMENT
WARNING WARNING
Serious injury may result if machine tips or falls. Be The following procedure involves the use of an open
sure machine is secure before beginning any procedure flame. Perform this procedure in a well ventilated area,
that requires machine lifting. Always wear eye away from fuel or other flammable materials. Be sure
protection. the area to be flame treated is clean and free of
gasoline or flammable residue.
SPECIAL TOOLS - BODY / FRAME WARNING

TOOL DESCRIPTION PART NUMBER Do not flame treat components that are installed on the
vehicle. Remove the component from the vehicle
Multi-Function Pliers 2876389 before flame treating.
Bosch Automotive Service Solutions: The vehicle body panels are plastic polyethylene
1-800-345-2233 or http://polaris.service-solutions.com material. Therefore, they must be “flame treated” prior to
Included in the tool kit, this multi-function pliers is installing a decal to ensure good adhesion. A bonus of
designed to remove plastic push rivets and install body the flame treating procedure is it can be used to reduce
components. or eliminate the whitish stress marks that are sometimes
left after a fender or cab is bent, flexed, or damaged.
CAUTION
Do not flame treat painted plastic components. Painted
plastic surfaces should only be wiped clean prior to
decal adhesion.
To flame treat the decal area:

1. Pass the flame of a propane torch back and forth
quickly over the area where the decal is to be applied
until the surface appears slightly glossy. This should
occur after just a few seconds of flame treating. Do
not hold the torch too close to the surface (2-3 inches
from the flame tip is recommended). Keep the torch
moving to prevent damage.
2. Apply the decal on one edge first. Slowly lay down
remainder of the decal while rubbing lightly over the
decal surface to eliminate any air bubbles during the
application.

BODY / FRAME
BODY COMPONENTS ASSEMBLY VIEWS

CHASSIS ASSEMBLY VIEW
q FRAME, MAIN NA
w WELD, CROSSBAR NA
e WELD-SEAT BASE, MAIN NA
r WELD-SEAT SUPPORT MOUNT, PASSENGER NA
t GROMMET, SEAT BASE NA
y PLATE, SKID NA
u SKID PLATE FASTENERS 6 ft-lbs (8 Nm)
i SEAT BASE FASTENERS 10 ft-lbs (14 Nm)
o CROSS BAR FASTENERS 14 ft-lbs (19 Nm)
a WASHER, SKID PLATE NA

11

BODY / FRAME
CHASSIS ASSEMBLY VIEW (CREW)
q CROSS BAR FASTENERS 14 ft-lbs (19 Nm)
w CROSS BAR NA
e SEAT BASE WELD FASTENERS 10 ft-lbs (14 Nm)
r REAR SEAT BASE WELD NA
t WELD-FRONT, MAIN NA
y SEAT BASE FASTENERS 10 ft-lbs (14 Nm)
u SEAT BASE BRACKET 10 ft-lbs (14 Nm)

FASTENERS
i SEAT BASE BRACKET NA
o PUSH DART NA
a MIDDLE CROSS BAR FASTENER 14 ft-lbs (19 Nm)

BODY / FRAME
ROPS ASSEMBLY VIEW
q Rear Cab Frame NA
w Windshield Plate NA
e Front Cab Frame Fastener Nut 40 ft-lbs (54 Nm)
r Cab Frame-Front Left NA
t Front Cab Frame Fastener 40 ft-lbs (54 Nm)
y Rear Cab Frame Fastener 45 ft-lbs (61 N·m)
u Rear Cab/Seat Belt Fastener Nut 45 ft-lbs (61 N·m)
i Bolster Lower Fastener 6 ft-lbs (8 Nm)
o Passenger Bolster NA
a Side Bezel Fastener 6 ft-lbs (8 Nm)
s Passenger Grab Handle Fasteners 10 ft-lbs (14 Nm)

11
d Passenger Grab Handle NA
f Cab Frame- Front Right NA
g Windshield Plate Fastener 36 ft-lbs (49 Nm)
h Seat Back Screw 18 inch-lbs (2 Nm)
j Seat Belt Fastener 40 ft-lbs (54 Nm)
k Rubber Washer NA

BODY / FRAME
l Bolster Handle Nut 6 ft-lbs (8 Nm)
1( Closeout Panel Fastener 42 in-lbs (5 Nm)
2) Heat Shield Fastener 42 in-lbs (5 Nm)
2! Heat Shield Washer NA

BODY / FRAME
ROPS ASSEMBLY VIEW (CREW)
q HANDLE-GRAB, ROPS NA
w WELD-CAB FRAME. FRT, RH NA
e SCR-HXL-M10X1.5X20 10.9 RIE P NA
r WELD-CAB FRAME, CTR, M NA
t SCR-M10X1.50X35 HX/FL-Y/D NA
y WED-CAB FRAME, REAR, RH NA
u NUT-HEX-M10X1.5 10 ZB3 NYL 36 ft-lbs (54 N·m)
i SCR-HXFL-M10X1.5X45 10.9 RIE NA
o WELD-CAB FRAME, REAR, LH NA
a WELD-CAB FRAME, REAR, M NA
s SCR-TXTH-M6X1.025 RIE 6 ft-lbs (8 Nm)

11
d SCR-HXFL-M12X1.75X90 10.9 ZPC NA
f NUT-HEX-M8X1.25 10 P&O NA
g NUT-HXFL M12X1.75 8 ZOD NYL 45 ft-lbs (61 N·m)
h SCR-HXFL-M8X1.25X20 8.8 ZOD P3 6 ft-lbs (8 Nm)
j WELD-BOLSTER, LH, M NA
k WELD-BOLSTER, RH, M NA

BODY / FRAME
l WELD-CAB FRAME, FRT, LH NA
1( WELD-BOLSTER, FRONT, RH, M NA
2) SCR-HXFLSH-M12X1.75–M14X9 40 ft-lbs (54 Nm)
2! WASHER-SEATBELT, RUBBER NA
2@ BOLT-M8X1.25X20, HXFLG 10 ft-lbs (14 Nm)
2# NUT-HXFL-M10X1.5 8 ZB3 NYL 36 ft-lbs (49 Nm)
2$ PLATE-WINDSHIELD MNT, UPR, 17 NA

BODY / FRAME
DASH PANEL / GLOVE BOX ASSEMBLY VIEW
q DASH GAUGE, HOOD NA
w TUFLOK RIVET NA
e DASH GAUGE, BEZEL NA
r DASH, CENTER TRAY NA
t GLOVEBOX PIN-HINGE NA
y RUBBER GROMMET NA
u COVER, UPPER GLOVEBOX NA
i UPPER GLOVEBOX FASTENER 10 in-lbs (1 Nm)
o UPPER GLOVEBOX BIN NA
a DASH-UPPER NA
s DASH, STORAGE FASTENER 42 in-lbs (5 Nm)

11
d LOWER STORAGE BIN NA
f DASH, LOWER STORAGE NA

BODY / FRAME
q CUP HOLDER NA
w DASH, MAIN NA
e BRACKET-DASH, LH NA
r DRIP PLATE NA
t PUSH RIVET NA
y DASH BRACKET FASTENER 6 ft-lbs (8 Nm)
u BRACKET-DASH, RH NA
i DASH, MAIN FASTENER 42 in-lbs (5 Nm)
o UPPER GLOVEBOX FASTENER 42 in-lbs (5 Nm)
a HINGE PIN-GLOVEBOX NA
s GLOVEBOX SEAL SEAM NA
d GLOVEBOX LATCH 1/4 TURN 36 in lbs (4 Nm)
f UPPER GLOVEBOX COVER NA
g DASH CONTROLS NA
h DASH-MAIN FASTENING NUT NA

BODY / FRAME
FRONT BODY ASSEMBLY VIEW
q LINER, UNDER HOOD NA
w HOOD NA
e FENDER, FRONT RH 22 in lbs (3 Nm)
r FENDER FLARE, RH NA
t GRILL, UPPER NA
y FRONT FASCIA 42 in-lbs (5 Nm)
u FENDER, FRONT LH 22 in lbs (3 Nm)
i FENDER FLARE, LH NA
o GROMMET, LATCH NA
a WASHER NA
s LATCH, 1/4 TURN NA

11
d FRONT FASCIA AND GRILL FASTENERS 42 in-lbs (5 Nm)

BODY / FRAME
FLOORS / FENDER ASSEMBLY VIEW
q DRIVER FLOOR NA
w LH FENDER FLARE NA
e FLOOR, UPPER CLOSEOFF NA
r FLOOR FASTENER 42 in-lbs (5 Nm)
t PUSH RIVET NA
y LINDER, UNDER HOOD NA
u RH FENDER FLARE NA
i COVER, TUNNEL-FLOOR NA
o PASSENGER FLOOR NA

BODY / FRAME
q PUSH RIVET NA
w REAR CLOSE OFF PANEL 42 in-lbs (5 Nm)

FASTENER
e RIGHT REAR UPPER FENDER NA
FLARE
r REAR CLOSE OFF PANEL NA
t LEFT REAR UPPER FENDER NA

FLARE
y PUSH RIVET NA
u LEFT REAR ROCKER PANEL NA
i PLUG COMPARTMENT NA
o RH BIN STORAGE NA
a PUSH RIVET NA
s REAR LOWER CLOSE OFF PANEL NA 11

d M6 NUT NA
f RIGHT REAR ROCKER PANEL NA
g COVER, SEAT-PIVOT NA

BODY / FRAME
SEAT COMPONENTS ASSEMBLY VIEW
q PASSENGER SEAT BACK ASSEMBLY NA
w SEAT BELT WASHER NA
e SEAT BELT FASTENER 40 ft-lbs (54 Nm)
r SEAT BUCKLE FASTENER 40 ft-lbs (54 Nm)
t SEAT BUCKLE WASHER NA
y SEAT BUCKLE FASTENING NUT NA
u DRIVER SEAT BACK ASSEMBLY NA
i DRIVER SEAT BOTTOM ASSEMBLY NA
o DRIVER SEAT BUCKLE NA
a PASSENGER SEAT BUCKLE NA
s PASSENGER SEAT BOTTOM NA

BODY / FRAME
q SEAT BELT ASSEMBLY NA
w SEAT BELT ASSEMBLY FASTENER 40 ft-lbs (54 Nm)
e SEAT BRACKET HINGE FASTENER 6 ft lbs (9 Nm)
r SEAT BRACKET HINGE NA
t SEAT BRACKET PIVOT FASTENING NUT M10 NA
y SEAT BRACKET PIVOT NA
u SEAT BRACKET PIVOT WASHER NA
i SEAT BRACKET PIVOT FASTENER 10 ft lbs (14 Nm)
o SEAT SHOCK BALL END FASTENER 7 ft lbs (9 Nm)
a SEAT SHOCK NA
s SEAT BACK FASTENER 18 inch-lbs (2 Nm)
d SEAT SLIDE ASSEMBLY FASTENER 6 ft lbs (8 Nm)
f SEAT SLIDE ASSEMBLY NA 11

g SEAT PIVOT BRACKET MOUNTING FASTENER 10 ft lbs (14 Nm)
h SEAT SLIDE ASSEMBLY FASTENER 6 ft lbs (8 Nm)
j SEAT BACK FRAME FASTENER 10 ft lbs (14 Nm)
k SEAT BACK FRAME NA
l SEAT BACK FASTENER 18 inch-lbs (2 Nm)

BODY / FRAME
ROOF ASSEMBLY VIEW
q Roof Fastener: M6 x 1.0 x 25 42 in-lbs (5 Nm)
w Roof Fastener: M6 x 1.0 x 40 42 in-lbs (5 Nm)
e Rubber Washer NA
r Washer NA
t Spacer NA
y Front Roof Seal NA
u A-Pillar Seal NA
i Side Roof Seal NA
o Rear Roof Seal NA
a Roof Bracket Fastener: M6 x 1.0 x 15 42 in-lbs (5 Nm)
s Driver Roof Bracket NA
d Passenger Roof Bracket NA
f Roof Panel NA

BODY / FRAME
ROOF ASSEMBLY VIEW (CREW)
q Roof Fastener: M6 x 1.0 x 25 42 in-lbs (5 Nm)
w Roof Fastener: M6 x 1.0 x 40 42 in-lbs (5 Nm)
e Rubber Washer NA
r Washer NA
t Spacer NA
y Front Roof Panel NA
u Front Roof Seal NA
i A-Pillar Seal NA
o Side Roof Seal NA
a Roof Fastener: 24 in-lbs (3 Nm)
s Driver Roof Bracket NA 11

d Roof Bracket Fastener: M6 x 1.0 x 15 42 in-lbs (5 Nm)
f Passenger Roof Bracket NA
g Rear Roof Seal NA
h Rear Roof Panel NA

BODY / FRAME
REAR PANEL ASSEMBLY VIEW
q REAR PANEL GLASS NA
w SLEEVE NA
e HANDLE, REAR WINDSHIELD NA
r SHIM NA
t WINDSHIELD BASE NA
y MOUNT-REAR WINDSHIELD NA
u SEAL-REAR GLASS NA
i REAR GLASS FASTENER Torque until lock and ride clamps are
fully seated
o REAR GLASS FASTENER NUT Torque until lock and ride clamps are
fully seated
a WASHER NA
s WASHER NA
d WASHER NA

BODY / FRAME
CARGO BOX ASSEMBLY VIEW

TAILGATE ASSEMBLY
REF DESCRIPTION TORQUE / NOTE
q TAILGATE CAP FASTENER 22 in lbs (2 Nm)
w INNER TAILGATE PANEL NA
e TAILGATE SUPPORT BRACKET NA
r TAILGATE ROD LEFT AND RIGHT ROD
t TAILGATE SUPPORT FASTENER 42 in-lbs (5 Nm)
y TAILGATE LATCH NA
u TAILGATE CAP NA
i TAILGATE LOWER PANEL FASTENER 42 in-lbs (5 Nm)
o TAILGATE OUTER PANEL NA
a OUTER TAILGATE PANEL FASTENER 22 in lbs (2 Nm)

NA
11
s TAILGATE OUTER PANEL
d TAILGATE CABLE NA
f TAILGATE ROD CLIP NA
g TAILGATE LATCH SPRING NA

BODY / FRAME
CARGO BOX ASSEMBLY
q CARGO BOX ASSEMBLY NA
w INNER CARGO BOX FASTENER 14X0.75 8 in lbs (1 Nm)
e INNER CARGO BOX FASTENER 1/4X2 8 in lbs (1 Nm)
r
t OUTER CARGO BOX PANEL FASTENER 8 in lbs (1 Nm)
y PUSH RIVET NA
u CARGO BOX FASTENER 42 in-lbs (5 Nm)
i CARGO BOX OUTER PANEL NA
o PUSH RIVET NA
a CARGO BOX OUTER TRIM PANEL NA
s LOWER TAILGATE SUPPORT FASTENER M8X1.25 10 ft lbs (14 Nm)
d TAILGATE SUPPORT BRACKET NA
f TAILGATE SUPPORT FASTENER M6x1.0 42 in-lbs (5 Nm)
g TAILGATE LATCH FASTENER 7 ft lbs (9 Nm)
h TAILGATE LATCH NA
j TAILGATE SUPPORT FASTENER M6x1.0 42 in-lbs (5 Nm)
k TAILGATE BUMPER NA

BODY / FRAME
CARGO BOX FRAME ASSEMBLY
q CARGO BOX HEAT SHIELD FASTENER M6X1.0 42 in-lbs (5 Nm)
w CARGO BOX HEAT SHIELD FASTENER 14X5/8 18 in lbs (2 Nm)
e CARGO BOX LATCH BUSHING FASTENING NUT 13 ft lbs (18 Nm)
r CARGO BOX LATCH BUSHING NA
t LATCH SPRING NA
y CARGO BOX LATCH BUSHING FASTENER 13 ft lbs (18 Nm)
u HITCHPIN CLIP NA
i CARGO BOX SHOCK CABLE NA
o CARGO BOX SHOCK NA
a CLEVIS PIN NA
s CARGO BOX FRAME FASTENER 14 ft lbs (19 Nm)

11
d CARGO BOX FRAME FASTENING NUT 14 ft lbs (19 Nm)
f CARGO BOX SUPPORT FRAME NA
g CARGO BOX LATCH HANDLE NA
h BOX BUMPER NA
j CARGO BOX HEAT SHIELD NA

BODY / FRAME
EXTERIOR BODY SERVICE

FRONT BUMPER SERVICE INSTALLATION
REMOVAL 1. Align the bumper mount to frame mount.
1. Remove the two fasteners retaining the bottom of the
bumper to the frame.
2. Loosely install the two fasteners retaining the top of

the bumper to the frame.
2. Remove the two fasteners w retaining the top of the
bumper to the frame.
3. Loosely install the two fasteners retaining the bottom

of the bumper to the frame.
3. Carefully pull the bumper straight out to remove it
from the vehicle.

BODY / FRAME
4. Torque all fasteners to specification. 4. Pull upper fender straight out as shown.
TORQUE
Front Bumper Fasteners
30 ft-lbs (41 Nm)
FRONT FENDER SERVICE

UPPER FENDER REMOVAL
1. Remove the hood by turning each 1/4 turn fastener
90 degrees to unlock the hood. Lift the hood straight
up and out.
2. Remove the three push rivets q and the T-30 torx
fastener w.
UPPER FENDER INSTALLATION
1. Install the fender straight on as shown.
CAUTION
Ensure all alignment clips on the back of the fender are
properly inserted or damage may occur to upper fender.
3. Remove the two push rivets e behind the front

fascia.
2. Install the two push rivets q behind the front fascia.
11

BODY / FRAME
3. Install the three push rivets e. Install the T-30 torx LOWER FENDER SERVICE
fastener w and torque to specification.
1. Remove the upper fender.
2. Remove the four push rivets q.
TORQUE
Front Fender Fasteners:
3. Remove the five T-40 torx fasteners w.
22 in lbs (3 Nm)
4. Install the hood by inserting into slots and locking

down with 1/4 turn fasteners.
4. Pull the lower fender straight out from vehicle to

remove.

BODY / FRAME
LOWER FENDER INSTALLATION 3. Install the four push rivets w.

1. Install the lower fender straight on as shown.
4. Reinstall the upper fender.

2. Install the five T-40 torx fasteners q and torque to
specification.
FRONT FASCIA SERVICE
FRONT FASCIA REMOVAL
Necessary Preliminary Tasks
• Remove Upper Fender. SeeFront Fender Service
page 11.23
1. Remove the three push rivets q and T-40 torx

fastener w. Repeat procedure on passenger side.
TORQUE
Body Fastener
42 in-lbs (5 Nm)
11

BODY / FRAME
2. Remove the two T-40 torx fasteners e. FRONT FASCIA INSTALLATION

1. Install the front fascia straight down and align with
fastener holes.
NOTICE
Front Bumper removed for clarity.
3. Disconnect the headlight connector. Remove the

three T-25 torx fasteners r. Remove the headlight
assembly.
2. Reinstall the headlight assembly. Install the three T-

25 torx fasteners q. Do not tighten. Connect the
headlight connector.
4. Pull the front fascia straight up to remove as shown.

NOTICE
Front Bumper removed for clarity.

BODY / FRAME
3. Install the two T-40 torx fasteners w. Torque to ROCKER PANEL SERVICE
specification.
1. Remove the push rivet q on the inside of the rear
upper fender and the two T-40 fasteners w retaining
the lower fender cover.
TORQUE
Body Fasteners
42 in-lbs (5 Nm) TORQUE
Lower fender fasteners:
4. Install the three push rivets e and the T-40 torx 42 in-lbs (5 Nm)
fastener r. Torque to specification.
2. Remove the two push rivets e on the back side of
the rear upper fender. Lift up and remove the upper
fender.
TORQUE
Body Fastener
42 in-lbs (5 Nm)
5. Perform Headlight Adjustment. SeeHeadlight Adjust-

ment page 12.61 11
6. Reinstall upper fender. SeeFront Fender Service
page 11.23

BODY / FRAME
3. Remove the remaining eight T-40 fasteners r and 3. Remove the (4) Rear Close-Off Panel fasteners w.
push rivet t retaining the lower fender. Remove the
lower fender.
4. Remove the (7) push rivets e retaining the Rear

Close Off Panel to the ROPS assembly.
TORQUE
Lower fender fasteners:
42 in-lbs (5 Nm)
REAR CLOSE-OFF PANEL SERVICE

REMOVAL
1. Remove the Cargo Box.
2. Remove the (3) heat shield fasteners q.
5. Remove the Rear Close-Off Panel from the vehicle.

INSTALLATION
1. Install the Rear Close Off Panel q.
2. Push in on the Rear Close-Off Panel q in areas w to
help align mounting holes.

BODY / FRAME
3. Install the (3) heat shield retaining fasteners and DECAL REPLACEMENT
washers e and the (4) rear Close Off Panel fasteners APPLICATION TOOLS
r Do not torque the fasteners.
• Clean, Lint-Free Cloth
4. Install the (7) push rivets o retaining the rear close
off panel to the ROPS assembly. • Isopropyl Alcohol
• Blue or Gold Plastic Applicator (e.g. Squeegee)
• Low Friction Sleeve
• Propane Torch
ENVIRONMENTAL CONDITIONS
The following factors ensure successful decal
application:
• An air temperature between 40°F to 100°F (4° to 38°
C), depending on surface contours
– Decals above or below these temperatures may
not adhere or, if applicable to the film, may lose
their repositionability.
– Humidity should also be taken into consideration.
5. Torque the heat shield fasteners e and the Rear • Allowing the decals to reach room temperature prior to
Close Off Panel fasteners r. application
TORQUE • A lighting distance of a minimum of 80 foot candles of
Rear Close Off Panel Fasteners: direct fluorescent lighting
42 in-lbs (5 Nm) • Decals must be allowed to cure for 72 hours to obtain
100% adhesion to the surface
TORQUE • Ample cure time has been allowed for painted
substrates or time required for in-molds to outgas
42 in-lbs (5 Nm)
APPLICATION BY SURFACE TYPE
Painted Plastic, Powder-Coated Metal, or
Hydrographic Surfaces
Surface Preparation
1. Gently wipe the surface with a clean, lint-free cloth
dampened with isopropyl alcohol.
2. Re-wipe the surface with a clean, lint-free cloth before
the isopropyl alcohol dries. The flash of the isopropyl
alcohol is quick, so it is important that it is done
immediately following the use of it.
11

BODY / FRAME
Removal of the Adhesive Liner In-Mold Surfaces

1. Lay the decal graphic-side down on a clean, flat Surface Preparation
surface.
1. Gently wipe the surface with a clean, lint-free cloth
2. If available, use the tab on the decal to remove the dampened with isopropyl alcohol.
liner.
2. Re-wipe the surface with a clean, lint-free cloth before
3. Peel back the liner at 180° to the decal. Use a clean the isopropyl alcohol dries. The flash of the isopropyl
finger lightly placed in the middle of the decal alcohol is quick, so it is important that it is done
adhesive to assist in the removal. immediately following the use of it.
CAUTION Flame-Treating
Do not apply a finger to the corners or edges of the 1. Use a torch to create a continuous flame.
adhesive. Contamination towards the edge may 2. Touch the flame’s outer blue envelope to each part of
prevent the decal from adhering to the surface properly. the surface where the decal will be applied for one (1)
second.
Application CAUTION
1. Register the decal to the surface, taking note of the Do not over flame treat as it will alter the chemistry of
lock-in shape of the pre-mask to assist in alignment. the plastic. In certain substrates and color
2. Gently tack the decal to the surface. Use a squeegee combinations, the effects of over flame treating will be
to continue to press the decal into place working from permanently etched into the surface.
the center of the decal outwards.
CAUTION Removal of the Adhesive Liner

Squeegees should not be used on urocals and other 1. Lay the decal graphic-side down on a clean, flat
domed adhesive graphics to prevent damage to the surface.
surface.
2. If available, use the tab on the decal to remove the
liner.
3. The decal can be repositioned if not completely 3. Peel back the liner at 180° to the decal. Use a clean
pressed down to the surface. If necessary, reposition finger lightly placed in the middle of the decal
the decal to allow air bubbles to escape. Gently adhesive to assist in the removal.
reapply the decal in the same manner as listed
above. CAUTION
4. Ensure the entire surface of the decal has contact Do not apply a finger to the corners or edges of the
with the surface. adhesive. Contamination towards the edge may
prevent the decal from adhering to the surface properly.
Pre-mask Removal
1. Use a clean finger to gently swipe away the edge of
the pre-mask.
2. Slowly pull the remainder of the pre-mask away at a
180° angle from the decal until it has been entirely
removed.
Inspection
1. Check the decal for imperfections.
2. Reapply the squeegee over the surface of the
exposed decal as the pre-mask removal may loosen
the edges.
3. If air bubbles are found, press firmly with a clean
finger or squeegee to work the bubble out from the
center of the decal to the outside edges.

BODY / FRAME
Application 4. If the decal did not come off in one piece, remove the
remaining portions of the decal that reside on the
1. Register the decal to the surface, taking note of the surface, again being careful not to damage the
lock-in shape of the pre-mask to assist in alignment. surface.
2. Gently tack the decal to the surface. Use a squeegee 5. Once the decal has been completely removed,
to continue to press the decal into place working from assess the amount of residue from the adhesive glue
the center of the decal outwards. that has been left on the surface.
CAUTION 6. If the use of Goo-Gone® is required to remove the
Squeegees should not be used on urocals and other adhesive glue, apply it as thinly as possible with a
domed adhesives to prevent damage to the surface. clean, lint-free cloth.
7. When the adhesive glue has been removed from the
surface, the surface must be cleaned with isopropyl
3. The decal can be repositioned if not completely alcohol and a lint-free cloth to remove the residue left
pressed down to the surface. If necessary, reposition by the Goo-Gone®. Continue to clean the surface
the decal to allow air bubbles to escape. Gently until all remaining residue has been removed from the
reapply the decal in the same manner as listed surface.
above.
4. Ensure the entire surface of the decal has contact
with the surface.
Pre-mask Removal
1. Use a clean finger to gently swipe away the edge of
the pre-mask.
2. Slowly pull the remainder of the pre-mask away at a
180° angle from the decal until it has been entirely
removed.
Inspection
1. Check the decal for imperfections.
2. Reapply the squeegee over the surface of the
exposed decal as the pre-mask removal may loosen
the edges.
3. If air bubbles are found, press firmly with a clean
finger or squeegee to work the bubble out from the
center of the decal to the outside edges.
RE-WORK
In the event that a decal needs to be removed and
reapplied, certain steps must be followed to
accommodate the replacement decal.
1. Determine how to best remove the decal to ensure

that the most amount of surface area, if not all, can be
removed at once. How long the decal has been
allowed to cure to the surface, may pose some
difficulties in removal if using a more aggressive
11
adhesive film.
2. Attempt to cleanly remove the decal from the surface
by lifting up and edge, being careful not to damage
the surface.
3. Pull on the decal edge and slowly remove as much of
the decal as possible.

BODY / FRAME
IMPORTANCE OF COMPLIANCE
Surface Preparation
It is important to remove all contaminants from the
surface prior to applying the decal. This is to ensure that
the entire surface of the decal is adhered to the substrate
surface to promote a maximum bond. The same holds
true for any oils or chemicals on the surface, which may
prevent achieving full adhesion.
If not properly cleaned, the following issues may occur:
• Poor adhesion resulting in the decal coming off.

• Debris becoming noticeable under the decal.
Flame-Treating
Flame-treating is mandatory on in-mold materials as it
oxidizes the surface to strengthen the bond between the
adhesive and the substrate. Heating treating is not the
same and will not adequately prepare the surface.
The decal must be applied shortly after flame-treating so
that the oxidization process does not disappear.
Should the proper flame-treating techniques not be
followed, one may witness:
• Poor adhesion resulting in the decal coming off, if

under flame-treated.
• Distortion of color and/or appearance of surface, if
over flame-treated.
Use of a Squeegee
The purpose of the squeegee is the ‘break’ the
microbeads in the comply liner. The edge of the
squeegee provides the pressure needed to initiate the
bonding process. Foregoing the use of a squeegee could
result in:
• Poor adhesion resulting in the decal coming off,

allowing debris or water to reside behind it.
• Screened ink of the decal lifting from the surface,
which stems from an unsupported peel.

BODY / FRAME
REAR CARGO BOX SERVICE

CARGO BOX REMOVAL CARGO BOX INSTALLATION
1. Pull the lever and tilt the rear cargo box. 1. Place the cargo box onto the frame. Align the hinges
of the box with the bracket on the frame.
IMPORTANT
2. Install the cargo box hinge fasteners on both sides
Verify shock orientation. The body of the shock is to be and torque to specification.
on the upside for proper dampening.
TORQUE
2. Pull the clip q and remove the pin at the upper cargo Cargo Box Bracket Fasteners:
box shock mount. 5 ft-lbs (7 Nm)
3. With the hinge bolts installed, attach the shock to the

cargo box by inserting the pin and clip.
4. Connect the tail light harness connector to the main
harness.
5. Lower the box and secure the latch.
3. Disconnect the tail light harness connector w from

the main harness.
4. Remove the clip and pin at the bottom shock mount
for replacement or removal of cargo box shock.
CAUTION
Safely support the box during the remainder of the
removal process. The box is not as stable with the
shock removed.
5. Remove the two hinge fasteners that retain the cargo

box to the frame.
CAUTION
Use caution when removing the box. It is recommended
to have two people carefully remove the box from the
frame.
6. Lift the cargo box from the frame. Two people or an 11

appropriate overhead hoist may be needed to remove
the box from the frame.

BODY / FRAME
INTERIOR BODY SERVICE

DASH PANELS / GLOVE BOX SERVICE 3. Disconnect plug connection r and remove the three
UPPER DASH REMOVAL bolts t retaining the instrument cluster to trim piece.
1. Remove the two push rivets q from the instrument

panel cover w and rotate the cover forward.
NOTICE
It is only necessary to remove the three bolts when
replacing the instrument cluster.
2. Un-clip the two retaining tabs e from the instrument
cluster panel.
TORQUE
Instrument Cluster Screws:
12 in lbs (1 Nm)
4. Remove the two push rivets w on the upper center

storage cover and unlock the two retaining tabs u.

BODY / FRAME
5. Open upper storage compartment lid and remove the LOWER DASH PANEL REMOVAL
four retaining screws i. Lift the storage compartment
1. Disconnect the ignition, headlight and AWD switches,
o out. instrument cluster, and both 12V power points on the
control dash panel.
2. Remove the shifter cap and remove the T-25 Torx-
head screw and pull up on the shifter grip to remove
it.
3. Remove the two rivets q on the bottom of the control
dash panel and un-clip the top clips to remove the
panel.
TORQUE
Upper Storage Compartment Fastener:
10 in-lbs (1 Nm)
6. Remove all push rivets s from upper dash panel and

pull upper dash panel forward to remove.
4. Remove the six plastic rivets r retaining lower

storage compartment and remove lower storage
compartment.
11

BODY / FRAME
5. Remove the seven T-40 Torx and four T-25 Torx DRIVER’S SEAT SERVICE
screws t retaining the lower dash y. REMOVAL
1. Remove the two fasteners q retaining the front of the
driver seat base bracket.
NOTICE
2. If necessary, slide the seat base forward to access

the fasteners securing the rear of the seat base
bracket.
3. Remove the two fasteners w from the rear of the seat
base bracket e.
6. Remove the four push rivets u on top of the main

dash
7. Remove the five T-40 Torx i bolts retaining the main
dash to the body.
8. Tilt the steering wheel to its lowest position and put
the gear selector in Low or High gear to ease
removal.
9. Carefully pull the lower dash panel towards the seat
and up to remove it.


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4. Tilt seat forward and remove from the vehicle.
5. Remove the seat base.

6. Remove the four 13 mm seat slider fastening nuts r
using a swivel joint extension, and remove the slider
t.
NOTICE
7. Remove the four T-25 fasteners y on the seat base

and DISCARD.
11

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INSTALLATION 4. Install the previously removed rear seat bracket

fasteners r. Torque to specification.
1. Install four fasteners q on the seat base and torque
to specification.

TORQUE
TORQUE
Seat Base Fasteners:
Rear Seat Bracket Fasteners:
7 ft-lbs (9 Nm)
6 ft-lbs (8 Nm)
2. Install the seat slider assembly w and four previously

5. Install the two previously removed front fasteners t
removed fastening nuts e. Torque to specification.
retaining the front of the seat base to the vehicle and
TORQUE
Seat Slider Assembly Fasteners: TORQUE
18 ft-lbs (24 Nm) Front Seat Base Bracket Fasteners:
6 ft-lbs (8 Nm)
3. Install the seat base in the vehicle.

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PASSENGER SEAT BACK SERVICE 2. Install the (4) mounting screws q.

REMOVAL
1. Remove the Cargo Box. Refer to Cargo Box Removal
page 11.33
2. Remove the ECU. Refer to ECU Replacement page
4.4
3. Remove the Rear Close-Off Panel. Refer to Rear
Close-Off Panel Service page 11.28
4. Remove the (4) mounting screws q.
TORQUE
Passenger Seatback Screws:
18 inch-lbs (2 Nm)
3. Install the Rear Close-Off Panel. Refer to Rear Close-

Off Panel Service page 11.28
4. Install the ECU. Refer to ECU Replacement page 4.4
5. Install the Cargo Box. Refer to Cargo Box Installation
5. Remove the passenger seat back from the vehicle. page 11.33
INSTALLATION
1. Slide passenger seatback down and line up with FLOOR REMOVAL / INSTALLATION
mounting holes. FLOOR REMOVAL
1. Remove both rocker panels. SeeRocker Panel
Service page 11.27.
2. Remove driver’s seat.
4. Remove both push rivets retaining the back of the
floor tunnel.
11

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5. Remove the push rivets q retaining the center 8. Remove the T-40 torx fasteners y and the push
console, and remove the cover from the vehicle. rivets u.
6. Remove the T-40 torx fasteners w and the push 9. Remove the T-40 torx fasteners i. Lift and remove
rivets e retaining the passenger floor. the driver’s floor from the vehicle.
7. Remove the push rivets r and the T-40 torx FLOOR INSTALLATION
fasteners t. Lift and remove the passenger floor 1. Install the driver’s floor and the T-40 torx fasteners q.
from the vehicle. Torque to specification.
TORQUE
Body Fasteners:
42 in-lbs (5 Nm)

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2. Install the push rivets w and the T-40 torx fasteners 4. Install the push rivets y and T-40 torx fasteners.
e. Torque to specification. Torque to specification.
TORQUE TORQUE
Body Fasteners: Body Fasteners:
3. Install the passenger floor. Install the push rivets r 5. Install the center console. Install the push rivets i
and the T-40 torx fasteners. Torque to specification. retaining the center console.
TORQUE
Body Fasteners:
42 in-lbs (5 Nm)
11

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SEAT BELT SERVICE (3-SEAT MODELS) 8. Remove the push rivet e from inside the bolster
SEAT BELT REMOVAL panel.
1. Place the vehicle in park and turn the ignition key off.
2. Tilt the cargo box and disconnect the box shock from
the upper mount for ease of access during repair
procedure.
3. If equipped with doors, open the doors for ease of
access during repair procedure.
4. If equipped with rear glass, remove the rear glass.
5. Slide the drivers side seat fully forward to gain access
to the seat belt fasteners.
6. Remove the push rivets q from the rear of the bolster
panel.
9. Slide the bolster panel up and towards the front of the

vehicle to remove from the vehicle. Repeat steps 6-9
on the passenger side of the vehicle.
7. Remove the T40 fasteners w from the bolster bar /

bolster panel.
IMPORTANT
Ensure that the panel or door (if equipped) is not
damaged during removal. The door should be open
approximately half way during the removal.

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10. Remove the T25 fasteners retaining ECU to the back 12. Loosen the hose clamp q from the PVT outlet duct
of cab. and remove the PVT snorkel tube from the vehicle.
NOTICE
The ECU harness does not need to be disconnected.
With fasteners removed move the ECU and harness to
the side for access during the repair procedure.
13. Loosen the hose clamp w from the PVT inlet duct
and remove the PVT snorkel tube from the vehicle.
NOTICE
High Lifter / Back Country Models: perform steps 11-
14.
11. Remove the fasteners securing the PVT and intake

snorkel tubes to the vehicle.
14. Loosen the hose clamp e from the intake duct and
remove the snorkel tube from the vehicle.
11
IMPORTANT
Certain models will have variations in the number of
heat shield and close off panel fasteners. Both
variations of the fasteners are shown. Please follow the
instruction for the model being serviced.

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15. Remove the heat shield fasteners q. 16. Remove the rear close-off panel fasteners w.
HIGH LIFTER / BACK COUNTRY / STANDARD HIGH LIFTER / BACK COUNTRY / STANDARD
MODELS (3 BOLTS) MODELS (4 BOLTS)
NORTHSTAR MODELS (2 BOLTS) NORTHSTAR MODELS (5 BOLTS)
17. Remove the push rivets e retaining the rear close-off

panel to the ROPS assembly.

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18. Lift the panel up and out to a 45 degree angle to allow 21. Remove the lower anchor bolt q, washer w, and nut
for access to the retractor. e holding the webbing to the chassis.
NOTICE
Perform steps 19 and 20 if removing the passenger
side or center seat belts.
19. Remove the T25 fastenersq from the passenger

seat back.
IMPORTANT
Note the location of the lower anchor bolt q, washer w,
and nut e in relation to the bracket, as this will be a
critical step during installation.
20. Slide the passenger seat back up and out of slots.

Remove from vehicle.
22. Remove the upper anchor nut r.
11

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23. Remove the retractor nut t on the affected seat belt. SEAT BELT INSTALLATION
1. Install the retractor q. Ensure the installation tab is
located and clocked properly.
24. Remove the retractor y from the vehicle.
2. Install the retractor nut w. Torque to specification.

TORQUE
Retractor Nut:
40 ft-lbs (54 N·m)
3. Install the upper seat belt anchor nut e and bolt.

TORQUE
Upper Seat Belt Anchor Nut:
40 ft-lbs (54 N·m)
IMPORTANT
Verify that when the anchor bolt is installed that the seat
belt is installed straight and is not twisted. Twisting the
seat belt can result in incorrect operation.

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4. Install the lower anchor bolt r, washer t, and nut y 5. Ensure that the center seat belt is routed in front of
holding the webbing to the chassis. Torque to the seat back. Reinstall the passenger side seat
specification. back. Install the T25 fasteners q to the passenger
seat back. Torque to specification.
IMPORTANT
Pay close attention to the order the bolt and nut is TORQUE
installed. It is important that they are installed as Seat Back Fasteners:
shown. Lower anchor bolt r, washer t, and nut y. 18 in-lbs (2 N·m)
IMPORTANT
Certain models will have variations in the number of
heat shield and close off panel fasteners. Both
variations of the fasteners are shown. Please follow the
instruction for the model being serviced.
TORQUE
Lower Seat Belt Anchor Bolt / Nut:
40 ft-lbs (54 N·m)
NOTICE
Perform step 5 if the passenger side or center seat
belts were replaced. 11

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6. Loosely install the rear close-off panel fasteners w. 7. Loosely install the heat shield fasteners e.
HIGH LIFTER / BACK COUNTRY / STANDARD HIGH LIFTER / BACK COUNTRY / STANDARD
MODELS (4 BOLTS) MODELS (3 BOLTS)
NORTHSTAR MODELS (5 BOLTS) NORTHSTAR MODELS (2 BOLTS)
8. Install the push rivets r retaining the rear close off

panel to the ROPS assembly.

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9. Torque the rear close-off panel fasteners and heat 10. Install the T25 fasteners retaining ECU to the back of
shield fasteners. cab. Torque to specification.
TORQUE
Rear Close Off Panel Fasteners:
42 in-lbs (5 N·m)
TORQUE
42 in-lbs (5 N·m)
HIGH LIFTER / BACK COUNTRY / STANDARD

MODELS (3 BOLTS)
TORQUE
ECU Fasteners:
24 in-lbs (3 N·m)
NOTICE
High Lifter / Back Country Models: perform steps 11-
13.
11. Install the intake duct snorkel tube. Torque hose

clamp q to specification.
NORTHSTAR MODELS (2 BOLTS)
TORQUE
Hose Clamp: 11
35 in-lbs (4 N·m)

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12. Install the PVT inlet duct snorkel tube. Torque hose 14. Reinstall the bolster panel. Partially install the push
clamp w to specification. rivet q inside the bolster panel to ease installation.
TORQUE 15. Install the T40 fasteners w retaining the bolster bar /
bolster panel. Torque to specification.
Hose Clamp:
35 in-lbs (4 N·m)
13. Install the PVT outlet duct snorkel tube. Torque hose
clamp e to specification.
TORQUE
Bolster Bar Fasteners:
6 ft-lbs (8 N·m)
TORQUE 16. Install the push rivets e in the bolster panel. Fully
seat the inner push rivet at this time.
Hose Clamp:
35 in-lbs (4 N·m)

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17. Repeat steps 14-16 on the passenger side of the

vehicle.
18. If equipped with doors, close doors and ensure fit of
the bolster panel.
19. If removed, reinstall the rear glass.
20. Tilt the cargo box and connect the box shock to the
upper mount if removed during repair procedure.
Lower the cargo box.
11

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NOTES

CHASSIS / BODY ELECTRICAL
CHAPTER 12
GENERAL INFORMATION - ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.4
SERVICE NOTES - ELECTRICAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.4
SPECIAL TOOLS - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.5
SERVICE SPECIFICATIONS - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.5
CHASSIS HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.6
CHASSIS HARNESS ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.6
CHASSIS HARNESS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.8
CHASSIS HARNESS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.8
INSTRUMENT CLUSTER SERVICE C4 GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.9
C4 GAUGE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.9
INSTRUMENT CLUSTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.10
INSTRUMENT CLUSTER PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.10
BATTERY SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.11
GENERAL BATTERY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.11
BATTERY SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.11
BATTERY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.11
BATTERY OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.13
BATTERY TERMINAL BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.13
CHASSIS / ENGINE ELECTRICAL GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.13
BATTERY IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.14
LEAD ACID CONVENTIONAL BATTERY ACTIVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.14
LEAD ACID CONVENTIONAL BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.15
LEAD ACID CONVENTIONAL BATTERY CHARGING AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . 12.15
LEAD ACID CONVENTIONAL BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.16
DRY SHIPPED AGM BATTERY ACTIVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.16
DRY SHIPPED AGM BATTERY CHARGING AND TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.18
DRY SHIPPED AGM BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.19
LEAD ACID LOW MAINTENANCE BATTERY CHARGING AND TESTING . . . . . . . . . . . . . . . . . . . . . . 12.19
LEAD ACID LOW MAINTENANCE BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.19
AGM LOW MAINTENANCE BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.20
AGM BATTERY CHARGING - LOW CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.20
AGM BATTERY CHARGING - DEEPLY DISCHARGED (BELOW 3 VOLTS) . . . . . . . . . . . . . . . . . . . . . 12.20
AGM LOW MAINTENANCE BATTERY TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.20
AGM LOW MAINTENANCE BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.21
BATTERY CONDUCTANCE ANALYZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.21
BATTERY OPEN CIRCUIT VOLTAGE TEST (OCV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.21
BATTERY LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.22 12
BATTERY SPECIFIC GRAVITY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.22
BATTERY CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.23
FUSE BOX / CIRCUIT PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.24
FUSE BOX OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.24

RANGER XP 1000 / CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.25

RANGER XP 1000 WITH RIDE COMMAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.28
RANGER XP 1000 NORTHSTAR / CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.31
RANGER XP 1000 NORTHSTAR / CREW WITH RIDE COMMAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.34
RANGER XP 1000 HIGH LIFTER / CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.38
RANGER XP 1000 FACTORY CHOICE PACKAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.41
RELAY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.45
CHARGING SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.47
CHARGING SYSTEM OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.47
STATOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.47
REGULATOR / RECTIFIER REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.47
CHARGING SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.48
ALTERNATOR CONNECTOR PIN OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.49
ALTERNATOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.50
CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.52
CHARGING SYSTEM “BREAK EVEN” TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.52
CHARGING SYSTEM STATOR (ALTERNATOR) TESTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.53
REGULATOR TESTING (900 WATT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.54
STARTING SYSTEM SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.55
STARTING SYSTEM OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.55
STARTER MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.55
STARTER SOLENOID BENCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.56
STARTER SOLENOID OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.57
STARTING SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.58
VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.59
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.59
LIGHTING SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.60
HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.60
HEADLIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.61
HEADLIGHT BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.63
HEADLIGHT HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.63
HEADLIGHT HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.64
TAIL LIGHT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.64
SWITCHES / CONTROLS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.65
IGNITION KEY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.65
TRANSMISSION (GEAR POSITION) SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.66
SEAT BELT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.66
BRAKE FLUID LEVEL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.67
SPEED SENSOR LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.67
SPEED SENSOR TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.67
DIFFERENTIAL SOLENOID OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.69
DIFFERENTIAL SOLENOID CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.69
DIFFERENTIAL SOLENOID REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.69
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.71
AWD / 2WD / TURF SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.71
DIAGNOSING SYSTEM FAILURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.71
AMBIENT TEMPERATURE SENSOR LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.73

AMBIENT TEMPERATURE SENSOR TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.73
12

GENERAL INFORMATION - ELECTRICAL SYSTEM

SERVICE NOTES - ELECTRICAL
Keep the following notes in mind when diagnosing an The following components can be accessed under the
electrical problem: hood.
• Refer to wiring diagram for stator and electrical • Voltage Regulator (in front of radiator)
component resistance specifications.
• Terminal Block
• When measuring resistance of a component that has a
• Headlight Connectors
resistance value under 10 Ohms, remember to
subtract meter lead resistance from the reading.
Connect the leads together and record the resistance. The following components can be accessed with the
The resistance of the component is equal to tested upper dash panel removed.
value minus the lead resistance.
• Instrument Cluster (Speedometer)
• Become familiar with the operation of your meter. Be
sure leads are in the proper jack for the test being • AWD/2WD/TURF Switch
performed (i.e. 10A jack for current readings). Refer to • Headlight Switch
the Owner’s Manual included with your meter for more
information. • 12 VDC Accessory Power Points
• Voltage, amperage, and resistance values included in • Ignition Key Switch

this manual are obtained with a Fluke™ 77 Digital • Drive Mode Switch
Multimeter (PV-43568). This meter is used when
diagnosing electrical problems. Readings obtained The following components can be accessed with the
with other meters may differ. passenger seat base removed.
• Pay attention to the prefix on the multimeter reading
(K, M, etc.) and the position of the decimal point. • Battery*
• For resistance readings, isolate the component to be • Battery Cables*

tested. Disconnect it from the wiring harness or power • Starter Solenoid*
supply.
• Relays*
• Fuses*
• Digital Wrench ® Diagnostic Connector*
• Speed Key Accessory (if installed)

SPECIAL TOOLS - ELECTRICAL SERVICE SPECIFICATIONS -

PART ELECTRICAL
TOOL DESCRIPTION
NUMBER SERVICE
PART DESCRIPTION
Fluke™ 77 Digital Multimeter PV-43568 SPECIFICATION
Seat Belt Switch Normally Open
Static Timing Light Harness 2871745
Drive Mode Switch - 4750 Ω
Hall Effect Sensor Probe Harness 2460761 Performance
Battery Conductance Analyzer Drive Mode Switch - 25,000 Ω
(MDX-610P) PU-50296 Standard
Connector Test Kit PV-43526 Drive Mode Switch - Work 1600 Ω
Timing Light 2870630 AWD Hub Coil Resistance 24 Ω ± 5%

Fuel Sender Resistance - 450 ± 5%
Relay Bypass PU-49466 Empty
Bosch Automotive Service Solutions: Fuel Sender Resistance - 100 ± 3%

1-800-345-2233 or http://polaris.service-solutions.com/ Full
CTS Resistance (77 °F) 29.9 kΩ ± 6%
CTS Resistance (248 °F) 1.22 kΩ ± 2%
Current Draw - Key Off .01 DCA (10 mA)
(Max)
Stator Leg to Leg Less than 1 Ω
Resistance
Stator Leg to Ground Open Line (OL / ∞)
Resistance
Stator Leg Voltage (1300 21 VAC ± 25%
RPM)
RPM)
RPM)
Starter Solenoid Terminal 2.5 Ω ± 20%
Resistance (77 °F)
Parking Brake Switch Normally Open
12

CHASSIS HARNESS
CHASSIS HARNESS ROUTING
FRONT BODY HARNESS ROUTING
DASH BOARD HARNESS ROUTING

ENGINE HARNESS ROUTING
CARGO BOX HARNESS ROUTING
12

CHASSIS HARNESS REMOVAL CHASSIS HARNESS INSTALLATION

1. Remove the upper and lower fenders. Refer to Front 1. Install the harness in the vehicle. Refer to Chassis
Fender Service page 11.23. Harness Routing.
2. Remove the front fascia. Refer to Front Fascia 2. Install the lower steering shaft and unbolt the EPS
Service. unit from the frame. Refer to Steering Rack
Installation page 9.10.
3. Remove the under hood liner. Refer to Front Body
Assembly View. 3. Install the radiator assembly. Refer to Radiator
Removal / Installation.
4. Remove the floors. Refer to Floor Removal /
Installation. 4. Install the battery and battery tray. Torque the
5. Remove the upper and lower dash panels.
6. Remove the battery and battery tray. TORQUE
Battery Tray Fasteners:
7. Remove the radiator assembly. Refer to Radiator
Removal / Installation. 42 in-lbs (5 Nm)
8. Remove the lower steering shaft and unbolt the EPS

unit from the frame. Refer to Steering Rack Removal TORQUE
page 9.9. Battery Terminal Fasteners:
9. Remove the harness from the vehicle. Refer to 40 in-lbs (5 Nm)
Chassis Harness Routing.
TORQUE
Battery Bracket Fasteners:
42 in-lbs (5 Nm)
5. Install the upper and lower dash panels.

6. Install the floors. Refer to Floor Removal / Installation.
7. Install the under hood liner. Refer to Front Body
Assembly View.
8. Install the front fascia. Refer to Front Fascia Service.
9. Install the upper and lower fenders. Refer to Front
Fender Service page 11.23.
10. Verify proper vehicle operation.

INSTRUMENT CLUSTER SERVICE C4 GAUGES

C4 GAUGE OVERVIEW
ACCESSING MENUS AND OPTIONS
Press and release the MODE button to cycle through the
Area 1 modes until the desired default mode displays.
See Mode Information Displays page .
Press and hold the MODE button to enter the settings
menu.
The OPTIONS screen will display for a few seconds.
1. Press and release either toggle button to cycle to the
desired option.
2. Press MODE to select the option.
PROGRAMMABLE SERVICE INTERVAL
3. Press either toggle button to cycle to the desired The service interval counter is programmed to 25 hours
setting. at the factory. As hours of engine operation increase, the
4. Press MODE to save and exit to the settings menu. counter decreases. The wrench icon will flash for about
10 seconds when the counter reaches zero (0), and each
5. Press and hold the MODE button to exit the settings time the key is turned on thereafter, until the counter is
menu. reset.
When this feature is enabled, it provides a convenient
reminder to perform routine maintenance. Refer to the
Periodic Maintenance Chart for recommended service
intervals.
Use the following procedure to reset or change the
service interval.

menu.
2. Press either toggle button to cycle to the “Service
Hours” option. Press MODE to select.
3. Press MODE to reset the existing value and exit, or
CLOCK press either toggle button to change the value. Press
The clock must be reset any time the battery has been MODE to save and exit to the settings menu.
disconnected or discharged.
menu.
2. Press either toggle button to cycle to the “CLOCK”
option. Press MODE to select.
3. Press either toggle button to cycle to the desired
setting (12H or 24H). Press MODE to select.
4. Press either toggle button to change each segment of
the clock. Press MODE to accept a change and
advance to the next segment.
12

INSTRUMENT CLUSTER SERVICE 3. Disconnect plug connection r and remove the three
bolts t retaining the instrument cluster to trim piece.
1. Remove the two push rivets q from the instrument
panel cover w and rotate the cover forward.
NOTICE
2. Un-clip the two retaining tabs e from the instrument It is only necessary to remove the three bolts when
cluster panel. replacing the instrument cluster.
TORQUE
Instrument Cluster Screws:
12 in lbs (1 Nm)
INSTRUMENT CLUSTER PINOUTS
FUNCTION PIN
CAN High 1
CAN Low 2
Switched Power (Vdc) 3
Constant Power (Vdc) 4
Ground 5
High Beam Input 8

BATTERY SERVICE
GENERAL BATTERY INFORMATION Nominal Open
Circuit Voltage 12.8 VDC
WARNING
Recommended 1.8A @ 5-10 HR or 6.0A @ 1
CALIFORNIA PROPOSITION 65 WARNING:Batteries,
Charging Rate HR
battery posts, terminals and related accessories contain
lead and lead compounds, and other chemicals known
to the State of California to cause cancer and birth
CAUTION
defects or other reproductive harm. WASH HANDS
AFTER HANDLING. Never attempt to open the battery.
WARNING
Battery electrolyte is poisonous. It contains acid! BATTERY REPLACEMENT
Serious burns can result from contact with the skin, REMOVAL
eyes, or clothing.ANTIDOTE:External: Flush with water.
Internal: Drink large quantities of water or milk. Follow 1. Flip up passenger seat. .
with milk of magnesia, beaten egg, or vegetable oil. Call
a physician immediately.Eyes: Flush with water for 15
minutes and get prompt medical attention.Batteries
produce explosive gases. Keep sparks, flame,
cigarettes, etc. away. Ventilate when charging or using
in closed space. Always shield eyes when working near
batteries.Keep out of reach of children.
1. Check battery voltage with a volt/ohm meter. A fully

charged battery should be 12.8 V or higher.
2. If the voltage is below 12.6 V, the battery will need to
be recharged.
To service a Maintenance Free battery:
1. Remove battery from the vehicle.

2. Test battery with a voltage meter or load tester to
determine battery condition. This will determine the
length of time required to charge the battery to full
capacity.
3. Charge the battery as recommended.
BATTERY SPECIFICATIONS
BATTERY PN 4014043 / 4014132-P / 4015591 VARTA
(ZUG/EU/TRACTOR)
Type Polaris Maintenance Free

Voltage 12 VDC
Nominal Capacity
@ 20 HR Rate 32 AH
12
CCA 575 CCA

3. Disconnect the black (negative) battery cable. 2. Place the battery in the vehicle. Install Bracket e and
Battery Bracket Fastener w. Torque fastener to
specification.
4. Disconnect the red (positive) battery cable.
CAUTION TORQUE
To reduce the chance of sparks, disconnect the black Battery Bracket Fastener:
(negative) cable first. When reinstalling the battery, 42 in-lbs (5 Nm)
connect the black (negative) cable last.
3. Coat the terminals with dielectric grease or petroleum
5. Remove Battery Bracket Fastener w and Bracket e. jelly.
Remove Battery.
4. Install and tighten the red (positive) cable first. Torque
to specification.
TORQUE
40 in-lbs (5 Nm)
5. Install and tighten the black (negative) cable last.
CAUTION
To reduce the chance of sparks, disconnect the black
(negative) cable first. When reinstalling the battery,
connect the black (negative) cable last.
6. Verify the cables are properly routed and reinstall the

INSTALLATION
battery cover and flip down passenger seat.
CAUTION
Using a new battery that has not been fully charged can
damage the battery and result in a shorter life. It can
also hinder vehicle performance. SeeBattery Charging
Procedure page 12.23 before installing the battery.
1. Ensure the battery is fully charged.

BATTERY OFF SEASON STORAGE CHASSIS / ENGINE ELECTRICAL

Whenever vehicle is not used for a period of three GROUND
months or more, remove the battery from the vehicle, Inspect the ground cable connections. Remove ground
ensure that it's fully charged, and store it out of the sun in terminals and clean if necessary.
a cool, dry place. Check battery voltage each month
during storage and recharge as needed to maintain a full 1. Remove the passenger seat base and storage bin to
charge. access the chassis ground terminal q, located below
the starter solenoid w next to the battery.
NOTICE
Battery charge can be maintained by using a Polaris
battery tender charger or by charging once a month to
make up for normal self-discharge. Battery tenders can
be left connected during the storage period, and will
automatically charge the battery if the voltage drops
below a pre-determined point.
BATTERY TERMINAL BLOCK

The terminal block q is located under the hood near the
radiator pressure cap. The terminal block provides easy
hookup for accessories.
2. Inspect the chassis ground terminals. Be sure they

are clean and tight.
3. Inspect the engine ground terminal, attached to the
upper starter mounting bolt. The other end of the
engine ground cable is attached to the chassis
ground terminal).
4. Inspect the engine ground terminals. Be sure they are
clean and tight.
TORQUE
Terminal Block Fasteners:
24 in-lbs (3 Nm)
12

BATTERY IDENTIFICATION LEAD ACID CONVENTIONAL BATTERY

IMPORTANT LEAD ACID CONVENTIONAL BATTERY
It is important to identify what type of battery is installed ACTIVATION
in the vehicle. Different types of batteries require
different service procedures. Proper servicing and WARNING
upkeep of the battery is very important for maintaining CALIFORNIA PROPOSITION 65 WARNING:
long battery life. Batteries, battery posts, terminals and related
accessories can expose you to chemicals including
The types of batteries are lead, which is known to the State of California to cause
birth defects or other reproductive harm. For more
• Lead Acid Conventional information go to www.P65Warnings.ca.gov.
• Dry Shipped Absorbed Glass Mat (AGM)
• Lead Acid Low Maintenance WARNING
• AGM Low Maintenance Battery electrolyte is poisonous. It contains sulfuric
acid. Serious burns can result from contact with skin,
To identify which type of battery the vehicle has, refer to eyes or clothing. Antidote:
the examples below and follow the correct service
procedures that follow in the manual. • External: Flush with water.
• Internal: Drink large quantities of water or milk.
Follow with milk of magnesia, beaten egg, or
LEAD ACID CONVENTIONAL / DRY vegetable oil. Call physician immediately.
SHIPPED AGM BATTERY
• Eyes: Flush with water for 15 minutes and get
• Battery NOT activated when packaged prompt medical attention.
• Removable cap plugs / strip on top of battery
Batteries produce explosive gases.
• Distilled water added as required (Lead Acid only) Keep sparks, flame, cigarettes, etc. away. Ventilate
when charging or using in an enclosed space. Always
• Vent tube on side of battery (Lead Acid only)
shield eyes when working near batteries.
KEEP OUT OF REACH OF CHILDREN.
WARNING
The gases given off by a battery are explosive. Any
spark or open flame near a battery can cause an
explosion which will spray battery acid on anyone close
to it. Should there be contact with battery acid, wash the
affected area with large quantities of cool water and
seek immediate medical attention.
LOW MAINTENANCE BATTERY
• Battery activated when packaged IMPORTANT
Do not activate the battery unless it will be put into
• Non removable cap(s) on top of battery
regular service within 30 days. After initial service, add
• Distilled water or electrolyte NEVER added only distilled water to the battery. Never add electrolyte
after a battery has been in service.
Battery must be fully charged before use or battery life
will be significantly reduced 10-30% of the battery's full
potential.
To activate a Lead Acid Conventional battery, do the

following:

1. Remove sealing cap from the vent elbow. Remove LEAD ACID CONVENTIONAL BATTERY
cap plugs. INSPECTION
Inspect the battery fluid level. When the battery fluid
WARNING nears the lower level, remove the battery and fill with
NEVER put the sealing cap back onto the battery. The distilled water only to the upper level line.
gas pressure can cause the battery to rupture.
2. Using bulk acid, fill battery to upper level marks on

case.
3. Set battery aside to allow for acid absorption and
stabilization for 30 minutes.
4. Add electrolyte to bring level back to upper level
mark on case.
IMPORTANT
This is the last time that electrolyte should be added. If
the level becomes low after this point, add only distilled
water.
5. Charge battery at 10% of its amp-hour rating.

Examples: 10% of 9 amp battery = .9 amp; 10% of
14 amp battery = 1.4 amp; 10% of 18 amp battery =
1.8 amp (recommended charging rates).
6. Check specific gravity of each cell with a hydrometer
to assure each has a reading of 1.270 or higher. LEAD ACID CONVENTIONAL BATTERY
CHARGING AND TESTING
7. Once the battery is fully charged, replace cap plugs Polaris recommends using a BatteryMINDer® 1510- 1.5
by hand. Do NOT use a tool to install the cap plugs. AMP charger (or a similar charger), which can be ordered
through your normal parts channel.
BatteryMINDer® 1510- 1.5 AMP charger
2830404
Nominal voltage is 12.6 to 12.8 Volts when fully charged.

If the voltage falls below 12.5V, charge it immediately, or
the battery runs the risk of sulfation.
The battery must be fully charged before use or battery
life will be significantly reduced by 10-30% of the
battery's full potential.
To charge a Lead Acid Conventional battery, do the
following:
1. Remove the battery from the vehicle to prevent
damage from leaking or spilled acid during charging
(see Battery Removal).
2. Charge the battery with a charging output no larger
than 10% of the battery's amp-hour rating. Charge as
needed to raise the specific gravity to 1.270 or
greater.
3. Install the battery (see Battery Installation).
12

Test the battery using the PU-50296 battery tester. If the DRY SHIPPED AGM BATTERY
test fails, fully charge the battery.
DRY SHIPPED AGM BATTERY ACTIVATION
WARNING
LEAD ACID CONVENTIONAL BATTERY
ALWAYS wear safety glasses and protective gloves
MAINTENANCE when activating a battery. Clean all spills immediately.
Recharge the battery to its full capacity every 30 to 60
days.
To activate a Dry Shipped AGM battery, do the following:
condition, hard crystal sulfation will form on the plates, 1. Remove the battery from the vehicle and place on a
reducing the efficiency and service life of the battery. level surface.
2. Remove the electrolyte container from the package.
IMPORTANT
3. Remove the sealing strip on top of the battery.
NEVER add electrolyte to the battery once the battery
is in service. IMPORTANT
Only add distilled water to the battery if necessary.
Do not remove the sealing strip until ready to activate
the battery.
Batteries will self discharge more rapidly when stored in

4. Remove the top strip of caps on the electrolyte 7. Leave the container in place until it empties
package. completely. This can take over 20 minutes to
complete.
NOTICE
Retain this strip of caps for battery sealing after it has IMPORTANT
been filled. The entire container must empty into the battery. DO
NOT tilt or puncture the electrolyte container to aid in
filling.
WARNING
DO NOT pierce or otherwise open the foil seals on the NOTICE
electrolyte container or attempt to separate the
individual electrolyte containers. If no air bubbles rise from the battery or if the container
has not completely emptied after 20 minutes, gently tap
on the top of the container to aid the flow of electrolytes
into the battery.
5. Place the electrolyte container with the foil seals

facing down into the cell filler ports on the battery.
6. Press down evenly to break the foil seals and allow
electrolyte to flow into the battery.
NOTICE
Air bubbles will begin to rise, indicating the flow of
electrolytes.
12

8. Remove the empty electrolyte container from the DRY SHIPPED AGM BATTERY CHARGING
battery and immediately install the previously AND TESTING
removed strip of sealing caps onto the top of the
Polaris recommends using the BatteryMINDer® 2012
battery.
AGM - 2 AMP battery charger to charge and maintain
IMPORTANT Absorbent Glass Mat (AGM) batteries. The charger can
be ordered through your normal parts channel.
Only install caps by hand. DO NOT use a hammer or
excessive force. BatteryMINDer® 2012 AGM - 2 AMP battery charger
2830438
Nominal voltage is 12.8 Volts when fully charged. If the

voltage falls below 12.5V, charge it immediately, or the
battery runs the risk of sulfation.
To charge a Dry Shipped AGM battery, do the following:
1. Charge the battery for 1 hour using the Polaris
recommended charger.
IMPORTANT
Reference the recommended charging information on
the battery decal. Battery charger must be designed to
work with AGM batteries. Internal damage may occur if
a non-AGM compliant battery charger is used or if too
much current is applied during charging.
IMPORTANT
Ensure the sealing caps are flush with the battery. NOTICE
Battery voltage may reach more than 16 volts during
initial charging session.
NOTICE
Maximum battery performance and longevity depends
on adhering to the following rest and charging activation 2. Allow battery to stand for 1-2 hours before checking
steps. voltage.
3. Check open circuit voltage. Continue charging as
9. Allow battery to stand for 1-2 hours. This allows the needed.
electrolyte to permeate the plates for optimal
performance. Battery Open Circuit Voltage:
12.6 Volts

Test the battery using the PU-50296 battery tester. If the LEAD ACID LOW MAINTENANCE
test fails, fully charge the battery. If the battery is too low BATTERY
to accept a charge, see AGM Battery Charging - Deeply
Discharged (Below 3 Volts) page 12.20. LEAD ACID LOW MAINTENANCE BATTERY
CHARGING AND TESTING
Polaris recommends using a BatteryMINDer® 1510- 1.5
DRY SHIPPED AGM BATTERY AMP charger (or a similar charger), which can be ordered
MAINTENANCE through your normal parts channel.
IMPORTANT BatteryMINDer® 1510- 1.5 AMP charger

2830404
NEVER add electrolyte or distilled water to the battery
once the battery is in service.
Nominal voltage is 12.8 Volts when fully charged. If the
voltage falls below 12.5V, charge it immediately, or the
If you do not drive the vehicle for more than TWO weeks, battery runs the risk of sulfation.
BatteryMINDer® 2012 AGM - 2 AMP charger. The battery must be fully charged before use or battery
life will be significantly reduced by 10-30% of the
BatteryMINDer® 2012 AGM - 2 AMP battery charger battery's full potential.
2830438 To charge a Lead Acid Low Maintenance battery, do the
following:
If you plan to store the vehicle for ONE month or longer, 1. Remove the battery from the vehicle to prevent
remove the battery from the vehicle and store the battery damage from leaking or spilled acid during charging
in a cool / dry location. Continue to maintain the battery (see Battery Removal).
with the BatteryMINDer® 2012 AGM - 2 AMP charger
and inspect the battery every 60 days. 2. Charge the battery with a charging output no larger
than 10% of the battery's amp-hour rating. Charge as
needed to raise the specific gravity to 1.270 or
greater.
3. Install the battery (see Battery Installation).
Test the battery using the PU-50296 battery tester. If the

LEAD ACID LOW MAINTENANCE BATTERY

MAINTENANCE
Recharge the battery to its full capacity every 30 to 60
days.
condition, hard crystal sulfation will form on the plates,
IMPORTANT
the battery.

Batteries will self discharge more rapidly when stored in 12

AGM LOW MAINTENANCE BATTERY AGM BATTERY CHARGING - DEEPLY DIS-

CHARGED (BELOW 3 VOLTS)
AGM batteries discharged to a voltage of 3 volts or less
CHARGING may not be recognized by the recommended automatic
Polaris recommends using the BatteryMINDer® 2012 battery charger. (The minimum voltage threshold
AGM - 2 AMP battery charger to charge and maintain recognized by other battery chargers may be as high as
Absorbent Glass Mat (AGM) batteries. The charger can 10.5 volts). Often times deeply discharged batteries can
be ordered through your normal parts channel. be restored by attaching another, fully-charged, battery
to “jump start” the low battery. Follow the steps below to
BatteryMINDer® 2012 AGM - 2 AMP battery charger
restore a deeply discharged battery.
2830438
1. Carefully connect the two batteries’ positive
Nominal voltage is 12.8 Volts when fully charged. If the terminals, then the negative terminals using jumper
voltage falls below 12.5V, charge it immediately, or the cables.
battery runs the risk of sulfation. 2. Connect the recommended battery charger to the low
AGM chargers are designed specifically for charging battery and initiate the charging sequence.
AGM type batteries and use high frequency pulses to
partially reverse sulfation. WARNING
Always check to ensure the positive cables are
IMPORTANT connected to the positive terminals before powering the
The use of non-AGM battery chargers or non-AGM charger on. Reversing polarity when charging can
battery tenders may result in a misleading “battery not damage electrical components and risk personal injury.
found” or “open cell” fault message. Please ensure you Be careful not to let battery cable clamps touch each
are using the recommended AGM charger when other.
charging AGM type batteries.
3. After the charging sequence has initiated, disconnect
the fully-charged battery. Always disconnect the fully-
charged battery positive first, followed by low battery
AGM BATTERY CHARGING - LOW CHARGE positive, low battery negative, and finally fully-
The nominal voltage for an AGM battery is 12.8 Volts charged battery negative.
when fully charged. The battery will self-discharge when 4. Proceed with charging both batteries to full capacity.
disconnected from a vehicle, and will discharge at a Listed in the table below are the approximate
faster rate when connected. If the battery voltage falls charging times for deeply discharged batteries.
below 12.5V, it should be charged immediately using the Always use the recommended automatic battery
recommended battery charger. Listed below are the charger, and wait for the charger to complete the
recommended battery inspection schedules. charge cycle before disconnecting it. The
recommended automatic charger will indicate when
• Batteries which are not connected to a vehicle should the battery is fully charged on its display.
be inspected every 60 days. The battery must be
charged if found to be below 12.5 volts. BATTERY CHARGING BATTERY CHARGING
PN TIME CAPACITY RATE
• Batteries which are connected to a vehicle should be
inspected when they arrive at your dealership and at 4011496 11 hours 18 AH 2 amps
least once every month thereafter. The battery must be
charged if found to be below 12.5 volts. 4014770 8 hours 12 AH 2 amps
• Showroom vehicles used to demonstrate radio, display
and infotainment features should be charged daily. If
possible, these vehicles should be connected to the
recommended battery charger continuously. AGM LOW MAINTENANCE BATTERY
TESTING
IMPORTANT Test the battery using the PU-50296 battery tester. If the
Always use the recommended automatic battery
charger, and wait for the charger to complete the If the battery is too low to accept a charge, see AGM
charge cycle before disconnecting it. Battery Charging - Deeply Discharged (Below 3 Volts)
page 12.20.

If the tester indicates a test result other than “Good BATTERY TESTING
Battery,” follow the steps below before replacing the
battery: BATTERY CONDUCTANCE ANALYZER
Conductance describes the ability of a battery to conduct
1. Connect battery to the recommended battery charger.
current. A conductance tester functions by sending a low
If charging sequence begins as normal, fully charge
frequency AC signal through the battery and capturing a
battery and proceed to step 3.
portion of the current response to calculate conductance.
The time listed on the PU-50296 battery tester Conductance testing is more accurate than voltage,
printout is an estimate. The recommended automatic specific gravity, or load testing.
charger will indicate when the battery is fully charged
Authorized Polaris dealers / distributors are required to
on its display.
use the conductance analyzer when testing 12V Polaris
2. If charging sequence does not initialize, refer to AGM batteries.
Battery Charging - Deeply Discharged (Below 3 Volts)
page 12.20 to attempt to restore the deeply
discharged battery. If charging sequence will not
finish as intended, the battery needs to be replaced.
3. Re-test battery. If the test results show that battery
failed, proceed with battery replacement.

MAINTENANCE
IMPORTANT
the battery.
If you do not drive the vehicle for more than TWO weeks,
BatteryMINDer® 2012 AGM - 2 AMP charger.
BatteryMINDer® 2012 AGM - 2 AMP battery charger Polaris MDX-610P

2830438 PU-50296

in a cool / dry location. Continue to maintain the battery
BATTERY OPEN CIRCUIT VOLTAGE TEST
with the BatteryMINDer® 2012 AGM - 2 AMP charger (OCV)
and inspect the battery every 60 days. Battery voltage should be checked with a digital
multimeter. Readings of 12.5 volts or less require further
battery testing and charging.
NOTICE
Lead Acid batteries should be kept at or near a full
charge as possible. If the battery is stored or used in a
partially charged condition, hard crystal sulfation will
form on the plates, reducing the efficiency and service
life of the battery.
Use a voltmeter or multimeter to test battery voltage.
12

LEAD ACID LEAD ACID

STATE OF CONVENTIONAL LOW STATE OF CONVENTIONAL LOW
CHARGE / DRY SHIPPED MAINTENANCE CHARGE / DRY SHIPPED MAINTENANCE
AGM AGM
100% Charged 12.70V 13.0V 25% Charged 11.90V 12.0V
75% Charged 12.50V 12.80V 0% Charged less than 11.80V Less than 11.90V
50% Charged 12.20V 12.50V
LEAD ACID
25% Charged 12.0V 12.20V STATE OF CONVENTIONAL LOW
0% Charged less than 11.9V less than 12.0V CHARGE* / DRY SHIPPED MAINTENANCE
AGM
100% Charged 1.265 1.275
BATTERY LOAD TEST 75% Charged 1.210 1.225
50% Charged 1.160 1.175
NOTICE
25% Charged 1.120 1.135
This test can only be performed on machines with
electric starters. This test cannot be performed with an 0% Charged less than 1.100 Less than 1.115
engine or starting system that is not working properly.
* Measurement at 80° F
A battery may indicate a full charge condition in the OCV NOTICE
test and the specific gravity test, but still may not have
the storage capacity necessary to properly function in the Subtract .01 from the specific gravity reading at 40° F
electrical system. For this reason, a battery capacity or
load test should be conducted whenever poor battery
performance is encountered. To perform this test, hook a
multitester to the battery in the same manner as was
done in the OCV test. The reading should be 12.6 volts
or greater. Engage the starter and observe the battery
voltage while cranking the engine. Continue the test for
15 seconds. During cranking the observed voltage
should not drop below 9.5 volts. If the beginning voltage
is 12.6 volts or higher and the cranking voltage drops
below 9.5 volts during the test, replace the battery.
BATTERY SPECIFIC GRAVITY TEST

A tool such as a Battery Hydrometer (2870836) can be
used to measure electrolyte strength or specific gravity.
As the battery goes through the charge / discharge cycle,
the electrolyte goes from a heavy (more acidic) state at
full charge to a light (more water) state when discharged.
The hydrometer can measure state of charge and
differences between cells in a multi-cell battery.
Readings of 1.270 or greater should be observed in a
fully charged battery. Differences of more than .025
between the lowest and highest cell readings indicate a
need to replace the battery.
LEAD ACID
STATE OF CONVENTIONAL LOW
CHARGE / DRY SHIPPED MAINTENANCE
AGM
100% Charged 12.60V 12.70V
75% Charged 12.40V 12.50V
50% Charged 12.10V 12.20V

BATTERY CHARGING PROCEDURE

If battery voltage is 12.6 Vdc or less, the battery may
need recharging. When using an automatic charger, refer
to the charger manufacturer’s instructions for recharging.
Recommended Charging Rate: 1 hour @ 6-10 Amps.
Do not exceed 10 amps when charging the battery.
NOTICE
Charge the battery using an automatic charger that will
not exceed 14.6 Vdc. An automatic charger will signal
when charging is complete.
Allow the battery to stand disconnected for at least 1-2
hours after being properly charged. If the voltage drops
below 12.6 volts, charging was ineffective or the battery
needs to be replaced.
DANGER
An overheated battery could explode, causing severe
injury or death. Always watch charging times carefully.
Stop charging if the battery becomes very warm to the
touch. Allow it to cool before resuming charging.
BATTERY PN 4014043 / 4014132-P
STATE OF VOLTAGE CHARG-

(DC) ACTION
CHARGE E TIME
None, check None
12.8 or
100% again in 3 Required
more
months
75% - May need
12.6 - 12.8 slight charge 3 - 6 hrs
100%
Needs
50% - 75% 12.3 - 12.6 Charge 5 - 11 hrs
Needs At least
25% - 50% 12.0 - 12.3 Charge 13 hrs
Needs At least
0% - 25% 12.0 or less Charge 20 hrs
NOTICE
Follow the charger instructions supplied by the
manufacture regarding the order or connections, switch
positions and when to connect the charger to an outlet.
12

FUSE BOX / CIRCUIT PROTECTION

FUSE BOX OVERVIEW
The fuse box is located under the passenger seat, the
fuses provide overload protection for wiring and
components such as the instrument cluster, ECU, EFI
system, main harness, lights and accessories. The
relays assist with component operation like the cooling
fan, fuel pump, EFI system, and drive system. A
separate 20-amp circuit breaker, located near the fuse/
relay box, protects the fan motor circuit.
NOTICE
EPS models have an electrical system which
includes a 30-amp fuse and relay. Refer to EPS
System Breakout page 9.4 for EPS electrical
component details.

RANGER XP 1000 / CREW
CIRCUIT PIN FROM COMPONENT TO COMPONENT FUNCTION

1 — — —
Spare 10A Fuse
7 — — —
2 — — —
Spare 15A Fuse
8 — — —
3 — — —
Spare 20A Fuse
9 — — —
4 — — —
Spare 20A Fuse
10 — — —
5 — — —
Spare 30A Fuse
11 — — —
SPLICE, #2 R/S B+ RELAY/FUSE BLOCK ACCESSORY RELAY COIL,
25
+
RELAY/FUSE BLOCK RELAY/FUSE BLOCK B+ ACCESSORY FUSE
26 OUT
Accessory Relay
RELAY/FUSE BLOCK SPLICE, B+ ACCESSORY B+ ACCESSORY FUSE
31 FUSE OUT OUT
RELAY/FUSE BLOCK SPLICE, RELAY GROUND GROUND, ACCESSORY
32 RELAY COIL
RELAY/FUSE BLOCK SPLICE 2, B+ CIRCUITS ACCESSORY,
27 UNSWITCHED B+
Accessory 20A
Fuse
33
OUT
12
29 RELAY/FUSE BLOCK SPLICE, ECM B+ #2 ECM B+, FAN RELAY COIL
Fan Relay
RELAY/FUSE BLOCK ENGINE COOLANT FAN UNSWITCHED FUSED, B+
30 20A CIRCUIT BREAKER FAN RELAY POWER IN


35 RELAY/FUSE BLOCK FAN B+ FAN RELAY OUT
36 ECM, CODE 4 RELAY/FUSE BLOCK COOLING FAN RELAY
38 RELAY/FUSE BLOCK SPLICE 1, B+ CIRCUITS EPS FUSED B+

EPS 30A Fuse
44 RELAY/FUSE BLOCK RELAY/FUSE BLOCK EPS FUSED B+
39 FUSE OUT OUT
Accessory Plug &
Play 10A Fuse RELAY/FUSE BLOCK SPLICE, B+ ACCESSORY B+ ACCESSORY FUSE
45 FUSE PLUG & PLAY OUT
40 RELAY/FUSE BLOCK SPLICE, #1 R/S B+ KEY SWITCH B+

Fuel Pump 15A
Fuse RELAY/FUSE BLOCK RELAY/FUSE BLOCK KEY SWITCH, FUEL PUMP
46 FUSE OUT
RELAY/FUSE BLOCK SPLICE, ECM B+ #2 ECM B+, FUEL PUMP
41 RELAY
RELAY/FUSE BLOCK RELAY/FUSE BLOCK KEY SWITCH, FUEL PUMP
Fuel Pump Relay 42 FUSE OUT
47 RELAY/FUSE BLOCK FUEL PUMP & SENDER FUEL PUMP RELAY OUT
48 ECM, CODE 4 RELAY/FUSE BLOCK FUEL PUMP RELAY

EPS Relay RELAY/FUSE BLOCK EPS POWER (A) EPS RELAY POWER OUT
50
RELAY/FUSE BLOCK SPLICE, RELAY GROUND RELAY COIL GROUND,

56 EPS
RELAY/FUSE BLOCK SPLICE, DRIVE SWITCHED B+ DRIVE
51 FUSE OUT
Drive 15A Fuse
RELAY/FUSE BLOCK SPLICE, CHASSIS RELAY CHASSIS RELAY B+ OUT,
57
B+ OUT DRIVE FUSE
RELAY/FUSE BLOCK SPLICE, ECM UNSWITCHED FUSED B+
52 UNSWITCHED B+ FUSED
EFI 20A Fuse #1
58 RELAY/FUSE BLOCK SPLICE 1, B+ CIRCUITS EFI FUSED B+
RELAY/FUSE BLOCK SPLICE, ECM ECM FUSED B+

#2
EFI Relay 54 UNSWITCHED B+ FUSED
#2
ENGINE COOLANT FAN SPLICE 1, B+ CIRCUITS FAN FUSED B+
59 20A CIRCUIT BREAKER
60 ECM, CODE 4 RELAY/FUSE BLOCK MAIN ECU RELAY
61 RELAY/FUSE BLOCK IGNITION SW. START CRANK SIGNAL
62 RELAY/FUSE BLOCK SPLICE, ECM B+ #2 ECM B+, START RELAY

Start Relay
RELAY/FUSE BLOCK START SOLENOID START SOLENOID
67
ENABLE


68 RELAY/FUSE BLOCK ECM, CODE 13 START RELAY COIL - SINK
RELAY/FUSE BLOCK SPLICE, LIGHTS B+ LIGHTS, B+ LIGHTS FUSE

63
OUT
Lights 20A Fuse
64 B+ OUT LIGHT FUSE
69 RELAY/FUSE BLOCK SPLICE 1, B+ CIRCUITS CHASSIS FUSED B+

Chassis 20A Fuse
70 RELAY/FUSE BLOCK RELAY/FUSE BLOCK FUSED B+
65 RELAY/FUSE BLOCK SPLICE, ECM B+ #2 ECM B+

Chassis Relay RELAY/FUSE BLOCK SPLICE, CHASSIS RELAY CHASSIS RELAY B+ OUT
71 B+ OUT
ECM, CODE 4 RELAY/FUSE BLOCK CHASSIS RELAY ENABLE,
72 SW. LOW
12

RANGER XP 1000 WITH RIDE COMMAND

1 — — —
Spare 10A Fuse
7 — — —
2 — — —
Spare 15A Fuse
8 — — —
3 — — —
Spare 20A Fuse
9 — — —
4 — — —
Spare 30A Fuse
10 — — —
13 RELAY/FUSE BLOCK SPLICE, #2 R/S B+ AMP RELAY KEY POWER
14 RELAY/FUSE BLOCK RELAY/FUSE BLOCK AMP FUSE TO RELAY

Amp Relay RELAY/FUSE BLOCK SPLICE, AMP B+ AMP POWER FROM
19
RELAY
RELAY/FUSE BLOCK SPLICE, RELAY GROUND GROUND, AMP RELAY
20 COIL
RELAY/FUSE BLOCK SPLICE, WINCH FUSE FUSED ACCESSORY,
15 RELAYS B+ WINCH IN
SPLICE, WINCH RELAY B+ RELAY/FUSE BLOCK WINCH IN RELAY KEY
Winch In Relay 16 POWER
21 SPLICE, WINCH IN RELAY/FUSE BLOCK WINCH IN
22 RELAY/FUSE BLOCK DISPLAY 32 PIN WINCH IN TO DISPLAY

17 RELAYS B+ WINCH OUT
Winch Out Relay
RELAY/FUSE BLOCK SPLICE, WINCH RELAY B+ WINCH OUT RELAY KEY
18
POWER


24 RELAY/FUSE BLOCK DISPLAY 32 PIN WINCH OUT TO DISPLAY

25 +
26 OUT
Accessory Relay
31 FUSE OUT OUT
32 RELAY COIL
27 UNSWITCHED B+
Accessory 20A
Fuse RELAY/FUSE BLOCK RELAY/FUSE BLOCK B+ ACCESSORY FUSE
33 OUT
28 RELAY/FUSE BLOCK SPLICE 2, B+ CIRCUITS AMP FUSE B+

Amp 15A Fuse

Fan Relay

EPS 30A Fuse
39 FUSE OUT OUT
Accessory Plug and

Fuel Pump 15A
46 FUSE OUT
41 RELAY
50 RELAY/FUSE BLOCK RELAY/FUSE BLOCK EPS FUSED B+ 12

55

56 EPS


51 FUSE OUT
Drive 15A Fuse
57
B+ OUT DRIVE FUSE
EFI 20A Fuse #1

#2
#2

Start Relay RELAY/FUSE BLOCK START SOLENOID START SOLENOID
67
ENABLE

63 OUT
Lights 20A Fuse

Chassis 20A Fuse

71 B+ OUT
72 SW. LOW

RANGER XP 1000 NORTHSTAR / CREW

1 — — —
Spare 15A Fuse
7 — — —
2 — — —
Spare 20A Fuse
8 — — —
3 — — —
Spare 30A Fuse
9 — — —
13 OUT
Lights 20A Fuse
14 RELAY/FUSE BLOCK BATTERY (B+) HVAC POWER RELAY B+

HVAC 30A Fuse RELAY/FUSE BLOCK RELAY/FUSE BLOCK FUSED HVAC POWER
20
RELAY B+
RELAY/FUSE BLOCK SPLICE, HVAC POWER HVAC SWITCHED B+
15
RELAY
16 HPCO Switch RELAY/FUSE BLOCK HPCO SWITCH OUTPUT

AC Compressor
Clutch Relay RELAY/FUSE BLOCK SPLICE, A/C AC COMPRESSOR
21 COMPRESSOR CLUTCH CLUTCH
ECM, CODE 13 RELAY/FUSE BLOCK AC COMPRESSOR
22 CLUTCH RELAY ENABLE
17 RELAY/FUSE BLOCK SPLICE, A/C SWITCH AC SWITCH RELAY COIL

12
AC Switch Relay RELAY/FUSE BLOCK SPLICE, RELAY GROUND GROUND, AC SWITCH
18
RELAY
23 ECM, CODE 4 RELAY/FUSE BLOCK AC COMMAND SIGNAL


RELAY/FUSE BLOCK SPLICE, RELAY GROUND GROUND, AC SWITCH
24 RELAY
25 RELAY/FUSE BLOCK SPLICE, R/S B+ R/S B+
RELAY/FUSE BLOCK RELAY/FUSE BLOCK FUSED HVAC POWER

26
RELAY B+
HVAC Power Relay
RELAY/FUSE BLOCK SPLICE, HVAC POWER HVAC POWER RELAY
31
RELAY
RELAY/FUSE BLOCK SPLICE, RELAY GROUND GROUND, HVAC RELAY
32 GROUND
27 SPLICE, B+ CIRCUITS #3 RELAY/FUSE BLOCK FAN, UNFUSED B+

Fan 30A Fuse
33 FAN RELAY/FUSE BLOCK ENGINE COOLANT FAN

Fuel Pump 15A
34 FUSE OUT
29
RELAY
RELAY/FUSE BLOCK RELAY/FUSE BLOCK FUSED B+ ALTERNATOR

Alternator (L) 15A 37 (L)
Fuse
RELAY/FUSE BLOCK SPLICE, 046 CIRCUIT ALTERNATOR L TERMINAL

38 LOAD
Alternator Resistor
44 (L)
RELAY/FUSE BLOCK SPLICE, UNSWITCHED UNSWITCHED CHASSIS B

39 CHASSIS B+ FUSED + FUSED
Alternator (S) 15A
Fuse RELAY/FUSE BLOCK SPLICE, 045 CIRCUIT UNSWITCHED CHASSIS B
45
+

Chassis 20A Fuse

47 B+ OUT
48 SW. LOW
49 FUSE OUT
Drive 15A Fuse
55
B+ OUT DRIVE FUSE


50 OUT
Accessory 20A
Fuse RELAY/FUSE BLOCK SPLICE, B+ CIRCUITS #3 ACCESSORY,
56 UNSWITCHED B+
51 RELAY/FUSE BLOCK SPLICE, B+ CIRCUITS #1 EPS FUSED B+

EPS 30A Fuse
ECM 20A Fuse #1
58 RELAY/FUSE BLOCK SPLICE, B+ CIRCUITS #1 EFI FUSED B+

#2
#2

61
+
62 OUT
Accessory Relay
RELAY/FUSE BLOCK SPLICE, B+ ACC FUSE B+ ACC FUSE OUT
67 OUT
68 RELAY COIL

69

70 EPS

71 ENABLE
12

RANGER XP 1000 NORTHSTAR / CREW WITH RIDE COMMAND

1 — — —
Spare 15A Fuse
9 — — —
2 — — —
Spare 20A Fuse
10 — — —
3 — — —
Spare 30A Fuse
11 — — —
17 OUT
Lights 20A Fuse
18 RELAY/FUSE BLOCK BATTERY (B+) HVAC POWER RELAY B+

HVAC 30A Fuse RELAY/FUSE BLOCK RELAY/FUSE BLOCK FUSED HVAC POWER
26
RELAY B+
RELAY/FUSE BLOCK SPLICE, HVAC POWER HVAC SWITCHED B+
19
RELAY
20 HPCO Switch RELAY/FUSE BLOCK HPCO SWITCH OUTPUT

AC Compressor
Clutch Relay RELAY/FUSE BLOCK SPLICE, A/C AC COMPRESSOR
27 COMPRESSOR CLUTCH CLUTCH
ECM, CODE 13 RELAY/FUSE BLOCK AC COMPRESSOR
28 CLUTCH RELAY ENABLE


21 RELAY/FUSE BLOCK SPLICE, A/C SWITCH AC SWITCH RELAY COIL

22 RELAY
AC Switch Relay
29 ECM, CODE 4 RELAY/FUSE BLOCK AC COMMAND SIGNAL

30
RELAY
23 RELAY/FUSE BLOCK SPLICE 2, B+ CIRCUITS AMP FUSE B+

Amp 20A Fuse
33 RELAY/FUSE BLOCK SPLICE, R/S B+ R/S B+
RELAY/FUSE BLOCK RELAY/FUSE BLOCK FUSED HVAC POWER

34
RELAY B+
HVAC Power Relay
RELAY/FUSE BLOCK SPLICE, HVAC POWER HVAC POWER RELAY
41 RELAY
RELAY/FUSE BLOCK SPLICE, RELAY GROUND GROUND, HVAC RELAY
42 GROUND
35 FUSE RELAY BOX SPLICE,B+ CIRCUITS #1 BATT, TO DISP FUSE

Display 15A Fuse
43 FUSE RELAY BOX IN-LINE RC HARNESS FUSED DISP B+

Fuel Pump 15A
44 FUSE OUT
37
RELAY
40 SPLICE, B+ CIRCUITS #3 RELAY/FUSE BLOCK FAN, UNFUSED B+

Fan 30A Fuse
48 FAN RELAY/FUSE BLOCK ENGINE COOLANT FAN
49 (L)
Alternator (L) 15A
Fuse
RELAY/FUSE BLOCK SPLICE, 046 CIRCUIT ALTERNATOR L TERMINAL

50 LOAD
Alternator Resistor
58 (L)
RELAY/FUSE BLOCK SPLICE, UNSWITCHED UNSWITCHED CHASSIS B

51 CHASSIS B+ FUSED + FUSED
Alternator (S) 15A
Fuse
59
RELAY/FUSE BLOCK SPLICE, 045 CIRCUIT UNSWITCHED CHASSIS B 12
+

Chassis 20A Fuse



61 B+ OUT
62 SW. LOW
55 RELAYS B+ WINCH IN
SPLICE, WINCH RELAY B+ RELAY/FUSE BLOCK WINCH IN RELAY KEY
Winch In Relay 56 POWER

65 FUSE OUT
Drive 15A Fuse
73 B+ OUT DRIVE FUSE
66 OUT
Accessory 20A
Fuse RELAY/FUSE BLOCK SPLICE, B+ CIRCUITS #3 ACCESSORY,
74 UNSWITCHED B+
67 RELAY/FUSE BLOCK SPLICE, B+ CIRCUITS #1 EPS FUSED B+

EPS 30A Fuse
ECM 20A Fuse #1
76 RELAY/FUSE BLOCK SPLICE, B+ CIRCUITS #1 EFI FUSED B+

#2
#2

71 RELAYS B+ WINCH OUT
RELAY/FUSE BLOCK SPLICE, WINCH RELAY B+ WINCH OUT RELAY KEY
Winch Out Relay 72 POWER
80 RELAY/FUSE BLOCK DISPLAY 32 PIN WINCH OUT TO DISPLAY

81
+
Accessory Relay
82
OUT


RELAY/FUSE BLOCK SPLICE, B+ ACC FUSE B+ ACC FUSE OUT
89 OUT
90 RELAY COIL

91

92 EPS

93
ENABLE

Amp Relay RELAY/FUSE BLOCK SPLICE, AMP B+ AMP POWER FROM
95
RELAY
RELAY/FUSE BLOCK SPLICE, RELAY GROUND GROUND, AMP RELAY
96 COIL
12

RANGER XP 1000 HIGH LIFTER / CREW

1 — — —
Spare 10A Fuse
7 — — —
2 — — —
Spare 15A Fuse
8 — — —
3 — — —
Spare 20A Fuse
9 — — —
4 — — —
Spare 20A Fuse
10 — — —
5 — — —
Spare 30A Fuse
11 — — —
UNSWITCHED FUSED, B+
15 RELAY/FUSE BLOCK RELAY/FUSE BLOCK
Fan 20A Circuit FAN RELAY POWER IN
Breaker SPLICE, FL, FAN FUSED B
21 RELAY/FUSE BLOCK FAN FUSED B+
+
25
+
26 OUT
Accessory Relay
31 FUSE OUT OUT
32 RELAY COIL


27 UNSWITCHED B+
Accessory 20A
Fuse RELAY/FUSE BLOCK RELAY/FUSE BLOCK B+ ACCESSORY FUSE
33 OUT

Fan Relay

EPS 30A Fuse
39 FUSE OUT OUT
Accessory Plug &

Fuel Pump 15A
46 FUSE OUT
41 RELAY

55

56 EPS
51 FUSE OUT
Drive 15A Fuse
57
B+ OUT DRIVE FUSE
EFI 20A Fuse #1

53 UNSWITCHED B+ FUSED 12
#2
EFI Relay
#2



67
ENABLE

63 OUT
Lights 20A Fuse

Chassis 20A Fuse

71 B+ OUT
72 SW. LOW

RANGER XP 1000 FACTORY CHOICE PACKAGES

1 — — —
Spare 10A Fuse
9 — — —
3 — — —
Spare 15A Fuse
11 — — —
5 — — —
Spare 20A Fuse
13 — — —
7 — — —
Spare 30A Fuse
15 — — —
18 SPLICE 2, B+ CIRCUITS RELAY/FUSE BLOCK B+ TO HEATER FUSE

Heater 20A Fuse
26 RELAY/FUSE BLOCK RELAY/FUSE BLOCK FUSE TO HEATER RELAY
20 RELAY/FUSE BLOCK SPLICE, RELAY GROUND HEATER RELAY GROUND
21 RELAY/FUSE BLOCK SPLICE, HEATER B+ HEATER B+

Heater Power Relay
28 RELAY/FUSE BLOCK RELAY/FUSE BLOCK FUSE TO HEATER RELAY
KEY POWER TO HEATER
12
29 SPLICE, #2 R/S B+ RELAY/FUSE BLOCK
RELAY
SPLICE, ECM
EFI 20A Fuse 22 RELAY/FUSE BLOCK UNSWITCHED B+ FUSED UNSWITCHED FUSED B+
#1


SPLICE, ECM
23 RELAY/FUSE BLOCK UNSWITCHED B+ FUSED ECM FUSED B+
#1
SPLICE, ECM
EFI Relay 24 RELAY/FUSE BLOCK UNSWITCHED B+ FUSED ECM FUSED B+
#1
33 RELAY/FUSE BLOCK SPLICE 1, B+ CIRCUITS EPAS FUSED B+

EPS 30A Fuse
41 RELAY/FUSE BLOCK RELAY/FUSE BLOCK EPAS FUSED B+
SPLICE, WINCH FUSE FUSED ACCESSORY,
34 RELAY/FUSE BLOCK
RELAYS BATT WINCH OUT
SPLICE, WINCH RELAY B+ WINCH OUT RELAY KEY

35 RELAY/FUSE BLOCK
Winch Out Relay POWER
SPLICE, WINCH OUT WINCH OUT FUSE TO

42 RELAY/FUSE BLOCK
CONTACTOR
43 RELAY/FUSE BLOCK INLINE RC HARNESS WINCH OUT TO DISPLAY
SPLICE, WINCH FUSE FUSED ACCESSORY,
38 RELAY/FUSE BLOCK
RELAYS BATT WINCH IN
SPLICE, WINCH RELAY B+ WINCH IN RELAY KEY

Winch In Relay 39 RELAY/FUSE BLOCK
POWER
47 RELAY/FUSE BLOCK INLINE RC HARNESS WINCH IN TO DISPLAY

Chassis 20A Fuse
SPLICE, ECM B+ #2 ECM B+, FUEL PUMP

49 RELAY/FUSE BLOCK
RELAY
KEY SWITCH, FUEL PUMP
Fuel Pump Relay 50 RELAY/FUSE BLOCK RELAY/FUSE BLOCK
FUSE OUT

Fuel Pump 15A
Fuse KEY SWITCH, FUEL PUMP
FUSE OUT
53 RELAY/FUSE BLOCK RELAY/FUSE BLOCK EPAS FUSED B+

EPS Relay EPS POWER (A)
60 RELAY/FUSE BLOCK EPS RELAY POWER OUT
SPLICE, RELAY GROUND RELAY COIL GROUND,

61 RELAY/FUSE BLOCK
EPS
SPLICE, DRIVE SWITCHED B+ DRIVE

Drive 15A Fuse 54 RELAY/FUSE BLOCK
FUSE OUT


SPLICE, CHASSIS RELAY CHASSIS RELAY B+ OUT,
62 RELAY/FUSE BLOCK
B+ OUT DRIVE FUSE

Chassis Relay SPLICE, CHASSIS RELAY
63 RELAY/FUSE BLOCK CHASSIS RELAY B+ OUT
B+ OUT
ECM, CODE 4 CHASSIS RELAY ENABLE,

64 RELAY/FUSE BLOCK
SW. LOW
65 RELAY/FUSE BLOCK SPLICE 2, B+ CIRCUITS AMP FUSE BATT

Amp 15A Fuse

Amp Relay AMP POWER FROM
74 RELAY/FUSE BLOCK INLINE RC HARNESS
RELAY
SPLICE, RELAY GROUND GROUND, AMP RELAY

75 RELAY/FUSE BLOCK
COIL
70 — — —
71 — — —
Start Relay
78 — — —
79 — — —
SPLICE, LIGHTS B+ LIGHTS, B+ LIGHTS FUSE

72 RELAY/FUSE BLOCK
OUT
Lights 20A Fuse
SPLICE, CHASSIS RELAY CHASSIS RELAY B+ OUT,
80 RELAY/FUSE BLOCK
B+ OUT LIGHT FUSE

Start Relay
START SOLENOID
89 RELAY/FUSE BLOCK START SOLENOID
ENABLE
SPLICE, B+ ACC FUSE

83 RELAY/FUSE BLOCK B+ ACC FUSE OUT
Acc Plug & Play OUT
10A Fuse SPLICE, B+ ACC FUSE
91 RELAY/FUSE BLOCK B+ ACC FUSE OUT
PLUG & PLAY
SPLICE, #2 R/S B+ ACCESSORY RELAY COIL,

84 RELAY/FUSE BLOCK
+
B+ ACCESSORY FUSE
OUT
Access Relay
SPLICE, B+ ACC FUSE
92 RELAY/FUSE BLOCK
OUT
B+ ACC FUSE OUT 12
SPLICE, RELAY GROUND GROUND, ACCESSORY
93 RELAY/FUSE BLOCK
RELAY COIL
SPLICE 2, B+ CIRCUITS ACCESSORY,

Access 20A Fuse 86 RELAY/FUSE BLOCK
UNSWITCHED B+


B+ ACCESSORY FUSE
OUT
ENGINE COOLANT FAN UNSWITCHED FUSED, B+

88 RELAY/FUSE BLOCK
Fan Relay 20A CIRCUIT BREAKER FAN RELAY POWER IN

RELAY OPERATION
Located in the fuse box under the passenger seat, the • Seat Belt Switch
relays assist with component operation like the cooling
fan, fuel pump, EFI system, drive system and EPS. • Purge Solenoid
• Chassis Relay
NOTICE
The Rear Diff Solenoid Relay is mounted separately,
EFI RELAY
attached to the rear portion of the main frame and can
be accessed by tilting the rear cargo box. COLOR FUNCTION
20-Amp fuse protected 12 Vdc
CHASSIS RELAY provides power to the following Red / White constant battery voltage.
systems:
Dark Green / ECU ground input to enable
• Lights (Headlights / Taillights) Yellow relay.
• Drive (AWD / TURF)
Red / White constant battery voltage.
CHASSIS RELAY Provides 12 Vdc power for EFI
Red / Dark Blue system circuits.
COLOR FUNCTION
BUSS Bar - 12 Vdc constant FAN RELAY provides power to the following system:
Red battery voltage (fusible link
protected). • Fan Motor
Brown / White Relay coil ground.
COOLING FAN RELAY
12 Vdc power input from key
Orange
switch to enable relay. COLOR FUNCTION
Provides 12 Vdc power for lights, 20-Amp circuit breaker protected
White drive and accessory circuits. Red 12 Vdc constant battery power.
ACCESSORY RELAY provides power to the following ECU ground input to enable
Orange / White
systems: relay.
BUSS Bar - 12 Vdc switched
• Accessories: 12V Receptacles & Accessory options Red / Dark Blue power from EFI relay.
Provides 12 Vdc power for fan
ACCESSORY RELAY Orange / Black
operation.
COLOR FUNCTION
FUEL PUMP RELAY provides power to the following
Orange/White B+ Accessory Fuse Out system:
Brown Ground • Fuel Pump
Orange/White B+ ACC Fuse out
Orange R/S B+ Accessory Relay FUEL PUMP RELAY
COLOR FUNCTION
EFI RELAY provides power to the following systems:
• Fuel Injectors Red / Dark Green battery voltage.
• Ignition Coil
Dark Green / ECU ground input to enable 12
• Fan Relay Yellow relay.
• Fuel Pump Relay
• Brake Pressure Switch

COLOR FUNCTION
BUSS Bar - 12 Vdc switched
Red / Dark Blue power from ECF relay.
Provides 12 Vdc power for fuel
Red / Light Blue
pump operation.
EPS RELAY (OPT) provides power to the following

system:
• Electronic Power Steering Unit
EPS RELAY (OPT)
COLOR FUNCTION
Red constant battery voltage.
Brown Relay coil ground.

12 Vdc power input from key
Orange
switch to enable relay.
Provides 12 Vdc power for EPS
Orange
operation.
REAR DIFF SOLENOID RELAY provides power to the

following system:
• Rear Differential Solenoid
REAR DIFF SOLENOID RELAY
COLOR FUNCTION
Red / Dark Green battery voltage.
Dark Green / ECU input to enable relay.
White
Brown Relay coil ground.
Relay switched power to operate
Red
the Rear Diff Solenoid.
Ground to energize the Rear Diff
Blue
Solenoid.
NOTICE
The Rear Diff Solenoid Relay is mounted separately,
attached to the rear portion of the main frame under the
rear cargo box.

CHARGING SYSTEM SERVICE

CHARGING SYSTEM OPERATION 4. Carefully remove the front fascia assembly from the
OVERVIEW vehicle to access the regulator / rectifier.
The purpose of the charging system is to keep the
battery fully charged and provide the ignition system, EFI
system and chassis electrical components with enough
electricity to power the vehicle.
The charging system consists of three main components:
1. Alternator: Uses engine rotation to generate AC

electrical current.
2. Regulator / Rectifier: Converts AC current to DC and
regulates voltage output to 13.8 volts. Located inside
the alternator assembly.
3. Battery: The battery supplies DC power to the electric
starter motor. While cranking the engine to start, the
battery supplies DC power to all vehicle electrical
systems. During times when the engine is idling and
5. If replacing the regulator / rectifier, remove the two
current drain is high, the battery will supplement the
retaining screws and disconnect the wire harness.
alternators current output and maintain a steady
Remove the regulator and heat sink plate from the
system voltage.
vehicle.
STATOR
STATOR REPLACEMENT
Refer to Stator Cover Removal / Inspection page 3.52
procedure to service the stator.
NOTICE
The stator cover can be removed with the engine
Be sure to thoroughly clean the area around the stator
cover prior to removal.
REGULATOR / RECTIFIER REPLACEMENT 6. Reverse this procedure to install the new regulator /
rectifier and heat sink plate.
NOTICE
NOTICE
The regulator / rectifier is located in front of the radiator.
If the regulator / rectifier case temperature exceeds
230° F or 110° C, the unit will turn itself off to cool down.
1. Remove the hood. The unit will turn on again after it has cooled down to at
least 212° F or 100° C. If it turns off, verify the cooling
2. Disconnect the wire harness from both headlights. fins are clean, free from debris and that adequate
3. Remove the front fascia. See Front Fascia Service airflow is present.
page 11.25
12

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:

ALTERNATOR (HVAC)
ALTERNATOR CONNECTOR PIN OUT
• The alternator contains a four pin connector.
• Click HERE to view the alternator wiring diagram.
PIN NUMBER FUNCTION

q (FR) Terminal Field Regulation
w (L) Terminal Indicator Lamp
e (S) Terminal Remote Sensing Wire
r (G) Terminal Alternator ECU Control (Duty Cycle)
12

ALTERNATOR REPLACEMENT 5. To aid with belt installation, remove the fasteners

REMOVAL holding the inner alternator cover to the engine.
Disconnect the air outlet hose and remove the cover
1. Position the vehicle on a level surface, place the from the vehicle.
2. Tilt the rear cargo box to the upright position.
the vehicle.
6. Disconnect the alternator.

7. Loosen the three alternator fasteners and remove the
alternator.
4. Cut the compressor drive belt to remove it from the

vehicle.
INSTALLATION
1. Install new alternator. Do not torque fasteners.
2. Connect alternator electrical connection.

3. Route the new belt between the alternator pulley and 6. Route the belt over the wedge of the tool and then
the engine HVAC cover to install around the turn the tool counter-clockwise using 3/8-in drive
compressor pulley. ratchet until the belt is fully seated on the pulley.
4. Re-tighten the alternator fasteners and route the belt 7. Verify the belt is properly routed around all of the
around the alternator, compressor and idler pulleys. pulleys.
8. Remove the belt installation tool from the crankshaft
drive pulley.
9. Torque the alternator fasteners to specification in the
sequence as shown.
5. Install drive belt installation tool PU-52087 onto the

crankshaft drive pulley. Ensure the pin is inserted into
one of the pulley holes.
TORQUE
Alternator Mounting Fasteners:
37 lb-ft (50 Nm)
10. Install the inner alternator cover and torque the

fasteners to specification. Reconnect the alternator
air outlet hose.
TORQUE
48 lb-in (5.4 Nm)
11. Install the outer alternator cover and torque the

12
TORQUE
48 lb-in (5.4 Nm)

CHARGING SYSTEM CHARGING SYSTEM “BREAK EVEN” TEST

TROUBLESHOOTING
CAUTION
CURRENT DRAW - KEY OFF Do not allow the battery cables to become
disconnected with the engine running. Follow the steps
CAUTION below as outlined to reduce the chance of damage to
Do not connect or disconnect the battery cable or electrical components.
ammeter with the engine running. Damage will occur to
electrical components. The “break even” point of the charging system is the
point at which the alternator overcomes all system loads
(lights, etc.) and begins to charge the battery. Depending
CAUTION on battery condition and system load, the break even
Charging system damage will occur if incompatible point may vary slightly. The battery should be fully
components are installed. Always reference Polaris charged before performing this test.
Electric Parts Catalog for proper part numbers.
CAUTION
Never start the engine with an ammeter connected in
NOTICE series. Damage to the meter or meter fuse will result.
Wait ten minutes with the key off for the ECU to power Do not run test for extended period of time.
down to avoid a faulty readout while testing amperage Do not run test with high amperage accessories.
draw.
1. Using an inductive amperage metering device, (set
Connect an ammeter in series with the negative battery to DC amps) connect to the negative battery cable.
cable. Check for current draw with the key off. If the draw
is excessive, loads should be disconnected from the 2. With engine off, and the key switch and lights in the
system one by one until the draw is eliminated. Check ON position, the ammeter should read negative
component wiring as well as the component for partial amps (battery discharge). Reverse meter lead if a
shorts to ground to eliminate the draw. positive reading is indicated.
3. Shift transmission into Park and start the engine.
With the engine running at idle, observe meter
readings.
4. Increase engine RPM while observing ammeter and
tachometer.
5. Note RPM at which the battery starts to charge
(ammeter indication is positive).
6. With lights and other electrical loads off, the “break
even” point should occur at approximately 1500 RPM
or lower.
7. With the engine running, turn the lights on and press
the brake pedal to turn the brake lights on.
8. Repeat test, observing ammeter and tachometer.
With lights on, charging should occur at or below
2000 RPM.
Current Draw - Key Off (Max):10 mA

CHARGING SYSTEM STATOR (ALTERNA- 3. Each test should measure: OL (Open Line - Infinity)
TOR) TESTS
Three tests can be performed using a multi-meter to CONNECT
OHMS
determine the condition of the stator (alternator). TEST METER
READING
LEADS TO:
OL (Open
Battery Charge Y1, Y2, or Y3 Line -
Coil to Ground Infinity)
NOTICE
Any measurement other than Infinity (open) will indicate
a failed or shorted stator leg.
TEST 3: Measure AC Voltage Output of Each

Stator Leg at Charging RPM
4. Set the selector dial to measure AC Voltage.
5. Start the engine and let it idle.
TEST 1: Resistance Value of Each Stator Leg 6. While holding the engine at a specified RPM,
1. Measure the resistance value of each of the three separately measure the voltage across each ‘leg’ of
stator legs: Y1 to Y2, Y1 to Y3, and Y2 to Y3. Each the stator by connecting the meter leads to the wires
test should measure: 0.15 Ω ± 20% leading from the alternator (Y1 to Y2, Y1 to Y3, Y2 to
Y3).
CONNECT
OHMS 7. Refer to the following table for approximate AC
TEST METER
READING Voltage readings according to RPM. Test each leg at
LEADS TO:
the specified RPM in the table.
Battery Charge Less than 1
Y1 to Y2
Coil Ω
8. Example: The alternator current output reading
Battery Charge Less than 1 should be approximately 18 VAC at 1300 RPM
Y1 to Y3
Coil Ω between each ‘leg’.
Battery Charge Less than 1 NOTICE
Y2 to Y3
Coil Ω
If one or more of the stator leg output AC voltage varies
significantly from the specified value, the stator may
NOTICE need to be replaced.
If there are any significant variations in ohm readings
between the three legs it is an indication that one of the
stator legs may be weak or failed. AC VOLTAGE (VAC)
RPM READING
READING
TEST 2: Resistance Value of Each Stator Leg to 1300 21 VAC ± 25 %

Ground 3000 49 VAC ± 25 %
2. Measure the resistance value of each of the stator
legs to ground: Y1 to Ground, Y2 to Ground, Y3 to 5000 80 VAC ± 25 %
Ground.
12

REGULATOR TESTING (900 WATT)

IMPORTANT
Before starting, engine temperature must be cool
enough to prevent fan activation. Fan activation will
cause a false reading.
1. With the engine off, disconnect the DC connectors q

on both regulators.
2. Connect a multi-meter to the battery and observe

battery voltage.
3. Start the engine and allow voltage to stabilize.
IMPORTANT
Ensure the headlights are off, and the cooling fan does
not activate.
4. Connect the DC connectors one at a time while

observing battery voltage. A properly operating
regulator will cause battery voltage to rise by a few
tenths of a volt or more.
a. If the voltage does not rise by a few tenths of a
volt, replace the suspect regulator.

STARTING SYSTEM SERVICE

STARTING SYSTEM OPERATION 5. Using a 10 mm wrench, remove the two nuts
OVERVIEW retaining the starter motor battery cable and the
engine to chassis ground cable.
Starter solenoid control is via an external relay controlled
by the ECU. The ECU uses “smart-start” technology
which operates independent of the driver turning the
ignition key. Once the ignition key is switched to the ON
position, the engine can be started. Turning the ignition
key to START signals the ECU to energize the starter
relay and start the engine. The starter is de-energized
once the engine speed reaches a set RPM.
STARTER MOTOR REMOVAL

1. Lift up the passenger seat base and disconnect the
battery.
2. Drain the coolant low enough so the coolant level is
lower than the thermostat housing. Refer to Coolant
NOTICE
3. Loosen the hose clamp and remove the coolant hose
from the thermostat cover. The negative (-) battery cable is mounted to the engine
using the upper starter mounting bolt / stud.
6. Using a ¼" ratchet and 10 mm deep well socket,

remove the upper starter mount bolt. Use an 8 mm
deep well socket to remove the lower starter mount
bolt.
4. Using an 8 mm socket, remove the two bolts that

retain the thermostat cover to the engine.
7. Pull starter motor towards the driver's side to

disengage it from the engine and remove the starter
motor out the passenger side of the vehicle.
12

STARTER MOTOR INSTALLATION STARTER SOLENOID BENCH TEST

1. Inspect and replace starter motor O-rings if needed. Test the start solenoid by powering the solenoid using
2. Lubricate the starter motor O-rings with clean engine battery voltage for a maximum of 5 seconds. With the
oil. solenoid energized at room temperature 77 °F (25 °C),
resistance should be 2.5 Ω ± 20% between terminals (A)
and (B). If resistance measurement is out of
specification, replace the starter solenoid.
3. Install the starter motor onto the engine case.

4. Hand tighten the upper starter motor bolt / stud.
5. Install the lower mounting bolt and torque to
specification.
NOTICE
Tighten the lower starter bolt first, as the bottom hole
acts as a pilot hole to properly align the starter drive
(bendix) with the flywheel. This helps prevent binding
and starter damage.
TORQUE
Starter Motor Fasteners:
7 lb-ft (10 Nm)
6. Torque upper starter mounting bolt to specification.

7. Install the negative (-) battery cable to the upper
starter mounting bolt / stud. Torque nut to
specification.
8. Install the thermostat cover and mounting bolts.
Torque the bolts to specification.
TORQUE
Thermostat Cover Bolts:
7 ft-lbs (10 Nm)
9. Install coolant hose back on the thermostat cover

and securely tighten the hose clamp.
10. Reconnect the battery.
11. Fill cooling system and proceed to Chapter 3
“Cooling System Bleeding Procedure”.

STARTER SOLENOID OPERATION

To energize the Starter Solenoid the following must
occur:
• The brake must be applied to close the brake pressure switch and provide 12V power to the key switch and ECU.
• The key switch must be turned to the “start” position to provide 12V power to the starter solenoid via the Green /
White wire.
• Once the pull-in coil is energized, the solenoid provides a current path for 12V power to reach the starter motor.
12

STARTING SYSTEM TESTING FLOW CHART

VOLTAGE DROP TEST

The Voltage Drop Test is used to test for bad
connections. When performing the test, you are testing
the amount of voltage drop through the connection. A
poor or corroded connection will appear as a high
voltage reading. Voltage shown on the meter when
testing connections should not exceed .1 VDC per
connection or component.
To perform the test, place the meter on DC volts and
place the meter leads across the connection to be tested.
Refer to the voltage drop tests in the “Starting System
Testing Flow Chart” page 12.58.
Voltage should not exceed .1 DC volts per connection
TROUBLESHOOTING
Starter Motor Does Not Run
• Battery discharged
• Loose or faulty battery cables or corroded
connections. Refer to “Voltage Drop Test” page
12.59.
• Related wiring loose, disconnected, or corroded
• Poor ground connections at battery cable, starter
motor or starter solenoid. Refer to “Voltage Drop
Test” page 12.59.
• Faulty key switch
• Faulty starter solenoid or starter motor
• Engine problem - seized or binding (can engine be
rotated easily)
Starter Motor Turns Over Slowly
• Battery discharged
• Excessive circuit resistance - poor connections. Refer
to “Voltage Drop Test” page 12.59.
• Engine problem - seized or binding (can engine be
rotated easily)
• Faulty or worn brushes in starter motor
Starter Motor Turns - Engine Does Not Rotate
• Faulty starter drive

• Faulty starter drive gears or starter motor gear
• Faulty flywheel gear or loose flywheel 12

LIGHTING SYSTEM SERVICE

HEADLAMP SWITCH
1. Disconnect the headlamp switch harness by
2. Test between the 3 sets of outputs (HIGH / LOW /
OFF). If any of the tests fail, replace headlamp switch
assembly.
• Move the switch to HIGH. There should be continuity

between switch pins 2 and 4; 7 and 8.
• Move the switch to LOW. There should be continuity
• Move the switch to OFF. There should be continuity
NOTICE
Pins 9 and 10 provide power and ground to light the
switch lamp.

HEADLIGHT ADJUSTMENT
The headlight beams are adjustable.
1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) e from a wall.
ITEM DESCRIPTION
q Measure Distance = 7.5 in (19.0 cm)
w Measure Distance = 25 ft (7.6 m)
e Headlight Center of Bulb
2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.
3. With the machine in PARK, start the engine and turn the headlight switch to the LOW position.
4. The most intense part of the LOW beam headlight beam should be aimed 7.5 in. (19.0 cm) q below the mark
placed on the wall.
NOTICE
Rider weight must be included in the seat while performing this procedure.
5. Adjust the beam to the desired position by loosening or tightening the adjustment screws and moving the lamp to
the appropriate height.
12

6. Tighten Headlight adjustment screws q to adjust the beam to desired position. Repeat the procedure to adjust the
other headlight.
WARNING
Due to the nature of light utility vehicles and where they are operated, headlight lenses become dirty. Frequently
washing is necessary to maintain lighting quality. Riding with poor lighting can result in severe injury or death.

HEADLIGHT BULB REPLACEMENT HEADLIGHT HOUSING REMOVAL

1. Remove the hood from the front cab. 1. Remove the hood from the front cab.
2. Locate the bulb on the back side of the headlight 2. Remove the front fenders. See Front Fender
housing. Service page 11.23.
3. Disconnect the harness from the bulb. Be sure to pull 3. Disconnect the harness from the bulb. Refer to
on the connector, not on the wiring. Headlight Bulb Replacement page 12.63
procedure.
4. Remove the three Torx fasteners q.
4. Turn the bulb counterclockwise and remove it from

the headlight housing.
5. Carefully push on the face of the headlight housing to
disengage the housing tabs from the front fascia
brackets.
6. Remove the headlight housing from the vehicle.
5. Install the new bulb into the housing and rotate it

clockwise 90° to lock it in place.
NOTICE
Make sure the tab on the bulb locates properly in the
housing.
6. Install the harness onto the new headlight bulb and

install the hood.
12

HEADLIGHT HOUSING INSTALLATION TAIL LIGHT SERVICE

1. Install the headlight housing by pressing the housing 1. Open the rear tailgate.
tabs back into the front fascia brackets.
2. Remove the two screws retaining the LED lamp
2. Install the three Torx fasteners q. Do not tighten. assembly.
3. Connect the harness to the bulb. 3. Remove the LED lamp from the rear cargo box and
disconnect the tail light / brake light wire harness.
4. Adjust headlights. See Headlight Adjustment page
12.61.
5. Install the front fenders. See Front Fender Service
page 11.23.
6. Install the hood.
NOTICE
Before replacing the LED lamp assembly, use a digital
multi-meter to test the harness to ensure the lamp is
receiving 12 volts and that a ground path is present.
4. Install the new LED lamp assembly by reversing this

procedure.
5. Test the tail light / brake light after installation to verify
proper function.

SWITCHES / CONTROLS SERVICE

IGNITION KEY SWITCH INTL MODELS
1. Disconnect the key switch harness by lifting the
connector lock and pulling on the connector. Do not
pull on the wiring.
2. Test between the 3 sets of outputs (OFF / ON /
START). If any of the tests fail, replace ignition switch
assembly.
• Turn the ignition key to ON. There should be continuity

between switch pins B and C.
• Turn the ignition key to START. There should be
continuity between switch pins B and C; A and D.
PIN LOCATION
P1 A
P2 B
P3 C
P4 D
12

TRANSMISSION (GEAR POSITION) SEAT BELT SWITCH

SWITCH The vehicle is equipped with a seat belt interlock switch
The transmission switch is located on the right side of the to prevent the vehicle from exceeding 15 MPH (24 KPH)
transmission. The switch can be accessed through the unless the driver seat belt is secured in the seat belt lock.
right rear wheel well opening. The switch is powered by the EFI Relay, sending a signal
to the ECU.
1. Disconnect the transmission switch harness by lifting
the connector lock and pulling on the 2-pin connector. NOTICE
Do not pull on the wiring. Tractor models are fitted with Operator Presence
2. Test transmission switch for continuity in each gear Control. If the seat belt is unbuckled and the
position and compare to the specifications below. transmission is not in Park, an audible alarm with sound
for 11 seconds. This alarm is located behind the
dashboard.
1. Disconnect the seat belt switch harness by

2. Test for continuity between the EFI Relay and the
switch.
3. Test for continuity between the switch and the ECU
pin.
4. Test for continuity across the switch.
Seat Belt Switch: Normally Open

BRAKE FLUID LEVEL SWITCH VEHICLE SPEED SENSOR

The brake fluid level switch q is located on the master
cylinder just below the MAX/MIN marks.
SPEED SENSOR LOCATION
The speed sensor q is located on the ride side of the
transmission, accessed through the right rear wheel well.
TESTING
1. Disconnect wire harness from fluid level switch.
2. Connect an ohmmeter across switch pins and check
for continuity. There should be continuity between
SPEED SENSOR TESTING
Special Tools Required:
pins if the fluid level is at or above the MINIMUM level
mark. Static Timing Light Harness (2871745)
3. Leave the meter leads connected to switch pins. Hall Sensor Probe Harness (2460761)
Using a suction gun, remove brake fluid from 1. Disconnect the 3 wire harness from the speed
reservoir chamber until it is below the MINIMUM level sensor and remove the sensor from the
mark. The meter should read OPEN CIRCUIT. transmission.
FLUID LEVEL CONTINUITY BETWEEN 2. Connect the wires from the Static Timing Light
Harness to the sensor 3 pin connector using the Hall
Proper Brake Fluid Level Continuity between pins Sensor Probe Harness (2460761).
No continuity between 3. Pass a screwdriver back and forth in front of the
Low Brake Fluid Level pins sensor tip.
REPLACEMENT
The brake fluid level switch is non-serviceable. If the
switch fails testing, replacement of the master cylinder is
required. Refer to the Brake System chapter for master
cylinder removal and installation procedures.
12

4. Be sure connections are good and 9V battery is in

good condition. If the light flashes, the sensor is
good.

REAR DIFF SOLENOID SERVICE

DIFFERENTIAL SOLENOID OVERVIEW
The differential solenoid q is located on the rear portion
of the transmission case. The solenoid actuates a shift
fork with an engagement dog, which locks and unlocks
the rear differential.
DIFFERENTIAL SOLENOID CIRCUIT

OPERATION
The Rear Diff Solenoid Relay is attached to the rear
portion of the main frame and can be accessed by tilting
the rear cargo box.
When the switch is pushed to activate “TURF”, a ground
signal is provided to the ECU from the AWD switch.
Depending on engine speed and gear position criteria, DIFFERENTIAL SOLENOID REPLACEMENT
the ECU energizes the Rear Diff Solenoid Relay allowing
it to enable the differential solenoid. 1. Disconnect the wire harness from the solenoid.
If the rear diff fails to switch from operational modes: 2. Remove the nut q holding the solenoid to the
transmission.
• Check the solenoid and relay connectors. Look for
loose wires or bad connections.
• Check for power from the relay connector, to ensure
the solenoid has power to be activated.
• Check the AWD switch wires for loose connections.
• Remove solenoid from rear differential and ensure the
solenoid plunger is actuating.
CAUTION
Do not power the solenoid with 12 Volts for more than 1
second, or damage may occur to solenoid.
12

3. To install, reverse the removal procedure. Torque the

solenoid fastener to specification.
TORQUE
Differential Solenoid Nut:
25 ft-lbs (34 N·m)

ALL WHEEL DRIVE CIRCUIT SERVICE

OPERATION OVERVIEW
• With the key on and the AWD switch “ON”, 12 VDC
power is present at the hub coil.
• When the AWD switch is “ON”, and if the criteria is
met, the Engine Controller provides a ground path
(brown/white wire). When this occurs the AWD icon
should display in the instrument cluster.
• The AWD system must be grounded to operate.
AWD / 2WD / TURF SWITCH

1. Disconnect the AWD / 2WD / TURF switch harness
by depressing the connector locks and pulling on the
2. Test between the 3 sets of outputs (AWD / 2WD /
TURF). If any of the tests fail, replace the switch
assembly.
• Move the switch to AWD. There should be continuity

• Move the switch to 2WD. There should be no
continuity between any pins.
• Move the switch to TURF. There should be continuity
NOTICE
Pins 2 and 9 provide power and ground to light the
switch lamp.
DIAGNOSING SYSTEM FAILURES

1. Verify AWD switch is functional and that a minimum
of 11 volts is present at the hub coil.
12

2. Verify AWD hub coil is functional. Test the AWD hub

coil using an ohm meter. See specifications below:
CONNECT
OHMS
TEST METER LEADS
READING
TO:
AWD Coil GY to BN/WH ~ 23 Ω
AWD Coil GY to Ground Open Line (OL)
AWD Hub Coil Resistance:23 Ω ± 5%
3. Verify the wiring harness, wiring, connectors,

connector pins and grounds are undamaged, clean
and connected properly.
4. Verify continuity of wire connections with a volt/ohm
meter.
NOTICE
Verify all wires and wiring connections have been
tested properly with a known good volt/ohm meter
before suspecting a component failure. 80% of all
electrical issues are caused by bad/failed connections
and grounds.

AMBIENT TEMPERATURE SENSOR

SERVICE
AMBIENT TEMPERATURE SENSOR LOCATION
The ambient temperature sensor is located under the hood and is routed through the wiring harness grommet.
AMBIENT TEMPERATURE SENSOR TESTING

Operating Range -40° - 185° F (-40° - 85° C)
Resistance Value 30k Ω - 3450k Ω
12

NOTES

FACTORY-INSTALLED OPTIONS
CHAPTER 13
13
FACTORY-INSTALLED OPTIONS OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.3
ROOF / HEADLINER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.4
ROOF SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.4
ROOF SERVICE (CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.6
HEADLINER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.9
HEADLINER SERVICE (CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.11
WINDSHIELD / REAR PANEL SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.16
WINDSHIELD SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.16
TIP-OUT WINDSHIELD SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.17
TIP-OUT WINDSHIELD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.18
REAR PANEL REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.19
DOOR / WINDOW SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.20
FULL-SIZE POLY DOOR ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.20
DOOR REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.21
DOOR REMOVAL / INSTALLATION - HIGH LIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.21
STANDARD DOOR PANEL SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.22
PREMIUM DOOR PANEL SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.24
DOOR LATCH SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.27
DOOR LATCH SERVICE - HIGH LIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.27
WINDOW REGULATOR / DOOR GLASS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.29
SIDE MIRROR SERVICE (INTL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.32
WINCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.33
WINCH ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.33
WINCH CABLE ROUTING / RETENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.34
WINCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.36
WINCH SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.38
RIDE COMMAND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.39
RIDE COMMAND OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.39
RIDE COMMAND MONITOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.39
RIDE COMMAND PINOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.41
PLOW MODE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.44
PLOW MODE SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.44
PLOW MODE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.44
FRONT CAMERA SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.45
REAR CAMERA SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.47
GPS ANTENNA SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.50
RIDE COMMAND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.52
AUDIO SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.54
DOOR SPEAKER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.54
FRONT AUDIO BAR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.55
FRONT SPEAKER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.57

REAR SPEAKER SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.58

AUDIO AMPLIFIER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.59
SUBWOOFER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.60
SUBWOOFER AMPLIFIER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.62
SUBWOOFER HARNESS ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.63
OPTIONAL ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.64
FACTORY CHOICE HARNESS ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.64
REAR PULSE™ BUSBAR HARNESS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.68
ADDITIONAL HARNESS ROUTING – 3 SEAT MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.71
ADDITIONAL HARNESS ROUTING — CREW MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.73
PREMIUM DOOR HARNESS ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.75
PREMIUM DOOR HARNESS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.76
PREMIUM DOOR HARNESS REPLACEMENT (CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.78

OVERVIEW
The processes included in this chapter depict features
and options that may come equipped as part of a
standard model package and/or a factory-installed
package. These features or options may cause standard
service procedures to vary depending on what options 13
are installed on the vehicle being serviced.
Always inspect the vehicle to ensure there are not
additional accessories, such as electrical components,
that would need to be removed to allow the vehicle to be
safely serviced.
NOTICE
For any installed accessories that are not covered as
an option in this chapter, refer to accessory kit
instructions for accessory removal and installation.
Standard options found on base models (such as EPS)

may be found in the other chapters in this service
manual. If you cannot find a particular service topic,
please reference the INDEX prior to submitting feedback
to Polaris.

ROOF / HEADLINER SERVICE

ROOF SERVICE 3. Disengage the rear roof retainers e from the rear
PRELIMINARY STEPS ROPS assembly.
1. If equipped, remove the headliner. Refer to Headliner

Service page 13.9.
2. If equipped, remove any electrical harnesses
attached to the roof.
REMOVAL
1. Remove the four T40 Torx fasteners q securing the
rear roof panel.
4. Move the roof towards the front of the vehicle to

disengage the front retainers r from the windshield
plate.
2. Remove the two T27 Torx fasteners w retaining the

front of the roof panel.
5. With the aid of an assistant, lift the roof straight up to

remove.

INSTALLATION 4. Install the roof on the vehicle.

1. If necessary, install the front windshield sealing tape
on the edge of the visor and against the A-pillars as
shown.
13
5. Engage the front retainers r of the roof in the

windshield plate frame.
2. If necessary, install the front and side roof seals q &

w.
6. Engage the rear roof retainers t into the rear ROPS.
3. If necessary, install the rear roof seal e, and align

with mounting holes.

7. Install the two front roof fasteners, washers, and ROOF SERVICE (CREW)
spacers y. Torque to specification. PRELIMINARY STEPS
1. If equipped, remove the headliner. Refer to Headliner
Service (CREW) page 13.11 or Headliner Service -
MB QUART® Audio (CREW) page .
2. If equipped, remove any electrical harnesses
attached to the roof. Refer to Factory Choice Harness
Routing — Crew Models page .
REMOVAL
1. Remove the four rear roof fasteners.
TORQUE
Roof Fasteners:
42 in-lbs (5 Nm)
8. Install the four rear roof fasteners u and torque to

specification.
2. Remove the two T27 Torx fasteners w retaining the

front of the roof panel.
TORQUE
Roof Fasteners:
42 in-lbs (5 Nm)
9. If equipped, install the headliner. Refer to Headliner

Service page 13.9.
10. If equipped, install the audio unit..
11. If equipped, install any electrical harnesses attached
to the roof.

3. Remove the eight T25 Torx fasteners e securing the 6. Lift the rear of the rear roof assembly and slide
front and rear roof. forward to remove the rear roof.
13
4. Disengage the front retainers r securing the roof to INSTALLATION

the windshield plate frame.
1. If necessary, install the front windshield sealing tape
on the edge of the visor and against the A-pillars as
shown.
5. Remove the front roof assembly.
2. If necessary, install the front and side roof seals q &

w.

3. If necessary, install the rear roof seal e, and align 6. Engage the rear roof retainers t into the rear ROPS.
with mounting holes.
7. Install the front roof assembly.

4. Install the rear roof on the vehicle.
8. Engage the front retainers y of the roof in the

5. Engage the front retainers r on the center ROPS. windshield plate frame.

9. Install the eight T25 Torx fasteners u to secure the 11. Install the four rear roof fasteners o and torque to
front and rear roof. Torque to specification. specification.
13
TORQUE TORQUE
T25 Roof Fasteners: Roof Fasteners:
10. Install the two front roof fasteners i. Torque to

specification.
HEADLINER SERVICE
REMOVAL
1. Remove the two rear push rivets.
TORQUE
Roof Fasteners:
42 in-lbs (5 Nm)

2. Remove the five push rivets securing both headliners 5. Remove the front headliner.
to the windshield plate.
3. Remove the rear headliner.

NOTICE
If equipped, removing the dome light may ease removal
of the headliner. This can also prevent damage to the
headliner and dome light.
4. Remove the two T30 fasteners from the front

headliner.

INSTALLATION 4. Install the five push rivets to secure both headliners to

the windshield plate.
1. Install the front headliner and tuck behind the ROPS
on both sides.
13
5. Install the two rear push rivets.

2. Install the two T30 fasteners from the front headliner.
HEADLINER SERVICE (CREW)

TORQUE
REMOVAL
24 in-lbs (3 N·m)
1. Remove the two rear push rivets securing the
headliner to the rear ROPS.
3. Install the rear headliner and tuck behind the ROPS
on both sides.

2. Remove the two T25 fasteners and washers retaining 5. Remove the rear headliner.
the center of the headliner to the roof.
6. Remove the five push rivets securing both front

3. Remove the four T40 Torx fasteners securing the rear headliners to the windshield plate.
headliner to the roof.
7. Remove the center headliner from the vehicle.

4. Remove the three fasteners retaining the front of the
rear headliner to the roof. NOTICE
If equipped, removing the dome light may ease removal
of the headliner. This can also prevent damage to the
headliner and dome light.

8. Remove the two T30 fasteners from the front INSTALLATION

headliner.
1. Install the front headliner and tuck behind the ROPS
on both sides.
13
9. Lower the front headliner.

2. Loosely install the two T30 fasteners from the front
headliner.
3. Install the five push rivets to secure both headliners to

the windshield plate.

4. Torque the T30 fasteners in the front headliner. 7. Install the two rear push rivets.
TORQUE
24 in-lbs (3 N·m)
5. Install the rear headliner and tuck behind the ROPS

on both sides.
NOTICE
The rear headliner wraps over the center ROPS cross
bar and center headliner will be under the rear
headliner.
8. Loosely install the four T40 Torx fasteners securing

the rear headliner to the roof.
6. Loosely install the two T25 fasteners and washers

retaining the center of the headliner to the roof.
9. Install the three fasteners retaining the front of the

rear headliner to the roof. Torque to specification.
TORQUE
Rear Headliner Fasteners:
42 in-lbs (5 Nm)

10. Torque the four T40 Torx fasteners securing the rear
headliner to the roof.
TORQUE
T40 Rear Headliner Fasteners:
42 in-lbs (5 Nm)
13
11. Torque the two T25 fasteners and washers retaining
the center of the headliner to the roof.
TORQUE
T25 Rear Headliner Fasteners:
24 in-lbs (3 N·m)

WINDSHIELD / REAR PANEL SERVICE

WINDSHIELD SERVICE 4. With the aid of an assistant, remove the windshield
REMOVAL and set aside.
1. Remove the four T20 Torx fasteners q securing the INSTALLATION

wiper motor trim panel to the windshield. 1. With the aid of an assistant, install the windshield.
2. Rotate the lock-and-ride connections e to secure the
windshield to the ROPS.
2. Disconnect the wiper motor connectors w and set the

trim panel with rear view mirror aside.
3. Connect the wiper motor connectors w, and install
the trim panel with rear view mirror.
3. Release the lock-and-ride connections e securing

the windshield to the ROPS.

4. Install the four T20 Torx fasteners q to secure the 2. Remove the four fasteners q securing the windshield
wiper motor trim panel to the windshield. Torque to to the windshield plate.
specification.
13
3. With the aid of an assistant, remove the windshield

TORQUE from the vehicle.
Windshield Wiper Motor Trim: INSTALLATION
1. With the aid of an assistant, install the windshield on
the vehicle.
2. Install the four fasteners q securing the windshield to
TIP-OUT WINDSHIELD SERVICE the windshield plate. Do not torque.
REMOVAL
1. Rotate the windshield lever on the dash to release the
windshield.
3. Perform windshield adjustment. Refer to Tip-out

Windshield Adjustment page 13.18.

TIP-OUT WINDSHIELD ADJUSTMENT 4. With the aid of an assistant, pivot the windshield on
the top hinges until all four sides are evenly aligned
1. Rotate the windshield level counter-clockwise to
with the ROPS and the lower dash panel.
release the windshield.
2. Loosen the four T40 Torx fasteners q securing the 5. Torque the four hinge fasteners q to specification.
windshield to the windshield plate.
NOTICE
Do not remove screws.
TORQUE
Tip-out Windshield Hinge Fasteners:
17 ft-lbs (23 Nm)
3. Align the windshield seal with the notch in the center 6. Rotate the windshield clockwise to secure to the
of the upper dash panel. vehicle.

REAR PANEL REMOVAL /

INSTALLATION
NOTICE
Two people should work together to remove and install
the rear panel windshield.
13
1. Rotate the LOCK & RIDE handles counterclockwise
into the unlocked position
2. Rotate the top of the rear window slightly away from

the vehicle, then lift the windshield up and away from
the vehicle.
NOTICE
Store windshield in an upright position in a location
where it will not be bumped into and where it will not be
subject to things falling on it. Polaris recommends that
the lower frame of the glass be set onto a wood or other
semi-soft support structure to prevent unexpected
movement and potential breakage of the window during
storage.
3. Reverse the removal procedure for installation. Turn

the LOCK & RIDE handles clockwise to the locked
position to secure the windshield.

DOOR / WINDOW SERVICE

FULL-SIZE POLY DOOR ASSEMBLY VIEW
q HINGE, UPPER-LH NA
w HINGE, UPPER-RH NA
e HINGE, LOWER-LF NA
r HINGE, LOWER-RH NA
t STRIKER NA
y DOOR ASSEMBLY-LH NA
u DOOR ASSEMBLY-RH NA
i DOOR RETAINER SPAER NA
o WASHER NA
a STRIKER HARDWARE 17 ft-lbs (23 Nm)
s DOOR RETAINER FASTENER 6 lb-ft (8 Nm)
d DOOR RETAINER NUT 6 lb-ft (8 Nm)

DOOR REMOVAL / INSTALLATION 2. Lift the door straight up off the lower hinge.
1. Open the door and lift straight off the hinge.
13
INSTALLATION
2. Reinstall by gently installing the door over both 1. Reinstall the door on the lower hinge.
hinges. Ensure proper door alignment.
DOOR REMOVAL / INSTALLATION -

HIGH LIFTER
REMOVAL
1. Remove the top hinge bolts of the door.
2. Install the top hinge bolts and torque to specification.
TORQUE
Door Hinge Fasteners:
17 ft-lbs (23 Nm)

STANDARD DOOR PANEL SERVICE 5. Remove the door seal t.

REMOVAL
1. Remove the fasteners q securing the door handle to
the door assembly and remove the door handle.
6. Remove the nine push rivets y retaining the door

panels to the door assembly.
2. Remove the u-clip securing the crank handle w, and

remove the crank handle.
7. Pull the upper trim panel u out and lift straight up to

remove from the vehicle.
3. Remove the fastener e securing the door panel trim

to the door assembly.
4. Gently pry the retainers r away from the door panel
to remove.

8. Lift the lower trim panel i straight up and over the 3. Install the nine push rivets y to secure the door
door handle to remove from the vehicle. panels to the door assembly.
13
INSTALLATION 4. Install the door seal t.

1. Install the lower trim panel i straight down over the
door handle to install in the vehicle.
5. install the door trim panel and engage the retainers

r. Install and torque the fastener e to specification.
2. Install the upper trim panel u and push into the door
to engage the retainers.
TORQUE
Door Panel Trim Fastener:
42 in-lbs (5 Nm)

6. Install the crank handle and u-clip to secure the crank PREMIUM DOOR PANEL SERVICE
handle w to the door. REMOVAL
1. Remove the fasteners q securing the door handle to
the door assembly and remove the door handle.
7. Install the door handle and fasteners q to secure the

door handle to the door assembly. Torque to
specification.
2. Remove the fastener w securing the door panel trim
to the door assembly.
3. Gently pry the retainers e away from the door panel
to gain access to the window switches.
TORQUE
Door Handle Fastener:
42 in-lbs (5 Nm)
4. Disconnect the window switch connectors r.

5. Remove the door seal t. 8. Lift the lower trim panel i straight up and over the
door handle to remove from the vehicle.
13
6. Remove the nine push rivets y retaining the door

panels to the door assembly. INSTALLATION
1. Install the lower trim panel i straight down over the
door handle to install in the vehicle.
7. Pull the upper trim panel u out and lift straight up to

remove from the vehicle.
2. Install the upper trim panel u and push into the door
to engage the retainers.

3. Install the nine push rivets y to secure the door 7. Install the fastener w to secure the door panel trim to
panels to the door assembly. the door assembly. Torque the fastener to
specification.
4. Install the door seal t.

TORQUE
Door Panel Trim Fastener:
42 in-lbs (5 Nm)
8. Install the door handle and fasteners q to secure the

door handle to the door assembly. Torque to
specification.
5. Install the door panel trim and connect the window

switch connectors r.
TORQUE
Door Handle Fastener:
42 in-lbs (5 Nm)
6. Engage the retainers e in the door panel to secure

the panel trim.

DOOR LATCH SERVICE DOOR LATCH SERVICE - HIGH LIFTER

REMOVAL REMOVAL
1. Remove the door panel. 1. Remove both door seals.
2. Remove the four fasteners q securing the door latch
w and remove the door latch.
13
2. Remove the two fasteners retaining the lower door

panel bracket trim. Remove the lower door panel
bracket trim.
INSTALLATION
1. Install the door latch w and four fasteners q to
secure the latch. Torque to specification.
3. Remove fastener retaining door panel above door

latch q.
TORQUE
Door Latch Fasteners
8 ft-lbs (11 Nm)
2. Install the door panel.

4. Remove door panel fasteners w and handle 2. Install door panel r. Install door handle fasteners e
fasteners e. Remove door panel r. and door panel fasteners w. Torque to specification.
5. Remove the four fasteners retaining the door latch t, TORQUE

and remove the door latch.
Door Handle Fasteners:
42 in-lbs (5 Nm)
TORQUE
Door Panel Fasteners:
42 in-lbs (5 Nm)
3. Install door panel fastener above door latch q.

INSTALLATION
1. Install the door latch and four retaining fasteners t.
TORQUE
Door Panel Fastener:
42 in-lbs (5 Nm)
TORQUE
Door Latch Fasteners:
8 ft-lbs (11 Nm)

4. Install the lower door panel bracket trim and the two WINDOW REGULATOR / DOOR GLASS
retaining fasteners. Torque to specification. SERVICE
REMOVAL
1. Remove the door panels.
2. Remove the three window motor fasteners q and
window regulator fastener w.
13
TORQUE
Lower Door Panel Bracket Trim:
6 ft-lbs (8 Nm)
5. Reinstall the door seals. Ensure seals are fully

3. Disconnect the speaker and window harness from the
seated.
regulator support.
4. Remove the five fasteners e securing the upper

regulator support bracket, and remove the bracket.

5. Remove the lower regulator fastener r. INSTALLATION

1. Install the glass in the window regulator and tighten
the fasteners.
6. Lift the regulator and rotate clockwise to allow the

regulator to be remove from the door.
TORQUE
Window Glass Fasteners:
2. Angle the window regulator clockwise to install in the

window tracks.
3. Rotate the regulator assembly counter-clockwise
while installing straight down and align with mounting
holes.
7. Loosen the fasteners securing the glass to the

regulator to service the glass or regulator.

4. Install the lower regulator fastener r. 6. Reconnect the speaker and window harness from the
regulator support.
13
TORQUE
7. Install the three window motor fasteners q and
Window Regulator Fastener:
window regulator fastener w. Torque to specification.
8 ft-lbs (11 Nm)
5. Install the upper regulator support bracket and five

fasteners e to secure the bracket. Torque the
TORQUE
Window Regulator Fastener:
8 ft-lbs (11 Nm)
TORQUE TORQUE
Window Regulator Support Fastener: Window Motor Fastener:
6 ft-lbs (8 Nm) Torque until fully seated
8. Install the door panels.

SIDE MIRROR SERVICE (INTL)

1. Remove the protective cover.
2. Remove the two front ROPS fasteners q and r
securing the mirror assembly w and spacers e to the
vehicle and remove the mirror.
TORQUE
Mirror Fasteners:
36 ft-lbs (54 N·m)

WINCH SERVICE
WINCH ASSEMBLY VIEW
13
q Hook i Mounting Nut, Hex Flange, Locking - M10 X 1.5
w Magnetic Stop o Mounting Screw, Hex Flange - M10 X 1.5 X 25
e Screw, Socket Cap - M10 X 1.5 X 25 a Winch Assembly
r Autostop Fairlead s Wireless Receiver
t Roller Fairlead d Wireless Remote holder
y Fairlead Backer Plate f Wireless Remote
u Mounting Screw, Hex Flange - M10 X 1.5 X 20

WINCH CABLE ROUTING / RETENTION

ELECTRICAL CABLE ROUTING OVERVIEW

WINCH CABLE SERVICE 3. Route the two winch cables behind the winch bracket
and attach the power cable e and ground cable r to
1. Route the two winch cables from pulse bar and
the winch contactor.
ground stud through the attachment clip q and
through the underhood closeoff panel. NOTE
When removing or installing the cables to the contactor,
note the location of the power and ground cables. If the
cables are not installed in the correct location the winch
13
will not function properly.
2. Pass the two winch cables through closeoff panel and

through the remaining attachment clipsw behind the
grille.

WINCH REPLACEMENT 7. Remove (4) fasteners y securing the mounting plate

REMOVAL to the chassis. Remove the plate and winch assembly
from the vehicle.
1. Disconnect Battery.
2. Remove the Winch Hook q and Magnetic Stop w.
8. If winch replacement or service is required, remove

the (4) fasteners u retaining the winch to the
mounting plate.
3. Disconnect the Auto Stop Fairlead connector e.
4. Remove wiring harness retained to the front bumper

INSTALLATION
and remove the front bumper. 1. If the winch was removed from the mounting plate
install the (4) winch to mounting plate fasteners.
5. Disconnect the contactor electrical connectors.
6. Disconnect the power cable r and ground cable t.

2. Install (4) fasteners w securing the mounting plate to 6. Install the Winch Hook y and Magnetic Stop u.
the chassis.
13
7. Connect Battery.
3. Connect the power cable e and ground cable r.
4. Connect the contactor electrical connectors.

5. Connect the Auto Stop Fairlead connector t.

WINCH SWITCH TESTING

1. Disconnect the winch switch harness on the back
side of the center console by depressing the
connector locks and pulling on the connector. Do not
pull on the wiring.
PIN CONTINUITY
SWITCH POSITION CONTINUITY BETWEEN

Out Pins 2 and 3 2. Test between the 3 sets of outputs (ON / OFF / ON). If
any of the tests fail, replace winch switch assembly.
NO continuity between • Move the switch to Position 1, ON. There should be
Off pins 2 and 3; 1 and 2 continuity (< 1 Ω) between switch pins 2 and 3.
In Pins 1 and 2 • Move the switch to Position 2, OFF. There should
be NO continuity (∞ - OL) between switch pins 2
and 3; 1 and 2.
SWITCH FUNCTION
• Move the switch to Position 3, ON. There should be
PIN FUNCTION continuity (< 1 Ω) between switch pins 1 and 2.
1 Winch Switch In
Switched B+, Winch
2
Switch
3 Winch Switch Out
4 —
5 —
6 —
7 Ground, Winch Switch
Key Switch B+, Winch
8 Switch Light
9 Ground, Winch Switch
Key Switch B+, Winch
10 Switch Light

RIDE COMMAND SERVICE

RIDE COMMAND OVERVIEW 3. Disconnect the electrical connectors on the back of
the monitor and remove the monitor.
NOTICE
Reference the owners manual for ride command
description and operation.
13
RIDE COMMAND MONITOR SERVICE
REMOVAL
1. Remove the four T-40 Torx fasteners q and two push
rivets w retaining the back panel of the ride
command monitor.
INSTALLATION
1. Install the monitor and connect all electrical
connectors.
2. Remove the three fasteners e retaining the mounting

bracket r to the monitor. Remove the mounting
bracket.

2. Install the mounting bracket q and three mounting

fasteners w. Torque to specification.
TORQUE
Ride Command Monitor Mounting Bracket Fasteners:
12 in-lbs (1.3 Nm)
3. Install the rear panel on the ride command monitor.

4. Install the two push rivets e.
5. Install the four T-40 Torx fasteners r and torque to
specification.
TORQUE
Rear Ride Command Monitor Panel Fasteners:
42 in-lbs (5 Nm)

RIDE COMMAND PINOUT

CONNECTOR OVERVIEW
13

C1 CONNECTOR
PIN DESCRIPTION PIN DESCRIPTION
q LINEOUT 2 REAR RIGHT NEGATIVE k LINEOUT 1 FRONT RIGHT POSITIVE
w LINEOUT 2 REAR RIGHT POSITIVE l LONGOUT 2 FRONT RIGHT NEGATIVE
e LINEOUT 2 SHIELD 1( LINEOUT 1 SHIELD
r LINEOUT 2 REAR LEFT NEGATIVE 2) LINEOUT 1 FRONT LEFT NEGATIVE
t LINEOUT 2 REAR LEFT POSITIVE 2! LINEOUT 1 FRONT LEFT POSITIVE
y ANALOG IN 3 (RIGHT TURN) 2@ VIDEO 1 IN NEGATIVE
u ANALOG IN 2 (LEFT TURN) 2# VIDEO 1 IN POSITIVE
i ANALOG IN 1 AMBIENT TEMPERATURE SENSOR 2$ VIDEO 1 SHIELD
REMOVE 4 ORV: PLOW MODE, WINCH IN CONTROL REMOVE 2 ORV: PLOW MODE WINCH UP/HOME
o 150 mA LOW SIDE DRIVE 2% INPUT SIGNAL
REMOVE 3 ORV: PLOW MODE WINCH OUT CONTROL REMOVE 1 (HIGH BEAM AC/DC CAPABLE INPUT)
a 150mA LOW SIDE DRIVE 2^
s USB1 SHIELD 2& USB1 POSITIVE
d USB1 GROUND 2* USB1 NEGATIVE
f USB1 VBUS 2( CAN1 HIGH
g MODE IN 3) CAN1 LOW
h AMP TURN ON 3! IGNITION
j GROUND 3@ BATTERY

C2 CONNECTOR
13
PIN DESCRIPTION PIN DESCRIPTION
q CAN2 LOW o VIDEO 3 IN NEGATIVE
w CAN2 HIGH a VIDEO 3 IN POSITIVE
e LINEOUT 3 POSITIVE s VIDEO 2 IN NEGATIVE
r LINEOUT 3 NEGATIVE d VIDEO 2 IN POSITIVE
t LINEOUT 3 SHIELD f LINE IN LEFT RETURN
y LINEOUT 3 g LINE IN LEFT
u LINEOUT 3 h LINE IN RIGHT
AMP TURN ON SUB FRONT / REAR SWITCHED

i CAMERA POWER VBATT @ 300 mA j LINE IN RIGHT RETURN
USB CONNECTOR
PIN DESCRIPTION
q GROUND - RETURN
w +5 VBUS - 2.1A
e D+
r D-
t GROUND SHIELD
y (VBUS REMOVE SENSOR) - N/C

PLOW MODE OVERVIEW PLOW MODE SERVICE

OVERVIEW PLOW MODE TESTING
Plow Mode is an automated plow control system based 1. Ensure Plow Mode is Enabled.
on vehicle gear position. This can also be overridden and
used as a manual function where the rider can use the 2. Perform a visual inspection. Inspect all electrical
display to raise and lower the plow with the touch components.
screen. The user must touch and slide the up or down 3. Ensure that the winch is operating properly when
arrow buttons to initiate the winch operation to raise or plow mode is not active.
lower the plow.
4. Check for fault codes through the Ride Command
NOTICE Screen or Digital Wrench®.
Plow Mode is ONLY available for use with RANGER XP Plow mode will set fault codes within the Ride Command
1000 vehicles that have a factory installed Ride Unit. These faults can be viewed from the unit, by going
Command System with a winch equipped with auto into the vehicle settings, and vehicle fault codes or can
stop winch fairlead as part of the factory wiring harness. be viewed using Digital Wrench®.
Digital Wrench® can be used to monitor plow functions
AUTO OPERATION while the plow mode is being used. The following PID’s
Once Plow Mode is enabled and the Auto feature is will be shown :
turned on the plow is lowered in “L” gear shift and raised
• Plow Mode Auto Stop Status- Home/Not Home
in “R” gear shift.
• Plow Mode Winch In Commanded State - Active/Not
MANUAL OPERATION Active
When the Manual control is active from the Plow Mode
screen the plow can be raised and lowered by pressing • Plow Mode Winch Out Commanded State - Active/Not
and holding the raise or lower arrow and sliding it to the Active
left. • Plow Mode Down State - Plow Down/Plow Not Down
BACK-DRAG MODE • Plow Mode Active State - Not Active (Manual Mode),
This function also features a Backdrag mode that Active Normal Mode (Auto Mode), Active Back Drag
reverses the system operation. This allows a rider to Mode
drive up to a building or object, shift to reverse and drop • Plow Mode Winch In Relay Coil Voltage (volts)
the plow to pull snow away from it. Shifting to “L” will
then raise the plow. Back Drag Mode will not take affect • Plow Mode Winch Out Relay Coil Voltage (volts)
unless the vehicle is in Low or Reverse.
• Plow Mode Autostop Signal Analog Voltage (volts)
If a fault code is set during use this can be reset by a

PLOW MODE SETUP power off cycle, or a complete power down cycle.
ENABLING PLOW MODE
• Minor Fault Codes — Reset by turning the key off and
1. On the display, go to “Settings”, “Vehicle”, and then back on.
select “Plow Installed”.
• Critical Fault Codes — Reset by powering the machine
2. Move the toggle switch from “No” to “Yes”. down for 6 seconds and cycling back on. If the fault still
Once Plow Mode is enabled, the Auto Plow Mode exists the power button on the screen can be held for 5
lowering time can be adjusted. This should not require seconds and powering down the Ride Command unit.
adjustment and will default to 2.0 seconds.
These codes will also be stored as a historic code in
digital wrench.

FRONT CAMERA SERVICE 4. Remove the (2) push rivet fasteners r attaching the
inner close-off panel to the front fascia.
NOTICE
Front and rear cameras are similar in appearance
except that REAR camera has ring of LED lamps, front
camera does not.
13
REMOVAL
1. Remove the hood.
2. Remove the (2) upper radiator racket to chassis
fasteners q and (2) grille to radiator bracket torx
fasteners w.
5. The inner close-off panel can then be opened to gain

access to the front camera and connector.
3. Remove the (2) upper radiator mount bracketse.
6. Disconnect the camera electrical connector.

7. Depress four tabs on front camera mount to free it INSTALLATION

from the grille. Carefully pull the front camera mount /
1. If removed, route wiring on front camera e through
camera forward while routing the wiring attached to
front camera mount t. Orient spline on camera with
front camera through the grille.
slot in mount, then insert camera into mount until
locking clips snap into place.
NOTICE
Pay close attention to the placement of the front 2. Route wiring attached to front camera rearward
camera and camera mount so that the camera is through grille, then carefully push front camera mount
installed in the same orientation it is removed. into grille until all four tabs lock in place. Ensure the
following:
8. Remove the edge clip securing the harness to grille • Camera mount is positioned as high as possible on
and remove the camera and front camera mount. grille with camera pointing DOWNWARD
9. If required, remove the front camera from the front • Camera wiring is not pinched or kinked as it passes
camera mount. through grille
3. Connect the camera electrical connector.

4. Install the (2) push rivet fasteners r attaching the REAR CAMERA SERVICE
inner close-off panel to the front fascia.
NOTICE
Front and rear cameras are similar in appearance
except that REAR camera has ring of LED lamps, front
camera does not.
13
REMOVAL
1. Remove the two edge clips q securing the main
harness.
5. Install the (2) upper radiator mount bracketse.
2. Remove the edge clip w securing the camera

harness / connector.
3. Disconnect main chassis connector e from rear
camera connector r.
6. Install the (2) upper radiator racket to chassis

fasteners q and (2) grille to radiator bracket torx
fasteners w.
NOTICE
The location of the rear camera connector r may vary
based on build date. This image is for reference only.

4. Remove the fasteners t and washers y that secure 2. Install rear camera bracket u to lower rear surface of
the rear camera bracket u and remove the bracket/ vehicle bed using two fasteners t and washers y.
camera. Do not overtighten screws.
5. If required, remove the rear camera from the rear 3. Join main chassis connector e to rear camera
camera bracket. connectorr.
INSTALLATION NOTICE
1. If removed, route wiring on rear camera through rear The location of the rear camera connector r may vary
camera bracket. Orient spline on camera with slot in based on build date. This image is for reference only.
bracket, then insert camera into bracket until locking
clips snap into place.
4. Secure harnesses using edge clips to prevent contact
with hot components, sharp edges, or moving parts
(including bed throughout its full range of travel).
• Main chassis harness using pre-installed edge clip
q and additional edge clip q
• Camera using edge clip w

NOTICE
Inset view looking up at camera bracket.
13

GPS ANTENNA SERVICE 6. Carefully pull the harness forward through firewall
REMOVAL grommet.
1. Remove hood.
2. If windshield is installed, then open or remove it as
required to gain access to upper dash.
3. Remove push rivets q and the Ride Command®
Display and Bezel.
7. Cut cable tie w securing the GPS harness wiring to

the under-hood liner.
8. Carefully peel the GPS antenna e from the under-
hood liner.
NOTICE
The antenna is secured to the under-hood liner with
4. Disconnect the GPS antenna connector from the
adhesive.
Ride Command® display.
INSTALLATION
1. Route connector on GPS antenna rearward through
firewall grommet.
5. Cut cable tie securing excess harness length in upper

dash compartment.

2. Route antenna q to mounting location on under-

hood liner.
13
NOTICE
Ensure harness is routed to prevent contact with hot
components, sharp edges, or moving parts.
3. Clean upper surface of under-hood liner to permit

proper adhesive application. If installing new GPS
antenna, peel backing from antenna and press firmly
in place. If installing the existing GPS antenna, apply
commercially available double sided adhesive tape
and press firmly in place.
4. Install new cable tie retainers w in locations where
ties were previously cut.
5. Use cable tie to coil and secure excess harness
length in upper dash compartment.
6. Install push rivets e and the Ride Command®
Display and Bezel.

RIDE COMMAND TROUBLESHOOTING

Problem: Black Screen / Will Not Power On
STEP ACTION YES NO

Power cycle by switching ignition on and off with main power switch.
1 Did you find and repair the condition? Go to Step 8 Go to Step 2
Check the 5amp fuse labeled INST in the main fuse box.
2 Refer to Fuse Box page . Go to Step 9 Go to Step 3
Is the fuse blown?
Reinstall INST fuse and test screen for proper operation.
3 Did you find and repair the condition? Go to Step 8 Go to Step 4
1. Turn ignition on
2. Check for battery voltage on pin 16 (Ground), 31 (Switched Power)
4 and 32 (Battery Power) of display connector. Go to Step 8 Go to Step 5
Is there Battery Voltage at all pins?
Refer to the wiring schematic and check circuits without voltage for Go to Step 1
5 continuity and proper operation. Go to Step 7 and repeat
Did you find any problems in the circuit? diagnosis
Replace display with known good display. Go to Step 1

6 Did you find and repair the condition? Go to Step 8 and repeat
diagnosis
Repair, replace and check all affected power/ground circuits. Go to Step 1
7 Check for battery voltage at pin 16, 31 and 32. Go to Step 8 and repeat
Is there battery voltage at pin 16, 31 and 32? diagnosis
Update display with newest software available. Confirm

Refer to Update Software / Maps page for instructions on how to display
8 update/reflash software. operation and
Go to Step 6
Is display working properly? continue use.
1. Test circuit for continuity and/or shorts in wiring.
9 2. Fix any shorts in the wiring and reinstall new fuse. Go to Step 8 Go to Step 4
Did you find and repair the condition?

Problem: Screen missing pixels, LCD screen flaw, software glitch or problem
STEP ACTION YES NO

Power cycle bike by switching ignition on and off with main power
1 switch in fairing. Go to Step 2 Go to Step 2
Did you find and repair the condition? 13
Update display with newest software available. Confirm
Refer to Update Software / Maps page for instructions on how to display
2 update/reflash software. operation and
Go to Step 3
Is display working properly? continue use.
1. Remove and reinstall the 5amp fuse labeled INST in the main fuse
box under the left side upper panel.
3 Refer to Fuse Box page Go to Step 2 Go to Step 4
Did you find and repair the condition?
Replace display with known good display. Repeat

4 Did you find and repair the condition? Go to Step 2
Diagnosis
GPS Antenna Troubleshooting

1. Unplug connector from GPS antenna and verify all contacts are securely seated in the connector.
2. Turn ignition on and make the following measurements on the antenna connector:
WIRING CONNECTION TO MEASURE VOLTAGE SPECIFICATION

Power Between Pins 4 and 3 12Vdc (Battery Voltage)
3. If antenna connector has 0Vdc supplied, check harness for loose connection or breaks in wiring. Check for power
at SW PWR fuse in fuse box.
4. If antenna connector shows proper voltage, check operation of GPS. If GPS still is not functioning, proceed to step
5.
5. Turn the ignition off and make the following measurements on the antenna connector:
6.
WIRING CONNECTION TO MEASURE RESISTANCE SPECIFICATION
CAN Between Pins 1 and 2 60 Ohms
7. If resistance value is out of spec, check for breaks in yellow/green CAN wiring.
8. If all values are within specification, replace GPS antenna with new unit.

AUDIO SYSTEM SERVICE

DOOR SPEAKER SERVICE INSTALLATION
REMOVAL 1. Connect the connectors to the speaker.
1. Remove the four fasteners q securing the speaker
cover w to the door panel.
2. Install the speaker assembly in the door and install

the four fasteners e to secure the speaker to the
2. Remove the four fasteners e securing the speaker to door. Torque the fasteners to specifications.
the door and remove the speaker.
TORQUE
3. Disconnect the connectors from the speaker. Door Speaker Fasteners:

3. Install the speaker cover w and the four fasteners q FRONT AUDIO BAR SERVICE
to secure the speaker cover w to the door panel. REMOVAL
Torque the fasteners to specification.
1. Loosen the roof assembly to gain access to the
fasteners and connectors underneath. Refer to Roof
Service page 13.4.
2. Remove the four T25 Torx fasteners q securing the 13
front audio bar to the cab frame.
TORQUE
Door Speaker Cover Fasteners:
3. Pivot the audio bar downwards to gain access to the

connectors.
CAUTION
Do not allow the audio bar to hang by the electrical
harness.
4. Disconnect the connectors, and remove the audio bar

from the vehicle.

INSTALLATION 4. Install the four T25 Torx fasteners q to secure the

front audio bar to the cab frame. Torque to
1. Connect the audio bar connectors and properly route
specification.
the audio harness. Refer to Speaker Harness Routing
in Factory Choice Harness Routing — 3 Seat Models
page or Factory Choice Harness Routing — Crew
Models page
2. Install the audio bar assembly and rotate into place.
TORQUE
Audio Bar Fasteners:
6 ft-lbs (8 Nm)
3. Ensure the bar is engaged in the roof frame 5. Install the roof assembly. Refer to Roof Service page
assembly. 13.4.

FRONT SPEAKER SERVICE INSTALLATION

REMOVAL 1. Install the speaker and fasteners w securing the
1. Remove the six fasteners q securing the speakers speaker(s) to the speaker cover. Torque to
and cover to the audio bar. Disconnect the speaker specification.
connections and remove the speakers with cover
from the vehicle. 13
CAUTION
Do NOT allow the speakers to hang by the speaker
wires.
2. Disconnect the speaker connections and remove the

speakers with cover from the vehicle.
CAUTION
Do NOT allow the speakers to hang by the speaker
wires.
TORQUE
Front Speaker Fasteners:
2. Install the speaker with cover assembly and connect

the speaker connectors.
3. Install the six fasteners q to secure the speakers to
the audio bar and torque to specification.
3. Remove the fasteners w securing the speaker(s) and

remove the speaker from the speaker cover.
TORQUE
Front Speaker Cover Fasteners:
6 ft-lbs (8 Nm)

REAR SPEAKER SERVICE INSTALLATION

REMOVAL 1. Connect the speaker connectors r, and install the
1. Remove the four T25 Torx fasteners q securing the speaker.
rear speaker cover w and speaker e to the
headliner, and remove the speaker cover.
CAUTION
Do not allow the speaker to hang from the harness.
2. Install the speaker e, speaker cover w and the four

T25 Torx fasteners q to secure the speaker cover
and speaker to the headliner. Torque to specification.
CAUTION
Do not allow the speaker to hang from the harness.
2. Disconnect the speaker connectors r, and remove
the speaker.
TORQUE
Rear Speaker Fasteners:
6 ft-lbs (8 Nm)

AUDIO AMPLIFIER SERVICE INSTALLATION

When equipped with Ride Command and Audio, the 1. Install the two fasteners r that secure the Audio
Audio Amplifier is located behind the center control dash Amplifier to the amplifier bracket.
panel.
REMOVAL
1. Remove the two rivets q on the bottom of the Center 13
Control Dash Panel and un-clip the top clips to re-
move the panel.
2. Connect the amplifier electrical connector.

NOTICE
The Audio Amplifier electrical connector does not
disconnect directly from the amplifier. Removal of the
Upper Center Dash panel or Ride Command display
2. Disconnect the electrical connectors from the Drive may assist with access to the electrical plug in.
Mode Switch, AWD Switch, and 12V power points.
3. Disconnect HVAC control panel if equipped. 3. Connect the HVAC control panel controls if equipped.
4. Remove the two fasteners r that secure the Audio 4. Connect the electrical connectors to the drive mode,
Amplifier to the amplifier mounting bracket. AWD switches, and 12V power points.
5. Install the Center Control Dash Panel by inserting the
top clips of the panel w into the slot in the center
dash panel. Gently push in on the panel e locking it
in place. Install the two rivets q on the bottom of the
Center Control Dash Panel.
5. Disconnect the Audio Amplifier electrical connection.

NOTICE
The Audio Amplifier electrical connector does not
disconnect directly from the amplifier. Removal of the
Upper Center Dash panel or Ride Command display
may assist with access to the electrical plug in.
6. Remove the Audio Amplifier from the vehicle through

the dash opening.

SUBWOOFER SERVICE 4. Lift the subwoofer straight up and disconnect the

REMOVAL connectors. Remove from vehicle.
1. Remove the eight T25 Torx fasteners q securing the

subwoofer box cover.
INSTALLATION
1. Connect the subwoofer connectors and install the
2. Lift the subwoofer cover straight up and remove from subwoofer in the vehicle.
the vehicle.
2. Install the eight subwoofer fasteners w and torque to

3. Remove the eight T25 Torx fasteners w securing the specification.
subwoofer to the subwoofer box.
TORQUE
Subwoofer Fasteners:
6 ft-lbs (8 Nm)

3. Install the subwoofer cover and align mounting holes.
13
4. Install the eight T25 Torx fasteners q to secure the

subwoofer box cover.
TORQUE
Subwoofer Fasteners:
6 ft-lbs (8 Nm)

SUBWOOFER AMPLIFIER SERVICE INSTALLATION

REMOVAL 1. Lift the amplifier straight out of the subwoofer box.
1. Remove the subwoofer. Refer to Subwoofer Service
page 13.60.
2. Disconnect the connectors on the amplifier.
3. Remove the four fasteners q securing the amplifier
to the vehicle.
2. Install the four fasteners q to secure the amplifier to

the vehicle. Torque to specification.
4. Lift the amplifier straight out of the subwoofer box.
TORQUE
Amplifier Mounting Fasteners:
3. Connect the connectors on the amplifier.

4. Install the subwoofer. Refer to Subwoofer Service
page 13.60.

SUBWOOFER HARNESS ROUTING

NOTICE
View is from the top looking down.
13
IMPORTANT
Note the location of all zip ties.

OPTIONAL ELECTRICAL SYSTEMS

FACTORY CHOICE HARNESS ROUTING
FRONT LOWER VEHICLE ROUTING
IMPORTANT
Not all routing and images will apply to the vehicle being serviced. This is dependant upon what features and options
the vehicle was manufactured with.
REF DESCRIPTION
q Front Camera
w Fan Connector
e AWD Hub Coil
r Brake Pressure Switch
t Voltage Regulator Connector (AC)
y Voltage Regulator Connector (DC)
u Winch Contactor
i Auto-stop Jumper
o Fairlead
a Retention Clip (Into Bumper Trim)
s Voltage Regulator Connector (AC)
d Voltage Regulator Connector (DC)
f HPCO Switch Connector
g Tree Clip (Into Vehicle Frame)
h Retention Clip (Into Front Fascia)
j Vehicle Ground
k Tree Clip (Into Bulkhead)

FRONT UPPER VEHICLE ROUTING
13
REF DESCRIPTION
q Terminal Block
w Terminal Block Ground Connection
e Terminal Block Connector
r Terminal Block Power Cable
t Left Headlight Connector
y GPS Antenna
u Retention Clip (Into front Fascia)
i Front Camera Connection
o Front Ground Connection
a Right Headlight Connector
s Audio Antenna

LEFT DASH ROUTING
REF DESCRIPTION
q Retention Clip (Into Chassis Frame)
w In-line Speaker Connector
e Tree Clip (Into Dash Bracket)
r Tree Clips (Into Upper Dash Panel)
t Left and Right Speaker Accessory Connectors
y EPS Signal Connector
u EPS Power Connector
i Retention Clip (Into Dash Bracket)
o Ignition Switch Connector
a Instrument Cluster Connector
s Headlight Connector

CENTER DASH ROUTING
13
REF DESCRIPTION REF DESCRIPTION
q Tree Clip (Into Upper Dash Panel) d In-line Rear Accessory Switch Connector
w Ambient Air Temp Sensor f Box Lift Harness Connector
e Retention Clip (Into Chassis Frame) g Amp Connector
In-line RC Harness Connector (Tree Clip into

r upper Dash Panel) h Subwoofer Connector
t USB j AWD Switch
y 32 Pin Display Connector k Drive Mode Switch
u AM/FM Connector (Black) l Temperature Control Connector
i GPS Connector (Blue) 1( Blower Motor Control Connector
o V2V (gold) 2) 12V Receptacles
a 16 Pin Display Connector 2! In-line Winch Connector
s USB Connector

REAR PULSE™ BUSBAR HARNESS 6. Disconnect connector t and remove the rear
REPLACEMENT harness.
REMOVAL
1. Remove the ground connector i from the terminal
block.
2. Remove the two 10 mm nuts o securing the power
cables.
7. Remove the front harness r from the retention strap

e.
3. Remove the sub-harnesses on the roof panel. Refer

to Factory Choice Harness Routing — 3 Seat Models
page .
4. Remove the rear harness from the retention strap u
on the B-pillar.
8. Remove the four terminal block fasteners w and the

rear terminal block q.
5. Release the harness retaining clips y and u.

/ Glove Box Service page 11.34

10. Disconnect the connectors behind the dash and 3. Install the rear harness. Connect connector t to rear
remove the harness. Refer to Factory Choice close off connector and route behind the rear seat.
Harness Routing — 3 Seat Models page .
4. Secure the harness with retaining clips y and u.
INSTALLATION
1. Install the rear terminal block q and four terminal
block fasteners w. Torque to specification. 13
5. Install the rear harness retention strap u on the B-

pillar, and route the rear harness through the
retention strap.
TORQUE
Terminal Block Fasteners:
24 in-lbs (3 Nm)
2. Install the front harness retention strap e, and route

the A-pillar harness r through the retention strap.
6. Route the sub-harnesses on the roof panel. Refer to

Factory Choice Harness Routing — 3 Seat Models
page .
IMPORTANT
Ensure the harnesses are properly secured to the roof
using the retention clips.

7. Install the ground connector t into the terminal

block.
8. Install the two power cables with 10 mm nuts y.
TORQUE
Terminal Block Cables:
30 in-lbs (3.5 Nm)

ADDITIONAL HARNESS ROUTING – 3 SEAT MODELS

ROOF HARNESS ROUTING
NOTICE
View is from bottom looking up at roof.
NOTE
13
q Visor Harness
w Front Lightbar Extension Harness
e Rear Audio Harness
r Dome Light Harness
t Accessory Rear Power Harness
y Rear Lightbar Extension Harness
u Retention Clip (Note the location of all highlighted retention clips)
IMPORTANT
Note the location of all retention clips.

REAR SPEAKER HARNESS ROUTING

NOTICE
View is from top looking down.
IMPORTANT
The front audio harness routes over the windshield plate.

ADDITIONAL HARNESS ROUTING — CREW MODELS

ROOF HARNESS ROUTING
NOTICE
View is from bottom looking up at roof.
13
IMPORTANT
q Accessory Rear Power Harness y Front Lightbar Harness
w Rear Audio Harness u Rear Lightbar Extension Harness
e Rear Light Bar Harness i Visor Harness
r Dome Light Extension Harness o Retention Clip (Note the location of all
highlighted retention clips)
t Dome Light Harness

REAR SPEAKER HARNESS ROUTING

NOTICE
View is from top looking down.
IMPORTANT
The front audio harness routes over the windshield plate.

PREMIUM DOOR HARNESS ROUTING

IMPORTANT
13

PREMIUM DOOR HARNESS 5. Disconnect the lower retention clips t from the door.
REPLACEMENT
REMOVAL
1. Remove the door panel. Refer to Premium Door
Panel Service page 13.24.
2. Remove the headliner. Refer to Headliner Service
page 13.9.
3. Disconnect the power window harness connector q
and speaker harness connector w located next to the
rear speaker bracket.
6. Disconnect the upper retention clips y from the door

and remove the door harness.
4. Disconnect the window motor connector e and

window motor harness clip r.
INSTALLATION
1. Install the door harness and connect the upper
retention clips y into the door.

2. Route the lower portion of the harness and connect 6. Install the door panel. Refer to Premium Door Panel
retention clips t into the door. Refer to Premium Service page 13.24.
Door Harness Routing page 13.75 for proper routing.
13
3. Connect the window motor connector e and install

the window motor harness clip r.
4. Connect the power window harness connector q and

speaker harness connector w located next to the rear
speaker bracket.
5. Install the headliner. Refer to Headliner Service page

13.9.

PREMIUM DOOR HARNESS 5. Disconnect the lower retention clips t from the door.
REPLACEMENT (CREW)
REMOVAL
1. Remove the door panel. Refer to Premium Door
Panel Service page 13.24.
2. Remove the headliners. Refer to Headliner Service
(CREW) page 13.11 or Headliner Service - MB
QUART® Audio (CREW) page .
3. Disconnect the power window harness connector q
and speaker harness connector w located in the
middle of the roof.
6. Disconnect the upper retention clips y from the door

and remove the door harness.
4. Disconnect the window motor connector e and

window motor harness clip r.
INSTALLATION
1. Install the door harness and connect the upper
retention clips y into the door.

2. Route the lower portion of the harness and connect 6. Install the door panel. Refer to Premium Door Panel
retention clips t into the door. Refer to Premium Service page 13.24.
Door Harness Routing page 13.75 for proper routing.
13
3. Connect the window motor connector e and install

the window motor harness clip r.
4. Connect the power window harness connector q and

speaker harness connector w located in the middle
of the roof..
5. Install the headliners. Refer to Headliner Service

(CREW) page 13.11 or Headliner Service - MB
QUART® Audio (CREW) page .

NOTES

INDEX
A Testing ............................................................ 12.19

Load Test ........................................................... 12.22
A-Arm Bushing
Replacement................................................. 9.14, 9.20
Open Circuit Voltage (OCV) .................................... 12.21 IX
Specific Gravity Test ............................................. 12.22
Accelerator Position Sensor (APS) Storage .............................................................. 12.13
APS Sensor Replacement......................................... 4.9 Terminal Block ..................................................... 12.13
APS Sensor Test ..................................................... 4.9 Battery Maintenance
Operation Overview ................................................. 4.9 AGM Dry Shipped .........................................2.65, 12.19
Air Box AGM Low Maintenance ..................................2.66, 12.21
Assembly View ......................................................3.15 Lead Acid Conventional ..................................2.65, 12.16
Air Conditioning Lead Acid Low Maintenance ............................2.65, 12.19
Charging with Recovery / Charging .......................... 3.125 Battery Service
Condenser Cleaning ............................................. 3.151 Identification........................................................ 12.14
Description ......................................................... 3.122 Body..................................................................... 11.27
Diagram ............................................................. 3.136 Body Assembly View
Refrigerant.......................................................... 3.125 Roof Assembly View .......................................... 11.16
Safety Precautions ............................................... 3.121 Roof Assembly View (CREW) .............................. 11.17
Air Filter Body Component Service.........................................13.4
Assembly View ......................................................3.15 Driver’s Seat Service.......................................... 11.36
Air Intake Maintenance Premium Door Panel Service ............................... 13.24
Air Filter Replacement .............................................2.43 Side mirror Service (INTL) ................................... 13.32
All Wheel Drive (AWD) Coil Standard Door Panel Service ............................... 13.22
Diagnosing ......................................................... 12.71 Cab Component Service
Operation Overview .............................................. 12.71 Headliner Service ................................................13.9
Alternator Headliner Service (CREW) .................................. 13.11
Replacement....................................................... 12.50 Roof Service (CREW) ..........................................13.6
Assembly View Tip-out Windshield Adjustment ............................. 13.18
Drive Clutch ................................................... 6.24-6.25 Tip-out Windshield Service .................................. 13.17
Driven Clutch.........................................................6.42 Door Service
Fuel Tank .............................................................5.17 Door Latch Service ............................................ 13.27
PVT Covers / Ducting ..............................................6.10 Door Removal / Installation.................................. 13.21
Audio Door Removal / Installation - High Lifter.................. 13.21
Amplifier Service .................................................. 13.59 Window Regulator / Door Glass Service ................. 13.29
AWD System Service Notes ........................................................ 11.2
Diagnosis .............................................................8.41 Special Tools ......................................................... 11.2
Operation .............................................................8.40 Body / Frame
Body Component Service
Windshield Service ............................................ 13.16
B Body Component
Dash Panel / Glove Box Removal ............................ 11.34
Balance Shaft Front Bumper Install.............................................. 11.22
Installation ............................................................3.79 Front Bumper Removal.......................................... 11.22
Removal / Inspection...............................................3.59 Body Component Service
Ball Joint Rocker Panel Service............................................ 11.27
Removal...............................................................9.16 Body Electrical
Service Preparation ................................................9.16 Audio Service
Battery Subwoofer Service ............................................ 13.60
AGM Audio System Service
Charging - Deeply Discharged ............................. 12.20 Door Speaker Service ........................................ 13.54
Charging - Low Charge....................................... 12.20 Front Audio Bar Service ...................................... 13.55
AGM Dry Shipped Rear Speaker Service ........................................ 13.58
Activation ........................................................ 12.16 Subwoofer Amplifier Service ................................ 13.62
Charging ......................................................... 12.18 Battery Service
Testing ............................................................ 12.18 Battery Specifications......................................... 12.11
AGM Low Maintenance Charging System
Charging ......................................................... 12.20 Charging System Troubleshooting
Testing ............................................................ 12.20 Regulator Testing (900 Watt)............................. 12.54
Charging Procedure.............................................. 12.23 Harness Service
Conductance Analyzer .......................................... 12.21 Rear Pulse™ Busbar Harness Replacement ........... 13.68
General Information .............................................. 12.11 Instrument Cluster Service ..................................... 12.10
Lead Acid Conventional Vehicle Harness Service
Activation ........................................................ 12.14 Premium Door Harness Replacement (CREW) ........ 13.78
Charging ......................................................... 12.15 Premium Door Harness Routing ........................... 13.75
Inspection........................................................ 12.15 Subwoofer Harness Routing ................................ 13.63
Testing ............................................................ 12.15 Body Service
Lead Acid Low Maintenance Rear Close-Off Panel ............................................ 11.28
Charging ......................................................... 12.19 Brake

© Copyright Polaris Inc. IX.1
INDEX
Brake Warning System Parking Brake Caliper Service.............................. 10.54

Half Plausibility ................................................. 10.59 Parking Brake Disc Service ................................. 10.56
Brake Burnishing............................................ 10.26, 10.33 Parking Brake (INTL)
Brake Caliper, Front Parking Brake Cable Routing ............................... 10.47
Assembly Parking Brake Cable Service ............................... 10.48
3 Seat / Crew Models ......................................... 10.30 Parking Brake Service
Assembly View Parking Brake Assembly ..................................... 10.46
3 Seat / Crew Models ......................................... 10.27 Rear Brake Pad Inspection ..................................... 10.33
Disassembly Rear Brake Pad Installation .................................... 10.33
3 Seat / Crew Models ......................................... 10.28 Rear Brake Pad Removal....................................... 10.32
Inspection Service Notes ........................................................10.3
3 Seat / Crew Models ......................................... 10.29 Service Specifications .............................................10.4
Installation Special Tools .........................................................10.3
3 Seat / Crew Models ......................................... 10.30 Brake System Maintenance
Removal Brake Disc Inspection..............................................2.63
3 Seat / Crew Models ......................................... 10.28 Brake Pad Inspection ..............................................2.62
Brake Caliper, Rear Fluid Level Inspection..............................................2.62
Assembly Fluid Replacement / Brake Bleeding ......................... 10.16
Crew Models .................................................... 10.42 Brake System Service
Assembly View Brake Line Routing .................................................10.7
3 Seat Models .................................................. 10.34 Brake,
Crew Models .................................................... 10.39 Brake Pedal Switch Inspection ................................ 10.59
Disassembly Brake Warning System Inspection
Crew Models .................................................... 10.41 Half Plausibility ................................................. 10.60
Inspection Brakes
Crew Models .................................................... 10.41 Brake Vibration ......................................................1.83
Installation Brakes Lock ..........................................................1.84
Crew Models .................................................... 10.42 Overheating ..........................................................1.84
Removal Performance Issues ................................................1.84
Crew Models .................................................... 10.40 Troubleshooting Brake Noise ....................................1.83
Brake Disc Break-In Period.......................................................... 2.5
Brake Disc Replacement........................................ 10.45 Bushing Replacement
Brake Disc, Front A-Arm .......................................................... 9.14, 9.20
Inspection........................................................... 10.44
Runout............................................................... 10.44
Brake Line C
Clocking ............................................................. 10.11
Brake Pads, Front Cab Frame
Inspection........................................................... 10.25 Doors Assembly View ........................................... 13.20
Installation .......................................................... 10.25 Camshaft
Removal............................................................. 10.24 Camshaft / Bore Inspection ......................................3.44
Brake Pads, Rear Installation / Timing .................................................3.90
Inspection........................................................... 10.33 Removal...............................................................3.42
Installation .......................................................... 10.33 Sprocket Inspection ................................................3.43
Removal............................................................. 10.32 Camshaft Timing - Quick Reference ..............................3.97
Brake Pedal Cargo Box
Replacement....................................................... 10.21 Assembly View .................................................... 11.19
Brake Pedal installation ............................................ 10.23 Installation .......................................................... 11.33
Brake System Removal............................................................. 11.33
Assembly View ......................................................10.6 Charging System
Brake Burnishing Procedure .......................... 10.26, 10.33 Alternator Replacement ......................................... 12.50
Brake Hose and Fitting Inspection..............................2.63 Break Even Test................................................... 12.52
Brake Pedal Replacement...................................... 10.21 Current Draw - Key Off .......................................... 12.52
Brake System Service Operation Overview .............................................. 12.47
ABS Brake System Assembly View (INTL) .............. 10.58 Regulator / Rectifier Operation ................................ 12.47
Brake System Clocking (INTL) ............................. 10.13 Stator Replacement .............................................. 12.47
Front Brake Disc Inspection .................................... 10.44 Stator Tests......................................................... 12.53
Front Brake Disc Runout ........................................ 10.44 Testing Flow Chart................................................ 12.48
Front Brake Pad Inspection .................................... 10.25 Chassis / Main Frame................................................. 11.3
Front Brake Pad Installation.................................... 10.25 Chassis/Main Frame
Front Brake Pad Removal ...................................... 10.24 Assembly View
Master Cylinder Installation .................................... 10.20 Frame............................................................... 11.4
Master Cylinder Removal ....................................... 10.19 ROPS
Operation Overview ................................................10.5 Assembly View ................................................... 11.5
Parking Brake Clutch
Front Parking Brake Assembly Service .................. 10.51 Bushing Service .....................................................6.34
Parking Brake Cable Adjustment .......................... 10.50 Clutching

IX.2 © Copyright Polaris Inc.
INDEX
Clutch Chart .................................................... 1.42, 6.4 Bevel Differential Assembly ......................................7.38

Combustion Chamber Cleaning....................................3.49 Operation .............................................................7.25
Connecting Rod Differential Solenoid IX
Assembly .............................................................3.75 Circuit Operation .................................................. 12.69
Bearing Selection ...................................................3.72 Overview ............................................................ 12.69
Inspection.............................................................3.69 Digital Wrench
Coolant Flow Diagram ................................................3.99 Diagnostic Connector ..............................................1.58
Coolant Strength and Type ..........................................2.39 Digital Wrench®
Cooling System Communication Errors.............................................1.58
Assembly View ......................................................3.99 ECU Reprogramming ..............................................1.60
Bleeding Procedure .............................................. 3.102 Feature Map..........................................................1.59
Fan Control Circuit Bypass Test.................................4.20 Guided Diagnostics ................................................1.56
Fan Control Circuit Operation / Testing ........................4.20 Polaris Mobile Digital Wrench® (PMDW) .....................1.61
Pressure Cap Test ................................................ 3.101 Serial Number Location ...........................................1.58
Pressure Test ...................................................... 3.100 Software Installation and Updates ..............................1.57
Radiator Service (HVAC) ....................................... 3.105 Software Overview .................................................1.56
Specifications ...................................................... 3.100 Special Tools .........................................................1.56
Troubleshooting .....................................................1.55 Door Latch Removal / Installation
Cooling System Maintenance High Lifter
Coolant Level Inspection..........................................2.40 Door Panel....................................................... 13.27
Coolant Replacement..............................................2.42 Doors
Cooling System Hose Inspection ...............................2.41 Assembly View
Radiator Inspection.................................................2.41 HVAC ............................................................. 13.20
Crankcase Drive Belt
Assembly .............................................................3.80 Inspection.............................................................. 6.7
Disassembly / Inspection .........................................3.56 Installation ............................................................. 6.8
Inspection.............................................................3.62 Removal................................................................ 6.6
Lower Crankcase Preparation ...................................3.80 Drive Clutch
Upper Crankcase Preparation ...................................3.73 Assembly ..................................................... 6.36, 6.39
Crankshaft Assembly View ............................................... 6.24-6.25
Bearing Journal Inspection .......................................3.60 Bearing Inspection..................................................6.28
Installation (1000)...................................................3.77 Bushing
Main Bearing Selection............................................3.72 Inspection..........................................................6.33
Removal / Inspection...............................................3.60 Button to Tower Clearance .......................................6.28
Crankshaft Position Sensor (CPS) Clutch Inspection ............................................ 6.30-6.31
CPS Replacement ................................................... 4.6 Disassembly .........................................................6.26
CPS Test ............................................................... 4.5 EBS Sleeve Inspection ............................................6.33
Operation Overview ................................................. 4.5 Operation Overview ................................................. 6.5
Crankshaft PTO Seal Roller / Pin / Thrust Washer Inspection........................6.28
Installation ............................................................3.30 Shift Weight Inspection ............................................6.29
Removal...............................................................3.30 Spider Removal .....................................................6.28
Replacement.........................................................3.30 Spring..................................................................6.29
Cylinder Drive Shaft
Inspection.............................................................3.63 CV Joint Handling...................................................8.52
Installation ............................................................3.76 Inner Plunging Joint / Boot Replacement .....................8.55
Misfire..................................................................1.74 Outer CV Joint / Boot Replacement ............................8.52
Removal...............................................................3.65 Driven Clutch
Cylinder Head Alignment .............................................................. 6.9
Assembly .............................................................3.87 Assembly .............................................................6.45
Disassembly .........................................................3.47 Assembly View ......................................................6.42
Installation ............................................................3.89 Bushing Service .....................................................6.44
Removal...............................................................3.46 Disassembly .........................................................6.43
Warp Inspection .....................................................3.46 Operation Overview ................................................. 6.5
Driveshaft (Half Shaft)
Diagnostics ...........................................................1.82
D Dynamic
Testing .................................................................1.89
Dash
Assembly View ...................................................... 11.9
Panel Removal .................................................... 11.34 E
Decal Replacement .......................................... 11.2, 11.29
Diagnostic ...............................................................1.45 ECU
Engine Cranks but does Not Start ..............................1.48 Diagnostic Trouble Codes Overview ...........................1.62
No Crank No Start or Slow Crank...............................1.50 ETC Learn Procedure .............................................. 4.8
Over Heating .........................................................1.51 Electrical
Warning Lights.......................................................1.52 Ambient Temperature Sensor
Differential Location .......................................................... 12.73

INDEX
Testing ............................................................ 12.73 Crankcase Inspection..............................................3.62

Audio System Service Crankshaft Bearing Journal Inspection ........................3.60
Front Speaker Service........................................ 13.57 Crankshaft Installation (1000) ...................................3.77
C4 Instrument Cluster Crankshaft Main Bearing Selection ............................3.72
Gauge Overview .................................................12.9 Crankshaft Removal / Inspection ...............................3.60
Charging System Service Cylinder / Piston Installation......................................3.76
Alternator Specifications ..................................... 12.49 Cylinder Head Assembly..........................................3.87
Connector Probing Guidelines...................................1.90 Cylinder Head Disassembly......................................3.47
Continuity / Resistance ............................................1.91 Cylinder Head Installation ........................................3.89
Current Draw - Key Off ............................................1.94 Cylinder Head Removal ...........................................3.46
Digital Multi-Meter (DMM) ........................................1.89 Cylinder Head War Inspection ...................................3.46
Electrical Harness Service Cylinder Inspection .................................................3.63
Premium Door Harness Replacement .................... 13.76 Cylinder Removal ...................................................3.65
Service Notes ................................................ 1.89, 12.4 Engine Service
Service Specifications .............................................12.5 Engine Installation (HVAC) ....................................3.40
Special Tools .........................................................12.5 Engine Oil Cooler Service ................................... 3.113
Static and Dynamic Testing ......................................1.89 Engine Removal (HVAC).......................................3.35
Testing Current Flow (Amperage) ..............................1.93 Exhaust Service
Testing For A Short To Ground ..................................1.91 Exhaust System Assembly View - HVAC, High Lifter &
Testing For A Short To Voltage ..................................1.92 Back Country ....................................................3.24
Testing for Intermittent Conditions ..............................1.93 Muffler Service HVAC, High Lifter & Back Country ......3.26
Testing Voltage Drop ...............................................1.94 Flywheel Installation ...............................................3.85
Vehicle Harness Service Flywheel Removal ..................................................3.54
Chassis Harness Installation..................................12.8 General Information
Chassis Harness Removal ....................................12.8 Oil Pressure Test HVAC ......................................... 3.8
Electrical Harness Installation ............................................................3.36
Roof Harness Intake Service
3 Seat Models .................................................. 13.71 Intake System Assembly View - High Lifter & Back
Crew Models .................................................... 13.73 Country ...........................................................3.17
Electrical Maintenance Limiting / Misfire .....................................................1.74
Battery Replacement ............................................ 12.11 Lower Crankcase Preparation ...................................3.80
Chassis / Engine Electrical Ground .......................... 12.13 Mount Replacement................................................3.29
Spark Plug Replacement .........................................2.48 Piston / Con Rod Assembly ......................................3.75
Throttle Pedal Inspection .........................................2.64 Piston Disassembly / Inspection ................................3.66
Electronic Control Unit (ECU) Piston Removal......................................................3.65
ECU Replacement................................................... 4.4 Piston Ring Installation ............................................3.73
Operation Overview ................................................. 4.3 Piston Ring Installed Gap .........................................3.68
Electronic Power Steering (EPS) Piston Ring Removal...............................................3.67
Operation .............................................................. 9.3 Removal...............................................................3.32
System Breakout..................................................... 9.4 Special Tools .......................................................... 3.5
Troubleshooting - EPS Non-Functional MIL Off .............1.86 Specifications ........................................................ 3.11
Troubleshooting - EPS Non-Functional MIL On .............1.85 Starter Drive Installation...........................................3.85
Troubleshooting - Using Digital Wrench® ....................1.87 Starter One-Way Clutch Assembly .............................3.84
Electronic Throttle Body Starter One-Way Clutch Disassembly .........................3.55
Learn Procedure ..................................................... 4.8 Starter One-Way Clutch Inspection ............................3.54
Electronic Throttle Control (ETC) Stator Cover Installation...........................................3.86
ETC Replacement ................................................... 4.7 Stator Cover Removal / Inspection .............................3.52
ETC Test ............................................................... 4.7 Torque Sequences .................................................3.13
Operation Overview ................................................. 4.7 Troubleshooting .....................................................1.53
Engine .................................................................. 3.142 Upper Crankcase Preparation ...................................3.73
Accessible Components ..........................................3.29 Valve Clearance Adjustment .....................................3.94
Balance Shaft Removal / Inspection ...........................3.59 Valve Cover Installation ...........................................3.95
Bearing Selection Identification .................................3.71 Valve Cover Removal ..............................................3.42
Break-In Period......................................................3.10 Valve Inspection.....................................................3.48
Camshaft / Bore Inspection ......................................3.44 Valve Lash - Tappet Selection ...................................3.98
Camshaft Installation / Timing ...................................3.90 Valve Sealing Test ..................................................3.49
Camshaft Removal .................................................3.42 Valve Seat Reconditioning........................................3.50
Camshaft Sprocket Inspection...................................3.43 Valve Spring Removal .............................................3.47
Combustion Chamber Cleaning.................................3.49 Water Pump Housing Removal..................................3.53
Connecting Rod Bearing Selction ..............................3.72 Engine Coolant Temp Sensor (ECT)
Connecting Rod Inspection.......................................3.69 ECT Sensor Replacement........................................4.16
Cooling System ECT Sensor Test ....................................................4.15
Cooling Fan Service (HVAC)................................ 3.107 Operation Overview ................................................4.15
Cooling System Service Engine Designation Number ......................................... 1.3
Coolant Removal / Draining ................................. 3.101 Engine Electrical
Crankcase Assembly ..............................................3.80 Drive Mode Switch
Crankcase Disassembly / Inspection ..........................3.56 Drive Mode Switch Description and Operation ...........4.19

INDEX
Engine Electrical Diagnosis Rear Prop Shaft Removal ........................................8.14

Ignition System Testing.........................................4.17 Final Drive Maintenance
Ignition Service Drive Shaft Boot Inspection ......................................2.56 IX
Spark Plug Tire Inspection .......................................................2.57
Spark Plug Inspection .......................................4.18 Tire Pressure Inspection ..........................................2.57
Ignition System Service Wheel Replacement ...............................................2.56
Spark Plug Floor Removal / Installation
Spark Plug Service ...........................................4.18 Body.................................................................. 11.39
Oxygen Sensor Service Floors/Fender
O2 Sensor Replacement HVAC, High Lifter & Back Body
Country ........................................................... 4.11 Assembly View
Oxygen Sensor Replacement ................................4.10 Closeoff Panel ............................................... 11.12
Troubleshooting Fluid Inspection
Oxygen Sensor Diagnostic Tips..............................4.12 Fluid Condition ......................................................1.75
Engine Maintenance Fluid Leak.............................................................1.75
Cam Chain Tensioner Inspection ...............................2.38 Flywheel
Crankcase Breather Hose Inspection..........................2.35 Installation ............................................................3.85
Oil Level Inspection ................................................2.33 Removal...............................................................3.54
Valve Clearance Inspection ......................................2.36 Frame
Engine Serial Number Location ..................................... 1.4 Assembly View ...................................................... 11.3
Engine Troubleshooting Service Notes ........................................................ 11.2
Cylinder Leakdown Test............................................ 3.6 Special Tools ......................................................... 11.2
Engine, Camshaft Timing - Quick Reference ...................3.97 Front A-Arms
ETC Lower A-Arm Removal ............................................9.13
Learn Procedure ..................................................... 4.8 Upper A-Arm Removal ............................................9.14
EVAP Front Bearing Carrier
Fuel Vent Line Routing .................................... 5.13, 5.15 Bearing Replacement............................................... 8.4
Exhaust Installation ............................................................. 8.5
Assembly View ......................................................3.23 Removal / Inspection................................................ 8.2
Exhaust Service Front Body Component
Headpipe Service ................................................3.27 Front Bumper Removal.......................................... 11.22
Intake / Exhaust Service Front Camera
Muffler Service....................................................3.25 Installation .......................................................... 13.45
Exhaust Maintenance Removal............................................................. 13.45
Heat Shield Inspection.............................................2.45 Front Fascia
Spark Arrestor Inspection.........................................2.44 Assembly View .................................................... 11.11
Bumper
Body............................................................... 11.25
F Front Fender
Body Service
Factory-Installed Options Overview ...............................13.3 Lower Fender ................................................... 11.23
Fan Control Circuit Front Fenders
Bypass Test ..........................................................4.20 Assembly View .................................................... 11.11
Operation / Testing .................................................4.20 Front Gearcase
Final Drive Assembly ..................................................... 8.29, 8.32
AWD Diagnosis......................................................8.41 Assembly View ............................................... 8.18-8.19
AWD Operation......................................................8.40 AWD Diagnosis......................................................8.41
Front Bearing Carrier Bearing Replacement .................. 8.4 AWD Operation......................................................8.40
Front Bearing Carrier Installation ................................ 8.5 Disassembly ................................................. 8.22, 8.24
Front Bearing Carrier Removal / Inspection ................... 8.2 Inspection.............................................................8.27
Front Gearcase Assembly ................................ 8.29, 8.32 Installation ............................................................8.36
Front Gearcase Assembly View.......................... 8.18-8.19 Operation (ADC) ....................................................8.42
Front Gearcase Disassembly ............................ 8.22, 8.24 Removal...............................................................8.20
Front Gearcase Inspection .......................................8.27 Vent Line Routing ...................................................8.39
Front Gearcase Installation.......................................8.36 Front Gearcase Maintenance
Front Gearcase Removal .........................................8.20 Fluid Level Inspection..............................................2.54
Front Prop Shaft Installation ..................................... 8.11 Fluid Level Replacement..........................................2.54
Front Prop Shaft Removal ......................................... 8.8 Fuel
Propshaft U-Joint Assembly......................................8.16 Vent Line Routing (EVAP) ................................ 5.13, 5.15
Propshaft U-Joint Disassembly..................................8.15 Fuel Injectors
Rear Bearing Carrier Bearing Replacement .................8.46 Injector Replacement ..............................................5.29
Rear Bearing Carrier Inspection ................................8.45 Injector Test ..........................................................5.28
Rear Bearing Carrier Installation ................................8.47 Operation Overview ................................................5.28
Rear Bearing Carrier Removal ..................................8.45 Troubleshooting .....................................................5.29
Rear Drive Shaft Installation .....................................8.50 Fuel Line
Rear Drive Shaft Removal ........................................8.49 Replacement......................................................... 5.11
Rear Prop Shaft Installation ......................................8.14 Fuel Line Routing ....................................................... 5.8

INDEX
Fuel Pump Alternator Service................................................. 3.141

Fuel Sender Test ....................................................5.23 Assembly View .................................................... 3.134
Operation Overview ................................................5.23 Blower Unit Service .............................................. 3.142
Pressure Test ........................................................5.24 Breakout Diagram ................................................ 3.155
Replacement.........................................................5.25 Components ....................................................... 3.122
Fuel Sender Test .......................................................5.23 Compressor Drive Belt Inspection ............................ 3.151
Fuel System Compressor Drive Belt Service................................ 3.137
Component Locations .............................................. 5.6 Compressor Oil Inspection ..................................... 3.140
Components .......................................................... 5.5 Compressor Oil Specifications ................................ 3.139
Fuel Lines Compressor Service ............................................. 3.139
Fuel Vent Line Routing - High Lifter & Back-Country....5.14 Condenser Cleaning ............................................. 3.151
Fuel Vent Line Routing ............................................5.12 Condenser Service ............................................... 3.143
Operation Overview ................................................. 5.5 Control Operation Overview.................................... 3.154
Priming / Starting Procedure ...................................... 5.5 Cover Mount Service............................................. 3.145
Service Notes ......................................................... 5.2 Expansion Valve / Evaporator Coil Replacement ......... 3.147
Special Tools .......................................................... 5.3 Fan Switch Testing ............................................... 3.154
Troubleshooting .....................................................1.76 Filter Inspection / Replacement ............................... 3.153
Fuel System Maintenance Heater / Evaporator Unit Service.............................. 3.147
Fuel Line Inspection................................................2.46 Heater Coil Service............................................... 3.149
Fuel Pump / Filter Inspection.....................................2.46 Heater Valve Service............................................. 3.150
Fuel Tank Vent Line Inspection ..................................2.47 HPCO Switch Overview) ........................................ 3.142
Fuel Tank Refrigerant.......................................................... 3.125
Assembly View ......................................................5.17 Special Tools ....................................................... 3.121
Installation ............................................................5.20 Temperature Potentiometer Testing .......................... 3.154
Removal...............................................................5.18 Torque Specifications ............................................ 3.121
Fuse Box Troubleshooting ................................................... 3.129
Fuse Box View, .................................................... 12.41 A/C Performance............................................... 3.126
RANGER XP 1000 with Ride Command ................. 12.28 Blower Motor Settings ........................................ 3.130
XP 1000 / Crew................................................. 12.25 Temperature Does Not Change ............................ 3.126
XP 1000 High Lifter / Crew .................................. 12.38 HVAC System Service
XP 1000 Northstar / Crew.................................... 12.31 HPCO Switch Replacement.................................... 3.142
XP 1000 Northstar / Crew with Ride Command ........ 12.34 HVAC,
RANGER XP 1000 Factory Choice Packages............. 12.41 Reclamation with Recovery / Charging...................... 3.125
Relay Operation ................................................... 12.45
Fuse Box Overview.................................................. 12.24
I
G Ignition Coil
Operation Overview ................................................4.17
Glove Box Replacement.........................................................4.17
Assembly View ...................................................... 11.9 Inspection
Removal............................................................. 11.34 Pre-Ride................................................................ 2.6
GPS Antenna Instrument Cluster
Installation .......................................................... 13.50 Pinouts .............................................................. 12.10
Removal............................................................. 13.50 Intake
Throttle Body Adapter
Removal / Installation ...........................................3.22
H Intake Manifold
Installation ............................................................3.20
Harness Removal...............................................................3.18
Routing ................................................................12.6 INTL ..................................................................... 10.23
Headlights
Adjustment ......................................................... 12.61
Bulb Replacement ................................................ 12.63 K
Housing Installation .............................................. 12.64
Housing Removal ................................................. 12.63 Keys
Helix Replacement.......................................................... 1.6
Movable Sheave
Bushing Inspection ..............................................6.44
High Pressure Cut-Out (HPCO) Switch L
Overview ............................................................ 3.142
Hood Lubrication Specifications ............................................ 3.5
Assembly View .................................................... 11.11
HVAC
A/C Switch Testing................................................ 3.154
A/C Thermostat Overview ...................................... 3.149
M
Alternator Inspection ............................................. 3.141 Maintenance

INDEX
Engine Maintenance Overheating / Diagnosis...........................................1.80

Engine Oil and Filter Service..................................2.34 Overheating Diagnostics ..........................................6.49
Grease Lubrication Points ........................................2.29 PVT System Service IX
Lubricants.............................................................2.31 PVT Air Ducts - High Lifter / Back Country................. 6.11
Quick Reference Chart ............................................2.27 Service Notes ......................................................... 6.3
Service Notes ......................................................... 2.3 Service Specifications .............................................. 6.4
Service Specifications .............................................. 2.4 Special Tools .......................................................... 6.3
Special Tools .......................................................... 2.3 Troubleshooting ............................................. 1.78, 6.46
Maintenance Intervals ................................................. 2.7 PVT System Maintenance
Master Cylinder Drive Belt Inspection ...............................................2.49
Installation .......................................................... 10.20 PVT System Drying ................................................2.49
Removal............................................................. 10.19 PVT System Service
Model Specifications, Drive Clutch Removal / Installation ...................... 6.16-6.17
3 Seat Models .......................................................1.19 Driven Clutch Removal / Installation ...........................6.20
Crew Models .........................................................1.28 PVT Inner Cover Removal / Installation .......................6.21
International Models ...............................................1.36 PVT Outer Cover Removal / Installation ......................6.13
Motor Mount
Replacement.........................................................3.29
R
O Radiator
Removal / Installation ............................................ 3.103
Oil Pressure Test........................................................ 3.7 Radiator Fan
Oxygen Sensor .........................................................4.10 Removal / Installation ............................................ 3.107
Rear A-Arms
Lower A-Arm Installation ..........................................9.21
P Lower A-Arm Removal ............................................9.21
Upper A-Arm Installation ..........................................9.20
Periodic Maintenance Upper A-Arm Removal ............................................9.19
Overview ............................................................... 2.5 Rear Bearing Carrier
Piston Bearing Replacement..............................................8.46
Assembly .............................................................3.75 Inspection.............................................................8.45
Disassembly / Inspection .........................................3.66 Installation ............................................................8.47
Installation ............................................................3.76 Removal...............................................................8.45
Piston Ring Removal...............................................3.67 Rear Caliper
Removal...............................................................3.65 Assembly
Ring Groove Clearance ...........................................3.67 Single Piston .................................................... 10.37
Ring Installation .....................................................3.73 Disassembly
Ring Installed Gap ..................................................3.68 Single Piston .................................................... 10.35
Piston to Cylinder Clearance........................................3.68 Inspection
Plow Mode Single Piston .................................................... 10.36
Overview ............................................................ 13.44 Installation
Service .............................................................. 13.44 Single Piston .................................................... 10.37
Setup................................................................. 13.44 Removal
Power Steering Unit (EPS) Single Piston .................................................... 10.35
Installation ............................................................ 9.11 Rear Camera
Pre-Ride Inspection .................................................... 2.6 Installation .......................................................... 13.47
Prop Shaft, Front Removal............................................................. 13.47
Installation ............................................................ 8.11 Rear Cargo Box
Removal................................................................ 8.8 Assembly View .................................................... 11.19
Prop Shaft, Rear Installation .......................................................... 11.33
Installation ............................................................8.14 Removal............................................................. 11.33
Removal...............................................................8.14 Rear Close-Off Panel ............................................... 11.28
Propshaft U-Joint Rear Diff Solenoid Service
Assembly .............................................................8.16 Differential Solenoid Service
Disassembly .........................................................8.15 Differential Solenoid Replacement ........................ 12.69
PVT Rear Drive Shaft
Troubleshooting Installation ............................................................8.50
Vehicle Creeping .................................................6.50 Removal...............................................................8.49
PVT Covers / Ducting Rear Panel
Assembly View ......................................................6.10 Assembly View .................................................... 11.18
PVT Duct Removal / Install Removal / Installation ............................................ 13.19
Air Duct ................................................................6.12 Rear Stabilizer Bar
PVT System Removal / Installation ..............................................9.22
Assembly View ......................................................6.10 Regulator .............................................................. 12.47
Break-In ................................................................ 6.5 Relay Operation ...................................................... 12.45
Maintenance / Inspection .......................................... 6.5 Replacement.......................................................... 12.47

INDEX
Ride Command Engine Lubrication................................................... 3.5

Monitor .............................................................. 13.39 Engine Oil Pressure ................................................. 3.7
Overview ............................................................ 13.39 Speed Sensor
Pinout View......................................................... 13.41 Location ............................................................. 12.67
Plow Mode Testing ............................................................... 12.67
Overview ......................................................... 13.44 Starter
Service ........................................................... 13.44 Drive Installation ....................................................3.85
Setup.............................................................. 13.44 One-Way Clutch Assembly .......................................3.84
Troubleshooting ................................................... 13.52 One-Way Clutch Disassembly ...................................3.55
Ride Command Service ............................................ 13.41 One-Way Clutch Inspection ......................................3.54
ROPS Assembly Starter Motor
ROPS Installation .......................................................... 12.56
Assembly View ................................................... 11.7 Removal............................................................. 12.55
Starter Solenoid
Bench Test.......................................................... 12.56
S Operation ........................................................... 12.57
Starting System
Seat Belts Operation Overview .............................................. 12.55
Assembly View Starter Motor Installation ........................................ 12.56
Seat Frame ...................................................... 11.14 Starter Motor Removal .......................................... 12.55
Seats Starter Solenoid Bench Test ................................... 12.56
Assembly View .................................................... 11.14 Starter Solenoid Operation ..................................... 12.57
Sensor Testing Flow Chart................................................ 12.58
Oxygen ................................................................4.10 Troubleshooting ................................................... 12.59
Speed................................................................ 12.67 Voltage Drop Test ................................................. 12.59
Service Notes Static
Body / Frame......................................................... 11.2 Testing .................................................................1.89
Brake System ........................................................10.3 Stator
Electrical ..............................................................12.4 Cover Installation ...................................................3.86
Fuel System ........................................................... 5.2 Cover Removal / Inspection ......................................3.52
Maintenance .......................................................... 2.3 Replacement....................................................... 12.47
PVT System ........................................................... 6.3 Tests ................................................................. 12.53
Steering / Suspension .............................................. 9.2 Steering
Transmission.......................................................... 7.2 Inspection.............................................................. 9.6
Service Rules ............................................................ 1.5 Steering Assembly
Service Specifications Assembly View ....................................................... 9.5
Brake System ........................................................10.4 Power Steering Unit Installation ................................. 9.11
Electrical ..............................................................12.5 Steering Shaft Bearing Replacement ..........................9.12
Maintenance .......................................................... 2.4 Steering Shaft Removal ............................................ 9.8
PVT System ........................................................... 6.4 Steering Wheel Removal .......................................... 9.8
Steering / Suspension .............................................. 9.2 Steering Maintenance
Transmission.......................................................... 7.2 Steering System Inspection ......................................2.58
Shift Cable Steering Wheel Free-Play ........................................2.58
Shift Cable Adjustment .................................... 2.52, 7.10 Tie Rod End Inspection............................................2.59
Shift Cable Inspection ....................................... 2.51, 7.9 Wheel Toe Adjustment.............................................2.60
Shock Wheel Toe Measurement .........................................2.59
Analysis ....................................................... 1.88, 9.23 Wheel Toe Measurement / Adjustment ......................... 9.7
Removal / Installation ..............................................9.24 Steering Rack
Shock Spring Installation ............................................................9.10
Replacement.........................................................9.24 Removal................................................................ 9.9
Snorkel Gear Backlash ...............................................7.43 Steering Shaft
Special Tools Bearing Replacement..............................................9.12
Body / Frame......................................................... 11.2 Removal................................................................ 9.8
Brake System ........................................................10.3 Steering System
Digital Wrench® .....................................................1.56 Service Notes ......................................................... 9.2
Electrical ..............................................................12.5 Service Specifications .............................................. 9.2
Engine .................................................................. 3.5 Special Tools .......................................................... 9.2
Fuel System ........................................................... 5.3 Steering Wheel
HVAC ................................................................ 3.121 Removal................................................................ 9.8
Maintenance .......................................................... 2.3 Suspension
PVT System ........................................................... 6.3 Ball Joint Removal..................................................9.16
Special Tools Index.................................................. 1.8 Ball Joint Service Preparation ...................................9.16
Steering / Suspension .............................................. 9.2 Front Lower A-Arm Removal.....................................9.13
Transmission.......................................................... 7.2 Front Upper A-Arm Installation ..................................9.14
Website................................................................. 1.7 Rear Lower A-Arm Installation...................................9.21
Specifications Rear Lower A-Arm Removal .....................................9.21
Cooling System.................................................... 3.100 Rear Stabilizer Bar Removal / Installation ....................9.22

INDEX
Rear Upper A-Arm Installation...................................9.20 Transmission Isolation.............................................1.81

Rear Upper A-Arm Removal .....................................9.19 Transmission Maintenance
Service Notes ......................................................... 9.2 Fluid Level Inspection..............................................2.50 IX
Service Specifications .............................................. 9.2 Fluid Replacement .................................................2.50
Shock Analysis .............................................. 1.88, 9.23 Trouble Code List
Shock Removal / Installation .....................................9.24 (ORV Master) ........................................................1.63
Special Tools .......................................................... 9.2 Trouble Tree
Spring Replacement ...............................................9.24 Guided Symptom Diagnostic.....................................1.43
Suspension Inspection ...............................................2.61 Troubleshooting
Suspension Maintenance Brake Noise ..........................................................1.83
Shock Position Adjustment .......................................2.61 Cooling System......................................................1.55
Spring Pre-Load Adjustment .....................................2.61 Engine .................................................................1.53
Switch Engine Coolant Bypassing the Heater Valve............... 3.127
AWD / 2WD / TURF .............................................. 12.71 EPS Non-Functional MIL Off .....................................1.86
Gear Position ...................................................... 12.66 EPS Non-Functional MIL On .....................................1.85
Headlamp........................................................... 12.60 EPS Using Digital Wrench®......................................1.87
Ignition............................................................... 12.65 Front Gearcase (ADC).............................................8.43
Seat Belt Interlock ................................................ 12.66 Fuel System ..........................................................1.76
Switch Service HVAC ................................................................ 3.129
Brake Fluid Level Switch ........................................ 12.67 Misfire Detection ....................................................1.74
Winch ................................................................ 13.38 PVT System .................................................. 1.78, 6.46
Starting System ................................................... 12.59
T
T-MAP Sensor
V
Operation Overview ................................................4.14 Valve
Sensor Replacement ..............................................4.14 Clearance Adjustment .............................................3.94
Sensor Test...........................................................4.14 Inspection.............................................................3.48
Tail Lights Sealing Test ..........................................................3.49
LED Lamp Replacement ........................................ 12.64 Seat Reconditioning................................................3.50
Service .............................................................. 12.64 Spring Removal .....................................................3.47
Tailgate Valve Clearance
Assembly View .................................................... 11.19 Valve Lash - Tappet Selection ...................................3.98
Thermostat Replacement .......................................... 3.115 Valve Clearance - Tappet Selection ...............................3.98
Tie Rod End Inspection................................................ 9.6 Valve Cover
Torque List - Master ................................................... 1.11 Removal...............................................................3.42
Torque Sequences Valve Cover Installation ..............................................3.95
Engine .................................................................3.13 Vehicle Information
Torque Specifications VIN Number ........................................................... 1.3
HVAC ................................................................ 3.121 Vent Line
Transmission Termination Fitting ..................................................5.16
Assembly .............................................................7.43 Vent Line Routing
Assembly View ....................................................... 7.3 Front Gearcase......................................................8.39
Bevel Differential Assembly ......................................7.38 Transmission.......................................................... 7.8
Bevel Differential Disassembly ..................................7.37 VIN ......................................................................... 1.3
Disassembly .........................................................7.32 Location ................................................................ 1.4
Gear Cluster Disassembly........................................7.35 VIN Number .............................................................. 1.3
Gear, Shaft, Bearing Inspection .................................. 7.2 Voltage Drop Test .................................................... 12.59
Installation ............................................................7.29
Output Shaft Backlash.............................................7.40
Removal...............................................................7.26 W
Service Notes ......................................................... 7.2
Service Specifications .............................................. 7.2 Water Pump
Shift Cable Routing.................................................7.13 Housing Removal ...................................................3.53
Shift Cable Service .................................................7.14 Installation .......................................................... 3.117
Shift Cable Service (HVAC) ......................................7.19 Removal............................................................. 3.116
Shift Lever Installation .............................................7.10 Service .............................................................. 3.118
Shift Lever Removal................................................7.10 Winch
Snorkel Gear Backlash ............................................7.43 Assembly View .................................................... 13.33
Snorkel Tube Removal / Disassembly .........................7.36 Cable Routing / Retention ...................................... 13.34
Special Tools .......................................................... 7.2 Installation .......................................................... 13.36
Subassembly Views................................................. 7.4 Removal............................................................. 13.36
Troubleshooting .....................................................7.49 Wiring Diagrams
Vent Line Routing .................................................... 7.8 Circuit Diagrams ...................................................... 82
Transmission Diagnostics Wiring Harness Diagrams ............................................. 81
Hard Shifting .........................................................1.81


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Manual de Serviço Ranger 1000

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2021 RANGER XP 1000

Publication Printed November 2020 (PN 9850046 R01)

CHAPTER 1 : GENERAL INFORMATION

9850046 R01 - 2021 RANGER XP 1000 Service Manual

DIAGNOSTIC TROUBLE CODES OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.62

9850046 R01 - 2021 RANGER XP 1000 Service Manual

VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION

VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS

ENGINE DESIGNATION NUMBER

9850046 R01 - 2021 RANGER XP 1000 Service Manual

VEHICLE AND ENGINE SERIAL NUMBER LOCATION

9850046 R01 - 2021 RANGER XP 1000 Service Manual

9850046 R01 - 2021 RANGER XP 1000 Service Manual

SERIES# PART NUMBER

9850046 R01 - 2021 RANGER XP 1000 Service Manual

SPECIAL TOOLS WEBSITE

9850046 R01 - 2021 RANGER XP 1000 Service Manual

SPECIAL TOOLS INDEX ENGINE / COOLING / EXHAUST

Cylinder Holding Crank Seal

Engine Stand Water Pump Valve Spring

9850046 R01 - 2021 RANGER XP 1000 Service Manual

PVT SYSTEM STEERING / SUSPENSION

Clutch Bushing Piston Pin Puller Driven Clutch

Bearing Seal Crankcase BODY / FRAME

9850046 R01 - 2021 RANGER XP 1000 Service Manual

Digital Wrench® Digital Wrench® Wireless Vehicle

MultiLink XP Vehicle Interface MultiLink XP

Battery Connector Test Timing Light

9850046 R01 - 2021 RANGER XP 1000 Service Manual

MASTER TORQUE LIST ENGINE / COOLING / EXHAUST

Airbox Mount Fastener - High 42 in-lbs (5 Nm)

Cylinder Head Fastener (M8

Cylinder Head Fastener (M11 Torque in

Engine Mount Fastener 40 ft-lbs (54 Nm)

Engine Mount Isolator Nuts 22 ft-lbs (30 Nm)

Exhaust Head Pipe Mounting 18 ft-lbs (24 Nm)

9850046 R01 - 2021 RANGER XP 1000 Service Manual

Exhaust Silencer Heat Shield Oxygen Sensor 18 ft-lbs (24 Nm)

Intake Air Duct Covers - High 7 ft-lbs (10 Nm)

Isolator Fastener 40 ft-lbs (54 Nm)

Lambda Sensor - High Lifter 35 ft-lbs (47 Nm)

Lower Crankcase Fastener (M10) Step 1: 9 ft-lb (12

Lower Crankcase Fastener (M8) 26 ft-lbs (35 Nm)

Lower Crankcase Fastener (M6) 9 ft-lbs (12 Nm)

Lower Intake Plenum Fastener 18 ft-lbs (24 Nm)

Muffler Mount Fastener 10 ft-lbs (14 Nm)

Oil Cooler Retaining Fastener 7 lb-ft (10 Nm)

Oil Filter Adapter 21 ft-lbs (28 Nm)

Oil Pump Mounting Fastener 7 ft-lbs (10 Nm)

Oil Pump Pick-Up Retaining 7 ft-lbs (10 Nm)

9850046 R01 - 2021 RANGER XP 1000 Service Manual

ENGINE ELECTRICAL PVT SYSTEM

FUEL SYSTEM PVT Cover to Transmission 50 ft-lbs (68 Nm)

Shift Weight Fastener 20 in-lbs (2 N·m)

Windage Plate Fastener 4 ft-lbs (6 N·m)

9850046 R01 - 2021 RANGER XP 1000 Service Manual

TRANSMISSION FINAL DRIVE

Sector Cover Fastener 10 ft-lbs (14 Nm)

Shift Cable Bracket Fasteners 37 ft-lbs (50 Nm)

Shift Cable Fastening Nut 13 ft-lbs (18 Nm)

Shift Cable Locknut 13 ft-lbs (18 Nm)

Snorkel Locking Fastener 9 ft-lbs (12 Nm)

Solenoid 25 ft-lbs (34 Nm)

Speed Sensor 10 ft-lbs (14 Nm)