Sportsman 850

2018 Sportsman 850/1000
Service Manual
FOREWORD
The information printed within this publication includes the latest product information at time of print.
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.
Publication Printed August 2017 (PN 9928503 R02)

SAFETY WARNINGS
Throughout this manual, important information is brought to your attention by the following symbols:
WARNING
SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator,
bystander or person(s) inspecting or servicing the vehicle.
CAUTION
SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the
vehicle.
CAUTION
CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.
NOTE
NOTE provides key information by clarifying instructions.
IMPORTANT
IMPORTANT provides key reminders during disassembly, assembly and inspection of components.
TRADEMARKS
POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:
Loctite, Registered Trademark of the Loctite Corporation
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity-Vac, Registered Trademark of Neward Enterprises, Inc.
Torx, Registered Trademark of Textron
Hilliard, Trademark of the Hilliard Corporation
Warn, Trademark of Warn Industries
FOX, Registered Trademark of FOX RACING SHOX
RydeFX, Registered Trademark of ArvinMeritor
Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from
www.purepolaris.com or by contacting the nearest Polaris dealer.
REVISION INDEX: 2018 SPORTSMAN
REV RELEASE CHANGES

DATE
R01 9/20/2016 Initial release
R02 11/13/2017 Updated engine timing procedure
2018 Sportsman 850/1000
Service Manual
Chapter Summary
CHAPTER 1: GENERAL INFORMATION

CHAPTER 2: MAINTENANCE
CHAPTER 3: ENGINE / COOLING SYSTEM
CHAPTER 4: FUEL SYSTEM
CHAPTER 5: PVT SYSTEM
CHAPTER 6: TRANSMISSION
CHAPTER 7: FINAL DRIVE
CHAPTER 8: STEERING / SUSPENSION
CHAPTER 9: BRAKE SYSTEM
CHAPTER 10: BODY / FRAME
CHAPTER 11: ELECTRICAL
GENERAL INFORMATION
CHAPTER 1 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL NUMBER DESIGNATION (2015 +) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
REFERENCE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
POLARIS MOBILE DIGITAL WRENCH (PMDW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
MASTER TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
VEHICLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10
2018 SPORTSMAN 850 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10
2018 SPORTSMAN 850 SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12
2018 SPORTSMAN 850 TOURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14
2018 SPORTSMAN 1000 XP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.16
2018 SPORTSMAN 1000 XP TOURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.18
2018 SPORTSMAN XP 850 HIGH LIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.20
2018 SPORTSMAN XP 1000 HIGH LIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.22
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.24
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.24
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.25
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.25
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.26
1.1
GENERAL INFORMATION
VEHICLE IDENTIFICATION
MODEL NUMBER DESIGNATION (2015 +)
Example: R15RUE57AC
GROUP MODEL YEAR MAKE / CHASSIS CODE ENGINE CODE REGION OPTION
1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th 10th**
R 1 5 R U E 5 7 A C
* = 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: 4XAKA09A0F3000000
VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS
MFG. LOCATION
MODEL YEAR *
CHECK DIGIT
ENGINE SIZE
CATEGORY
DRIVELINE
MODIFIER
CHASSIS
ENGINE
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 G 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
1.2
GENERAL INFORMATION
VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS

Whenever corresponding about a Polaris ATV, be sure to refer to the vehicle identification number (VIN) and the
engine serial number.
1
The VIN can be found stamped on the lower frame rail on the front LH side of the ATV (see Figure 1-1).
The engine serial number can be found on the rear portion of the engine located on the valve cover (see Figure 1-2).
1.3
GENERAL INFORMATION
REFERENCE INFORMATION
PUBLICATION NUMBERS
YEAR MODEL MODEL NO. OWNERS MANUAL
SPORTSMAN 850 A18SXA85B1 / B7 9928123
SPORTSMAN 850 SP A18SXE85B9 / BM / BS 9928123
SPORTSMAN 1000 XP A18SXE95BR / BL / BP 9928123
2018
SPORTSMAN 850 TOURING A18SYE85BB 9928122
SPORTSMAN 1000 TOURING A18SYE95BU 9928122
SPORTSMAN 850 HIGH LIFTER A18SXN85B8 9928123
1.4
GENERAL INFORMATION
SPECIAL TOOLS
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 the Polaris official tool supplier.
Bosch Automotive Service Solutions 1-800-345-2233 or https://polaris.service-solutions.com
1.5
GENERAL INFORMATION
POLARIS MOBILE DIGITAL WRENCH • An electronic user’s guide is provided within the app.
(PMDW) To access the user’s guide, launch the app, and then
click on the “Help” button in the Settings/Preferences
Polaris Mobile Digital Wrench (PMDW) is a diagnostic menu.
software application (app) designed specifically for • Only CAN-based vehicles are compatible with PMDW
Android™ devices. When paired with the Wireless and the WVL. A complete list of compatible vehicles
Vehicle Link (WVL), part number PU-51435, PMDW can be found in the user’s guide.
provides Polaris service technicians with many of the
features and functions found in Digital Wrench.
PMDW Main Page:
Wireless Vehicle Link (WVL) – Part Number PU-

51435:
To download the PMDW app, navigate your Android

device to www. polarisdealers. com. Locate the Service
and Warranty drop-down menu. Select: “Mobile Digital
Wrench App Download”. Tap on the link to download the
app.
Android Device Minimum Specifications:
• Minimum operating system: Android 3.1 “Honeycomb”
or higher (Android 4.0 or higher preferred)
• Dual core processor / 2 GB internal memory / external
microSD (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
PMDW App Notes:

• PMDW will not work on Microsoft Windows 8™ or
Apple IOS™ products
• Device must be set to allow the installation of non-
market applications
1.6
GENERAL INFORMATION
MASTER TORQUE TABLE ENGINE / COOLING SYSTEM
MAINTENANCE ITEM TORQUE 1

ITEM TORQUE Cam Chain Tensioner 7 ft. lbs (10 Nm)
Fasteners
Oil Drain Plug 12 ft-lbs (16 Nm)
Camshaft Carrier 13 ft. lbs (18 Nm)
Turn by hand until filter Fasteners
O-ring contacts sealing
Oil Filter Spark Plug 18 ft. lbs (25 Nm)
surface, then turn an
additional 3/4 turn. Valve Cover Bolts 12-14 ft-lbs (16-19 Nm)
Spark Plug 18 ft. lbs (25 Nm) Exhaust System
Snorkel Clamps (HL Torque in sequence:
14 ft. lbs (2 Nm)
only) Step 1: Front to Rear: 8
Exhaust Head Pipe Nuts ft. lbs (11 Nm)
ENGINE / COOLING SYSTEM Step 2: Rear to Front: 14
ft. lbs (19 Nm)
ITEM TORQUE
Cooling System
Engine Components
Radiator Mounting 10 ft. lbs (13 Nm)
Engine Mount Fasteners 19 ft. lbs (26 Nm) Fasteners
Spark Arrestor Fastener 8 ft-lbs (11 Nm) Cooling Hose Gear
35 in-lbs (4 Nm)
Clamps
Step 1: 9 ft-lb (12 Nm)
Connecting Rod Bolts Step 2: 20 ft-lb (27 Nm) Thermostat Housing 7 ft-lbs (10 Nm)
Step 3: Tighten add’n Fasteners
90°
Water Pump Impeller 10 ft. lbs (13 Nm)
Connecting Rod Bolts: 16 ft. lbs (22 Nm) Bolt
For Measurement
Water Pump Cover 89 in. lbs (10 Nm)
Torque in sequence: Fasteners
Crankcase Bolts M9 Step 1: 71 in. lbs (8 Nm)
Step 2: 26 ft. lbs (35 Nm) Drive Coupler Fasteners 14 ft-lbs (19 Nm)
Crankcase Bolts M6 89 in. lbs (10 Nm)

EFI / FUEL SYSTEM
Crankcase Oil Gallery ITEM TORQUE
12 ft. lbs (16 Nm)
Plug
Air Box Mount Screw Until Fully Seated
Oil Pump Mounting 9 ft. lbs (12 Nm)
Bolts Engine Coolant Temp 17 ft. lbs (23 Nm)
Sensor
Oil Sump Baffle 89 in. lbs (10 Nm)
Fasteners Fuel Rail Mounting 44 in. lbs (5 Nm)
Screws
Flywheel Retaining Bolt 74 ft. lbs (100 Nm)
Fuel PFA Nut 70 ft. lbs (95 Nm)
Stator Cover Fasteners 89 in. lbs (10 Nm)
Fuel Tank Fastener Until Fully Seated
Torque in sequence:
Step 1: 8 ft. lbs (11 Nm) Plenum to Throttle Body 7 ft-lbs (10 Nm)
Step 2: 43 ft. lbs (59 Nm) Fastener
Cylinder Head Bolts
Step 3: Additional 180°
Step 4: M6 bolts: 7 ft-lb T-MAP Retaining Bolt 30 in. lbs (3.5 Nm)
(10 Nm) Crankshaft Position
89 in. lbs (10 Nm)
Camshaft Sprocket Sensor (CPS) Fastener
28 ft. lbs (38 Nm)
Fastener ETC Housing Retaining 7 ft-lbs (10 Nm)
Bolts
1.7
GENERAL INFORMATION
PVT SYSTEM FINAL DRIVE

ITEM TORQUE ITEM TORQUE
Drive Clutch Bolt 47 ft. lbs (64 Nm) Lug Nut (Aluminum
75 ft. lbs (102 Nm)
Wheel)
225 ft. lbs (305 Nm)
(Apply 0.4 mL Loctite® Lug Nut (Steel Wheel) 45 ft. lbs (61 Nm)
Spider Assembly
7088 Primer and 0.4 mL
Loctite® 620™) Hub Nut 80 ft. lbs (108 Nm)
Drive Clutch Cover Front Gearcase Fill /

100 in. lbs (12 Nm) 10 ft-lbs (14 Nm)
Bolts Drain Plug
Shift Weight Fastener 20 in. lbs (2 Nm) Front Gearcase Mount 36 ft. lbs (49 Nm)
Fasteners
Driven Clutch Retaining 37 ft. lbs (50 Nm)
Bolt Front Gearcase Cover 8 ft. lbs (11 Nm)
Fasteners
Driven Clutch Helix 48 in. lbs (5 Nm)
Fasteners Rear Gearcase Mount 40 ft. lbs (54 Nm)
Fasteners
Outer Clutch Cover
30 in. lbs (3.5 Nm) Rear Gearcase Cover
Retaining Fasteners 18 ft. lbs (25 Nm)
Fasteners
Inner Clutch Cover 5 ft. lbs (7 Nm)
Fasteners Rear Propshaft 18 ft. lbs (25 Nm)
Fasteners
Air Duct Clamp 24 in-lbs (3 Nm)
Rear Propshaft Coupler 100 ft. lbs (136 Nm)
Nut
TRANSMISSION
ITEM TORQUE STEERING / SUSPENSION
Transmission Fill / Drain ITEM TORQUE

14 ft. lbs (19 Nm)
Plug Steering
Engine / Transmission Steering Post to
19 ft. lbs (26 Nm) 18 ft. lbs (24 Nm)
Mounting Fasteners Bulkhead
Transmission Case 18 ft. lbs (25 Nm) Steering Post to
Bolts 18 ft. lbs (24 Nm)
Gearcase
Bell Crank Nut 15 ft. lbs (20 Nm) Tie Rod Jam Nuts 12 ft. lbs (16 Nm)
Bell Housing Fasteners 55 ft. lbs (76 Nm) Tie Rod End Nuts 42 ft. lbs (58 Nm)
Oil Deflector Plate 8 ft. lbs (11 Nm) EPS to Bracket
Fasteners 30 ft. lbs (40 Nm)
Fasteners
Shift Detent Plug 20 ft. lbs (27 Nm) Steering Shaft Pinch
Fasteners 14 ft. lbs (19 Nm)
Bolts
Transmission Mount 19 ft. lbs (26 Nm) Handlebar Block
Bolts 14 ft. lbs (19 Nm)
Fasteners
Transmission Mount 36 ft. lbs (49 Nm)
Torx Fasteners
Suspension
A-arm Fasteners 37 ft. lbs (50 Nm)
Ball Joint Pinch 17 ft. lbs (24 Nm) Plus

Fastener 90 Degrees
Front Shock Mounting 37 ft. lbs (50 Nm)
Fasteners
1.8
GENERAL INFORMATION
STEERING / SUSPENSION ELECTRICAL

ITEM TORQUE ITEM TORQUE 1
Tie Rod Jam Nut 14 ft-lbs (19 Nm) Tail Light Fasteners Until Fully Seated
Tie Rod End Fastener 42 ft-lbs (57 Nm) Battery Terminal 6 ft. lbs (8 Nm)
Fasteners
Rear Shock Mounting 30 ft-lbs (54 Nm)
Fasteners
Rear Stabilizer to
37 ft. lbs (50 Nm)
Linkage Fasteners
Rear Stabilizer Bracket 37 ft. lbs (50 Nm)
Fasteners
BRAKE SYSTEM
ITEM TORQUE
Caliper Mounting 37 ft. lbs (50 Nm)
Fasteners
Brake Line Banjo 15 ft. lbs (20 Nm)
Fasteners
Brake Line Flare
13 ft. lbs (17 Nm)
Fittings
Master Cylinder Cover 7 in. lbs (1 Nm)
Fasteners
Master Cylinder Clamp 70 in. lbs (8 Nm)
Fasteners
Brake Bleeder 47 in. lbs (5 Nm)
Brake Pedal Fastener 38 ft. lbs (52 Nm)
Rear Master Cylinder 8 ft. lbs (11 Nm)
Fasteners
BODY / FRAME
ITEM TORQUE
Body Fasteners Until Fully Seated
Upper Frame Rail 36 ft. lbs (49 Nm)
Fasteners
ELECTRICAL
ITEM TORQUE
Voltage Regulator 75 in. lbs (7 Nm)
Fasteners
Starter Mounting 20 ft. lbs (27 Nm)
Fasteners
Fuse Block Fasteners Until Fully Seated
1.9
GENERAL INFORMATION
VEHICLE SPECIFICATIONS
2018 SPORTSMAN 850 ENGINE
Lubrication Pressurized Wet Sump
Engine Oil Requirement PS-4 / 2 qt. (1.9 l)
Stainless Steel Dual Header
Exhaust System Pipe
w/ Dual Outlet Silencer
FUEL SYSTEM
Bosch Multi-Port
Fuel System Type
Sequential EFI
Throttle Body / Size Mikuni Dual Bore / 42 mm
Electronic Fuel Pump (in
Fuel Delivery
tank)
CATEGORY DIMENSION Fuel Pressure 58 psi (400 kPa)

Length 83.25 in. / 211.5 cm Fuel Capacity 5.25 gal. (20 l)
Width 47.6 in. / 121 cm
Fuel Requirements 87 Octane (minimum)
Height 50.75 in. / 129 cm
Wheel Base 53 in. / 135 cm
ELECTRICAL
Ground Clearance 11.6 in. / 30.5 cm
Turning Radius 84 in. / 213 cm (unloaded) Alternator Output 475 W @ 1200 RPM / Peak
630 W
Dry Weight 777 lbs. (352 kg) (850)
Voltage Regulator 3-Phase / 32 Amp
Front Rack Capacity 120 lbs. / 54 kg
Rear Rack Capacity 240 lbs. / 109 kg Pod: 12V / 50 Watts
Head Lights
Bumper: 12V / 50 Watts x 2
Max. Weight Capacity 575 lbs. / 261 kg
Towing Capacity 1500 lbs. / 680 kg Brake Light 12V / 3.6 watts
Unbraked Trailer Towing Tail Light 12V / 0.26 watts
Capacity (EU)* 1914 lbs. / 868 kg
* Data based on EU Starting System Electric
Directive 76/432/EEC
Bosch EFI (ECU
Hitch Tongue Weight 150 lbs. / 68 kg Ignition System
Controlled)
ENGINE Champion REA6MC / .035

Spark plug / Gap
Domestic Twin Cylinder, 4- in. (0.9 mm)
Platform Cycle
Battery / Model / AH / YUASA / YTX20HL / 18 AH
Engine Model Number SPM850–17 CCA / 310
Engine Displacement 850 cc Instrumentation Digital
Number of Cylinders 2
DC Outlet Standard
Bore & Stroke (mm) 87 x 71.5 mm
Chassis / Start Solenoid /
Compression Ratio 11.0:1 Relays
Fan /
(Located in Relay/Fuse
Compression Pressure 210 - 250 psi EFI / Bumper Lights / EPS
Box)
Engine Idle Speed (Optional)
1200 ± 50 RPM
Engine Max RPM Limit 7600 RPM
Cooling System / Cap. Liquid Cooled / 2.7 qt. (2.6 l)
Overheat Warning Instrument Cluster Indicator
1.10
GENERAL INFORMATION
ELECTRICAL WHEELS / BRAKES

Circuit Breaker Fan Motor: 20A
Brakes
Single Control 1
Hydraulic 3-Wheel Disc
Lights: 20 Amp
Drive: 20 Amp Brake Fluid Polaris DOT 4 Brake Fluid
Fuses
Accessory: 20 Amp
EFI: 20 Amp
Box) CLUTCH SETTINGS
Unswitched: 10 Amp
EPS: 30 Amp (Optional) DRIV-
SHIFT DRIVE
EN
ALTITUDE WEIG- SPRI- HELIX
DRIVETRAIN SPRI-
HT NG
NG
Transmission Type Automatic PVT
In-Line H-L-N-R-P 23-58 Black/
Transmission 0-1800 PN White 64-
Polaris AGL (0-6000) 56322- 42-140 0516_ 66FR
Fluid Type / Fluid
37 oz. (1100 ml) Me- 18 Purple
Capacity 140/ BA45
ters PN
Front Gearcase (Feet) 1800-3700 24-56 70438- 220 PN
Polaris Demand Drive Fluid PN 32359-
Fluid Type / Fluid PN 05
9.3 oz. (275 ml) (6000 - 70445- 71
Capacity 56323-
12000) 11
Front Gearcase 94
ADC Reservoir Fluid Polaris Demand Drive Fluid
Type
Rear Gearcase Polaris ATV Angle Drive
Fluid Type / Fluid Fluid
Capacity 7.1 oz. (210 ml)
Clutch Type PVT w/EBS
Belt 3211160
STEERING / SUSPENSION
Toe Out 1/4-1/2 in. (6.4-12.7 mm)
Front Suspension Dual A-arm
Front Travel 9.2 in. / 23 cm
Rear Suspension Dual A-arm w/Rolled IRS
Rear Travel 10.2 in. / 26 cm
Shock Preload
Adjustment Cam Adjustable
Front / Rear
WHEELS / BRAKES
Front Wheel Size / Bolt
Steel: 14 x 6 / 4-156
Pattern
Front Tire Model / Size Maxxis AT / 26 x 8 - 14
Rear Wheel Size / Bolt
Steel: 14 x 8 / 4-156
Pattern
Rear Tire Model / Size Maxxis AT / 26 x 10 - 14
Front: 7 psi (48 kPa)
Tire Air Pressure Rear: 7 psi (48 kPa)
1.11
GENERAL INFORMATION
2018 SPORTSMAN 850 SP ENGINE

+Engine Oil Requirement PS-4 / 2 qt. (1.9 l)
Exhaust System Pipe
FUEL SYSTEM
Bosch Multi-Port
Fuel System Type
Sequential EFI
Fuel Delivery
tank)
Fuel Pressure 58 psi (400 kPa)

CATEGORY DIMENSION Fuel Capacity 5.25 gal. (20 l)
Length 83.25 in. / 211.5 cm Fuel Requirements 87 Octane (minimum)
Width 47.6 in. / 121 cm
ELECTRICAL
Alternator Output 475 W @ 1200 RPM / Peak
630 W
Turning Radius 84 in. / 213 cm (unloaded)
Dry Weight 767 lbs. (347.9 kg) (850 SP)
Front Rack Capacity 120 lbs. / 54 kg Pod: 12V / 50 Watts
Head Lights
Rear Rack Capacity 240 lbs. / 109 kg
Max. Weight Capacity 575 lbs. / 261 kg Brake Light 12V / 3.6 watts
Towing Capacity 1500 lbs. / 680 kg Tail Light 12V / 0.26 watts
Unbraked Trailer Towing
Starting System Electric
* Data based on EU Bosch EFI (ECU
Directive 76/432/EEC Ignition System
Controlled)
Hitch Tongue Weight 150 lbs. / 68 kg
Champion REA6MC / .035
Spark plug / Gap
in. (0.9 mm)
ENGINE
Domestic Twin Cylinder, 4- Battery / Model / AH / YUASA / YTX20HL / 18 AH
Platform Cycle CCA / 310
Engine Model Number SPM850–17 Instrumentation Digital
Engine Displacement 850 cc
DC Outlet Standard
Relays Chassis / Start Solenoid /
Bore & Stroke (mm) 87 x 71.5 mm (Located in Relay/Fuse Fan /
Compression Ratio 11.0:1 Box) EFI / Bumper Lights / EPS
Compression Pressure 210 - 250 psi Circuit Breaker Fan Motor: 20A
Engine Idle Speed 1200 ± 50 RPM
Lights: 20 Amp
Engine Max RPM Limit 7600 RPM Drive: 20 Amp
Fuses
Cooling System / Cap. Liquid Cooled / 2.7 qt. (2.6 l) Accessory: 20 Amp
EFI: 20 Amp
Overheat Warning Instrument Cluster Indicator Box)
Unswitched: 10 Amp
Lubrication Pressurized Wet Sump EPS: 30 Amp
1.12
GENERAL INFORMATION
DRIVETRAIN CLUTCH SETTINGS

In-Line H-L-N-R-P SHIFT DRIVE
DRIV- 1
EN
Transmission ALTITUDE WEIG- SPRI- HELIX
Polaris AGL SPRI-
Fluid Type / Fluid HT NG
37 oz. (1100 ml) NG
Capacity
23-58 Black/
Front Gearcase 0-1800
Polaris Demand Drive Fluid PN White 64-
Fluid Type / Fluid
9.3 oz. (275 ml) (0-6000) 56322- 42-140 0516_ 66FR
Capacity Me- Purple
18 140/ BA45
Front Gearcase ters PN
(Feet) 1800-3700 24-56 70438- 220 PN
ADC Reservoir Fluid Polaris Demand Drive Fluid
PN PN 32359-
Type (6000 - 05
56323- 70445- 71
Rear Gearcase Polaris ATV Angle Drive 12000) 11
94
Belt 3211160
Toe Out 1/4-1/2 in. (6.4-12.7 mm)
Shock Preload
Front / Rear
WHEELS / BRAKES
Front Wheel Size / Bolt Aluminum: 14 x 5.5 / 4-
Pattern 156
Carlisle AT 489 II / 26 x 8 -
Front Tire Model / Size
14
Rear Wheel Size / Bolt Aluminum: 14 x 7.5 / 4-
Pattern 156
Rear Tire Model / Size
14
Single Control
Brakes Hydraulic 3-Wheel Disc
Brake Fluid Polaris DOT 4 Brake Fluid
1.13
GENERAL INFORMATION
2018 SPORTSMAN 850 TOURING ENGINE

Exhaust System Pipe
FUEL SYSTEM
Bosch Multi-Port
Fuel System Type
Sequential EFI
Fuel Delivery
tank)

Width 47.6 in. / 121 cm
ELECTRICAL
630 W
Dry Weight 798 lbs. / 362 kg
Front Box Capacity 120 lbs. / 54 kg Pod: 12V / 50 Watts
Head Lights
Max. Weight Capacity 575 lbs. / 261 kg Brake Light 12V / 27 Watts
Towing Capacity 1500 lbs. / 680 kg Tail Light 12V / 7 Watts
Controlled)
Spark plug / Gap
in. (0.9 mm)
ENGINE
Engine Model Number SPM850–17 Instrumentation Digital / Analog
DC Outlet Standard
Bore & Stroke (mm) 87 x 71.5 mm Fan /
Compression Ratio 11.0:1 Box) EFI / B. Lights / EPS / Rear
Compression Pressure 210 - 250 psi Diff
Engine Idle Speed 1200 ± 50 RPM Circuit Breaker Fan Motor: 20A
Engine Max RPM Limit 7600 RPM Lights: 20 Amp
Cooling System / Cap. Liquid Cooled / 2.7 qt. (2.6 l) Drive: 20 Amp
Fuses
Accessory: 20 Amp
Overheat Warning Instrument Cluster Indicator (Located in Relay/Fuse
EFI: 20 Amp
Box)
Lubrication Pressurized Wet Sump Unswitched: 10 Amp
EPS: 30 Amp
1.14
GENERAL INFORMATION

In-Line H-L-N-R-P
SHIFT DRIVE
DRIV-
EN
1
Transmission SPRI-
Polaris AGL HT NG
Fluid Type / Fluid NG
37 oz. (1100 ml)
Capacity 23-58
Front Gearcase 0-1800 PN 664-
Polaris Demand Drive Fluid (0-6000) 56322- Purple 140- 66FR
Fluid Type / Fluid Me-
9.3 oz. (275 ml) 18 220 PN BA45°
Capacity ters PN
Front Gearcase Polaris Demand Drive Fluid (Feet) 1800-3700 24-56 70438- 70445- PN
PN 05 11 32359-
Rear Gearcase Polaris ATV Angle Drive (6000 -
56323- 71
Fluid Type / Fluid Fluid 12000)
94
Belt 3211160
Toe Out 1/4-1/2 in. (6.4-12.7 mm)
Front Travel 9 in. / 22.9 cm
Shock Preload
Front / Rear
WHEELS / BRAKES
Pattern 156
14
Pattern 156
14
Single Control
1.15
GENERAL INFORMATION
2018 SPORTSMAN 1000 XP ENGINE

Exhaust System Pipe
with Silencer
FUEL SYSTEM
Bosch Multi-Port
Fuel System Type
Sequential EFI
Fuel Delivery
tank)

Width 47.6 in. / 121 cm
ELECTRICAL
630 W
Dry Weight 785 lbs. (356 kg)
Head Lights
Max. Weight Capacity 575 lbs. / 261 kg Brake Light 12V / 0.26 watts
Towing Capacity 1500 lbs. / 680 kg Tail Light 12V / 3.6 watts
Controlled)
Autolite 5682 / .030 in.
Spark plug / Gap
(0.76 mm)
ENGINE
Engine Model Number SPM1000–17 Instrumentation Digital
Engine Displacement 952cc
DC Outlet Standard
Bore & Stroke (mm) 90.5 x 74 mm Relays
Fan /
Compression Ratio 11.0:1 EFI / Bumper Lights / EPS /
Box)
Compression Pressure 210 - 250 psi Fuel Pump
1.16
GENERAL INFORMATION

Circuit Breaker Fan Motor: 20A Rear: 7 psi (48 kPa) 1
Lights: 20 Amp Single Control
Drive: 20 Amp Brakes Hydraulic 4-Wheel Disc
Fuses Accessory: 20 Amp
(Located in Relay/Fuse EFI: 20 Amp Brake Fluid Polaris DOT 4 Brake Fluid
Box) Unswitched: 10 Amp
EPS: 30 Amp CLUTCH SETTINGS
Fuel Pump: 10 Amp
DRIV-
SHIFT DRIVE
EN
DRIVETRAIN ALTITUDE WEIG- SPRI- HELIX
SPRI-
Automatic PVT HT NG
Transmission Type NG
In-Line H-L-N-R-P
Transmission 2-62 Black/
Polaris AGL 0-1800 PN White 64-
Fluid Type / Fluid
Capacity
37 oz. (1100 ml) (0-6000) 56323- 41-140 0516_ 66FR
Me- 37 Purple
Front Gearcase ters 140/ BA45
Polaris Demand Drive Fluid PN 220
Fluid Type / Fluid (Feet) 1800-3700 24-60 70438- PN
9.3 oz. (275 ml) PN 32359-
Capacity (6000 - PN 05
56322- 70445- 71
Front Gearcase 12000) 11
ADC Reservoir Fluid 16
Polaris Demand Drive Fluid
Type
Belt 3211123
Toe Out 1/4-1/2 in. (6.4-12.7 mm)
Shock Preload
Front / Rear
WHEELS / BRAKES
Pattern 156
14
Pattern 156
14
Tire Air Pressure Front: 7 psi (48 kPa)
1.17
GENERAL INFORMATION
2018 SPORTSMAN 1000 XP TOURING ENGINE

Exhaust System Pipe
with Silencer
FUEL SYSTEM
Bosch Multi-Port
Fuel System Type
Sequential EFI
Fuel Delivery
tank)

Width 47.6 in. / 121 cm
ELECTRICAL
630 W
Head Lights
Controlled)
Spark plug / Gap
(0.76 mm)
ENGINE
Engine Model Number SPM1000-17 Instrumentation Digital LCD
DC Outlet Standard
Lights: 20 Amp
Fuses
Cooling System / Cap. Liquid Cooled / 2 qt. (1.9 l) Accessory: 20 Amp
EFI: 20 Amp
Unswitched: 10 Amp
1.18
GENERAL INFORMATION

DRIV- 1
EN
Polaris AGL SPRI-
37 oz. (1100 ml) NG
Capacity
23-62
Front Gearcase 0-1800
Polaris Demand Drive Fluid PN 664-
Fluid Type / Fluid (0-6000) 140-
9.3 oz. (275 ml) 56323- Purple 66FR
Capacity Me- 220
37 PN BA45°
Front Gearcase Polaris Demand Drive Fluid ters PN
(Feet) 1800-3700 24-60 70438- PN
Rear Gearcase Polaris ATV Angle Drive 70445-
PN 05 32359-
Fluid Type / Fluid Fluid (6000 - 11
56322- 71
Capacity 7.1 oz. (210 ml) 12000)
16
Belt 3211123
Toe Out 1/4-1/2 in. (6.4-12.7 mm)
Rear Travel 10 in. / 25.4 cm
Shock Preload
Front / Rear
WHEELS / BRAKES
Pattern 156
14
Pattern 156
14
Single Control
1.19
GENERAL INFORMATION
2018 SPORTSMAN XP 850 HIGH LIFTER ENGINE

+Engine Oil Requirement PS-4 / 2 qt. (1.9 l)
Exhaust System Pipe
FUEL SYSTEM
Bosch Multi-Port
Fuel System Type
Sequential EFI
Fuel Delivery
tank)

Width 47.6 in. / 121 cm
ELECTRICAL
630 W
Dry Weight 921 lbs. / 418kg
Head Lights
Rear Rack Capacity 75lbs. / 34 kg
Controlled)
Spark plug / Gap
in. (0.9 mm)
ENGINE
Engine Model Number SPM850–17 Instrumentation Digital / Analog Cluster
DC Outlet Standard
Lights: 20 Amp
Fuses
Cooling System / Cap. Liquid Cooled / 2.7 qt. (2.6 l) Accessory: 20 Amp
EFI: 20 Amp
Unswitched: 10 Amp
1.20
GENERAL INFORMATION

DRIV- 1
EN
Polaris AGL SPRI-
37 oz. (1100 ml) NG
Capacity
BLK /
Front Gearcase Black/
Polaris Demand Drive Fluid WHT
Fluid Type / Fluid 0-1800 24–70 Red 64–
9.3 oz. (275 ml) 140–
Capacity (0-6000) 56331- PN 66FR
Me- 220
36 70442- 34° BA
Front Gearcase ters 70440-
63
ADC Reservoir Fluid Polaris Demand Drive Fluid (Feet) 86
Type
1800-3700
Rear Gearcase Polaris ATV Angle Drive (6000 - N/A N/A N/A N/A
Fluid Type / Fluid Fluid 12000)
Belt 3211160
Toe Out 1/4-1/2 in. (6.4-12.7 mm)
Shock Preload
Front / Rear
WHEELS / BRAKES
Pattern 156
Carlisle AT 489 II / 29.5 x
9.5 - 14
Pattern 156
Carlisle AT 489 II / 29.5 x
9.5- 14
Single Control
1.21
GENERAL INFORMATION
2018 SPORTSMAN XP 1000 HIGH LIFTER ENGINE

Exhaust System Pipe
with Silencer
FUEL SYSTEM
Bosch Multi-Port
Fuel System Type
Sequential EFI
Fuel Delivery
tank)

Width 47.6 in. / 121 cm
ELECTRICAL
630 W
Head Lights
Controlled)
Spark plug / Gap
(0.76 mm)
ENGINE
Engine Model Number SPM1000-17 Instrumentation Digital / Analog Cluster
Engine Displacement 952cc
DC Outlet Standard
Bore & Stroke (mm) 90.5 x 74 mm Relays
Fan /
Compression Ratio 11.0:1 EFI / Bumper Lights / EPS /
Box)
Compression Pressure 210 - 250 psi Fuel Pump
1.22
GENERAL INFORMATION

Circuit Breaker Fan Motor: 20A
Brakes
Single Control 1
Hydraulic 4-Wheel Disc
Lights: 20 Amp
Drive: 20 Amp Brake Fluid Polaris DOT 4 Brake Fluid
Fuses Accessory: 20 Amp
(Located in Relay/Fuse EFI: 20 Amp
CLUTCH SETTINGS
Box) Unswitched: 10 Amp
EPS: 30 Amp DRIV-
Fuel Pump: 10 Amp SHIFT DRIVE
EN
SPRI-
HT NG
DRIVETRAIN NG
Transmission Type Automatic PVT BLK/ 64-

Black/
In-Line H-L-N-R-P WHT
24–70 Red 66FR
Transmission 0-1800 140–
Polaris AGL PN 58–135 34°BA
Fluid Type / Fluid (0-6000) 220
37 oz. (1100 ml) Me- 56331- PN PN
Capacity PN
ters 36 70442- 32359-
70440-
Front Gearcase (Feet) 63 71
Polaris Demand Drive Fluid 86
Fluid Type / Fluid
9.3 oz. (275 ml) 1800-3700
Capacity
Front Gearcase (6000 - N/A N/A N/A N/A
ADC Reservoir Fluid 12000)
Type
Belt 3211123
Toe Out 1/4-1/2 in. (6.4-12.7 mm)
Shock Preload
Front / Rear
WHEELS / BRAKES
Pattern 156
Front Tire Model / Size 29.5 x 9.5 - 14
Pattern 156
Rear Tire Model / Size 29.5 x 9.5 - 14
1.23
GENERAL INFORMATION
MISC. SPECIFICATIONS AND CHARTS

CONVERSION TABLE
UNIT OF MEASURE MULTIPLIED BY CONVERTS TO
ft-lbs x 12 = in-lbs
in-lbs x 0.0833 = ft-lbs
ft-lbs x 1.356 = Nm
in-lbs x 0.0115 = kg-m
Nm x 0.7376 = ft-lbs
kg-m x 7.233 = ft-lbs
kg-m x 86.796 = in-lbs
kg-m x 10 = Nm
inch x 25.4 = mm
mm x 0.03937 = inch
inch x 2.54 = cm
mile (mi) x 1.6 = km
km x 0.6214 = mile
ounces (oz) x 28.35 = grams (g)
fluid ounces (fl oz) x 29.57 = cubic centimeters (cc)
cubic centimeters (cc) x .03381 = fluid ounces
grams (g) x 0.035 = ounces
pounds (lb) x 0.454 = kg

kilogram (kg) x 2.2046 = lbs
cubic inches (cu in) x 16.387 = cc
cubic centimeters (cc) x 0.061 = cubic inches

US quarts x 0.946 = liters (L)
liters (L) x 1.057 = US quarts
US gallons x 3.785 = liters (L)
liters (L) x 0.264 = US gallons
PSI x 6.895 = kilopascals (kPa)
kilopascals (kPa) x 0.145 PSI
π (3.14) x Radius² x Height = = cylinder volume
°C to °F: 9/5 (°C + 32) = °F
°F to °C: 5/9 (°F − 32) = °C
1.24
GENERAL INFORMATION
SAE TAP / DRILL SIZES METRIC TAP / DRILL SIZES

THREAD THREAD DECIMAL 1
SIZE DRILL SIZE SIZE DRILL SIZE EQUIVA- NEAREST
TAP SIZE DRILL SIZE LENT FRACTION
#0–80 3/64 1/2–13 27/64 3 x .50 #39 0.0995 3/32
#1–64 53 1/2–20 29/64 3 x .60 3/32 0.0937 3/32
#1–72 53 9/16–12 31/64 4 x .70 #30 0.1285 1/8
4 x .75 1/8 0.125 1/8
#2–56 51 9/16–18 33/64
5 x .80 #19 0.166 11/64
#2–64 50 5/8–11 17/32 5 x .90 #20 0.161 5/32
#3–48 5/64 5/8–18 37/64 6 x 1.00 #9 0.196 13/64
7 x 1.00 16/64 0.234 15/64
#3–56 45 3/4–10 21/32
8 x 1.00 J 0.277 9/32
#4–40 43 3/4–16 11/16 8 x 1.25 17/64 0.265 17/64
#4–48 42 7/8–9 49/64 9 x 1.00 5/16 0.3125 5/16
#5–40 38 7/8–14 13/16 9 x 1.25 5/16 0.3125 5/16
10 x 1.25 11/32 0.3437 11/32
#5–44 37 1–8 7/8
10 x 1.50 R 0.339 11/32
#6–32 36 1–12 59/64 11 x 1.50 3/8 0.375 3/8
#6–40 33 1 1/8–7 63/64 12 x 1.50 13/32 0.406 13/32
12 x 1.75 13/32 0.406 13/32
#8–32 29 1 1/8–12 1 3/64
#8–36 29 1 1/4–7 1 7/64
#10–24 24 1 1/4–12 1 11/64
#10–32 21 1 1/2–6 1 11/32
#12–24 17 1 1/2–12 1 27/64
#12–28 4.6 mm 1 3/4–5 1 9/16
1/4–20 7 1 3/4–12 1 43/64
1/4–28 3 2–4 1/2 1 25/32
5/16–18 F 2–12 1 59/64
5/16–24 I 2 1/4–4 1/2 2 1/32
3/8–16 O 2 1/2–4 2 1/4
3/8–24 Q 2 3/4–4 2 1/2
7/16–14 U 3–4 2 3/4
7/16–20 25/64
1.25
GENERAL INFORMATION
DECIMAL EQUIVALENTS
FRACTION DECIMAL MM TO INCHES FRACTION DECIMAL MM TO INCHES
1/64 0.0156″ 41/64 0.6406″
1/32 0.0312″ 1 mm = 0.0394″ 21/32 0.6563″ 17 mm = 0.6693″
3/64 0.0469″ 43/64 0.6719″
1/16 0.0625″ 11/16 0.6875″
5/64 0.0781″ 2 mm = 0.0787″ 45/64 0.7031″ 18 mm = 0.7087″
3/32 0.0938″ 23/32 0.7188″
7/64 0.1094″ 3 mm = 0.1181″ 47/64 0.7344″ 19 mm = 0.7480″
1/8 0.1250″ 3/4 0.750″
9/64 0.1406″ 49/64 0.7656″
5/32 0.1563″ 4 mm = 0.1575″ 25/32 0.7813″ 20 mm = 0.7874″
11/64 0.1719″ 51/64 0.7969″
3/16 0.1875″ 5 mm = 0.1969″ 13/16 0.8125″ 21 mm = 0.8268″
13/64 0.2031″ 53/64 0.8281″
7/32 0.2188″ 27/32 0.8438″
15/64 0.2344″ 6 mm = 0.2362″ 55/64 0.8594″ 22 mm = 0.8661″
1/4 0.25″ 7/8 0.875″
17/64 0.2656″ 7 mm = 0.2756″ 57/64 0.8906″ 23 mm = 0.9055″
9/32 0.2813″ 29/32 0.9063″
19/64 0.2969″ 59/64 0.9219″
5/16 0.3125″ 8 mm = 0.3150″ 15/16 0.9375″ 24 mm = 0.9449″
21/64 0.3281″ 61/64 0.9531″
11/32 0.3438″ 9 mm = 0.3543″ 31/32 0.9688″ 25 mm = 0.9843″
23/64 0.3594″ 63/64 0.9844″
3/8 0.375″ 1 1.000″
25/64 0.3906″ 10 mm = 0.3937″
13/32 0.4063″
27/64 0.4219″ 11 mm = 0.4331″
7/16 0.4375″
29/64 0.4531″
15/32 0.4688″ 12 mm = 0.4724″
31/64 0.4844″
1/2 0.500″ 13 mm = 0.5118″
33/64 0.5156″
17/32 0.5313″
35/64 0.5469″ 14 mm = 0.5512″
9/16 0.5625″
37/64 0.5781″ 15 mm = 0.5906″
19/32 0.5938″
39/64 0.6094″
5/8 0.625″ 16 mm = 0.6299″
1.26
MAINTENANCE
CHAPTER 2
MAINTENANCE
2
PERIODIC MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PERIODIC MAINTENANCE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PRE-RIDE CHECKLIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
MAINTENANCE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
GREASE LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
MAINTENANCE QUICK REFERENCE, HIGH LIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10
LUBRICANTS / SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
POLARIS LUBRICANTS / MAINTENANCE / SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
50/50 EXTENDED-LIFE ENGINE ANTIFREEZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12
FUEL SYSTEM / AIR INTAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13
FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13
FUEL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13
VENT LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13
THROTTLE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13
THROTTLE RELEASE SWITCH (TRS) /THROTTLE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14
AIR FILTER / PRE-FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16
ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16
ENGINE OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16
ENGINE BREATHER HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
VALVE CLEARANCE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18
COMPRESSION AND LEAKDOWN TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20
SPORTSMAN SILENCER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20
ENGINE MOUNT FASTENER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
COOLING SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
COOLANT LEVEL INSPECTION, HIGH LIFTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23
COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
PVT / FINAL DRIVE / WHEELS / TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
PVT DRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
DRIVE SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
WHEEL AND HUB SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
WHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26
WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26
2.1
MAINTENANCE
TIRE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

TRANSMISSION / GEARCASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27
TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27
FRONT GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28
REAR GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28
ELECTRICAL / IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30
EXTREME USE 30 AH BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30
ENGINE / CHASSIS GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30
SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31
BATTERY OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32
STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.33
STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.33
POWER STEERING UNIT (EPS MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.33
TIE ROD END / STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.33
TOE ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.34
TOE ALIGNMENT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.35
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.36
SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.36
SUSPENSION SPRING PRE-LOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.36
FOX SHOCK SPRING PRELOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.36
SHOCK COMPRESSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.37
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38
BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38
BRAKE PAD / DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38
HOSE / FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.39
AUXILIARY BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.39
2.2
MAINTENANCE
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE OVERVIEW
Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement
parts, use genuine Pure Polaris parts available from your Polaris dealer.
2
NOTE
Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a
qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of
approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the
oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to
rise, discontinue use and determine the cause or see your dealer.
BREAK-IN PERIOD
The break-in period consists of the first 20 hours of operation. Careful treatment of a new engine and drive
components will result in more efficient performance and longer life for these components.
• Drive vehicle slowly at first while varying the throttle position. Do not operate at sustained idle.
• Pull only light loads.
• Perform regular checks on fluid levels and other areas outlined on the daily pre-ride inspection checklist.
• Change both the engine oil and filter after 20 hours or one month.
• See “Owner’s Manual” for additional break-in information.
MAINTENANCE CHART KEY

The following symbols denote potential items to be aware of during maintenance:
■ = CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an
authorized Polaris dealer.
▶ = SEVERE USE ITEM: See information provided above.
E = Emission Control System Service (California).
NOTE
Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.
WARNING
Improperly performing the procedures marked ■ could result in component failure and lead to serious injury or death.
Have an authorized Polaris dealer perform these services.
2.3
MAINTENANCE
PRE-RIDE CHECKLIST
Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an
accident. Always inspect the vehicle before each use to make sure it's in safe operating condition.
ITEM REMARKS
Brake system/lever travel Ensure proper operation
Brake Pads Ensure sufficient brake pad matierial
Brake fluid Ensure proper level
Auxiliary brake Ensure proper operation
Front suspension Inspect, lubricate if necessary
Rear suspension Inspect, lubricate if necessary
Steering Ensure free operation
Tires Inspect condition and pressure
Wheels/fasteners Inspect, ensure fastener tightness
Frame nuts, bolts, fasteners Inspect, ensure tightness
Fuel and oil Ensure proper levels
Coolant level (if applicable) Ensure proper level
Coolant hoses (if applicable) Inspect for leaks
Throttle Ensure proper operation
Indicator lights/switches Ensure operation
Engine stop switch Ensure proper operation
Air filter, pre-filter Inspect, clean
Air box sediment tube Drain deposits whenever visible
Headlamp Check operation, apply POLARIS dielectric grease when
lamp is replaced
Brake light/taillight Check operation, apply POLARIS dielectric grease when
lamp is replaced
Heat Shields Inspect for damaged and are properly secured
Riding gear Wear approved helmet, goggles, and protective clothing
Winch (if equipped) Inspect cable and switch
2.4
MAINTENANCE
MAINTENANCE INTERVALS
MAINTENANCE INTERVAL
ITEM (WHICHEVER COMES FIRST) REMARKS
HRS. CALENDAR MILES (KM)
▶
E
Air Filter (main element) - Weekly - Inspect; replace as needed 2
■ Brake Pad Wear 10 H 1M 100 (160) Inspect periodically
Battery 20 H 1M 200 (320) Check terminals; clean; test
Inspect; Cycle key to pressurize fuel pump; check
Fuel System Check 20 H 1M -
lines and fittings for leaks and abrasion
Inspect;
▶ Engine Breather Replace if
25 H 150 (250)
E necessary
▶ Engine Oil Change Perform a break-in oil change at one month or 20
25 H 1M 250 (400)
E (Break-in Period) hours, whichever comes first
Inspect level; change demand drive fluid if
▶ Front Gearcase Fluid 25 H 1M 250 (400)
exposed to extreme use*
▶ Rear Gearcase Fluid 25 H 1M 250 (400) Inspect level
▶ Transmission Fluid 25 H 1M 250 (400) Inspect level
▶ General Lubrication 50 H 3M 500 (800) Lubricate all fittings, pivots, cables, etc.
Shift Linkage 50 H 6M 500 (800) Inspect, lubricate
■ Steering 50 H 6M 500 (800) Lubricate
▶ Front Suspension 50 H 6M 500 (800) Lubricate
▶ Rear Suspension 50 H 6M 500 (800) Lubricate
■ Throttle Cable /
50 H 6M 500 (800) Inspect; adjust; lubricate; replace if necessary
E TRS Switch
E Throttle Body Intake Duct 50 H 6M 500 (800) Inspect ducts for proper sealing / air leaks
Drive belt 50 H 6M 500 (800) Inspect; replace as needed
Inspect coolant strength seasonally; pressure test
Cooling System 50 H 6M 500 (800)
system yearly
▶ Radiator 50 H 6M 500 (800) Inspect; clean external surfaces
▶ Cooling Hoses 50 H 6M 500 (800) Inspect for leaks
Perform a break-in oil change at 20 hours or after
▶ Engine Oil Change 100 H 6M 1000 (1600) one month of operation; change more frequently
during cold weather operation
▶ Oil Filter Change 100 H 6M 1000 (1600) Replace with oil change
▶ Front Gearcase Fluid 100 H 12 M 1000 (1600) Change fluid; also refer to 25 H interval
▶ Rear Gearcase Fluid 100 H 12 M 1000 (1600) Change fluid
▶ Transmission Fluid 100 H 12 M 1000 (1600) Change fluid
■ Check for leaks at tank cap, fuel lines, fuel pump;
Fuel System 100 H 12 M 1000 (1600)
E replace lines every two years
▶ Engine Mounts 100 H 12 M 1000 (1600) Inspect
Exhaust Pipe / Silencer 100 H 12 M 1000 (1600) Inspect
■
Spark Plug 100 H 12 M 1000 (1600) Inspect; replace as needed
E
Inspect for wear, routing, security; apply dielectric
▶ Wiring 100 H 12 M 1000 (1600) grease to connectors subjected to water, mud,
etc.
Clutches
■ 100 H 12 M 1000 (1600) Inspect; clean; replace worn parts
(Drive and Driven)
2.5
MAINTENANCE
MAINTENANCE INTERVAL
ITEM (WHICHEVER COMES FIRST) REMARKS
HRS. CALENDAR MILES (KM)
■ Wheel Bearings 100 H 12 M 1000 (1600) Inspect; replace as needed
■ Brake Fluid 200 H 24 M 2000 (3200) Change every two years
Suspension Bushings 250 H 24 M 2000 (3200) Inspect; replace if necessary
Spark Arrestor
300 H 36 M 3000 (4800) Clean out; or remove clean out plug
(if applicable)
▶ Coolant - 60 M - Replace coolant (50/50 Extended Life Coolant)
■
Valve Clearance 1000 H - 10000 (16000) Inspect; adjust
E
■ Toe Adjustment - Inspect periodically; adjust as needed
Headlight Aim - Adjust as needed
▶ Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
■ Have an authorized Polaris dealer perform these services.
*Service Note: Under extreme use, change demand drive fluid every 25 hours. "Extreme Use" is defined as constant
ADC operation on hilly or mountainous terrain, or if ADC is the primary mode of AWD operation.
2.6
MAINTENANCE
GREASE LUBRICATION POINTS

There are grease fittings on each upper and lower front and rear A-arms, each rear bearing carrier, and on the front
prop shaft yoke. Apply grease until all traces of water have been purged out at each of these areas.
ITEM RECOMMENDED LUBE METHOD FREQUENCY
q Front Propshaft 2
Yoke
Grease before long periods
w Rear Bearing Grease fittings every 500 of storage, and after
Carrier Polaris Premium U-Joint Grease miles (800 km). thoroughly washing or
submerging the ATV.
e Front A-Arms
r Rear A-Arms
2.7
MAINTENANCE
MAINTENANCE QUICK REFERENCE

# ITEM LUBE REC. METHOD FREQUENCY*
Change after 1st month or first
20 hours of operation, 100
Add oil to proper level on hours thereafter; Change more
q Engine Oil PS-4 dipstick often (25 hours) in severe duty
conditions or short trip cold
weather operation
Add fluid until it is visible at Check level every 25 hours;

w Transmission Polaris AGL
the fill hole threads change fluid yearly
Polaris 50/50 Extended Maintain coolant level in Check level daily, change
e Engine Coolant
Life Antifreeze coolant reservoir bottle. coolant every 2 years
* More often under severe use, such as operated in water or under severe loads.
2.8
MAINTENANCE
# ITEM LUBE REC. METHOD FREQUENCY*

Front Gearcase Polaris Demand Drive Maintain fluid level in ADC Check level daily; change fluid
r ADC Reservoir Fluid Reservoir to indicated level every two years or 2000 miles
Polaris Demand Drive Add fluid until it is visible at Check level every 25 hours;
t Front Gearcase
Fluid the fill hole threads change according to intervals
2
Polaris Angle Drive Add fluid until it is visible at Check level every 25 hours;
y Rear Gearcase
Fluid the fill hole threads change fluid yearly
Maintain fluid level in both Check level during pre-ride

u Brake Fluid DOT 4 Brake Fluid master cylinder reservoirs to inspection; change fluid every
indicated levels two years
* More often under severe use, such as operated in water or under severe loads.
2.9
MAINTENANCE
MAINTENANCE QUICK REFERENCE, HIGH LIFTER

NOTE Top View
High Lifter models engine coolant system components
are located in different locations than other models.
Side View
REF. DESCRIPTION
1 Pressure Cap
2 Recovery Bottle Hose
REF. DESCRIPTION 3 Radiator
1 Recovery Bottle Cap
2 Recovery Bottle
3 MAX Coolant Level
4 MIN Coolant Level
2.10
MAINTENANCE
LUBRICANTS / SERVICE PRODUCTS

POLARIS LUBRICANTS / MAINTENANCE / SERVICE PRODUCTS
NOTE LUBRICANTS, MAINTENANCE, AND SERVICE
PRODUCTS
• Each item can be purchased separately at your local
Polaris dealer.
2871460 Starter Drive Grease (12 count) 2
2871515 Premium U-Joint Lube (3 oz.) (24 count)
• The number count indicated by each part number in
the table above indicates the number of units that are 2871551 Premium U-Joint Lube (14 oz.) (10 count)
shipped with each order. 2871329 Dielectric Grease (Nyogel™)
Additives / Sealants / Thread Locking Agents / Misc.
LUBRICANTS, MAINTENANCE, AND SERVICE Loctite Threadlock 242
PRODUCTS 2871950 (6 ml.) (12 count)
Part No. Description Premium Carbon Clean
2871326 (12 oz.) (12 count)
Engine / Transmission Lubricant
2870791 Fogging Oil (12 oz. Aerosol) 2870652 Fuel Stabilizer (16 oz.) (12 count)
2876244 PS-4 Synthetic 4-Cycle Engine Oil (Quart) 2872189 DOT 4 Brake Fluid (12 count)
2876245 PS-4 Synthetic 4-Cycle Engine Oil (Gallon) 2871557 Crankcase Sealant, 3-Bond 1215 (5 oz.)
PS-4 Extreme Duty Synthetic 4-Cycle Loctite Threadlock 242
2878920 2871950 (6 ml.) (12 count)
Engine Oil (Quart)
PS-4 Extreme Duty Synthetic 4-Cycle Premium Carbon Clean
2878919 2871326 (12 oz.) (12 count)
Engine Oil (Quart)
Gearcase Lubricants 2870652 Fuel Stabilizer (16 oz.) (12 count)
2877922 Demand Drive Fluid (Quart) 2872189 DOT 4 Brake Fluid (12 count)
2877923 Demand Drive Fluid (2.5 Gallon) 2871557 Crankcase Sealant, 3-Bond 1215 (5 oz.)
AGL Gearcase Lubricant
2878068 (1 Qt.) (12 Count)
2878069 (1 Gal.) (4 Count)
2878070 (2.5 Gal.) (2 Count)
ATV Angle Drive Fluid
2876160 (Quart) (12 count)
ATV Angle Drive Fluid
2872276 (2.5 Gallon) (2 count)
2870465 Pump for Gallon Jug
Coolant
50/50 Extended Life Coolant (Quart) (12
2880514 count)
50/50 Extended Life Coolant (Gallon) (6
2880513 count)
50/50 Extended Life Coolant (55 US
2880512 Gallon Drum)
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)
2.11
MAINTENANCE
50/50 EXTENDED-LIFE ENGINE ANTIFREEZE

Beginning in the later part of 2014, Polaris began using 50/50 Extended Life antifreeze in some vehicles. All model-
year 2015 and newer vehicles will use 50/50 Extended Life antifreeze.
Using the 50/50 Extended-life antifreeze extends the service interval from two to five years.
It is important to note that 60/40 antifreeze can be mixed with 50/50 Extended Life antifreeze, however, mixing the two
will not extend the service interval. To receive the full five year service interval benefit, the vehicles’s entire cooling
system must be drained and replenished with the new 50/50 Extended Life antifreeze.
To quickly determine if a vehicle is using 60/40 or 50/50 Extended Life antifreeze, simply note the color of the coolant.
60/40 antifreeze will be green, while 50/50 Extended Life antifreeze will be yellow.
50/50 EXTENDED- LIFE ANTIFREEZE PART NUMBERS
PART NUMBERS DESCRIPTION
2880514 1 US Quart (0.9 L) / 12 per case
2880513 1 US Gallon (3.8 L) / 6 per case
2880512 55 US Gallon Drum (208 L)
2.12
MAINTENANCE
FUEL SYSTEM / AIR INTAKE

FUEL SYSTEM FUEL FILTERS
This machine uses a serviceable high-volume, high-
WARNING pressure fuel pump that includes a preliminary filter and
Gasoline is extremely flammable and explosive under an internal fine filter located before the pump regulator. If
certain conditions. the fuel pump filters require service, the fuel pump must 2
be replaced as an assembly.
• 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.
NOTE
FUEL LINES Refer to Chapter 3 for fuel pump replacement and all
other information related to the EFI System.
1. Check fuel lines for signs of wear, deterioration,
damage, or leakage. Replace if necessary.
2. Be sure fuel lines are routed properly and secured VENT LINE
with cable ties where applicable.
1. Check the vent line from the fuel tank for signs of
CAUTION wear, deterioration, damage or leakage. Replace the
line every two years.
Make sure lines are not kinked or pinched.
2. Verify vent line is routed properly and secured with
3. Replace all fuel lines every two years. an appropriate number of cable ties.
CAUTION
Make sure lines are not kinked or pinched.
THROTTLE OPERATION
Check for smooth throttle opening and closing in all
handlebar positions. Throttle lever operation should be
smooth and lever must return freely without binding.
1. Place the gear selector in Park.
2. Set parking brake.
3. Start the engine and let it idle.
4. Turn handlebars from full right to full left. If idle speed
increases at any point in the turning range, inspect
throttle cable routing and condition. If cable is routed
properly and in good condition, no adjustment is
required.
2.13
MAINTENANCE
5. Replace the throttle cable if worn, kinked, or 5. Turn the cable adjuster sleeve clockwise (in) 1.5 - 2
damaged. turns; tighten locknut and reinstall boot. After this
adjustment there should be .079-.118” (2-3 mm) gap
THROTTLE RELEASE SWITCH (TRS) between throttle arm and throttle arm stop.
/THROTTLE CABLE ADJUSTMENT
NOTE
ONLY Mechanical throttle body vehicles are equipped
with a TRS Switch and throttle cable.
ETC vehicles are not equipped with these components.
1. Turn the ignition key to the “OFF” position.

2. Slide the boot back far enough to expose the in-line
cable adjuster sleeve and loosen the adjuster
locknut.
3. Remove the (4) screws and cover from the RH
control.
4. With handlebars centered and wheels pointing
6. Reinstall the RH control cover and ensure the O-ring
forward, slowly turn the adjuster sleeve counter-
is properly in place. Securely tighten the (4) screws.
clockwise (out) just until the gap is removed between
the throttle arm and the throttle arm stop (see 7. Place the vehicle in Park and start the engine. Turn
illustration below). the handlebars from full left to full right while listening
for any change in engine speed. If engine speed
NOTE changes, loosen the locknut and turn the adjuster
While moving the adjuster sleeve, “flip” the throttle lever sleeve clockwise (in) an additional 1/2 turn and
slightly to set the neutral position of the cable. repeat this step.
AIR FILTER / PRE-FILTER SERVICE

It is advisable to replace the filter when it is dirty.
However, in an emergency, it is permissible to clean the
main filter if you observe the following practices.
• Never immerse the filter in water since dirt can be
transferred to the clean air side of the filter.
• If compressed air is used never exceed a pressure of
40 PSI. Always use a dispersion type nozzle to prevent
filter damage and clean from the inside to the outside.
It is recommended that the air filter and pre filter be

replaced annually. When riding in extremely dusty
conditions, replacement is required more often.
Removal:
1. Remove the seat to access the airbox cover.
2.14
MAINTENANCE
2. Remove the rubber strap retaining the airbox cover 11. Close airbox cover and secure cover by installing the
and open the cover. rubber strap.
NOTE NOTE
High lifter Models: Use a T27 torx bit to remove the air High Lifter Models: Reinstall and tighten the cover
box cover screw and remove the cover. screw until the cover is sealed.
2
3. Remove the air filter assembly from the airbox.

Cleaning:
4. Slip the pre-filter screen w off of the main filter
element q. Clean the pre-filter with hot soapy water.
5. Rinse and dry thoroughly.
6. Inspect pre-filter screen for tears or damage.
7. Inspect main filter and replace if necessary. If the
filter has been soaked with fuel or oil it must be
replaced.
Installation:
8. Inspect airbox cover seal for damage. It should
adhere tightly to the cover and seal all the way
around. Replace seal as needed.
9. Reinstall pre-filter screen over main filter. Be sure the
screen covers entire surface of main filter without
folds, creases, or gaps.
NOTE
Apply a small amount of general purpose grease to the
sealing edges of the filter before reinstalling.
10. Install air filter assembly into the airbox and position
it correctly before closing the airbox cover.
NOTE
Proper placement of the air filter is important to prevent
air leaks.
2.15
MAINTENANCE
ENGINE
ENGINE OIL LEVEL ENGINE OIL AND FILTER CHANGE
Polaris recommends the use of Polaris PS-4 synthetic Always change engine oil and filter at the intervals
engine oil. Oil may need to be changed more frequently if outlined in the Periodic Maintenance Chart. Always
Polaris engine oil is not used. change the oil filter whenever changing the engine oil.
CAUTION 1. Position the ATV on a level surface.

Mixing brands or using a non-recommended engine oil 2. Place the transmission in park.
may cause serious engine damage. Always use the 3. Start engine and allow it to run for two to three
recommended engine oil. Never substitute or mix minutes until the engine is warm.
engine oil brands.
4. Stop the engine.
1. Locate engine oil dipstick on the left side of the ATV. 5. Remove the fasteners q and guard platew from the
frame. Clean the area around the drain plug.
2. Position the ATV on a level surface.

3. Stop engine and remove the dipstick. Wipe it dry with 6. Place a drain pan beneath the engine crankcase.
a clean cloth. 7. Using a 6 mm Hex driver, remove the drain plug and
4. Reinstall and tighten the dipstick. allow the engine oil to drain completely.
NOTE CAUTION
The dipstick must be screwed in completely to ensure Hot oil can cause serious burns to skin.
an accurate measurement. Do not allow hot oil to contact skin.
5. Remove the dipstick and check the oil level. 8. Replace the sealing washer on the drain plug.
NOTE
The sealing surfaces on the drain plug and crankcase
should be clean and free of burrs, nicks or scratches.
9. Reinstall drain plug and torque to specification.
TORQUE
Engine Drain Plug:
12 ft-lbs (16 Nm)
6. Maintain the oil level in the safe range. Do not

overfill.
2.16
MAINTENANCE
10. Locate oil filter e through the access hole in the CAUTION
frame. Place shop towels beneath the oil filter. Using
oil filter wrench (PU-50105) turn oil filter Make sure line is not kinked or pinched.
counterclockwise to remove it.
11. Use a clean dry towel to clean the filter sealing

surface on the crankcase.
12. Check to make sure the O-ring on the new oil filter is
in good condition. Lubricate O-ring on new filter with
a film of fresh engine oil.
13. Install new oil filter to specification.
TORQUE
Oil Filter:
Turn by hand until filter O-ring contacts sealing
surface, then turn an additional 3/4 turn.
14. Replace the guard plate.

15. Remove dipstick and fill engine with 2 qts. (1.9 l) of
the recommended engine oil.
FLUID CAPACITY
Recommended Engine Oil:
PS-4 Synthetic 4-Cycle Engine Oil
(PN 2876244) (Quart)
16. Start the engine and allow it to idle for one to two
minutes.
17. Stop the engine and check for leaks.
18. Re-check the oil level on the dipstick and add oil as
necessary to bring the level to the upper mark on the
dipstick.
19. Dispose of used oil and filter properly.
ENGINE BREATHER HOSE

Periodically inspect the engine breather hose q and
clamps. Be sure the breather hose is routed properly and
secured in place.
2.17
MAINTENANCE
VALVE CLEARANCE ADJUSTMENT 10. Disconnect the chassis harness q from the IAC
1. Remove seat and upper side panels. valve. Remove the two hoses from the valve ports
w.
2. Disconnect the shift linkage from the shift lever.
3. Remove the (4) push rivets from each front mud
guard and remove the mud guards from the vehicle.
4. Remove the front rack or storage box assembly.
5. Disconnect the negative battery cable.
NOTE
Be sure to cover fuel tank inlet with a shop towel prior to
front cab removal.
6. Remove the front cab assembly.

7. Remove the rubber strap retaining the ECU to the
airbox.
8. Remove the breather hose q from the side of the 11. Remove the two air box mounting fasteners t.
airbox.
12. Remove the 4 screws e that retain the intake

9. Remove the spark plug wires and spark plugs from runners to the throttle body.
the cylinder head.
NOTE
Step 11 does not apply for Models with Electronic
Throttle Control.
NOTE
DO NOT attempt to remove the intake runners from the
intake plenum or remove the plenum from the airbox.
2.18
MAINTENANCE
13. Lift up on the air box and rotate it towards the left 19. Turn the drive clutch counter-clockwise until the cam
side of the vehicle. Open the wire harness retainer sprocket is in the MAG adjustment position (both
and remove the harness. Set the airbox assembly marks parallel with the valve cover sealing surface)..
aside.
14. Thoroughly clean the area around the valve cover.
Take care not to allow any debris to get into the
throttle body. 2
15. Remove the push rivets retaining the right-hand
portion of the rear cab to gain access to the bolts
retaining the upper right-hand frame support.
16. Remove the 4 bolts retaining the upper right-hand
frame support. Pull the support forward and down to
remove it from the vehicle.
17. Remove the 6 valve cover bolts r and remove the
valve cover t from the engine.
20.
NOTE
The exhaust rocker arm moves both exhaust valves.
Ensure you do not rely on the play up and down of the
rocker after adjusting one exhaust valve.
Loosen the jam nut a and turn the lash adjuster s

in until the rocker arm bearing d lightly touches the
valve f and you feel a slight drag when spinning the
rocker arm bearing with your fingers.
18. Remove PVT cover so the engine can be rotated

(see “Drive Belt Removal” procedure within this
chapter).
MAG i & PTO o ADJUSTMENT PROCEDURE
MEASUREMENT
Intake / Exhaust Valve Clearance:
0.000″ (0.00 mm)
21. Hold the lash adjuster and torque the jam nut using a
torque wrench with a 10 mm crow’s foot adaptor.
Torque the rocker jam nut to specification.
TORQUE
Rocker Jam Nut:
80 in-lb (9 Nm)
2.19
MAINTENANCE
22. After tightening the jam nut, turn the rocker arm 31. Torque intake runner mounting bolts to specification.
bearing with your fingers. If it spins as it did before
contacting the valve, it is too loose. If it cannot be TORQUE
turned, it is too tight. Plenum to Throttle Body Fasteners:
NOTE 7 ft-lbs (10 Nm)
If rocker arm bearing does not turn with slight drag, you 32. Start the engine to ensure proper valve adjustment
will need to perform the adjustment again (see Step was performed.
20).
COMPRESSION AND LEAKDOWN TESTS
23. Turn the drive clutch counter-clockwise to rotate the
cam sprocket 225° to the PTO Adjustment Position. NOTE
This engine does NOT have decompression
components. Compression readings will vary in
proportion to cranking speed during the test.
Smooth idle generally indicates good compression. Low

engine compression is rarely a factor in running condition
problems above idle speed. Abnormally high
compression can be caused by worn or damaged
exhaust cam lobes.
A cylinder leak-down test is the best indication of engine
condition. Follow tester manufacturer’s instructions to
perform a cylinder leak-down test. (Never use high
pressure leakage testers as crankshaft seals may
dislodge and leak).
24. Repeat steps 20-22. Measured Cylinder Compression:
25. Clean sealing surfaces of the cylinder head and 210-250 psi (full throttle)
valve cover. Cylinder Leakage Service Limit: 10%
(Inspect for cause if leakage exceeds 10%)
26. Inspect the condition of the valve cover bolt rubber
isolators. If rubber has become hardened or cracked,
replace them.
27. Install a new valve cover seal and ensure the seal is
SPORTSMAN SILENCER CLEANING
fully seated into the groove of the cover.
WARNING
28. Install the valve cover and torque the cover bolts to
specification. Do not perform clean out immediately after the engine
has been run, as the exhaust system becomes very
TORQUE hot. Serious burns could result from contact with
exhaust components.
Valve Cover Bolts:
To reduce fire hazard, make sure that there are no
12-14 ft-lbs (16-19 Nm) combustible materials in the area when purging the
exhaust silencer.
29. Install the upper right-hand frame support and torque Wear eye protection.
the (4) mounting bolts to specification. Do not stand behind or in the front of the vehicle while
TORQUE purging the silencer.
Never run the engine in an enclosed area. Exhaust
Upper Frame Rail Fasteners: contains poisonous carbon monoxide.
36 ft. lbs (49 Nm) Failure to heed these warnings could result in serious
injury or death.
30. Reassemble vehicle by reversing this procedure.
The exhaust silencers must be periodically purged of
accumulated carbon as follows:
2.20
MAINTENANCE
1. Remove the spark arrestor nut q and bolt w. ENGINE MOUNT FASTENER TORQUE
Check engine mount fasteners q and ensure they are
tight. Also inspect the condition of the rubber mounts. If
mounts are cracked or show signs of fatigue, replace
them.
2. Remove the spark arrestor e.

3. Place the transmission in park, and start the engine.
4. Purge carbon by momentarily revving the engine
several times.
5. Cover the exhaust outlet and lightly tap the silencer
with a rubber mallet, and then rev the engine
momentarily a few more times.
6. Stop the engine and allow the silencer to cool.
7. Use compressed air and a non-synthetic brush to
clean the arrestor screen.
8. Reinstall the arrestor and fastener, and torque the
retaining screw to specification.
TORQUE
Spark Arrestor Fastener
8 ft/lbs (11 Nm)
2.21
MAINTENANCE
COOLING SYSTEM
COOLING SYSTEM OVERVIEW the coolant recovery bottle. If not, perform the following
The engine coolant level is controlled, or maintained, by procedure.
the recovery system. The recovery system components 1. Position the vehicle on a level surface.
are the recovery bottle, radiator filler neck, radiator 2. View the coolant level in the recovery bottle. The
pressure cap and connecting hose.
coolant level can be viewed from inside the front right
As coolant operating temperature increases, the wheel well.
expanding (heated) excess coolant is forced out of the
radiator past the pressure cap and into the recovery
bottle. As engine coolant temperature decreases the
contracting (cooled) coolant is drawn back up from the
bottle, past the pressure cap, and into the radiator.
NOTE
Some coolant level drop on new vehicles is normal as
the system is purging itself of trapped air. Observe
coolant level often during break-in period.
CAUTION
Overheating of engine could occur if air is not fully
purged from system.
3. If the coolant level is below the “MIN”w line on the
Polaris recommends the use of Polaris Premium 50/50 bottle, remove the front rack assembly to access the
anti-freeze or a 50/50 mixture of high quality aluminum radiator pressure cap and recovery bottle cap.
compatible anti-freeze/coolant and distilled water.
NOTE
NOTE If overheating is evident, allow system to cool
Polaris Premium 50/50 Antifreeze is already premixed completely and check coolant level in the radiator and
and ready to use. Do not dilute with water. inspect for signs of trapped air in system.
COOLANT LEVEL INSPECTION WARNING

The pressure cap and recovery bottle are located Never remove the pressure cap when the engine is
underneath the front rack and Storage tray as shown warm or hot. Escaping steam can cause severe burns.
below. Maintain the coolant level between the “MIN” and The engine must be cool before removing the pressure
“MAX” levels indicated on the recovery bottle. cap.
4. Remove the pressure cap. Using a funnel, add

coolant to the top of the radiator filler neck.
5. Reinstall the pressure cap.
NOTE
Use of a non-standard pressure cap will not allow the
recovery system to function properly.
6. Remove recovery bottle cap and add coolant using a

funnel.
7. Fill recovery bottle to “MAX”q level with Polaris
Premium 50/50 antifreeze /coolant or a 50/50 mixture
of antifreeze/coolant and distilled water as required
With the engine at operating temperature, the coolant for freeze protection in your area.
level should be between the MAXq and MINw marks on 8. Reinstall the recovery bottle cap.
2.22
MAINTENANCE
9. If coolant was required, start engine and check for 2. View the coolant level in the recovery bottle. The
leaks. Make sure radiator fins are clean to prevent coolant level can be viewed from inside the left right
overheating. wheel well.
10. Add coolant as needed. Maintain the coolant level Side View
between the “MIN” and “MAX” marks on the bottle.
11. Reinstall the front rack assembly.
2
COOLANT LEVEL INSPECTION, HIGH
LIFTER
The pressure cap is located underneath the front rack as
shown below. The recovery bottle is found in the left
wheel well. Maintain the coolant level between the “MIN”
and “MAX” levels indicated on the recovery bottle.
Top View
REF. DESCRIPTION
q Recovery Bottle Cap
w Recovery Bottle
e MAX Coolant Level
r MIN Coolant Level
3. If the coolant level is below the “MIN” line on the

bottle, remove the front rack assembly to access the
radiator pressure cap and recovery bottle cap.
REF. DESCRIPTION
NOTE
q Pressure Cap
If overheating is evident, allow system to cool
w Recovery Bottle Hose completely and check coolant level in the radiator and
inspect for signs of trapped air in system.
e Radiator
With the engine at operating temperature, the coolant WARNING

level should be between the MAX and MIN marks on the
coolant recovery bottle. If not, perform the following Never remove the pressure cap when the engine is
procedure. warm or hot. Escaping steam can cause severe burns.
The engine must be cool before removing the pressure
1. Position the vehicle on a level surface. cap.
4. Remove the pressure cap. Using a funnel, add

coolant to the top of the radiator filler neck.
5. Reinstall the pressure cap.
NOTE
Use of a non-standard pressure cap will not allow the
recovery system to function properly.
6. Remove recovery bottle cap and add coolant using a

funnel.
2.23
MAINTENANCE
7. Fill recovery bottle to “MAX” level with Polaris

Premium 50/50 antifreeze/coolant or a 50/50 mixture
of antifreeze/coolant and distilled water as required
for freeze protection in your area.
8. Reinstall the recovery bottle cap.
9. If coolant was required, start engine and check for
leaks. Make sure radiator fins are clean to prevent
overheating.
10. Add coolant as needed. Maintain the coolant level
between the “MIN” and “MAX” marks on the bottle.
11. Reinstall the front rack assembly.
COOLING SYSTEM HOSES

1. Inspect all hoses for cracks, deterioration, abrasion
or leaks. Replace if necessary.
2. Check tightness of all hose clamps.
CAUTION
Do not over-tighten hose clamps at radiator, or radiator
fitting may distort, causing a restriction to coolant flow.
TORQUE
Radiator Hose Clamp
35 in-lbs (4 Nm)
COOLANT STRENGTH / TYPE

Test the strength of the coolant using an antifreeze
hydrometer.
• A 50/50 mixture of antifreeze and distilled water will

provide the optimum cooling, corrosion protection, and
antifreeze protection.
• Do not use tap water, straight antifreeze, or straight
water in the system. Tap water contains minerals and
impurities which build up in the system.
• Straight water or antifreeze may cause the system to
freeze, corrode, or overheat.
FLUID CAPACITY
Recommended Antifreeze/Coolant:
Polaris 50/50 Extended Life Antifreeze
2.24
MAINTENANCE
PVT / FINAL DRIVE / WHEELS / TIRES

PVT DRYING DRIVE SHAFT BOOT INSPECTION
Inspect the front and rear drive shaft boots for damage,
NOTE tears, wear, or leaking grease. If the rubber boots exhibit
If operating the ATV through water, be sure to check the any of these symptoms, replace the boot (s). Refer to
PVT system components for water ingestion. After Chapter 8 for drive shaft boot replacement. 2
operating in water, the ATV should be checked
immediately.
1. Access the PVT drain plug e on the bottom of the

PVT cover q using a long flat blade screwdriver
between the frame and left-hand lower control arm
from the rear of the ATV.
2. Remove the PVT drain plug e and O-ring w.
NOTE
Remove the CV boot shield from the front lower A-arms
to inspect both front CV boots.
3. Allow the water to drain out completely.

4. Reinstall the drain plug and O-ring.
5. Start the engine and shift into park.
6. Apply varying throttle for 10-15 seconds to expel the
moisture and air-dry the belt and clutches.
NOTE
Do not hold the throttle wide open for more than 5
seconds.
7. Allow the engine RPM to return to idle, then shift into

low gear.
8. Test the PVT system for belt slippage. If the belt
slips, repeat the process.
WHEEL AND HUB SPECIFICATION
TORQUE
Aluminum Wheel Lug Nuts
75 ft-lbs (102 Nm)
TORQUE
Steel Wheel Lug Nuts
45 ft-lbs (61 Nm)
2.25
MAINTENANCE
WHEEL REMOVAL TIRE PRESSURE

1. Position the vehicle on a level surface.
TIRE PRESSURE INSPECTION (PSI - COLD)
2. Stop the engine, place the transmission in PARK and FRONT REAR
lock the parking brake.
7 psi (48 kPa) 7 psi (48 kPa)
3. Loosen the wheel nuts slightly.
4. Elevate the appropriate side of the vehicle by placing
a suitable stand under the footrest frame. TIRE INSPECTION
• Improper tire inflation may affect vehicle
WARNING maneuverability.
Ensure the vehicle is properly secured before • When replacing a tire always use original equipment
proceeding. The vehicle falling from being improperly size and type.
supported could result in serious injury or death. • The use of non-standard size or type tires may affect
vehicle handling.
5. Remove the wheel nuts and remove the wheel.
WHEEL INSTALLATION
1. Verify the transmission is still in PARK and the
parking brake is locked.
2. Place the wheel in the correct position on the wheel
hub. Be sure the valve stem is toward the outside
and rotation arrows on the tire point toward forward
rotation.
3. Install the wheel nuts and finger tighten them to align
the center of the wheel holes with the center of the
tapered nuts.
NOTE
It is possible to torque the wheel nut on a steel rim
without the nut being centered in the hole. Be sure to MEASUREMENT
center the wheel nuts before applying torque to prevent Tire Lug Service Limit:
wheel nuts from coming loose. Replace if 1/8″ (3 mm) or less.
4. Carefully lower the vehicle to the ground.

5. Torque the wheel nuts and/or hub nut to the proper WARNING
torque specification listed in the “Wheel and Hub Operating with worn tires will increase the possibility of
Torque Table”. Wheel and Hub Torque Specification, the vehicle skidding easily with possible loss of control.
page 2.25 Worn tires can cause an accident. Always replace tires
when the usable tread depth has worn out.
WARNING
Improperly installed wheels could affect vehicle
handling and tire wear increasing the risk of sever injury
or death.
2.26
MAINTENANCE
TRANSMISSION / GEARCASE
TRANSMISSION LUBRICATION 4. Reinstall the fill plug and torque to specification.
NOTE TORQUE
It is important to follow the transmission maintenance Drain/Fill Plug:
intervals described in the Periodic Maintenance Chart. 14 ft-lbs (19 Nm) 2
Regular lubricant level inspections should be performed
as well. Transmission Lubricant Change
The transmission lubricant level should be checked and Access the drain plug through the rear right-hand
changed in accordance with the maintenance schedule. wheel well. The plastic skid plate can be removed for
better access to the drain plug.
• Be sure vehicle is positioned on a level surface when
checking or changing the lubricant. 5. Remove the fill plug (refer to “Transmission Lubricant
• Check vent hose to be sure it is routed properly and Level Check”).
unobstructed. 6. Place a drain pan under the transmission drain plug.
Transmission Lubricant Level Check 7. Remove drain plug w and allow lubricant to drain
The fill plug is located on the right-hand side of the completely.
transmission. Access the fill plug through the rear right- 8. Clean the drain plug magnetic surface.
hand wheel well. Maintain the lubricant level even with
the bottom threads of the fill plug hole. 9. Reinstall drain plug with a new O-ring and torque to
specification.
1. Position vehicle on a level surface.
10. Add the recommended amount of lubricant through
2. Remove the fill plug q and check the lubricant level. the fill plug hole. Maintain the lubricant level at the
bottom of the fill plug hole when filling the
transmission. Do not overfill.
FLUID CAPACITY
Recommended Transmission Lubricant:
Polaris AGL
Capacity:
37 oz (1100 mL)
11. Reinstall fill plug with a new O-ring and torque to

specification.
TORQUE
Drain/Fill Plug:
14 ft-lbs (19 Nm)
NOTE
Wheel removed for clarity. Not required for transmission 12. Check for leaks. Dispose of used lubricant properly.
oil check/change.
3. If lubricant level is not even with the bottom threads,

add the recommended lubricant as needed. Do not
overfill.
2.27
MAINTENANCE
FRONT GEARCASE LUBRICATION 5. Remove the fill plug (refer to “Front Gearcase Fluid
Level Check”).
NOTE
6. Place a drain pan under the front gearcase drain
It is important to follow the front gearcase maintenance plug.
intervals described in the Periodic Maintenance Chart.
Regular fluid level inspections should be performed as 7. Remove the drain plug and allow fluid to drain
well. completely.
8. Clean the drain plug magnetic surface.
SERVICE NOTE: Under extreme use, change fluid every
25 hours. "Extreme Use" is defined as constant ADC 9. Reinstall drain plug with a new O-ring and torque to
operation on hilly or mountainous terrain, or if ADC is the specification.
primary mode of AWD operation. 10. Add the recommended amount of fluid through the fill
The front gearcase fluid level should be checked and hole. Maintain the fluid level even with the bottom
changed in accordance with the maintenance schedule. threads of the fill plug hole.
• Be sure vehicle is positioned on a level surface when FLUID CAPACITY
checking or changing the fluid.
• Check vent hose to be sure it is routed properly and Recommended Front Gearcase Fluid:
unobstructed. Polaris Demand Drive Fluid
Front Gearcase Fluid Level Check Capacity:

The fill plug is located on the right side of the front 9.3 oz (275 mL)
gearcase. Access the fill plug through the front right-hand
wheel well or through the front lower bumper. Maintain 11. Reinstall fill plug and torque to specification.
the fluid level even with the bottom threads of the fill plug
hole. TORQUE
1. Position vehicle on a level surface. Drain / Fill Plug:
10 ft-lbs (14 Nm)
2. Remove the fill plug q and check the fluid level.
12. Check for leaks. Dispose of used fluid properly.
REAR GEARCASE LUBRICATION

NOTE
It is important to follow the rear gearcase maintenance
intervals described in the Periodic Maintenance Chart.
Regular fluid level inspections should be performed as
well.
The rear gearcase fluid level should be checked and

changed in accordance with the maintenance schedule.
• Be sure vehicle is positioned on a level surface when
checking or changing the fluid.
3. If fluid level is not even with the bottom threads, add • Check vent hose to be sure it is routed properly and
the recommended fluid as needed. Do not overfill. unobstructed.
4. Reinstall the fill plug and torque to specification. Rear Gearcase Fluid Level Check:
The fill plug is located on the right side of the rear
TORQUE
gearcase. Maintain the fluid level even with the bottom
Drain / Fill Plug: threads of the fill plug hole.
10 ft-lbs (14 Nm)
Front Gearcase Fluid Change:

The drain plug w is located on the bottom side of the
front gearcase. Access the drain plug through the
access hole in the front skid plate.
2.28
MAINTENANCE
2. Remove the fill plug q and check the fluid level. 12. Reinstall fill plug with a new O-ring and torque to
specification.
TORQUE
Drain / Fill Plug:
14 ft-lb (19 Nm)
2
13. Check for leaks. Dispose of used fluid properly.
3. If fluid level is not even with the bottom threads, add

the recommended fluid as needed. Do not overfill.
4. Reinstall fill plug and torque to specification.
TORQUE
Drain / Fill Plug:
14 ft-lb (19 Nm)
Rear Gearcase Fluid Change:

The drain plug is located on the bottom right-hand
side of the rear gearcase. Access the drain plug from
the rear right-hand side of the ATV.
5. Remove the fill plug (refer to “Rear Gearcase Fluid
Level Check”).
6. Place a drain pan under the rear gearcase drain
plug.
7. Remove the drain plug w and allow the fluid to drain
completely.
9. Reinstall drain plug with a new O-ring and torque to
specification
TORQUE
Drain / Fill Plug:
14 ft-lb (19 Nm)
10. .
11. 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 Rear Gearcase Lubricant:
Polaris Angle Drive Fluid
Capacity:
7.1 oz (210 mL)
2.29
MAINTENANCE
ELECTRICAL / IGNITION SYSTEM

BATTERY MAINTENANCE EXTREME USE 30 AH BATTERY
Keep battery terminals and connections free of Polaris offers an optional 30 AH battery (PN 4011224) for
corrosion. If cleaning is necessary, remove the corrosion use in extreme conditions where the factory installed
with a stiff wire brush. Wash with a solution of one battery can not maintain a charge because of multiple
tablespoon baking soda and one cup water. Rinse well electrical accessories.
with tap water and dry off with clean shop towels. Coat
the terminals with dielectric grease or petroleum jelly.
ENGINE / CHASSIS GROUND
Periodically inspect the electrical ground cable
WARNING
attachments. Cables and connections should be tight
CALIFORNIA PROPOSITION 65 WARNING: and corrosion-free.
Batteries, battery posts, terminals and related Inspect the battery-to-chassis connection underneath the
accessories contain lead and lead compounds, and front cab between the rack support and fuel fill hose. This
other chemicals known to the State of California to connection allows the chassis to provide a ground path.
cause cancer and birth defects or other reproductive
harm. WASH HANDS AFTER HANDLING.
WARNING
Battery electrolyte is poisonous. It contains sulfuric
acid. Serious burns can result from contact with skin,
eyes or clothing. Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow
with milk of magnesia, beaten egg, or vegetable oil. Call
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 an enclosed space.
Always shield eyes when working near batteries. Inspect the chassis-to-engine connection on the front of
KEEP OUT OF REACH OF CHILDREN. the engine attached to the engine crankcase. This
connection allows the engine to provide a ground path.
NOTE
Never attempt to open the battery. If the seal is broken,
the battery will be ruined and will fail within a few
weeks.
If battery voltage is below 12.6V, fully charge the battery
before putting into service. Refer to the “Charging
Procedure” provided in Chapter 12 for more
information.Charging Procedure , page 11.76
2.30
MAINTENANCE
SPARK PLUG SERVICE CAUTION

1. Remove the seat and upper right-hand side panel. Severe engine damage may occur if the incorrect spark
plug is used.
2. Disconnect the shift linkage from the shift lever.
3. Remove the spark plug wires q from the plugs.
Clean plug area so no dirt and debris can fall into Recommended Spark Plug for 850 Engine:
engine when plugs are removed. 2
Champion REA6MC
Spark Plug Torque:

18 ± 1.5 ft-lbs (24 ± 2 Nm)
Gap: .035'' (0.90 mm)
Recommended Spark Plug for 1000 Engine:
Autolite 5682
Spark Plug Torque:

18 ± 1.5 ft-lbs (24 ± 2 Nm)
Gap: .030'' (0.76 mm)
4. Using a 14 mm deep-well socket with an extension, 9. Apply a small amount of anti-seize compound to the
remove the spark plug. spark plug threads.
5. Inspect electrodes for wear and carbon buildup. Look 10. Install spark plugs and torque to specification.
for a sharp outer edge with no rounding or erosion of
11. Fully seat the plug wires on the spark plugs.
the electrodes.
6. Clean with electrical contact cleaner or a glass bead
spark plug cleaner only.
CAUTION
A wire brush or coated abrasive should not be used.
Use of non-recommended cleaning methods may lead
to component damage.
7. Measure gap with a wire gauge. Refer to

specifications in the following illustration for proper
spark plug type and gap. Adjust gap if necessary by
carefully bending the side electrode.
12.
NOTE
The spark plug wires are marked with MAG w and PTO
e. The PTO (long) wire on the coil terminal is nearest
the airbox.
13. Reinstall the shift linkage, upper right-hand side panel

and seat.
8. If necessary, replace spark plug with proper type.
2.31
MAINTENANCE
BATTERY OFF SEASON STORAGE

Whenever the vehicle is not used for a period of three
months or more, remove the battery from the vehicle,
ensure that it's fully charged, and store it out of the sun in
a cool, dry place. Check battery voltage each month
during storage and recharge as needed to maintain a full
charge.
NOTE
Battery charge can be maintained by using a Polaris
battery tender charger or by charging once a month to
make up for normal self-discharge. Battery tenders can
be left connected during the storage period, and will
automatically charge the battery if the voltage drops
below a pre-determined point.
2.32
MAINTENANCE
STEERING
STEERING INSPECTION
The steering components should be checked periodically
for loose fasteners, worn tie rod ends, and damage. Also
check to make sure all cotter pins are in place. If cotter
pins are removed, they must not be re-used. Always use 2
new cotter pins.
Replace any worn or damaged steering components.
Steering should move freely through entire range of
travel without binding. Check routing of all cables, hoses,
and wiring to be sure the steering mechanism is not
restricted or limited.
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 NOTE
Polaris Dealer. Only a qualified technician should Be sure to clean these areas thoroughly after riding
replace worn or damaged steering parts. Use only through muddy conditions.
genuine Polaris replacement parts.
TIE ROD END / STEERING INSPECTION

POWER STEERING UNIT (EPS MODELS)
The power steering unit q can be accessed through the NOTE
front right wheel well by removing the mud guard. Whenever steering components are replaced, check
front end alignment. Use only genuine Polaris parts.
To check for play in the tie rod end, grasp the steering tie
rod, pull in all directions feeling for movement.
• Repeat inspection for inner tie rod end (on steering
post).
Frequently clean the areas around and on top of the

power steering unit w to allow for proper cooling.
2.33
MAINTENANCE
• Replace any worn steering components. Steering 3. Tie a length of string between two stands as shown
should move freely through entire range of travel in the following illustration. Position the stands so the
without binding. string is flush or parallel with the side of the rear tire.
• Elevate front end of machine so front wheels are off

the ground. Check for any looseness in front hub /
wheel assembly by grasping the tire firmly at top and
bottom first, and then at front and rear. Try to move the
wheel and hub by pushing inward and pulling outward.
• If abnormal movement is detected, inspect the hub and
wheel assembly to determine the cause. NOTE
If available, you may use a long straight-edge instead of
TOE ALIGNMENT a string.
Use the following procedure to check the toe alignment
of the vehicle. The recommended toe alignment is 1/4 to 4. Measure the distance from the string to the rim at the
1/2” (6 to 13 mm) toe out. front (1) and rear (2) of the front rim. The rear
measurement should be 1/8” to 1/4” (3.2 to 6.4 mm)
1. Position the vehicle on a smooth level surface. more than the front measurement on each side of the
vehicle to obtain the recommended 1/4” to 1/2” (6.4
2. Set handlebars in a straight ahead position and
to 12.7 mm) toe out alignment.
secure handlebars in this position.
5. Repeat the measurement procedure on the other
NOTE side of the vehicle.
The steering post frog can be used as an indicator of NOTE
whether the handlebars are straight. The frog should
always point straight back from the steering post. If you discover improper alignment, refer to “Toe
Alignment Adjustment” procedure.
MEASUREMENT
Wheel Toe-Out Alignment:
1/4 to 1/2” (6.4 to 12.7 mm)
2.34
MAINTENANCE
TOE ALIGNMENT ADJUSTMENT

If toe alignment is incorrect, measure the distance
between vehicle center and each wheel. This will tell you
which tie rod needs adjusting.
NOTE
Be sure handlebars are straight ahead before
2
determining which tie rod(s) need adjustment.
CAUTION
During tie rod adjustment, it is very important that the
following precautions be taken when tightening tie rod
end jam nuts.
If the rod end is positioned incorrectly it will not pivot,
and may break.
To adjust toe alignment:

• Hold tie rod end to keep it from rotating.
• Loosen jam nuts at both ends of the tie rod.
• Shorten or lengthen the tie rod until alignment is as
required to achieve the proper toe out 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. See
illustration.
2.35
MAINTENANCE
SUSPENSION
SUSPENSION INSPECTION FOX SHOCK SPRING PRELOAD
Compress and release the suspension. Damping should ADJUSTMENT
be smooth throughout the range of travel. The front and rear shocks on EPS and International
• Check all suspension components and mounting models have a spring preload adjustment. Suspension
fasteners for wear or damage. spring preload may be adjusted to suit different riding
• Inspect each shock body for leakage. conditions or vehicle payloads.
WARNING
SUSPENSION SPRING PRE-LOAD Uneven adjustment may cause poor handling of the
ADJUSTMENT vehicle, which could result in an accident and serious
The front and rear shock absorber springs are injury or death. Always adjust both the left and right
adjustable. Rotate the adjuster cam either direction to spring preloads equally.
increase or decrease spring tension. Always adjust both
sides equally.
SPRING PRELOAD ADJUSTMENT-FACTORY
1. Elevate the front or rear of the vehicle to allow the SETTINGS
suspension to fully extend. Front Rear
2.41 in. (6.1 cm) 4.86 in. (12.3 cm)
CAUTION
Serious injury may result if machine tips or falls. Be NOTE
sure machine is secure before adjusting.
Refer to the shock illustrations within this procedure for
spring preload measurement location.
2. To adjust the suspension, rotate the adjustment cam
clockwise to increase spring tension or counter-
clockwise to decrease spring tension. The factory preload setting is appropriate for nearly all
riding conditions. Since this vehicle is equipped with full
skid plates, adjustment is not necessary.
If desired, the spring preload setting may be adjusted to
maintain vehicle clearance height when carrying loads.
1. Raise and safely support the front or rear of the
vehicle off the ground to allow the suspension to fully
extend.
2. Loosen the upper jam nut adjustment ring using the
spanner wrench (PN 2877408) included in the
vehicle’s tool kit.
Operator weight and vehicle loading affect

suspension spring pre-load requirements. Use
Spanner Wrench (PN 2877408) to adjust pre-load as
necessary to avoid bottoming of the shocks.
Shock Spanner Wrench:
PN 2877408
Shock Spanner Wrench:

PN 2877408
2.36
MAINTENANCE
3. Turn the lower adjustment ring (1) clockwise to SHOCK COMPRESSION ADJUSTMENT
increase preload or counter-clockwise to decrease The compression damping adjustment is located on top
preload. of the shock ‘Piggyback’ reservoir of each shock.
Turn the clicker adjuster knob to make damping
adjustments.
NOTE 2
When clicker adjuster is turned clockwise until it stops,
damping is in the fully closed position.
Turn the clicker clockwise to increase compression

damping. Turn the clicker counter-clockwise to decrease
compression damping.
NOTE
DO NOT increase the spring preload by more than one
inch (25.4 mm) over the factory setting.
4. Once you have obtained the correct preload, hold

the lower adjustment ring while tightening the upper
adjustment ring to lock them in place.
NOTE
Always return the spring preload to the factory setting
after the load is removed from the vehicle. The
increased suspension height will negatively impact
vehicle stability when operating without a load. COMPRESSION ADJUSTMENT TABLE
SETTING COMPRESSION DAMPING
Softest Full counter-clockwise position
Factory 10 clicks from closed
Firmest 2 clicks from closed
2.37
MAINTENANCE
BRAKE SYSTEM
BRAKE FLUID INSPECTION • Check the fluid level of the auxiliary brake master
The following checks are recommended to keep the cylinder reservoir. Add fluid to the indicated level.
brake system in good operating condition. Service life of
brake system components depends on operating
conditions. Inspect brakes in accordance with the
maintenance schedule and before each ride.
• Keep fluid level in the hand master cylinder reservoir to
the indicated level inside reservoir.
• Check the fluid level “eye” q. If it is clear, it is an
indication that fluid is needed or the brake pads may
be worn, which can reduce the fluid level.
• Use Polaris DOT 4 Brake Fluid (PN 2872189).
CAUTION
DO NOT OVERFILL!
Excess brake fluid may cause brake drag.
Fill to the indicated fill line or specification.
• Check brake system for fluid leaks, excessive travel or

spongy feel.
• If required, add brake fluid to .25” - .30” (6 - 8 mm) • Check brake pads for wear, damage or looseness.
from the top of the reservoir. • Check surface condition of the disc.
• Inspect thickness of brake pad friction material.
BRAKE PAD / DISC INSPECTION

1. Check the brake pads for wear, damage, or
looseness.
2. Inspect the brake pad surface for excessive wear.
2.38
MAINTENANCE
3. Pads should be changed when the friction material HOSE / FITTING INSPECTION
q is worn below the service limit. Check brake system hoses and fittings for cracks,
deterioration, abrasion, and leaks. Tighten any loose
fittings and replace any worn or damaged parts.
AUXILIARY BRAKE PEDAL 2

The hydraulic auxiliary brake system requires no
adjustment. It is controlled by the foot brake pedal q.
Frequently check the brake fluid level for the auxiliary
brake system by viewing the level in the master cylinder
reservoir located underneath the front rack assembly.
MEASUREMENT
Brake Pad / Backing Plate Thickness
Service Limit: .180″ (4.6 mm)
4. Check surface condition of the brake discs.

5. Measure the thickness of the front and rear brake
discs.
6. The disc(s) should be replaced if thickness is below
the service limit.
• Check the effectiveness of the auxiliary brake by
applying approximately 50 lbs. (23 kg) of downward
force on the pedal.
• If brake pedal requires an excessive amount of travel
to operate, inspect brake pads, pedal, linkage springs,
rear master cylinder and hoses for wear, damage or
leakage. Replace components as needed.
MEASUREMENT
Brake Disc Thickness
Service Limit: .170″ (4.32 mm)
2.39
MAINTENANCE
NOTES
2.40
ENGINE / COOLING SYSTEM
CHAPTER 3
GENERAL INFORMATION - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 3
OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
OIL FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
ENGINE SPECIFICATIONS - 850 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
ENGINE SPECIFICATIONS - 1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
COOLING SYSTEM LAYOUT AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
COOLING SYSTEM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
COOLING SYSTEM BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.12
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.12
RADIATOR CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.12
COOLANT DRAIN / RADIATOR SERVICE (SPORTSMAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.13
COOLANT DRAIN / RADIATOR SERVICE (HIGH LIFTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15
COOLING SYSTEM ASSEMBLY VIEW (HIGH LIFTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15
COOLANT DRAIN/FILL (HIGH LIFTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16
RADIATOR REMOVAL (HIGH LIFTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16
RADIATOR INSTALLATION (HIGH LIFTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17
WATER PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17
WATER PUMP IMPELLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17
WATER PUMP MECHANICAL SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.18
STATOR COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20
WATER PUMP ASSEMBLY / TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21
STATOR COVER ASSEMBLY TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.22
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.23
THERMOSTAT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.23
INTAKE / EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.24
AIR INTAKE ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.24
INTAKE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.25
EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.26
850/1000 1-UP HEAT SHIELDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.26
2-UP HEAT SHIELDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.26
HIGH LIFTER HEAT SHIELDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.26
ENGINE ASSEMBLY VIEWS / TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.27
TORQUE SPECIFICATION AND TORQUE SEQUENCE - MAIN ENGINE COMPONENTS . . . . . . . . . . . . .3.27
VALVE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.28
CAMSHAFT CARRIER / CAMSHAFT / ROCKER ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.29
CYLINDER HEAD / VALVES / INTEGRATED THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.30
VALVE AND SPRING HEIGHT DETAIL - SPM850 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.31
3.1
VALVE AND SPRING HEIGHT DETAIL - SPM1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.32

PISTON / CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.33
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.34
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.35
CRANKCASE - UPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.36
BALANCE SHAFT / BALANCE SHAFT TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.37
CRANKCASE (LOWER) WITH OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.38
STATOR COVER / FLYWHEEL / WATER PUMP COUPLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.39
WATER PUMP / WATER PUMP COUPLER / STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.40
DRIVE COUPLER (REAR) / STARTER GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.41
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.42
ACCESSIBLE ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.42
TOP-END SERVICE (ENGINE IN CHASSIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.42
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.42
ENGINE INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.46
ENGINE DISASSEMBLY / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.47
VALVE COVER REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.47
ROCKER CARRIER / CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.47
ROCKER ARM / ROCKER ARM SHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.48
CAMSHAFT / CAMSHAFT BORE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.48
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.49
CYLINDER HEAD CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.49
CYLINDER HEAD WARP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.50
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.50
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.51
COMBUSTION CHAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.52
VALVE GUIDE REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.52
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.52
CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.55
CRANKCASE (LOWER) / OIL PUMP DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.56
CRANKCASE DISASSEMBLY (UPPER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.57
PISTON / CONNECTING ROD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.57
COUNTERBALANCE SHAFT REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.58
CRANKSHAFT / CAM CHAIN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.59
CAM CHAIN / SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.59
CRANKCASE INSPECTION (LOWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.59
CRANKSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.59
CONNECTING ROD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.59
CONNECTING ROD BIG END BEARING SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.62
PISTON / PISTON RING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.63
PISTON RING REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.63
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.63
PISTON PIN BORE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.64
CYLINDER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.64
PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.65
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.66
CRANKCASE PREPARATION - UPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.66
3.2
PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.66

PISTON / CONNECTING ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.67
PISTON / CONNECTING ROD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.67
CRANKSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.68
OIL PASSAGE TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.68
CRANKCASE ASSEMBLY - UPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.69
BALANCE SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.70
BALANCE SHAFT TIMING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.71
CRANKCASE PREPARATION (LOWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.72
CRANKCASE SEALANT AND TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.73 3
CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.74
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.74
VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.75
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.75
CAMSHAFT / CARRIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.76
CAMSHAFT / CAMSHAFT CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.76
CAMSHAFT TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.77
CAM CHAIN TENSIONER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.79
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.80
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.80
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.80
3.3
GENERAL INFORMATION - ENGINE

SPECIAL TOOLS
PART NUMBER TOOL DESCRIPTION
PA-49318 CRANKSHAFT HOLDING TOOL
PA-49320 CRANKSHAFT SEAL INSTALLER
PA-49316 FLYWHEEL / WATER PUMP DRIVE NUT PULLER
PA-51880 FLYWHEEL BOLT TOOL - New for 2016
PS-48762 FUEL PRESSURE TEST ADAPTOR
2870975 MITY VAC PRESSURE TEST TOOL
PU-50105 OIL FILTER WRENCH
PV-43570-1 PISTON RING COMPRESSOR PLIERS
PV-43570-3 PISTON RING COMPRESSOR BAND - 87 mm
PU-45543 UNIVERSAL DRIVER HANDLE
PV-1253 or PV-4019 (Quick Release) VALVE SPRING COMPRESSOR
PV-43513-A VALVE SPRING COMPRESSOR ADAPTOR
PA-49378 WATER PUMP BEARING AND COUPLER PRESS
PA-49316 WATER PUMP DRIVE NUT / FLYWHEEL PULLER
PA-44995-A WATER PUMP MECHANICAL SEAL INSTALLER
PA-50995 WATER PUMP DRIVE BOLT TOOL
Bosch Automotive Service Solutions 1-800-345–2233 or www.polaris.service-solutions.com
ENGINE LUBRICATION SPECIFICATIONS

FLUID CAPACITY
Capacity - Approximately 2 U.S. Quarts (1.9 l)
Oil Type - Polaris PS-4 Synthetic Engine Oil
Oil Filter Wrench - PU-50105 or 2.5” (64 mm)
equivalent
Oil Pressure Specification - Using Polaris PS-4,
Engine at operating temperature, 12-100 PSI @ Idle
RPM, 60–85 PSI @ 7000 RPM
3.4
OIL PRESSURE TEST 5. If oil pressure is high, this indicates additional

1. Engine off, remove center Main Oil Gallery plug (A) restriction/resistance to flow. This could be from
from right side of upper crankcase. using oil with heavier viscosity than recommended. If
not, there may be a restriction in the oil galleries.
This could be from contamination in the crankcase,
or if the engine was recently serviced, from
excessive or misplaced crankcase sealant. This
could also be due to a stuck oil pressure regulator.
2. Insert a 1/4” NPT oil pressure gauge adaptor and oil

pressure gauge.
3. Start the engine and allow it to reach operating
temperature, monitoring gauge indication.
NOTE
Test results are based on the use of the recommended
engine oil at operating temperature, and may vary
considerably if any other oil is used or if engine is not up
to temperature.
Oil Pressure at Idle RPM (Engine Hot):

Maximum: 100 psi
Minimum: 12 PSI
Oil Pressure at 7000 RPM (Engine Hot):
Maximum: 85 psi
Minimum: 60 PSI
NOTE
Oil pressure results show the relationship between the
flow created by the oil pump and the restriction of the
engine oil passages.
4. If oil pressure is too low, this indicates either not

enough flow or not enough resistance to flow. This
could be due to using oil with lighter viscosity than
recommended. If not, there may be excessive
clearances in the pump, bearings, or a leak in the oil
delivery passages before bearing restrictions. Leaks
that could cause this are a gallery plug, regulator
stuck open, oil filter seal, or pump gasket.
3.5
OIL FLOW DIAGRAM
3.6
ENGINE SPECIFICATIONS - 850

CYLINDER HEAD (IN. / MM)
Cam Lobe Height - Intake (Standard) 1.566" (39.795 mm)
Cam Lobe Height - Exhaust (Standard) 1.577" (40.067 mm)
Camshaft Journal Outer Diameter - (All) .8632" ± 0.0004" (21.925 ± 0.01 mm)
Camshaft
Camshaft Journal Bore Inner Diameter - (All) .8665" ± 0.0004" (22.01 ± 0.01 mm)
Camshaft Oil Clearance 0.0033" ± 0.0008" (0.085 ± 0.02 mm)
Camshaft End Play 0.008" ± 0.004" (0.20 ± 0.10 mm)
Rocker Shaft O.D. (Intake and Exhaust) 0.5501" (13.973 - 13.984 mm)
3
Rocker Arm and Rocker Shaft Bore I.D. (Cylinder Head) 0.5543" ± 0.0006" (14.079 ± 0.014 mm)
Shaft
Rocker Arm Bore I.D. (Intake and Exhaust) 0.5514" - 0.5525" (14.006 - 14.033 mm)
Cylinder Head - Surface warp limit 0.004" (0.1 mm)
Cylinder Head
Cylinder Head - Standard height 3.611" (91.71 mm)
Valve Seat - Contacting Width - Intake 0.047" ± 0.008" - 0.0039" (1.20 ± 0.20 mm)
Valve Seat Valve Seat - Contacting Width - Exhaust 0.047" ± 0.008" - 0.0039" (1.20 ± 0.20 mm)
Valve Seat Angle 45.5° ± 0.25°
Valve Guide Inner Diameter 0.217" + .0005" - 0.0 (5.52 + .012 - 0.0 mm)
Valve Guide Protrusion Above Head - Intake 0.361" ± 0.010" (9.18 ± 0.25 mm)
Valve Guide
Valve Guide Protrusion Above Head - 0.276" ± 0.010" (7.00 ± 0.25 mm)
Exhaust
Valve Lash (Cold) - Intake 0.000" (.000 mm)
Valve Lash (Cold) - Exhaust Refer to Chapter 2 “Valve Clearance Adjustment”
Valve Margin Thickness - Intake 0.016" (.40 mm)
Valve Margin Thickness - Exhaust 0.024" (.60 mm)
Valve Stem Diameter - Intake 0.2163" ± 0.0003" (5.495 ± 0.0075 mm)
Valve
Valve Stem Diameter - Exhaust 0.2159" ± 0.0003" (5.485 ± 0.0075 mm)
Valve Stem Oil Clearance - Intake 0.0012" ± 0.0005" (0.031 ± 0.0135 mm)
Valve Stem Oil Clearance - Exhaust 0.0016" ± 0.0005" (0.041 ± 0.0135 mm)
Valve Stem Overall Length - Intake 4.6681" ± 0.012" (118.57 ± 0.30 mm)
Valve Stem Overall Length - Exhaust 4.5649" ± .012" (115.95 ± 0.30 mm)
Valve Spring Free Length 1.861" (47.26 mm)
Valve Spring Intake - 1.650" (41.91 mm)
Valve Spring Installed Height
Exhaust - 1.650" (41.91 mm)
CYLINDER / PISTON (IN. / MM)

Cylinder Cylinder - Surface warp limit (mating with 0.004" (0.10 mm)
cylinder head)
Cylinder Bore - Standard 3.4252" ± .0005 (87 mm ± .01 mm)
Cylinder Out of Round Limit 0.0003" (0.0075 mm)
Cylinder to Piston Clearance .0013" ± .0008" (.033 ± .02 mm)
Piston Piston - Standard O.D. - Measured 90° to 3.4239" ± .0008" (86.967 ± .02 mm)
pin, 1.3 in. (33.0 mm) down from piston
crown.
Piston Pin Bore I.D. (Standard) 0.7877" ± .0002" (20.007 ± .004 mm)
3.7

Piston Pin Piston Pin Outside Diameter 0.7873" ± .0001" (19.9975 ± .0025 mm)
Piston Pin - Standard Clearance - Piston Pin 0.0004" ± .0002" (0.0095 ± 0.0065 mm)
to Pin Bore
Piston Pin - Degree of Fit Piston pin must be push fit (by hand) at 68° F (20°
C)
PISTON / RINGS / CONNECTING ROD / CRANKSHAFT (IN. / MM)

Top Ring - Standard 0.008” - 0.014” (0.20 - 0.36 mm)
Top Ring - Service Limit 0.016” (0.41 mm)
Installed Second Ring - Standard 0.014” - 0.024” (0.36 - 0.61 mm)
Gap Second Ring - Service Limit 0.032” (0.81 mm)
Piston Ring
Oil Ring Rails - Standard 0.020” ± 0.010” (0.51 ± 0.25 mm)
Oil Ring Rails - Service Limit 0.032” (0.81 mm)
Ring to Top Ring - Standard 0.0024” ± 0.0008” (0.060 ± 0.020 mm)
Groove
Clearance Second Ring - Standard 0.0028” ± 0.0008” (0.070 ± 0.020 mm)
0.7886” + 0.000 / - .015” (20.030 + .000 / - .015
Connecting Rod Small End I.D.
mm)
Connecting Rod Small End 0.00098” ± .0004” (0.025 ± 0.010 mm)
Connecting Rod Diametral Clearance
Connecting Rod Big End 0.012” ± 0.0039” (0.30 ± .10 mm)
Side Clearance
Connecting Rod Big End 0.0098” - .0023” (0.025 - .059 mm)
Diametral Clearance
Crankshaft Runout Limit Refer to Procedure
PTO End Less than .001” (0.025 mm)
MAG End Less than .001” (0.025 mm)
Crankshaft
Main Journal Diameter (Standard) 2.1642” - 2.1649” (54.97 - 54.99 mm)
Connecting Rod Journal Diameter
1.7718” - 1.7726” (45.005 - 45.025 mm)
(Standard)
3.8
ENGINE SPECIFICATIONS - 1000

CYLINDER HEAD (IN. / MM)
Cam Lobe Height - Intake (Standard) 1.566" (39.795 mm)
Cam Lobe Height - Exhaust (Standard) 1.577" (40.067 mm)
Camshaft Journal Outer Diameter - (All) .8632" ± 0.0004" (21.925 ± 0.01 mm)
Camshaft
Camshaft Journal Bore Inner Diameter - (All) .8665" ± 0.0004" (22.01 ± 0.01 mm)
Camshaft Oil Clearance 0.0033" ± 0.0008" (0.085 ± 0.02 mm)
Camshaft End Play 0.008" ± 0.004" (0.20 ± 0.10 mm)
Rocker Shaft O.D. (Intake and Exhaust) 0.5501" (13.973 - 13.984 mm)
3
Rocker Arm and Rocker Shaft Bore I.D. (Cylinder Head) 0.5543" ± 0.0006" (14.079 ± 0.014 mm)
Shaft
Rocker Arm Bore I.D. (Intake and Exhaust) 0.5514" - 0.5525" (14.006 - 14.033 mm)
Cylinder Head - Surface warp limit 0.004" (0.1 mm)
Cylinder Head
Cylinder Head - Standard height 3.611" (91.71 mm)
Valve Seat - Contacting Width - Intake 0.047" ± 0.008" - 0.0039" (1.20 ± 0.20 mm)
Valve Seat Valve Seat - Contacting Width - Exhaust 0.047" ± 0.008" - 0.0039" (1.20 ± 0.20 mm)
Valve Seat Angle 45.5° ± 0.25°
Valve Guide Inner Diameter 0.217" + .0005" - 0.0 (5.52 + .012 - 0.0 mm)
Valve Guide Protrusion Above Head - Intake 0.361" ± 0.010" (9.18 ± 0.25 mm)
Valve Guide
Valve Guide Protrusion Above Head - 0.315" ± 0.010" (8.00 ± 0.25 mm)
Exhaust
Valve Lash (Cold) - Intake 0.000" (.000 mm)
Valve Lash (Cold) - Exhaust Refer to Chapter 2 “Valve Clearance Adjustment”
Valve Margin Thickness - Intake 0.04" (1.00 mm)
Valve Margin Thickness - Exhaust 0.027" (.70 mm)
Valve Stem Diameter - Intake 0.2163" ± 0.0003" (5.495 ± 0.0075 mm)
Valve
Valve Stem Diameter - Exhaust 0.2159" ± 0.0003" (5.485 ± 0.0075 mm)
Valve Stem Oil Clearance - Intake 0.0012" ± 0.0005" (0.031 ± 0.0135 mm)
Valve Stem Oil Clearance - Exhaust 0.0016" ± 0.0005" (0.041 ± 0.0135 mm)
Valve Stem Overall Length - Intake 4.6638" ± 0.012" (118.46 ± 0.30 mm)
Valve Stem Overall Length - Exhaust 4.5488" ± .012" (115.54 ± 0.30 mm)
Valve Spring Free Length 1.904" (48.35 mm)
Valve Spring Intake - 1.650" (41.91 mm)
Valve Spring Installed Height
Exhaust - 1.650" (41.91 mm)
3.9

Cylinder Cylinder - Surface warp limit (mating with 0.004" (0.10 mm)
cylinder head)
Cylinder Bore - Standard 3.5630" ± .0005 (90.5 mm ± .012 mm)
Cylinder Out of Round Limit 0.0003" (0.0075 mm)
Cylinder to Piston Clearance .0020" ± .0012" (.05 ± .031 mm)
Piston Piston - Standard O.D. - Measured 90° to 3.5610" ± .0007" (90.450 ± .019 mm)
pin, 1.3 in. (33.0 mm) down from piston
crown.
Piston Pin Bore I.D. (Standard) 0.7877" ± .0001" (20.007 ± .0025 mm)
Piston Pin Piston Pin Outside Diameter 0.7873" ± .0001" (19.9975 ± .0025 mm)
Piston Pin - Standard Clearance - Piston Pin 0.0004" ± .0002" (0.0095 ± 0.0055 mm)
to Pin Bore
Piston Pin - Degree of Fit Piston pin must be push fit (by hand) at 68° F (20°
C)
PISTON / RINGS / CONNECTING ROD / CRANKSHAFT (IN. / MM)

Top Ring - Standard 0.012” - 0.022” (0.30 - 0.55 mm)
Top Ring - Service Limit 0.024” (0.60 mm)
Installed Second Ring - Standard 0.039” - 0.047” (1.00 - 1.20 mm)
Gap Second Ring - Service Limit 0.049” (1.25 mm)
Piston Ring
Oil Ring Rails - Standard 0.008” - 0.028” (0.20 - 0.70 mm)
Oil Ring Rails - Service Limit 0.029” (0.75 mm)
Ring to Top Ring - Standard 0.0006” - 0.0024” (0.015 - 0.060 mm)
Groove
Clearance Second Ring - Standard 0.0006” - 0.0024” (0.015 - 0.060 mm)
0.7886” + 0.000 / - .015” (20.030 + .000 / - .015
Connecting Rod Small End I.D.
mm)
Connecting Rod Small End 0.00098” ± .0004” (0.025 ± 0.010 mm)
Connecting Rod Diametral Clearance
Connecting Rod Big End 0.012” ± 0.0039” (0.30 ± .10 mm)
Side Clearance
Connecting Rod Big End 0.0098” - .0023” (0.025 - .059 mm)
Diametral Clearance
Crankshaft Runout Limit Refer to Procedure
PTO End Less than .001” (0.025 mm)
MAG End Less than .001” (0.025 mm)
Crankshaft
Main Journal Diameter (Standard) 2.1642” - 2.1649” (54.97 - 54.99 mm)
Connecting Rod Journal Diameter
1.7718” - 1.7726” (45.005 - 45.025 mm)
(Standard)
3.10
COOLING SYSTEM
SPECIAL TOOLS 3. The system must retain 10 psi for five minutes or
longer. If pressure loss is evident within five minutes,
PART NUMBER TOOL DESCRIPTION check the radiator, all cooling system hoses, hose
Mity Vac™ Pressure clamps and water pump seal for leakage.
2870975
Test Tool Radiator Cap Pressure Test
Water Pump
PA-44995-A
Mechanical Seal Installer WARNING
Water Pump Bearing and Coupler Never remove radiator cap when engine is warm or hot.
PA-49378
Press Tool
Water Pump Drive Nut / Flywheel
3
PA-49316 The cooling system is under pressure and serious
Puller burns may result.
PA-50995 Water Pump Drive Bolt Tool
Allow the engine and cooling system to cool before
Bosch Automotive Service Solutions 1-800-345–2233
servicing.
or www.polaris.service-solutions.com
4. Remove radiator pressure cap and test using a cap
COOLING SYSTEM LAYOUT AND TESTING tester (commercially available).
FLOW 5. The radiator cap relief pressure is 13 lbs. Replace
Coolant is drawn into the water pump q, which creates cap if it does not meet this specification.
flow up through the engine to the thermostat housing w. Recommended Coolant
If the thermostat is open, it flows to the radiator and is
drawn back by the water pump. If it is closed, it flows Use only high quality antifreeze/coolant mixed with
back to the water pump in the bypass hose e. distilled water in a 50/50 ratio.
NOTE
Using tap water in the cooling system will lead to a
buildup of deposits which may restrict coolant flow and
reduce heat dissipation, resulting in possible engine
damage. Polaris Premium 50/50 Antifreeze/Coolant is
recommended for use in all cooling systems, and
comes pre-mixed and ready to use.
Polaris Premium Antifreeze

2871534 - Quart
2871323 - Gallon
COOLING SYSTEM SPECIFICATIONS

Cooling System Pressure Test
RESISTANCE READING @ IDLE
1. Remove the front rack.
APPROX.
READING TEMPERA-
WARNING CONDITION
(OHMS) TURE
Never remove radiator cap when engine is warm or hot.
Engine Shut Off 70Ω± 3% 284°F (140°C)
The cooling system is under pressure and serious Hot Lamp On
burns may result. (engine misfire 90Ω± 3% 266°F (130°C)
above idle)
Allow the engine and cooling system to cool before Hot Lamp
servicing. 100Ω± 3% 257°F (125°C)
Blinking
Fan On 215Ω± 3% 203°F (95°C)
2. Remove the pressure cap from the radiator and
pressure test the cooling system using a Fan Off 240Ω± 3% 192°F (89°C)
commercially available tester.
3.11
RESISTANCE READING @ IDLE 9. Stop the engine and allow it to cool. Top off the
APPROX. radiator with coolant. If you hear or see a “glug” at
READING TEMPERA- the filler neck or the coolant level drops indicating
CONDITION
(OHMS) TURE that coolant has been pulled into the system, fill the
radiator first before filling the recovery bottle.
Room
2.5kΩ± 3% 68°F (20°C) 10. Any air remaining in the system should continue to
Temperature
bleed out through the recovery bottle.
System Capacity 2 qts. (1.9 l)
11. Repeat this procedure if you are still having difficulty
Radiator Cap
13 PSI bleeding the system.
Relief Pressure
RADIATOR
COOLING SYSTEM BLEEDING
PROCEDURE RADIATOR CLEANING
1. Place the vehicle in PARK. 1. Check radiator air passages for restrictions or
damage.
CAUTION
2. Flush through the radiator core from the rear.
Be sure the engine has cooled and there is no pressure
built up in the cooling system before removing the
radiator cap. The coolant may be hot and could cause
severe injury or burns.
2. Remove the front rack to access the radiator

pressure cap and recovery bottle.
3. Remove the pressure cap and top off coolant. Leave
the pressure cap off at this point.
4. Remove recovery bottle fill cap and fill the bottle to
the “MAX” line. Reinstall the recovery bottle cap.
NOTE
If coolant level is very LOW in the radiator, or if there
are leaks in the system, the coolant system will not
draw coolant from the recovery bottle. 3. Carefully straighten any bent radiator fins.
4. Remove any obstructions with compressed air or low
5. Start the engine and allow it to idle for 5-10 minutes pressure water.
until the thermostat opens and allows coolant to
travel through the entire system. CAUTION
Washing the vehicle with a high-pressure washer could
NOTE damage the radiator fins and impair the radiators
When the thermostat opens the radiator coolant level effectiveness. Use of a high-pressure washer is not
will drop significantly. recommended.
6. Squeeze coolant lines to help purge the system of

air.
7. With engine still idling, top off the radiator with
Polaris Premium Antifreeze. If no air bubbles are
seen at the radiator filler neck, the system should be
purged of air.
8. Reinstall the radiator pressure cap.
NOTE
Be sure to install the radiator pressure cap before
shutting off the engine.
Coolant may spit out of the radiator.
3.12
COOLANT DRAIN / RADIATOR SERVICE 4. Remove recovery bottle return line w from the
(SPORTSMAN) radiator.
Coolant Drain
1. Remove the front rack to access the pressure cap.
CAUTION
Never drain the coolant when the engine and radiator
are warm or hot. Hot coolant can cause severe burns.
Allow engine and radiator to cool.
3
2. Slowly remove the pressure cap to relieve any
cooling system pressure.
3. Place a suitable drain pan underneath the radiator on
the right-hand side of the vehicle.
4. Drain coolant from radiator by removing the coolant
hose from the lower right-hand portion of the radiator. 5. Carefully pull rearward on the lower portion of the
recovery bottle to disengage the lower tab. Then lift
up on the bottle and remove it from the radiator fan
shroud.
6. Remove the fasteners e retaining the upper portion
of the radiator.
5. Completely drain coolant and properly dispose of it.

Radiator Removal
1. Drain coolant from radiator.
2. Remove the upper radiator hose.
3. Remove the front storage bin. 7. Disconnect the fan motor.
8. Remove the RF headlight.
9. Lift up and lift the radiator upward to allow the lower
grommets to clear the frame support holes. Remove
the radiator from the vehicle out the right-hand side
through the wheel well. Take care not to damage the
cooling fins during removal.
Radiator Installation
1. Reverse “Radiator Removal” procedure for
installation. When installing the recovery bottle, insert
the upper portion of the bottle into the shroud first,
then push the lower tab on the bottle into the shroud
until it snaps into place.
2. Be sure the lower grommets are positioned properly
in the frame upon installation.
3.13
3. After installation and reassembly, remove the

pressure cap and fill the radiator and recovery bottle
with coolant.
4. Refer to the “Cooling System Bleeding Procedure”.
Cooling System Bleeding Procedure, page 3.12
3.14
COOLANT DRAIN / RADIATOR SERVICE (HIGH

LIFTER)
COOLING SYSTEM ASSEMBLY VIEW (HIGH LIFTER)
COOLING SYSTEM ASSEMBLY VIEW

REF. DESCRIPTION NOTES
q RADIATOR
w COOLANT HOSE, ENGINE IN
e SPRINGBAND CLAMP
r GEAR CLAMP
t COOLANT HOSE, ENGINE OUT
y HOSE CLAMP
u SCREW Torque until fully seated
i SCREWS Torque until fully seated
o SURGE TANK
a FLANGE NUTS
s BOLTS Torque until fully seated
3.15
COOLANT DRAIN/FILL (HIGH LIFTER) 11. Fill the cooling system and overflow, and run the
engine up to operating temp. Verify the level is correct
1. Remove the upper radiator shroud to access the
before re-assembly. Refer to the cooling system
pressure cap.
bleeding procedure earlier in this chapter.
WARNING
WARNING
Never drain the coolant when the engine and radiator
are warm or hot. Hot coolant can cause severe burns. Never open the cooling system when the engine and
Allow engine and radiator to cool. radiator are warm or hot. Hot coolant can cause severe
burns. Allow engine and radiator to cool.
2. Slowly remove the pressure cap to relieve any

cooling system pressure. 12. Fit the lower shroud/fan assembly loosely. With the
front of the lower shroud/fan assembly lifted,
3. Remove the 4 fasteners q retaining the fan shroud reconnect both fan electrical connectors.
assembly.
13. Position the fuse block from the underside of the
shroud, and install both fasteners. Torque to
specification. Ensure the fuse block cap is re-installed
as well.
TORQUE
Fuse Block Fastener
Until Fully Seated
14. Install all 4 lower shroud/fan assembly fasteners q,

and torque to specification.
4. Remove the fuse block cap, and the two fasteners

retaining the fuse block to the lower fan shroud.
5. Gently lift up the front of the lower shroud/fan
assembly, and disconnect both fan electrical
connectors.
6. Remove the lower shroud/fan assembly.
7. Place a suitable drain pan underneath the radiator on
the right-hand side of the vehicle.
8. Drain coolant from radiator by removing the spring
clamp q coolant hose from the lower right-hand
portion of the radiator. TORQUE
Lower Shroud/Fan Assembly Fastener
Until Fully Seated
15. Re-install the upper shroud and secure Lock-and-

Ride fasteners.
RADIATOR REMOVAL (HIGH LIFTER)

1. Following the procedure in the manual for the High
Lifter model, drain the coolant.
2. Remove hose from left-hand portion of the radiator.
3. Remove overflow hose from radiator.
9. Completely drain coolant and properly dispose of it.
10. Re-install hose and position clamp w as previous.
3.16
4. Remove the (4) fasteners q to remove the radiator. 5. Position the fuse block from the underside of the
shroud, and install both fasteners. Torque to
specification. Ensure the fuse block cap is re-installed
as well.
TORQUE
Fuse Block Fastener
Torque until fully seated
6. Install all 4 lower shroud/fan assembly fasteners q,

and torque to specification. 3
RADIATOR INSTALLATION (HIGH LIFTER)

1. Place radiator on radiator support and install upper
hose and clamp, lower hose and clamp, and overflow
hose.
2. Install all 4 radiator retaining bolts q and torque to
specification.
TORQUE
Lower Shroud/Fan Assembly Fastener
Until Fully Seated
7. Re-install the upper shroud and secure Lock-and-

Ride fasteners.
WATER PUMP SERVICE

TORQUE
Radiator Fastener WATER PUMP IMPELLER REMOVAL
10 ft. lbs (13 Nm)
NOTE
The water pump impeller, mechanical seal, drive
3. Fill the cooling system and overflow, and run the coupler, pump shaft, and pump shaft bearing can be
engine up to operating temp. Verify the level is correct
serviced without removing the engine.
before re-assembly. Refer to the coolant bleeding
procedures earlier in this chapter.
1. Remove the front fuel tank (see Fuel System
WARNING chapter).
Never open the cooling system when the engine and 2. Remove the (4) screws retaining the engine skid
radiator are warm or hot. Hot coolant can cause severe plate and remove the plate from the vehicle.
burns. Allow engine and radiator to cool. 3. Place a drain pan under the front portion of the
engine.
4. Fit the lower shroud/fan assembly loosely. With the
front of the lower shroud/fan assembly lifted,
reconnect both fan electrical connectors.
3.17
4. Slide the clamp q back and remove the coolant inlet 8. Remove gasket, impeller bolt, washer, and impeller.
hose from the water pump housing.
5. Slowly drain the coolant into the drain pan. Dispose

of used coolant properly.
WATER PUMP MECHANICAL SEAL
6. Remove the coolant by-pass hose w from the water REPLACEMENT
pump cover fitting.
Perform “Water Pump Impeller Removal” procedure.
Water Pump Impeller Removal, page 3.17
1. Disconnect the stator wire harness and remove the
CPS from the stator cover.
2. Remove the (8) stator cover screws.
3. Carefully remove the stator cover taking care not to
damage the plastic coolant pipe.
CAUTION
The flywheel contains powerful magnets. Use caution
when removing the stator cover.
DO NOT place fingers between cover and crankcase at
any time during the removal process or injury could
7. Remove the ten cover screws e and pump cover r. result.
3.18
4. Remove CPS, stator wire guide, and stator from the 6. Press shaft down until flush with end of mechanical
cover. seal or until the seal spring starts to compress.
7. Select a suitable arbor (D) and press the shaft

through the seal until the shaft assembly is removed.
5. Support the stator cover by the stator mounting boss,

using an aluminum or PVC pipe section or other
suitable support block (C) positioned inside the stator
housing as shown. Do not attempt to press water
pump shaft out of stator housing without first
supporting the cover by the stator boss, or cover may
be damaged.
3.19
8. Protect water pump cover gasket surface and turn 10. Press pump shaft / bearing assembly into housing
cover over. Drive mechanical seal out from stator until firmly seated.
side of cover.
11. Turn cover over and press the new mechanical seal
squarely into the housing using seal installer PA-
44995-A.
12. Install the impeller and torque bolt to specification.
TORQUE
Water Pump Impeller Bolt:
10 ft-lbs (13.5 Nm)
13. Rotate impeller and check for smooth rotation.
STATOR COVER INSTALLATION

1. Install new O-rings on the plastic coolant pipe.
Lubricate the O-rings with P80 (rubber lubricant) or
lithium grease.
CAUTION
when installing the stator cover.
DO NOT place fingers between cover and crankcase at
any time during the installation process or injury could
result.
2. Carefully install the stator cover.
9. Clean the housing thoroughly. 3. Check to see that the water pump coupler splines
have engaged by turning the impeller bolt with a
If pump shaft assembly (shaft, drive coupler hub, and ratchet and 10 mm deep-well socket.
bearing) is in good condition, proceed to the next
step. If any of these parts require replacement, refer 4. Refer to the following pages for stator cover
to the “Water Pump Shaft & Bearing Replacement” assembly and torque information.
procedure.
3.20
WATER PUMP ASSEMBLY / TORQUE SPECIFICATIONS
3.21
STATOR COVER ASSEMBLY TORQUE SPECIFICATIONS
3.22
THERMOSTAT TORQUE
Fuel Rail Mounting Screws:
THERMOSTAT REPLACEMENT 44 in. lbs (5 Nm)
1. Drain coolant so the coolant level is below the
thermostat housing, see: Coolant Drain / Radiator TORQUE
Service (Sportsman), page 3.13.
Plenum to Throttle Body Fasteners:
2. Remove the intake/plenum., page 3.25
7 ft-lbs (10 Nm)
3. Thoroughly clean the area around the thermostat,
fuel injectors, and throttle body.
4. Remove the retaining fasteners i that secure the
10. Install of other removed components is reverse of
removal procedure.
3
fuel rail to the throttle body.
11. Perform the “Cooling System Bleeding Procedure”.
Cooling System Bleeding Procedure, page 3.12
5. Gently pry/pull up on the rail to remove the injector/

rail assembly from the injector ports.
6. Plug the injector ports with clean shop towels to
prevent debris from entering the clean side of the
intake.
7. Remove the fasteners o that retain the thermostat
housing, then the housing.
8. Replace the thermostat and seal.

9. Torque fasteners to specification.
TORQUE
Thermostat Housing Fastener
7 ft-lbs (10 Nm)
3.23
INTAKE / EXHAUST SYSTEM

AIR INTAKE ASSEMBLY VIEW
AIR INTAKE ASSEMBLY VIEW

q AIR INTAKE BOOT High Lifter only
w AIR IN DUCT High Lifter only
e BOLTS Torque until fully seated
r AIRBOX / INTAKE DUCT SEAL High Lifter only
t U-NUT High Lifter only
y CLOSEOUT PLATE
u AIRBOX COVER SEAL
i AIRBOX COVER
o RETAINER BOLT High Lifter only
a SCREW High Lifter only
3.24
INTAKE REPLACEMENT
1. Remove the following body components. Refer to
Chapter 9 “Body / Frame” for component removal.
• Seat
• Left Hand Upper Side Panel
• Right hand Upper Side Panel
2. Remove the breather hose from the side of the

airbox.
5. Remove the two hoses y from the IAC valve.
3. Disconnect wire harness r from ignition coil, intake

air temp sensor, and IAC valve.
6. Disconnect the spark plug wires.

7. Remove the rubber strap that retains the ECU to the
front of the air box.
8. Remove the screws u that retain the intake runners
to the throttle body.
4. Remove the two screws that retain the air box to the
frame.
9. Lift up on the air box and rotate it towards the left side
of the vehicle. Open the wire harness retainer and
remove the harness. Set the airbox assembly aside.
3.25
IMPORTANT
10. Install is reverse of removal.
EXHAUST
850/1000 1-UP HEAT SHIELDS

Inspect the heat shields. Ensure they are not damaged,
and are properly secured.
If any heat shields are found to be damaged or missing,
they must be replaced.
q Silencer Heat Shield
w Rear Cab Heat Shield
HIGH LIFTER HEAT SHIELDS

If any heat shields are found to be damaged or missing,
they must be replaced.
q Silencer Heat Shield
2-UP HEAT SHIELDS

If any heat shields are found to be damaged or missing, q Exhaust Spring Heat
they must be replaced. Shield
e Front Cab Heat Shield
r Storage Box Side Heat

Shield
t Silencer Heat Shield
y Storage Box Lower Heat

Shield
u Exhaust Manifold Heat
Shield
3.26
ENGINE ASSEMBLY VIEWS / TORQUE VALUES

TORQUE SPECIFICATION AND TORQUE SEQUENCE - MAIN ENGINE COMPONENTS
12-14 ft-lbs (16-19 Nm) Step 1: 8 ft. lbs (11 Nm)

VALVE COVER Step 2: 43 ft. lbs (59 Nm)
Step 3: Additional 180°
Step 4: M6 bolts: 7 ft-lb (10 Nm)
CYLINDER HEAD
13 ft. lbs (18 Nm) 9 ft. lbs (12 Nm) 89 in. lbs (10 Nm)
CAMSHAFT CARRIER OIL PUMP COVER WATER PUMP COVER
89 in. lbs (10 Nm) 14 ft-lbs (19 Nm) M9 Step 1: 71 in. lbs (8 Nm)
STATOR COVER COUPLER / STARTER GEAR M9 Step 2: 26 ft. lbs (35 Nm)
M6: 89 in. lbs (10 Nm)
CRANKCASE
3.27
VALVE COVER
3.28
CAMSHAFT CARRIER / CAMSHAFT /

ROCKER ARM
3.29
CYLINDER HEAD / VALVES / INTEGRATED THROTTLE BODY
3.30
VALVE AND SPRING HEIGHT DETAIL - SPM850
3.31
VALVE AND SPRING HEIGHT DETAIL - SPM1000
3.32
PISTON / CONNECTING ROD
3.33
CRANKSHAFT
3.34
CRANKCASE
3.35
CRANKCASE - UPPER
3.36
BALANCE SHAFT / BALANCE SHAFT TIMING
3.37
CRANKCASE (LOWER) WITH OIL PUMP
3.38
STATOR COVER / FLYWHEEL / WATER PUMP COUPLER
3.39
WATER PUMP / WATER PUMP COUPLER / STATOR
3.40
DRIVE COUPLER (REAR) / STARTER GEAR
3.41
ENGINE SERVICE
ACCESSIBLE ENGINE COMPONENTS ENGINE REMOVAL
Components serviceable with engine installed:
IMPORTANT
• Flywheel
• Alternator (Stator) Some engine repair procedures can be performed
• Starter Motor / Solenoid without removing the engine from the vehicle. Refer to
• Cylinder Head / Valves “Accessible Engine Components” for further
• Camshaft / Camshaft Carrier information.
• Rocker Arms
• Water Pump NOTE
Components that require engine removal for service: Upon engine removal, use a mechanical lift or have an
assistant help remove the engine from the vehicle to
• Counterbalance Shaft(s)
prevent personal injury or damage to vehicle
• Piston / Rings
components.
• Connecting Rod
• Crankshaft / Main Bearings
• Oil Pump 1. If vehicle was recently operated, allow it to cool down
• Crankcase before attempting to perform any work.
• Crankshaft End Seals (Use Driver PA-49320) 2. Thoroughly clean the engine and chassis.
3. Clean your work area.
TOP-END SERVICE (ENGINE IN CHASSIS) 4. Drain the engine oil (see Chapter 2 “Maintenance”).
The top-end of the engine can be serviced while the
engine is mounted in the chassis. A removable upper 5. Remove the following body components. Refer to
right-hand frame support allows access to the valve Chapter 9 “Body / Frame” for component removal.
cover and cylinder head. • Seat
To service the top-end of the engine refer to the “Valve • Side Panels (upper and lower)
Clearance Adjustment” procedure in Chapter 2, which • Footwells
provides detailed steps to access the valve cover. • Mud Guards (both sides)
• Front Rack or Storage Box
• Front Cab
6. Disconnect negative (-) battery cable.
7. Pull the shift linkage rod straight outward while
pushing on the two ears of the snap retainer q to
disconnect the rod from the shift lever. Allow the
linkage to hang down out of the way.
3.42
8. Remove the high tension leads w from the engine 13. Disconnect wire harness r from ignition coil, intake
and remove the nuts e from each exhaust flange at air temp sensor, and IAC valve.
the engine.
9. Remove the exhaust springs retaining the exhaust 14. Remove the two hoses y from the IAC valve.
pipe to the silencer and remove the pipe from the
vehicle. Insert a clean shop towel into the engine
exhaust ports.
airbox.
11. Remove the (2) screws retaining the lower portion of
the airbox to the frame.
12. Remove the breather hose from the side of the
airbox.
15. Remove the screws u that retain the intake runners

to the throttle body.
16. Lift up on the air box and rotate it towards the left
side of the vehicle. Open the wire harness retainer
and remove the harness. Set the airbox assembly
aside.
IMPORTANT
3.43
17. Remove the push rivets retaining the right-hand 26. Remove all bolts a rom both sides retaining the
portion of the rear cab to gain access to the bolts engine to the transmission.
retaining the upper right-hand frame support.
18. Remove the bolts i and upper right-hand frame
support to allow engine removal.
19. Disconnect the CPS and stator wire harnesses.

20. Depressurize the fuel system at the fuel Schrader
valve. Disconnect the fuel line fitting from the fuel rail
and remove the fuel tank (see Chapter 3 “Fuel Pump
/ Fuel Tank Removal”).
21. Remove the (4) screws retaining the engine skid
plate and remove the plate from the vehicle.
22. Place a drain pan under the front portion of the
engine.
23. Loosen the hose clamp and remove the coolant inlet
hose o rom the water pump housing. 27. Remove the top bolt s rom the RH engine isolator
mount.
24. Slowly drain the coolant into the drain pan. Dispose
25. The following steps may require you to use an
appropriate tool such as a pry bar to support the
engine.
3.44
28. Remove the fasteners d etaining the LH engine 31. Remove the screws j hat retain the throttle body to
isolator mount to the engine and remove the lower the cylinder head. Replace the gaskets upon
nut f fom the mount. Pry up between the frame and installation. Insert a clean shop towel into each
isolator mount and remove the mount assembly from intake track of the engine to prevent debris from
the frame. entering.
29. Remove the upper radiator hose g from the 32. Remove the spade wire (white/red) and battery cable
thermostat housing. Insert a clean shop towel into from starter motor solenoid.
the outlet.
33. Remove engine ground cable from crankcase.
34. Disconnect harness from ECT sensor.
35. Pull the engine toward the front of the vehicle to
disengage the engine coupler from the transmission
input shaft.
30. Use a heavy-duty tie strap h o retain the throttle

body and fuel rail assembly to the upper left-hand
frame support. Doing so allows the TPS, T-MAP, fuel
injectors, IAC hoses and throttle cable to remain
connected to the throttle body.
3.45
36. Remove the engine through the right side of the 12. Again remove radiator cap and slowly add coolant to
chassis and place on a work bench to begin engine top of fill neck.
disassembly.
13. Alternately elevate the front and back of the vehicle
to allow additional air to vent from the system.
14. Start engine and observe coolant level in the
radiator. Allow air to purge and top off as necessary.
Reinstall radiator cap securely and bring engine to
operating temp. Check coolant level in reservoir tank
after engine has cooled and add if necessary.
Engine Break In Period
The engine break-in period is defined as the first 20
hours of engine operation or 2 full tanks of fuel.
15. Use only Polaris PS-4 Synthetic engine oil. Never
substitute or mix oil brands. Serious engine damage
can result.
16. Use fuel with a minimum octane rating of 87 (R+M)/2
method.
ENGINE INSTALLATION NOTES 17. Change break-in oil and filter at 20 hours.
After the engine is installed in the frame, review this
checklist and perform all steps that apply:
General Items
1. Repeat steps in reverse order in the “Engine
Removal” section above to reinstall the engine.
2. Install previously removed components using new
gaskets, seals, and fasteners where applicable.
3. Perform regular checks on fluid levels, controls, and
all important areas on the vehicle as outlined in the
Daily Pre-ride Inspection Checklist and in the
Periodic Maintenance Table (refer to Chapter 2
“Maintenance”). , page 2.4
Exhaust
4. Replace exhaust seals before installation.
5. Install the exhaust pipe assembly into the cylinder
head and exhaust silencer.
6. Install the nuts and finger tighten only!
7. Install the springs retaining the pipe to the silencer.
8. Torque the exhaust retaining nuts to specification.
TORQUE
Exhaust Retaining Nuts:
Step 1: Front to Rear: 8 ft. lbs (11 Nm)
Step 2: Rear to Front: 14 ft. lbs (19 Nm)
Bleed Cooling System

9. Remove radiator cap and slowly add coolant to top of
filler neck.
10. Fill coolant reservoir tank to full mark.
11. Install radiator cap and squeeze coolant lines to
force air out of system.
3.46
ENGINE DISASSEMBLY / INSPECTION

VALVE COVER REMOVAL / INSPECTION 2. Using an 8mm socket, remove cam chain tensioner
1. Remove the six rocker cover bolts q and isolators bolts r evenly and remove tensioner. Note “TOP”
marked on plate t for assembly.
w.
2. Replace isolators and cover gasket e if oil leaks are 3. Using a 12mm socket, remove the cam sprocket bolt
evident. u and lift the chain and sprocket off camshaft.
Secure cam chain with a wire to prevent it from
falling off the crankshaft gear (if cylinder head will not
ROCKER CARRIER / CAMSHAFT REMOVAL be removed).
1. Using a 12 mm Allen socket, rotate the flywheel
clockwise (direction of engine rotation) until pin q is
facing UP. Rotate engine back 60° to the 10:00
position w to relieve valve spring pressure from
camshaft lobes.
4. Using a 10mm socket, loosen all cam carrier bolts

evenly and lift carrier / rocker arm assembly from
cylinder head.
5. Lift camshaft from cylinder head.
IMPORTANT
DO NOT rotate the engine using the camshaft sprocket
retaining bolt.
3.47
ROCKER ARM / ROCKER ARM SHAFT 4. Measure I.D. of rocker arms and O.D. of rocker arm
INSPECTION shafts. Measure shaft bore in cam carrier. Compare
to specifications (See “Engine Specifications”, page
1. Mark or tag rocker arms and shafts to keep them in 3.7).
their respective locations for assembly.
2. Slide rocker arm shafts from carrier and remove the
intake and exhaust rocker arms.
3. Inspect each rocker arm roller. Roller surface should

be smooth. Axial movement should be minimal. Roll
a smooth flat rod across the roller, applying firm
downward pressure on roller while observing roller
movement. Roller should turn smoothly without
binding. Replace rocker arm if roller surface is
damaged, or if roller does not turn smoothly.
CAMSHAFT / CAMSHAFT BORE

INSPECTION
1. After camshaft carrier is removed, lift camshaft from
cylinder head. Inspect all main journals and cam
lobes as described below and compare to
specifications (See “Engine Specifications”, page
3.7). Replace if worn beyond service limit or if any
surface is pitted or damaged.
3.48
2. Measure all cam lobe heights from base circle to CYLINDER HEAD REMOVAL
highest point on lobe. 1. Loosen two outer bolts q, then loosen all head bolts
w evenly, 1/8 turn at a time until all are loose.
Remove all bolts, cylinder head, and gasket e.
3. Temporarily install camshaft carrier as shown below

to measure the camshaft bore. Replace cylinder
head if worn.
NOTE
Head can be removed from cylinder / crankcase without
removing cam carrier (C) but the center two cylinder
head bolts cannot be removed from the head unless
carrier is removed.
CYLINDER HEAD CLEANING

Thoroughly clean cylinder head surface to remove all
traces of gasket material and carbon.
CAUTION
Use care not to damage gasket sealing surface. All
gasket surfaces must be clean, dry, and free of any oil
or grease upon assembly.
Clean sealing surfaces with rubbing alcohol, electrical
contact cleaner or a brake cleaner that does not leave a
solvent residue. Do not touch sealing surfaces of the
new head gasket.
3.49
CYLINDER HEAD WARP INSPECTION Valve Spring Compressor:

1. Lay a straight edge (A) across surface of cylinder PV-1253 (or PV-4019 with adapter PV-43513-A)
head at several different points and measure warp
by inserting a feeler gauge between the straight 1. Compress valve spring and remove split keepers w.
edge and the cylinder head surface. If warp exceeds
the service limit, replace the cylinder head.
2. Remove compressor, then remove top retainer,

spring and seal e. Discard seals. Repeat for all
remaining valves.
3. Clean combustion chamber and head gasket
surface.
MEASUREMENT 4. Measure free length of each spring with a Vernier
Cylinder Head Warp Limit: caliper and compare to specification.
0.004" (0.10 mm) max
CYLINDER HEAD DISASSEMBLY
WARNING
Wear eye protection when removing and installing
valve springs.
NOTE
Keep mated parts together for assembly. It is important
to put cylinder head parts back in the same location.
Mark parts or place them in a rack as you remove them. MEASUREMENT
Valve Spring Free Length:
Std: 1.861" (47.26 mm)
3.50
VALVE INSPECTION 5. Measure diameter of valve stem with a micrometer in

1. Remove all carbon from valves with a soft wire wheel three places, then rotate 90 degrees and measure
or brush. again (six measurements total). Compare to
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 end of valve stem for flaring, pitting, wear or In: 0.2163" ± 0.0003" (5.495 ± 0.0075 mm)
damage. Ex: 0.2159" ± 0.0003"(5.485 ± 0.0075 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.
MEASUREMENT
Valve Guide I.D.:
0.217" + 0.0005" - 0.0”
(5.52 + 0.012 - 0.0 mm)
7. Subtract valve stem measurement from the valve

guide measurement to obtain stem to guide
clearance. NOTE: The valve guides cannot be
replaced. Be sure to measure each guide and
valve combination individually.
4. Inspect split keeper groove for wear or flaring of the
keeper seat area.
NOTE
The valves can be re-faced or end ground, if necessary.
They must be replaced if extensively worn, burnt, bent,
or damaged.
3.51
COMBUSTION CHAMBER 4. Drive or press new guides from camshaft side of

1. Clean all accumulated carbon deposits from head to proper installed height. Note difference
combustion chamber and valve seat area. between intake and exhaust guide height:
NOTE
Carbon Clean Fuel Treatment (2871326) can be used
to help remove carbon deposits.
IMPORTANT
Do not use a metal scraper, a coarse wire brush, or
abrasive cleaners to clean the cylinder head. Damage
may result.
2. Visually inspect cylinder head gasket surface and

combustion chamber for cracks or damage. Pay
close attention to the areas around spark plug and
valve seats.
MEASUREMENT
VALVE GUIDE REMOVAL / INSTALLATION
Intake Valve Guide Height
1. Support cylinder head and place valve guide
9.18 mm ± 0.25 mm
remover into valve guide from the combustion
chamber side.
2. Drive or press old valve guides out of cylinder head. MEASUREMENT
Exhaust Valve Guide Height
CAUTION 7.00 mm ± 0.25 mm
Replacement of valve guides requires an oven, special
equipment and experience to do the job correctly. If you 5. Ream or hone new valve guides to size to obtain
are unsure of your ability to do the repair professionally specified stem-to-guide clearance. Ream from
it is best to sublet the labor to a competent machinist. combustion chamber side of head.
Valve seat reconditioning is required when valve guides
are replaced. CAUTION
Do not tilt the reamer while reaming the guide. Always
rotate the reamer in a clockwise direction.
CAUTION
The cylinder head can be easily damaged if the 6. Clean cylinder head thoroughly with clean solvent.
procedure is done carelessly. 7. Inspect valve seats and recondition if necessary.
3. Apply 90 weight oil to outside of new valve guides. VALVE SEAT RECONDITIONING
Valve seat reconditioning should be performed by a
technician proficient in cylinder head reconditioning
techniques. Reconditioning techniques vary, so follow
the instructions provided by the valve reconditioning
equipment manufacturer. Do not grind seats more than
necessary to provide proper seat surface, width, and
contact point on valve face.
Valve Seat Inspection
Inspect valve seat in cylinder head for pitting, burnt
spots, roughness, and uneven surface. If any of the
above conditions exist, the valve seat must be
reconditioned. If the valve seat is cracked the cylinder
head must be replaced.
Valve seat width and point of contact on the valve face is
very important for proper sealing. The valve must contact
the valve seat over the entire circumference of the seat,
3.52
and the seat must be the proper width all the way 5. To check the contact area of the seat on the valve
around. If the seat is uneven, compression leakage will face, apply a thin coating of Prussian Blue paste to
result. If the seat is too wide, seat pressure is reduced, the valve seat. If using an interference angle (46°)
causing carbon accumulation and possible compression apply black permanent marker to the entire valve
loss. If the seat is too narrow, heat transfer from valve to face (A).
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.
1. Install pilot into valve guide.
2. Apply cutting oil to valve seat and cutter.
3. Place 46° cutter on the pilot and make a light cut.
4. Inspect the cut area of the seat:
* If the contact area is less than 75% of the
circumference of the seat, rotate the pilot 180° and
make another light cut.
* If the cutter now contacts the uncut portion of the
seat, check the pilot. Look for burrs, nicks, or runout.
If the pilot is bent it must be replaced.
* If the contact area of the cutter is in the same place,
the valve guide is distorted from improper
installation.
* If the contact area of the initial cut is greater than
75%, continue to cut the seat until all pits are
removed and a new seat surface is evident. NOTE:
Remove only the amount of material necessary to
repair the seat surface.
3.53
7. Remove valve and check where the Prussian Blueä NOTE

indicates seat contact on the valve face. The valve
seat should contact the middle of the valve face or When using an interference angle, the seat contact
slightly above, and must be the proper width. point on the valve will be very narrow, and is a normal
condition. Look for an even and continuous contact
* If the indicated seat contact is at the top edge of the point all the way around the valve face (A).
valve face and contacts the margin area (B) it is too
high on the valve face. Use the 30° cutter to lower
the valve seat.
* If too low, use the 60° cutter to raise the seat. When
contact area is centered on the valve face, measure
seat width.
* If the seat is too wide or uneven, use both top and
bottom cutters to narrow the seat.
* If the seat is too narrow, widen using the 45° cutter
and re-check contact point on the valve face and
seat width after each cut.
MEASUREMENT
Valve Seat Width:
Intake Std: 0.028″ (0.7 mm)
Limit: 0.055″ (1.4 mm)
Exhaust Std: 0.039″ (1.0 mm)

Limit: 0.071″ (1.8 mm)
3.54
8. Clean all filings from the area with hot soapy water. 2. Remove all water pump cover screws q and stator
Rinse and dry with compressed air. cover screws w, noting location of hose retainer e.
9. Lubricate the valve guides with clean engine oil, and
apply oil or water based lapping compound to the
face of the valve.
NOTE
Lapping not required if an interference angle
reconditioning method is used.
10. Insert the valve into its respective guide and lap 3
using a lapping tool or a section of fuel line
connected to the valve stem.
11. Rotate the valve rapidly back and forth until the cut
sounds smooth. Lift the valve slightly off of the seat,
rotate 1/4 turn, and repeat the lapping process. Do
this four to five times until the valve is fully seated, 3. NOTE: Water pump cover removal is not required
and repeat process for the other valve(s). unless water pump or cover gasket service will
be performed. Water pump service is described
12. Thoroughly clean cylinder head and valves. in Chapter 4.
CRANKCASE DISASSEMBLY 4. Remove the retaining bolts r and coupler / starter

gear.
CAUTION
The rotor contains powerful magnets. Use caution
when removing and installing the stator cover. DO NOT
place fingers between cover and crankcase at any time
during the removal / installation process or injury could
result.
CAUTION
Do not attempt to lift the upper crankcase / cylinder
from the lower crankcase for piston / ring access
without first removing the lower crankcase and
connecting rod caps from the crankshaft. Pistons must
be removed through the top of the cylinders with the
connecting rod attached.
NOTE
1. Remove cylinder head (beginning on page 5.27, Due to the inherent motion of the damper/ring gear hub
page 3.47). in relation to the gear body, the holes to access the
bolts is not likely to align well. You may need to use a
ball hex and a screwdriver to carefully pry through the
holes to align the tool to the fasteners. Take care not to
damage the threads in the crankshaft when doing so.
3.55
5. Remove the water pump drive coupler / retaining bolt 8. Loosen the twelve outer crankcase bolts i evenly 1/
from the flywheel. 2 turn, then loosen the two longer case bolts o, then
• Hold the flywheel using a commercially available strap the six main crankcase bolts a. Remove all the
wrench. bolts.
• Remove the flywheel retaining bolt t using the Water
Pump Drive Bolt Tool PA-50995 y.
NOTE
The flywheel bolt has a LEFT HAND THREAD. Turn
CLOCKWISE to remove.
9. Tap lower crankcase in reinforced areas with a soft

faced hammer to loosen, then lift straight upward to
remove.
CRANKCASE (LOWER) / OIL PUMP

DISASSEMBLY
1. Remove oil pump cover plate screws q. Note
location of two longer (M6x20) screws w for
6. Fully install Flywheel Puller PA-49316 on threads of assembly. These screws secure the pump.
flywheel (left hand thread - turn flywheel puller
COUNTERCLOCKWISE to install on flywheel).
7. Hold puller body u and tighten center bolt i to
remove flywheel.
2. Remove three baffle plate screws e and plate.

3. Slide pump off mounting boss in crankcase.
4. Visually inspect pump rotors and drive gear for
damage or debris.
NOTE
Replace oil pump as an assembly and pressure relief
valve if debris has entered pump or if pump damage is
evident.
3.56
5. Rotate pump gear until rotors are positioned as 9. Remove oil pressure relief from crankcase. Replace
shown below. Use a feeler gauge to measure tip if debris has entered, or if oil pressure was outside of
clearance. . specified range.
TORQUE
Oil Pressure Relief Valve:
20 ft-lbs (27 Nm)
CRANKCASE DISASSEMBLY (UPPER)

1. Remove the oil passage connecting tube with O- 3
rings.
MEASUREMENT
Clearance should not exceed 0.006" (.15 mm)
6. Measure pump rotor clearance to pump cover plate

with a feeler gauge through the pump outlet window
and compare to specification.
2. Note connecting rod and cap marks so they can be

oriented properly and assembled in the same
manner as matched sets on proper rod journal q.
New rods can be installed with marks to front or rear.
Rods have no offset.
MEASUREMENT
Pump to Cover Clearance:
0.0010–0.0027" (0.025–0.070 mm)
7. Measure shaft axial (end) free play with a dial

indicator and compare to specification.
MEASUREMENT 3. Remove the two connecting rod bolts w.

Axial Play:
0.010–0.030" (0.24–0.82 mm) PISTON / CONNECTING ROD REMOVAL
1. Piston assemblies can be installed in either
8. Inspect inner rotor drive pin for wear or damage. orientation as each piston is symmetric.
NOTE
Replacement pistons can be installed in either
orientation as they are symmetric.
3.57
2. Push connecting rod / piston assembly out through 4. Inspect both counterbalance shaft bearings.
top of cylinder bore of upper crankcase.
NOTE
Due to extremely close tolerances, balance shaft
bearings must be inspected visually and by feel. Look
for signs of discoloration, scoring, galling or
contamination from moisture or dirt. Turn bearings on
shaft. Bearings should turn smoothly and quietly. The
outer race should be firm with minimal side to side
movement and no detectable up and down movement.
Replace the balance shaft as an assembly if any of the
above are present.
5. Inspect gear teeth for damage. Normal split gear

alignment is approximately 1/2 tooth in the relaxed
position as shown.
NOTE
If pistons are to be reused, mark them for assembly in
same cylinder.
3. See “Piston / Piston Ring Inspection listed in this

chapter.
COUNTERBALANCE SHAFT REMOVAL /

INSPECTION
1. Note timing marks on balance shaft drive gears and
crankshaft drive gear. Shafts must be properly timed
upon assembly.
2. Mark each shaft location for assembly (starter side or 6. Hold main gear q and rotate split gear w
oil pipe side). counterclockwise (viewed from gear end) to
compress springs e. Split gear should rotate and
3. Lift both balance shafts from upper crankcase and return freely and completely without binding.
remove end plugs.
3.58
CRANKSHAFT / CAM CHAIN REMOVAL 2. Measure each main journal (A) and rod journal (B) in
1. Remove crankshaft with cam chain and end seals. two locations, 90 degrees apart. Record
measurements for bearing selection on page 5.49,
page 3.62. Calculate the difference between the two
measurements for each journal to determine
concentricity (C). Replace crankshaft if any journal is
worn below the minimum diameter specification or if
journal out-of-round exceeds maximum specification.
MEASUREMENT
A - Crankshaft Main Journal Diameter:
2.1642 - 2.1650″ (54.970 - 54.990 mm) 3
C - Crankshaft Main Journal Concentricity:
< 0.00027″ (0.007 mm) Out Of Round
B - Connecting Rod Journal Diameter:

1.7718 - 1.7726″ (45.005 - 45.025 mm)
CAM CHAIN / SPROCKET INSPECTION
1. Cam chain should be replaced if damage is evident C - Connecting Rod Journal Concentricity:
or if sprockets show visible signs of wear. Inspect < 0.00027″ (0.007 mm) Out Of Round
drive and driven sprockets.
CRANKCASE INSPECTION (LOWER) D - Maximum Runout:
.001″ (.025 mm)
1. Remove main bearing inserts from lower crankcase
half. Replace crankcase assembly if a bearing bore
3. Support crankshaft on V-blocks or on-centers in a
is galled or if bearing inserts have rotated in the
crankshaft stand or lathe. Measure crankshaft runout
case.
(D) and replace if runout exceeds specification
above.
CRANKSHAFT INSPECTION
1. Visually inspect surface of crankshaft main and
connecting rod journals. Replace crankshaft if any
journal is scratched or pitted.
CONNECTING ROD INSPECTION

1. Secure connecting rod lightly in a soft jawed vise.
3.59
2. Remove piston circlip q. 6. Measure small end I. D. in two directions as shown.

Record measurements. The difference between
measurements is concentricity. Compare to
specifications.
NOTE
Notice the location of the piston circlip gap at top.
MEASUREMENT
3. Push piston pin out of piston. If necessary, heat
crown of piston slightly with a propane torch or heat Connecting Rod (Small End) Diameter:
gun. 0.7886 + 0.0 / - .015" (20.03 + 0.0 / - .015 mm)
CAUTION Connecting Rod (Small End) Concentricity:

< 0.00027" (0.007 mm) Out Of Round
Do not apply heat to piston rings or a loss of radial
tension could result.
7. Install matching rod cap on connecting rod (without
bearings). Lubricate bolt threads and install the bolts.
4. Measure piston pin O. D. in two directions and 3
locations on the length. 8. Torque bolts to specification.
TORQUE
Rod Cap Bolts:
16 ft. lbs (22 Nm)
9. Using a dial bore gauge, measure big end I.D. in two

directions shown. Record measurements. Difference
between measurements is concentricity. Compare to
specifications.
MEASUREMENT
Piston Pin O.D. :
0.7873 ± .0001" (19.9975 ± .0025 mm)
5. Inspect small end and big end of connecting rod (and

matching rod cap) for damage, galling of surface or
pitting.
3.60
10. Select appropriate bearing insert (color) from table

(Connecting Rod Bearing Selection Chart, page
3.62).
MEASUREMENT
Connecting Rod (Big End) Diameter:
1.8892 - 1.8902" (47.987 - 48.011 mm)
Connecting Rod (Big End) Concentricity:

< 0.00047" (0.012 mm)
3
3.61
CONNECTING ROD BIG END BEARING 2. If re-installing the original connecting rod, select the
SELECTION appropriate bearing from the table below based on
connecting rod big end I. D. measurements
1. If using NEW connecting rods, install the bearing (Connecting Rod Big End ID measurement, page
color that matches the bore tolerance letter marked 3.59).
on the connecting rod cap q.
Connecting Rod Bearing Selection Chart

Bearing Size Selection Chart – Inches (mm)
Connecting rod journal must be within standard size limits as determined by crankshaft measurements
Con Rod Letter R W B Y
1.8892-1.8895″ 1.8895-1.8897″ 1.8897-1.8899″ 1.8899-1.8902″
Con Rod Big End (47.987mm- (47.993mm - (47.999mm - (48.005mm -
Bore Diameter 47.993mm) 47.999mm) 48.005mm) 48.011mm)
Target Oil
0.0009- 0.0022″
Clearance (Con
(0.023 mm - 0.057 mm)
Rod Bearing)
Bearing color to
Red White Blue Yellow
install
3.62
PISTON / PISTON RING INSPECTION PISTON RING INSTALLED GAP

1. Measure piston ring to ring land clearance with a
1. Place each piston ring q inside the cylinder . Use the
thickness gauge (A) inserted between bottom edge
piston to push the ring squarely into cylinder.
of ring (B) and piston ring land (C). Replace both
piston and rings if clearance exceeds service limit.
2. Repeat for 2nd ring.
2. Measure installed gap with a feeler gauge w at both

the top and bottom of the cylinder.
NOTE
PISTON RING REMOVAL A difference between top and bottom end gap
1. Carefully remove top compression ring q by hand or measurements is a general indication of cylinder taper
using a ring removal pliers. (wear). The cylinder should be measured for taper and
out of round.
CAUTION
Do not expand the ring more than necessary to remove 3. If the installed gap measurement exceeds the service
it from the piston or the ring may break or lose radial limit, replace the rings.
tension.
MEASUREMENT
Carefully expand ring and lift it off the piston. Piston Ring Installed Gap
Top: 0.014" ± 0.008" (0.36 ± 0.20 mm)
Second: 0.014" ± 0.008" (0.36 ± 0.20 mm)
Oil Control Rails:

0.0196" ± 0.010" (0.50 ± 0.25 mm)
IMPORTANT
Always check piston ring installed gap when installing
new rings and/or a new cylinder.
2. Repeat procedure for second ring w.

3. Remove (3 piece) oil control ring e. Remove top rail
first, then bottom rail, then the expander.
3.63
PISTON PIN BORE INSPECTION 5. Inspect taper and out of round with a dial bore
1. Measure piston pin bore. gauge.
MEASUREMENT 6. Measure in two directions (front to back and side to

side) on three levels and record measurements. If
Piston Pin Bore: cylinder is tapered or out of round beyond .001", the
0.7877 ± .0002" (20.007 ± .004 mm) crankcase must be replaced.
CYLINDER INSPECTION
1. Remove all gasket material from gasket surface.
2. Lay a straight edge across cylinders (upper
crankcase).
3. Use a thickness gauge to measure gap between
straightedge and gasket surface. Measure at outer
edges and center, repeating measurements with
straightedge laid diagonally.
MEASUREMENT
Cylinder Taper Limit:
MEASUREMENT .001" (.025 mm) Maximum
Cylinder Warp:
0.002" (0.05 mm) Max. Cylinder Out of Round:
Limit: .001" (.025 mm) Maximum
4. Inspect cylinder for wear, scratches, or damage.
IMPORTANT MEASUREMENT
DO NOT hone the cylinders or attempt to repair a Standard Bore Size
damaged cylinder by honing. 3.4252" ± .0005 (87 mm ± .01 mm)
3.64
PISTON-TO-CYLINDER CLEARANCE
Measure piston outside diameter at a point 33 mm down
from piston crown, at a right angle to piston pin bore.
Subtract measurement from maximum measurement
obtained in Step 6 of Cylinder Inspection.
Piston to Cylinder Clearance:

.0013 ± .0008" (.033 ± .02 mm)
Piston O.D. (Standard):

3.4239 ± .0008" (86.967 ± .02 mm)
3.65
ENGINE ASSEMBLY
CRANKCASE PREPARATION - UPPER 4. Install second ring with undercut facing bottom of
1. Refer to Oil Flow Diagram (page 5.4, page 3.6) and piston. Rotate ring to place end gap generally toward
trace the oil path through the upper crankcase / (intake) side of piston as shown below.
cylinder. Flush all oil passages with solvent and then 5. Install top ring with “0” mark facing up (toward piston
warm soapy water. Rinse with clear, warm water and crown) and rotate to position the gap generally at the
dry with compressed air. Be sure passages are clean front as shown below.
and dry before assembling the upper crankcase.
6. Be sure top and second rings rotate freely in their
grooves and do not bind when compressed by hand.
PISTON RING INSTALLATION
Apply clean engine oil to rings. Check ring installed gap
before installation. Clean accumulated carbon from ring
grooves and lubrication holes if piston has been in
service.
1. Place oil control ring expander in oil ring groove. Tips
of expander gap (A) must face piston crown so
scraper edge (B) of expander faces piston skirt.
2. Rotate expander in groove until butt ends are on
intake side of piston. Ends must butt squarely
together and must not overlap.
3. Install bottom rail first, then top rail with end gap
located as shown at right.
3.66
PISTON / CONNECTING ROD ASSEMBLY 5. Install the remaining circlip with gap at the top or
1. Lubricate connecting rod small end, piston pin bore, bottom. Push the piston pin in both directions to
and piston pin with engine oil. make sure the clips are properly seated in the
groove.
CAUTION
IMPORTANT
Do not re-use cir-clips. Cir-clips become deformed
during the removal process. Never re-use a piston circlip.
Do not compress the new clip more than necessary to
prevent loss of radial tension. Severe engine damage 6. Check to be sure rings rotate freely in the grooves.
may result if circlips are re-used or deformed during
installation. PISTON / CONNECTING ROD 3
INSTALLATION
2. Install a new circlip on one side of piston with gap UP
(at the 12:00) or DOWN (at the 6:00) position. 1. Apply clean engine oil to piston assembly and
cylinder walls of upper crankcase.
2. Be sure ring end gaps are positioned at least 120
degrees apart. Oil ring rails at least 60 degrees
apart. (See “Piston Ring Installation”See “Piston
Ring Installation” on page 5.52, page 3.66).
3. Apply engine oil to ring compressor band and install
band (A) over piston rings.
CAUTION
Be sure compressor band end gap does not align with
any ring end gap when compressing the rings.
4. Fully compress piston rings using compressor pliers

(B) on band.
NOTE Piston Ring Compressor Band, 87 mm:

If re-installing connecting rods, orient marks on rod PV-43570-3
caps the same as when removed. Be aware of this
direction when installing pistons to rods. If new Piston Ring Compressor Pliers:
connecting rods are being installed, they can be PV-43570-1
installed either way (there is no piston pin offset)
however it is recommended they be installed with 5. Apply tape to the sides of connecting rods to protect
marks on both rods facing the same direction. cylinder from damage.
6. Align piston with bore and push into cylinder until all
3. Place piston on connecting rod. Replacement rings are captive. Remove ring compressor.
pistons can be installed in either orientation as they
are symmetrical.
4. Push piston pin through rod and piston until it seats
against the installed circlip.
IMPORTANT
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. DO NOT apply heat directly to piston
rings or a loss of radial tension could result.
3.67
CRANKSHAFT INSTALLATION 10. Torque the bolts using the following procedure:
Refer to Crankcase Assembly (Upper) page 5.56, page
3.69.
1. Clean the bearing bore surfaces of upper crankcase
(main bearings), connecting rods and connecting rod
caps.
2. Align tab of a new main bearing q with the slot in
main bearing bore of crankcase w. Press bearing
insert firmly into place. Repeat for all main bearings,
connecting rods, and connecting rod caps.
TORQUE
Connecting Rod Bolts:
Step 3: Tighten an add’n 90° (1/4 turn)
3. Apply Premium Starter Grease (2871460) to each OIL PASSAGE TUBE

main and rod bearing journal of crankshaft. 1. Replace O-rings (A) on both ends of the oil supply
tube.
4. Loop cam chain over crankshaft sprocket.
2. Apply a light film of engine oil to O-rings.
5. Apply engine oil to new crankshaft seals and install
seals on both ends of crankshaft with spring side of 3. Push oil tube into upper crankcase.
seal facing IN (toward crankshaft).
6. Carefully lower crankshaft into upper crankcase.
Guide connecting rods onto rod journals of
crankshaft as necessary.
7. Adjust crankshaft seals so each is flush with end of
crankcase.
8. Install rod caps on connecting rods with marks
aligned.
9. Install new connecting rod bolts (apply clean engine
oil to threads) and tighten evenly until snug.
3.68
CRANKCASE ASSEMBLY - UPPER
3.69
BALANCE SHAFT INSTALLATION 5. Align bearing locating ring in groove on crankcase

See “Balance Shaft Timing”, page 3.71. and fully seat the shaft.
1. Balance shafts are identical but should be installed in 6. Rotate crankshaft until SINGLE dot on crankshaft
the same location as removed. gear is visible.
2. Rotate crankshaft until the two alignment dots 7. Align single dot of drive gear between two dots of
crankshaft gear are visible (See “Balance Shaft balance gear.
Timing”, page 3.71). 8. Align bearing locating ring in groove on crankcase
3. As viewed from the front of the main gear end q, and fully seat the shaft.
rotate split gear w counter clockwise until teeth are 9. Verify balance shaft timing is correct by comparing to
aligned and hold in position. illustration (See “Balance Shaft Timing”, page 3.71).
10. Place balance shaft end plugs in upper crankcase.
4. Install balance shaft, placing the tooth with the single

dot between the two dots on the crankshaft gear.
3.70
BALANCE SHAFT TIMING
3.71
CRANKCASE PREPARATION (LOWER)

Clean lower crankcase gasket sealing surfaces. Refer to Oil Flow Diagram and trace the oil path from the through the
lower crankcase. Flush all passages with solvent and then warm soapy water. Rinse with clear warm water and dry
with compressed air. Be sure passages are clean and dry before assembling the lower crankcase. Assemble parts in
order A-J.
3.72
CRANKCASE SEALANT AND TORQUE VALUES
3.73
CRANKCASE ASSEMBLY 3. Install valve in guide.

1. Prepare upper and lower crankcase and install all 4. Valve seals should be installed after the valves are in
components as described previously. the head to avoid valve seal damage. Install NEW
2. Inspect crankshaft seals to be sure they are aligned valve seals on valve guides carefully with a rotating
flush with ends of crankcase. motion.
3. Be sure balance shaft end plugs are installed with 5. Dip valve spring and retainer in clean engine oil.
retaining flange fitted in the grooves of crankcase. 6. Install spring with tight wind facing DOWN (toward
4. Be sure oil passage tube is installed with new O- head).
rings..
NOTE
5. Clean crankcase mating surfaces to remove all oil Install valve spring with the orange coil marking towards
and grease. the top.
6. Apply a thin, continuous film of crankcase sealant
PN 2871557 to upper and lower crankcase mating 7. Place top retainer on spring.
surfaces as shown on Crankcase Sealant and
Torque values, page 3.73. Do not allow sealant to dry 8. Compress spring.
before assembly. 9. Install split keepers with gap even on both sides.
7. Apply engine oil to crankshaft main bearings in the NOTE
lower crankcase half.
To prevent damage to the valve seals, do not compress
8. Carefully place lower crankcase on upper case, the valve spring more than necessary to install the
making sure the oil supply tube and oil pump drive keepers. A small magnet can be used to aid installation.
gear are aligned.
9. Tap with a rubber hammer to seat cases together.
10. Apply a light film of engine oil o flange and threads of
M9 crankcase bolts.
11. Install all crankcase bolts and tighten all lightly by
hand.
12. Inspect mating surfaces to be sure they are joined
properly. Investigate the cause of any gaps.
13. Torque all crankcase in sequence shown on
Crankcase Sealant and Torque Values, page 3.73 to
final torque value, then repeat the sequence to verify
final torque.
TORQUE
M6 Bolts: 10. Repeat procedure for remaining valves. When all
7 ft-lb (10 Nm) valves are installed, tap lightly with soft faced
hammer on the end of the valves to seat the split
M8 Bolts: keepers.
14ft-lb (17 Nm)
WARNING
14. Install cylinder head (Cylinder Head Installation,
page 3.75). Do not tap on the top retainer or split keepers could
dislodge, causing serious injury. Tap only on the end of
the valve stem.
CYLINDER HEAD ASSEMBLY
NOTE
Assemble valves one at a time to maintain proper order.
1. Apply engine oil to valve guides and seats.

2. Coat valve stem with Premium Starter Grease
(2871460).
3.74
VALVE SEALING TEST 4. Lift cam chain and install chain guide.
1. Clean and dry the combustion chamber area q.
5. Be sure tabs w are engaged in slots. Secure cam

2. Pour a small amount of clean solvent into each chain with a wire so it will not fall into crankcase.
intake port w and check for leakage around the
valves. The valve seats should hold fluid with no
seepage.
3. Repeat for exhaust valves by pouring fluid into each
exhaust port e.
CYLINDER HEAD INSTALLATION

1. Prepare cylinder head gasket sealing surfaces by
cleaning thoroughly to remove all residue. The head
gasket must be installed clean and dry, free from oil
or grease.
NOTE
Do not touch sealing surfaces of gasket. 6. Thread cam chain through a new head gasket and
install gasket, locating it on the alignment pins.
2. Reinstall two head alignment pins in upper
crankcase. 7. Set cylinder head in place on alignment pins. Apply
engine oil to threads and flange of the six main
3. Install cam chain tensioner blade in upper cylinder head bolts.
crankcase. Install a new O-ring on pivot bolt and
lubricate with engine oil. Torque bolt q to
specification.
3.75
8. Tighten main head bolts finger tight, then install the 2. Place the camshaft in the cylinder head.
two 6 mm outer bolts.
3. Lubricate rocker arms, rollers and shafts with engine
CYLINDER HEAD TORQUE PROCEDURE oil. Lay out in proper location as marked upon
• Torque six main head bolts in sequence shown in the disassembly.
image below to specification. 4. Assemble camshaft carrier with rocker arms and
shafts. Slots q must face outward of carrier to allow
bolt installation and to properly orient the oiler holes
in shafts.
TORQUE
Cylinder Head Bolts:
Torque in sequence
Step 1: 8 ft-lbs (11 Nm) CAMSHAFT / CAMSHAFT CARRIER
INSTALLATION
1. Loosen all valve adjuster lock nuts.
Step 3: Tighten add’n 90° (¼ turn)
2. Turn adjuster screws out (counterclockwise) until
they lightly seat against rocker arm.
• Install two M6 outer head bolts e and torque to
specification. NOTE
TORQUE DO NOT force screws against rocker arm. The adjuster
pivot ball may be damaged if forced.
M6 Outer Head Bolts:
7 ft-lb (10 Nm)
3. Using a 12mm Allen socket, rotate the flywheel
clockwise (direction of engine rotation) until Top
Dead Center mark w on flywheel is aligned with
crankcase parting line e. This is TDC for MAG side
CAMSHAFT / CARRIER ASSEMBLY cylinder.
1. Lubricate all camshaft lobes and bearing journal
surfaces with black moly grease or Premium Starter
Grease (PN 2871460).
3.76
4. Rotate camshaft until pin r is at 10:00 position t. CAMSHAFT TIMING

Refer to Camshaft Timing Quick Reference ( [Either the
href or the keyref attribute should be set on xref
elements] page).
IMPORTANT
Valve and/or piston damage can occur if engine is
rotated with camshaft incorrectly timed.
1. Using an open-end wrench across the flats on the

end of the camshaft, rotate camshaft clockwise until 3
pin q is facing UP.
5. Install camshaft carrier and install all carrier bolts

snug. Torque in two steps following sequence
shown.
TORQUE
Carrier Bolts:
12 ft-lb (17 Nm)
3.77
2. Remove CPS from MAG cover. Rotate crank until 7. Screw in the sprocket bolt r finger tight. Sprocket
the appropriate timing mark is visible in the center of bolt must be fully tightened after cam chain tensioner
the CPS hole. is installed.
NOTE
• NON-Electronic Throttle machines will have an “I”

mark on the flywheel that indicates TDC.
8. Verify flywheel TDC mark is still aligned (be sure the

crankshaft has not rotated from TDC) and that
sprocket marks are aligned with gasket surface (note
that cam chain tensioner installation may change the
alignment slightly).
• Machines WITH Electronic Throttle will have an “V” 9. If marks are not aligned, remove sprocket bolt and
mark on the flywheel that indicates TDC. correct alignment.
10. Proceed to Cam Chain Tensioner Installation (
[Either the href or the keyref attribute should be set
on xref elements] ).
3. Pull cam chain upward, making sure it is engaged

with the drive sprocket on the crankshaft.
4. Place the sprocket (with marks facing out) on the
chain and engage all teeth.
5. Align two sprocket marks with valve cover gasket
surface.
6. Slide sprocket onto camshaft, aligning slot in
sprocket with pin.
3.78
CAM CHAIN TENSIONER INSTALLATION 7. Torque camshaft sprocket bolt e to specification.
1. Lubricate tensioner plunger and install in tensioner

bore with check valve end of plunger facing OUT
(toward cap plate).
TORQUE
Camshaft Sprocket Bolt:
28 ft-lb (38 Nm)
2. Start outer tensioner bolt q through cap plate w and
new gasket. Start bolt about 5 threads into outer hole.
Push the tensioner plunger in and hold. 8. Adjust valve clearance on all valves (refer to Chapter
2 “Maintenance”).
NOTE
“Top” mark on tensioner cap plate faces UP.
3. Rotate plate and gasket into position and start the

inner bolt.
4. Slowly draw bolts evenly until snug.
5. Torque tensioner cap bolts to specification.
TORQUE
Tensioner Cap Bolts:
7 ft-lb (10 Nm)
6. Rotate crankshaft through two revolutions and verify

camshaft timing is correct.
3.79
TROUBLESHOOTING
ENGINE Piston Failure - Scoring
Spark Plug Fouling • Lack of lubrication
• Dirt entering engine through cracks in air filter or ducts
• Restricted air filter (main or pre-cleaner) or breather • Engine oil dirty or contaminated (water)
system
• Improperly assembled air intake system Excessive Smoke and Carbon Buildup
• Restricted engine breather system
• Oil contaminated with fuel • Excessive piston-to-cylinder clearance
• Fuel quality poor (old) or octane too high • Worn rings, piston, or cylinder
• PVT system calibrated incorrectly/ components worn • Worn valve guides or seals
or mis-adjusted • Restricted breather
• Restricted exhaust • Air filter dirty or contaminated
• Spark plug cap loose or faulty Low Compression
• Incorrect spark plug heat range or gap
• Weak ignition (loose coil ground, faulty coil, or stator) • No valve clearance
• Low compression • Valve not seating properly (bent valve or carbon /
debris accumulated on sealing surface)
Engine Turns Over But Fails To Start • Cylinder head gasket leak
• No fuel • Cylinder or piston worn
• Dirt in fuel line, filter, or injectors • Piston rings worn, leaking, broken, or sticking
• Fuel pump inoperative/restricted • Bent valve or stuck valve
• Fuel valve off or restricted flow • Valve spring broken or weak
• Tank vent plugged or pinched • Rocker arm sticking
• Engine flooded Backfiring
• Low compression (high cylinder leakage)
• No CPS signal (debris on CPS pole, damaged CPS • Fouled spark plug or incorrect plug or plug gap
causing incorrect air gap) • Speed limiter system malfunction
• No spark (spark plug fouled) ignition component failure • Exhaust system air leaks
• Ignition system faulty:
Engine Does Not Turn Over • Spark plug cap cracked / broken
• Dead battery • Ignition coil faulty
• Starter motor does not turn • Ignition switch circuit faulty
• Engine seized, rusted, or mechanical failure • Poor connections in ignition system
• Ignition timing incorrect
Engine Runs But Will Not Idle • Sheared flywheel key
• Valve sticking
• Restricted fuel system
• Low compression (valves incorrectly adjusted)
• Crankcase breather restricted COOLING SYSTEM
Engine Idles But Will Not Accelerate Overheating
• Spark plug fouled / weak spark • Low coolant level
• Broken throttle cable • Air in cooling system
• Air intake obstructed • Wrong type/mix of coolant
• Air box removed (reinstall all intake components) • Faulty pressure cap or system leaks
• Reverse speed limiter limiting speed • Restricted system (mud or debris in radiator fins
• Incorrect ignition timing causing restriction to air flow, passages blocked in
• Restricted exhaust system radiator, lines, pump, or water jacket, accident
• Camshaft worn excessively damage)
• PVT not operating properly • Engine running lean (fuel system restriction)
• Fuel pump output weak
Engine Has Low Power • Electrical malfunction
• Spark plug fouled • Water pump failure/ Loose impeller
• Cylinder, piston, ring, or valve wear or damage (check • Engine Coolant Temperature Sensor failure
compression) • Cooling fan inoperative or turning too slowly (perform
• PVT not operating properly current draw test)
• Restricted exhaust muffler • Low oil level
• Camshaft worn excessively • Spark plug incorrect heat range
3.80
• Faulty hot lamp circuit

• Thermostat stuck closed or not opening completely
Temperature Too Low
• Thermostat stuck open
Leak at Water Pump Weep Hole
• Faulty water pump mechanical seal
• Worn pump shaft or pump shaft bearing
3.81
NOTES
3.82
FUEL SYSTEM
CHAPTER 4
FUEL SYSTEM
EFI SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
PART NUMBERS / DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
FUEL PRESSURE GAUGE KIT - PU-43506-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
DIGITAL WRENCH® - DIAGNOSTIC CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
SPORTSMAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
DIGITAL WRENCH® DIAGNOSTIC SOFTWARE U-47063-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
DIGITAL WRENCH® SMARTLINK MODULE KIT PU-47471 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 4
DIGITAL WRENCH® - DOWNLOAD WEBSITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
FUEL TANK ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
FUEL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
FUEL SENDER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
FUEL PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
FUEL TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
FUEL PUMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
FUEL TANK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.12
FUEL LINE / HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.13
QUICK DISCONNECT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.13
FUEL VENT LINE/ CHECK VALVE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.13
FUEL VENT LINE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.14
FUEL SUPPLY LINE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.15
EFI SYSTEM LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.16
EFI SYSTEM ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.16
EFI COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.17
IDENTIFICATION / LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.17
EFI SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.19
ELECTRONIC FUEL INJECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.20
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.20
EFI OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.20
INITIAL PRIMING / STARTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.20
ELECTRONIC CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.21
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.21
ECU SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.22
ECU REMOVAL / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.22
ECU CONNECTOR PINOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.23
ELECTRONIC THROTTLE CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.24
ETC OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.24
ETC TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.24
ETC REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.24
ETC LEARN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.25
4.1
FUEL SYSTEM
THROTTLE CONTROL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.25

DRIVE MODE SWITCH DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.25
THROTTLE CONTROL SWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.26
THROTTLE CONTROL SENSOR (TCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.27
THROTTLE LEVER POSITION SENSOR OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.27
THROTTLE CONTROL SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.27
THROTTLE CONTROL SENSOR REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.27
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.28
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.28
FUEL INJECTOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.28
FUEL INJECTOR O-RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.28
FUEL INJECTOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.29
INJECTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.29
CRANKSHAFT POSITION SENSOR (CPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.30
CPS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.30
TEMPERATURE / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.31
T-MAP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.31
TMAP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.31
IDLE AIR CONTROLLER (IAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.32
IAC TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.32
IAC REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.32
THROTTLE POSITION SENSOR (TPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.33
TPS RESISTANCE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.33
TPS REPLACEMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.34
ENGINE COOLANT TEMPERATURE SENSOR (ECT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.35
ECT SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.35
ECT SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.35
IGNTION COIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.36
IGNITION COIL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.36
IGNITION COIL AND HT LEAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.36
EFI DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.38
INSTRUMENT CLUSTER TROUBLE CODE DISPLAY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.38
DIAGNOSTIC TROUBLE CODES (DTCS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.39
DIGITAL WRENCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.41
DIGITAL WRENCH® DIAGNOSTIC SOFTWARE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.41
SPECIAL TOOLS (DIGITAL WRENCH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.41
DIGITAL WRENCH SOFTWARE VERSION AND UPDATE ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.42
DIGITAL WRENCH® UPDATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.42
DIGITAL WRENCH® COMMUNICATION ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.43
DIGITAL WRENCH® - CONNECTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.43
GUIDED DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.43
4.2
FUEL SYSTEM
DIGITAL WRENCH® SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.43

DIGITAL WRENCH® FEATURE MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.44
ECU REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.45
ETC LEARN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.45
ECU REPROGRAMMING (REFLASH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.45
POLARIS MOBILE DIGITAL WRENCH (PMDW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.48
FUEL SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.49
FUEL STARVATION / LEAN MIXTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.49
RICH MIXTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.49
POOR IDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.49
4.3
FUEL SYSTEM
EFI SPECIAL TOOLS

PART NUMBERS / DESCRIPTIONS FUEL PRESSURE GAUGE KIT - PU-43506-A
PART NOTE
TOOL DESCRIPTION
NUMBER
The EFI fuel system remains under high pressure, even
PU-43506-A Fuel Pressure Gauge Kit when the engine is not running. Before attempting to
PS-48762 Fuel Pressure Gauge Adaptor service any part of the fuel system, the pressure must
Digital Wrench® Diagnostic Software be relieved. The Fuel Pressure Gauge Kit has an
(Includes most recent version of integrated pressure relief valve that can be used to
software w/serial number, standard bleed off pressure. Use the included adapter PS-48762
PU-47063-B
interface cable, USB-Serial Adaptor for this vehicle.
cable and SmartLink Module Kit)
Digital Wrench® SmartLink Module Kit
PU-47471 (PU-47470, PU-47469, PU-47468)
PU-47470 Digital Wrench® PC Interface Cable
PU-47469 Digital Wrench® Vehicle Interface Cable
PU-47468 Digital Wrench® SmartLink Module

WARNING
* Gasoline is extremely flammable and explosive under
certain conditions.
* EFI components are under high pressure. Verify
system pressure has been relieved before disassembly.
* Never drain the fuel system when the engine is hot.
Severe burns may result.
* Do not overfill the tank. The tank is at full capacity
when the fuel reaches the bottom of the filler neck.
Leave room for expansion of fuel.
* Never start the engine or let it run in an enclosed area.
Gasoline powered engine exhaust fumes are poisonous
and can cause loss of consciousness and death in a
short time.
* Do not smoke or allow open flames or sparks in or
near the area where refueling is performed or where
gasoline is stored.
* If you get gasoline in your eyes or if you should
swallow gasoline, seek medical attention immediately.
* If you spill gasoline on your skin or clothing,
immediately wash with soap and water and change
clothing.
* Always stop the engine and refuel outdoors or in a
well ventilated area.
4.4
FUEL SYSTEM
DIGITAL WRENCH® - DIAGNOSTIC DIGITAL WRENCH® - DOWNLOAD

CONNECTOR WEBSITE
The diagnostic connector is located under the front rack, Located at: www.polaris.diagsys.com
as shown.
SPORTSMAN
Download Digital Wrench® Updates:
DIGITAL WRENCH® DIAGNOSTIC

SOFTWARE U-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.
DIGITAL WRENCH® SMARTLINK MODULE NOTE

KIT PU-47471 For the most recent information on Digital Wrench®
This module kit contains the necessary cables and software and update downloads please visit the
hardware to communicate between the vehicle ECU and website: www.polaris.diagsys.com
the Digital Wrench® diagnostic software. Polaris dealers
can also order the following separately: SmartLink
Module PU-47468, Vehicle Interface Cable PU-47469
and PC Interface Cable PU-47470. This kit is available to
Polaris dealers through our tool supplier, SPX (1-800-
328-6657).
4.5
FUEL SYSTEM
FUEL TANK
FUEL TANK ASSEMBLY VIEW
4.6
FUEL SYSTEM
FUEL PUMP ASSEMBLY FUEL SENDER TEST

If the fuel gauge reading on the instrument cluster is not
OPERATION OVERVIEW working, or if the display reading differs in large
An electric fuel pump assembly is used to transfer fuel to comparison to the fuel in the tank, perform a resistance
the EFI system from inside the fuel tank. This assembly test on the fuel sender.
includes the fuel pump, regulator and fuel gauge sender. Disconnect the fuel pump / sending unit connection and
The pump is rated for a minimum output of 25 liters per measure the resistance between PIN 1 and PIN 2 on the
hour at 58 psi and has a non-serviceable preliminary 10- fuel pump connector.. If out of specification, replace the
micron filter. fuel pump assembly.
Fuel Sender Resistance Specifications:
Full: 6 ± 1Ω
Empty: 90 ± 4.5Ω
4
FUEL PUMP TEST
NOTE
If determined faulty, the fuel pump can be replaced as
an assembly. If a fuel delivery problem is suspected,
make certain the pump is being activated by the ECU
and EFI relay, all electrical connections are properly
secured, the 20A EFI fuse is good, and a minimum of
7.0 volts is being supplied.
CAUTION
Fuel is extremely flammable and may cause severe
burns, injury, or death.
Do not use any device that produces a flame or
When the key switch is turned to "ON", the ECU electrical devices that may spark around fuel or fuel
activates the fuel pump, which pressurizes the system for vapors.
start-up.
1. Couple Fuel Pressure Gauge Adaptor (PS-48762) to
The ECU switches off the pump preventing the continued
the Fuel Pressure Gauge Kit (PU-43506-A).
delivery of fuel in these instances:
• If the key switch is not promptly turned to the "Start"
position.
• If the engine fails to start.
• If the engine is stopped with the key switch "ON" (as in
the case of an accident).
4.7
FUEL SYSTEM
2. Locate the fuel pressure valve q attached to the fuel 7. If voltage at the plug was within the specified range,
rail. and there was continuity across the pump terminals,
reconnect the plug to the pump, making sure you
have clean connections. Turn on the key switch and
listen for the pump to activate.
NOTE
If the pump starts, verify you have the correct amount of
fuel pressure.
8. If the pump still does not operate, check ECU

operation by plugging in a known-good ECU of the
same model.
NOTE
If the pump still does not operate, replace the fuel pump
assembly.
3. Remove the black cap and attach the fuel pressure
gauge kit and adaptor to the pressure valve. Route
the clear hose into a portable gasoline container or
the vehicle’s fuel tank.
4. Turn on the key switch to activate the pump and
check the system pressure on the gauge. If system
pressure of 58 psi (400 kPa) is observed, turn the
key switch “off” and depress the valve button on the
tester to relieve the system pressure.
Fuel Pump Pressure: 58 psi (400 kPa)
NOTE
If the fuel pressure is out of specification, replace the
fuel pump assembly.
5. If the pump did not activate (Step 4), disconnect the

plug from the fuel pump. Connect a DC voltmeter
across terminals “3” and “4” in the plug on the vehicle
harness side. Turn on the key switch and observe
voltage to ensure a minimum of 7 volts is present.
NOTE
If the voltage was below 7 VDC, test battery, ignition
switch, EFI relay and wiring harness.
6. If the reading is between 7 and 14 volts, turn key

switch off and connect an ohmmeter between the
terminals “3” and “4” in the plug on the pump to
check for continuity within the fuel pump.
NOTE
If there was no continuity between the pump terminals,
replace the fuel pump assembly.
4.8
FUEL SYSTEM
FUEL TANK REMOVAL 11. While holding a shop towel over the fuel line
connector, disconnect the quick connect fuel line
NOTE from the fuel pump.
Syphon as much fuel from the tank as possible before CAUTION
attempting to remove it from the ATV.
It is possible for pressurized fuel to be present when
disconnecting the fuel line.
WARNING It is recommended to allow the vehicle to sit for a period
of one hour after shutting off the engine before
Always wear safety goggles when working with high servicing the fuel pump. This allows the exhaust to cool
pressure or flammable fluids. Failure to do so could and fuel pressure to drop.
result in serious injury or complications.
1. Remove the seat and upper side panels from the NOTE
vehicle. A small amount of fuel may come out of the fuel line or
2. Remove the (4) push rivets from each front mud tank. Properly drain fuel into a suitable container. 4
12. If replacing the fuel pump, carefully pull the fuel tank
3. Remove the front rack. out far enough to service the fuel pump (see “Fuel
4. Disconnect the negative battery cable. Pump Replacement” procedure). Fuel Pump
Replacement, page 4.9 If removing fuel tank
NOTE assembly, proceed to the next step.
Be sure to cover the fuel tank inlet with a shop towel 13. Remove vent line w from fitting on top of the fuel
prior to front cab and fuel tank removal. tank.

6. Remove the (4) screws from the bottom of the right-
hand footwell.
7. Remove the air box assembly.
8. Remove the (2) fuel tank mounting screws q located
on the upper portion of the fuel tank.
14. Carefully pull fuel tank out the right side of the ATV.
FUEL PUMP REPLACEMENT

1. Slide fuel tank out to allow enough access to service
the fuel pump, see Fuel Tank Removal, page 4.9.
NOTE
9. Ensure that static has been discharged by touching a Take care not to damage the Idle Air Control (IAC) valve
ground source such as the engine or frame. upon fuel tank removal.
10. Disconnect the fuel pump electrical harness.
4.9
FUEL SYSTEM
2. Be sure top of fuel tank is clean. If it requires 4. Carefully lift the fuel pump out of the fuel tank. As the
cleaning, hand wash the top of the tank to ensure no fuel pump assembly is being removed, be aware of
debris will enter the fuel system when the fuel pump float arm and pump pre-filter. Hold the float arm to
is removed. the pump body as you lift and tilt the pump to ensure
that the float arm is not bent when removed from the
CAUTION tank.
Failure to clean area around fuel pump may lead to
debris entering the fuel tank during service. Excessive
debris in fuel tank may cause premature wear of fuel
pump and/or clogging of internal fuel filters.
3. Place the Fuel Pump Service Tool (PU-50326) q

over the fuel pump PFA nut w. Using a 1/2” drive
ratchet or breaker bar, loosen and remove the PFA
nut. Discard the PFA nut.
NOTE
Apply downward force on the fuel pump flange while
removing the fuel pump PFA nut.
5. Transfer old fuel pump to a suitable container

capable of safely holding fuel. The fuel pump will
retain some fuel.
6. Drain fuel from tank and wipe with a clean rag before
inspecting the inside of the fuel tank for debris (may
require flashlight and mirror). If debris like mud or
sand is present, fuel tank should be flushed and
cleaned out prior to installation of new fuel pump
assembly.
NOTE
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.
7. Remove new fuel pump assembly, gasket and PFA

nut from packaging. Use care not to bend float arm
during unpacking. Do not lift or carry fuel pump
assembly by the float arm.
4.10
FUEL SYSTEM
8. Use cleaning wipes provided to clean fuel tank 14. Torque PFA nut w to specification using the Fuel
surface and threads. Remove all debris, grease and Pump Service Tool (PU-50326) q and a calibrated
oil. Allow surfaces to dry completely. torque wrench. Hold or support the fuel tank to
prevent it from rotating while tightening the PFA nut.
9. Install new PFA gasket r onto fuel pump assembly
using care not to damage gasket or bend float arm.
TORQUE
10. Install fuel pump t into fuel tank e, hold float arm to
the pump body and tilt assembly to ensure float arm Fuel Pump PFA Nut:
does not get caught or bent during installation. 70 ft. lbs (95 Nm)
11. Gently push down on fuel pump flange ensuring 15. Verify alignment of fuel pump and tank orientation
flange is centered. marks.
12. Roughly align orientation mark on fuel pump u with 16. Carefully slide the fuel tank back into position.
orientation mark on fuel tank u to ensure float arm Ensure vent line has not been pinched during
does not get bent or snagged. installation of fuel tank.
NOTE
Take care not to damage the Idle Air Control (IAC) valve
upon fuel tank installation.
17. Refer to “Fuel Tank Installation” to complete the

repair.Fuel Tank Installation, page 4.12
CAUTION
Failure to align the orientation marks may lead to
interferences with the fuel level float arm and cause
incorrect function.
13. While maintaining downward pressure, thread new

PFA nut y onto fuel tank and hand tighten. Use care
when starting PFA nut, ensuring threads are properly
aligned. Verify orientation marks are still aligned
between fuel pump and fuel tank.
4.11
FUEL SYSTEM
FUEL TANK INSTALLATION 13. Test the fuel pump by turning on the key and
listening for the pump to activate.
1. Reinstall the fuel tank assembly through the right
side. Be sure the tabs on the bottom of the fuel tank
are sitting in the slots of the support bracket.
2. Connect the fuel line to the fuel pump outlet.
NOTE
Be sure to engage the white retainer on fuel line until it
snaps into place. Pull on fuel line lightly to confirm
connection.
3. Connect the fuel pump electrical harness.

4. Reinstall the vent line w to the tank fitting.
5. Install the fuel tank mounting screws q and tighten

securely.
6. Install the (4) screws into the bottom portion of the

right-hand footwell.
7. Remove the shop towel from the fuel tank inlet and
reinstall the front cab assembly.
8. Connect the fuel fill hose and tighten hose clamp
securely.
9. Reinstall the front rack or storage box assembly.
10. Install the front mud guards.
11. Reconnect the negative cable to the battery.
12. Install the upper side panels and seat.
4.12
FUEL SYSTEM
FUEL LINE / HOSE

QUICK DISCONNECT SERVICE FUEL VENT LINE/ CHECK VALVE TESTING
When removing the fuel line, follow these steps to avoid In-Tank Check Valveq
damage to the components:
1. Always thoroughly clean the fitting from both sides.

Grit can become lodged between the nipple and the
collar of the line, making it difficult to move the tabs of
the collar. Use air first, then water if necessary to
flush the fitting.
NOTE
Avoid using lubricants. It will damage the seals in the
fitting, and also will retain and attract dirt, making it
more difficult to dislodge the retaining collar. 4
2. Gently push outward and back on the retaining collar.
Only spread the ears q of the collar far enough to
allow the collar to move back. In-Line Check Valvew (If Equipped)
3. Have a shop towel prepared to clean the fuel that will

The fuel vent line and check valve (s) may be tested
be spilled when removing the fuel line.
using a Mityvac P/N 2870975
4. When installing, ensure that the collar is fully
installed. Mityvac P/N 2870975
5. Gently pull on the line to ensure it is fully seated.
6. Cycle the ignition key to prime the pump, and ensure 1. Access the fuel vent line any/or check valve.
there are no leaks before re-assembly.
2. Connect the Mityvac.
3. Apply vacuum (approx. 5 pumps)
a. If vacuum builds, the fuel vent line may be
pinched or an obstruction is present. Clear the
obstruction or replace the line and/or Valve.
NOTE
If the in-tank check valve must be replaced, the fuel
tank assembly must be replaced.
b. If the gauge quickly return to zero, the

components are operating properly.
4.13
FUEL SYSTEM
FUEL VENT LINE ROUTING

The primary fuel tank vent hose q runs from the tank vent nipple up to the vent tee. The vent splits to the upper line w
that runs into the headlight pod, and the lower line e that runs down along the frame rail.
4.14
FUEL SYSTEM
FUEL SUPPLY LINE ROUTING

The line routes under the frame rail. There are no anchor/retention fasteners related to this line.
4.15
FUEL SYSTEM
EFI SYSTEM LAYOUT

EFI SYSTEM ASSEMBLY VIEW
4.16
FUEL SYSTEM
EFI COMPONENTS
IDENTIFICATION / LOCATION 4. Crankshaft Position Sensor (CPS)
1. Electronic Control Unit (ECU) - Mounted in the top portion of the magneto cover on
- Attached to front of airbox, under the front cab. q the front of the engine r.
2. Temperature and Manifold Absolute Pressure 5. Fuel Injectors

Sensor (T-MAP) - Mounted in the throttle body assembly t.
- Located on the MAG end (front) of the throttle body
w.
6. Fuel Rail / Fuel Pressure Valve

- Attached to the top portion of the fuel injectors / Lo-
3. Idle Air Control (IAC) cated on the PTO end of the fuel rail y.
- Mounted to the RH side of the airbox e.
4.17
FUEL SYSTEM
7. Fuel Line (Quick Connect) 10. Throttle Position Sensor (TPS)

- Located between the injector fuel rail and the fuel - Mounted on the MAG end (front) of the throttle body
tank u. a.
8. Fuel Pump / Regulator / Fuel Gauge Sender 11. Throttle Body

Assembly - Mounted to the cylinder head on the side of the en-
- Located behind the upper RH side panel i. gine s.
- Located in the fuel tank as an assembly. 12. Ignition Coil

9. Engine Coolant Temperature Sensor (ECT) - Mounted to the RH side of the airbox d. The high
- Mounted in the cylinder head, below the throttle tension leads are retained by the airbox.
body o.
4.18
FUEL SYSTEM
EFI SERVICE NOTES

For more convenient and accurate testing of EFI
components, it is recommended dealers utilize the Digital
Wrench® Diagnostic Software (dealer only), or limited
testing may be done manually using procedures
provided.
80% of all EFI problems are caused by wiring harness
connections. Follow a common sense approach when
diagnosing a potential EFI issue:
1. Disconnect harness at suspected sensor connector.
2. Inspect the connector ends for damage or
contamination. If damaged, repair; if contaminated,
clean. Reconnect and check function.
3. If problem persists, perform a sensor bench test (if
applicable) according to sensor requirements.
4
4. If the sensor bench tests pass, disconnect the
connector at the ECU and perform a continuity check
between the sensor connector and the appropriate
pin at the ECU connector (all connections for that
sensor). Wiring resistance should be less than one
(1) ohm.
5. If the resistance is high (or open), a wiring harness
inspection is required (including a thorough
inspection of the ECU connector for contamination or
damage).
6. If the sensor and wiring passes inspection, and
reconnecting the ECU does not resolve the issue,
use a known-good ECU (from another Polaris 850)
to test for problem resolution.
• Never attempt to service any fuel system component
while engine is running or ignition switch "on".
• USE CARE when removing or installing the ECU
connector, as well as all other harness connections on
the unit. Properly connect and disconnect the ECU
harness to minimize damage to the connector pins and
locking mechanism.
• Although every precaution has been taken to prevent
water intrusion failure, avoid direct water or spray
contact with system components.
• Do not disconnect or reconnect the wiring harness
connector to the ECU or any individual components
with the ignition "on." This can send a damaging
voltage spike through the ECU.
• Do not allow battery cables to touch opposite
terminals.
• Never start the engine when the cables are loose or
poorly connected to the battery terminals.
• Never disconnect battery while engine is running.
• Always unplug ECU from the wire harness before
performing any welding on the unit.
4.19
FUEL SYSTEM
ELECTRONIC FUEL INJECTION

GENERAL INFORMATION During operation the ECU has the ability to re-adjust
The Electronic Fuel Injection (EFI) system is a complete temporarily, providing compensation for changes in
engine fuel and ignition management design. This overall engine condition and operating environment, so it
system includes the following principal components: will be able to maintain the ideal air/fuel ratio.
During certain operating periods such as cold starts,
• Fuel Pump / Fuel Filters / Pressure Regulator warm up, acceleration, etc., a richer air / fuel ratio is
• Fuel Line automatically calculated by the ECU.
• Fuel Rail
• Fuel Injectors
• Throttle Body INITIAL PRIMING / STARTING PROCEDURE
• Electronic Control Unit (ECU)
• Ignition Coil NOTE
• Engine Coolant Temperature Sensor (ECT) The injection system must be purged of all air prior to
• Throttle Position Sensor (TPS) the initial start up, and / or any time the system has
• Crankshaft Position Sensor (CPS) been disassembled.
• Intake Air Temperature / Manifold Absolute Pressure
Sensor (T-MAP) If the EFI system is completely empty of fuel or has been
• Idle Air Control (IAC) disassembled and repaired:
• Wire Harness Assembly
1. Cycle the key switch from “OFF” to “ON” 6 times,
waiting for approximately 3 seconds at each “ON”
EFI OPERATION OVERVIEW cycle to allow the fuel pump to cycle and shut down.
The EFI system is designed to provide peak engine 2. Once step 1 is completed, turn the key switch to
performance with optimum fuel efficiency and lowest “START” until the engine starts or 5 seconds has
possible emissions. The ignition and injection functions passed.
are electronically controlled, monitored and continually
corrected during operation to maintain peak 3. If the engine failed to start, repeat step 1 for 2 more
performance. cycles and attempt to start the engine.
If the engine fails to start, a problem still exists and
The central component of the system is the Bosch should be diagnosed.
Electronic Control Unit (ECU) which manages system
operation, determining the best combination of fuel NOTE
mixture and ignition timing for the current operating
conditions. Accurate testing of EFI components is recommended
utilizing the Digital Wrench® Diagnostic Software
An in-tank electric fuel pump is used to move fuel from (dealer only).
the tank, through the fuel line, to the fuel rail. The in-tank
fuel pressure regulator maintains a system operating
pressure of 58 psi and returns any excess fuel to the
tank. At the engine, fuel is fed through the fuel rail and
into the injectors, which inject into the intake ports. The
ECU controls the amount of fuel by varying the length of
time that the injectors are "on". This can range from 1.5-
8.0 milliseconds depending on fuel requirements. The
controlled injection of the fuel occurs every other
crankshaft revolution, or once for each 4-stroke cycle.
The total amount of fuel needed for one firing of a
cylinder is injected during each cycle. When the intake
valve opens, the fuel/air mixture is drawn into the
combustion chamber, ignited and burned.
The ECU controls the amount of fuel being injected and
the ignition timing by monitoring the primary sensor
signals for intake air temperature, manifold absolute
pressure (load), engine temperature, speed (RPM), and
throttle position. These primary signals are compared to
the programming in the ECU computer chip, and the
ECU adjusts the fuel delivery and ignition timing to match
the values.
4.20
FUEL SYSTEM
ELECTRONIC CONTROL UNIT

OPERATION OVERVIEW This process repeats it self in rapid succession, limiting
The ECU is a solid state component that serves as the operation to the preset maximum.
controller for the fuel injection system. Maximum RPM Limit: 7600
The ECU receives input from the EFI sensors including,
but not limited to:
• Engine Coolant Temperature
• Intake Temperature/Manifold Absolute Pressure (T-
MAP)
• Oxygen Sensor
• Throttle Position Sensor
The inputs cause the ECU to respond based on it’s

software calibration. The ECU responds by opening and
closing the output circuits of the EFI system. These 4
include but are not necessarily limited to:
• Fuel Injectors
• Electronic Throttle Control (ETC)
• Oxygen Sensor Heater
• Ignition Coil
• Idle Air Controller (IAC)
During operation, the ECU continually performs

diagnostic checks of itself, each of the sensors, and
system performance. If a fault is detected, the ECU turns
on the “Check Engine” light in the speedometer 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” 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, an
RPM-limiting feature is programmed into the ECU. If the
maximum RPM limit (7600) is exceeded, the ECU
suppresses the injection signals, cutting off the fuel flow.
4.21
FUEL SYSTEM
RPM Limit: 8. Carefully remove the ECU from the vehicle.

Hard Limit - Fuel injector suppression occurs
• All Gears: 7600 RPM
Soft Limit - Spark timing suppression occurs

• All Gears: 7250 RPM
ECU SERVICE
Never attempt to disassemble the ECU. It is sealed to
prevent damage to internal components. Warranty is void
if the case is opened or tampered with in any way.
All operating and control functions within the ECU are
pre-set. No internal servicing or readjustment may be
performed. If a problem is encountered, and you
determine the ECU to be faulty, the assembly needs to
9. To install, reverse the previous steps. DO NOT apply
be replaced. Do not replace the ECU under warranty
dielectric grease to the connector, as it is a sealed
without factory authorization. Coverage does not apply
connector.
without authorization from Polaris Technical Service.
For the purpose of troubleshooting, a known-good ECU NOTE
from another Polaris vehicle of the same model and year If replacing the ECU, you must reflash the new ECU
may be used, but ensure that you do not put an ECU with the correct calibration upon installation and prior to
from a machine equipped with EPS into a non-EPS attempting to start the vehicle.
model. This will force update the cluster, and it will be
permanently set it as an EPS cluster, leaving the EPS
warning light on with no way of turning it off.
ECU REMOVAL / REPLACEMENT

1. Remove the seat and upper side panels from the
vehicle.
2. Remove the (4) push rivets from each front mud
3. Remove the front rack or storage box assembly.
4. Disconnect the negative battery cable.
NOTE
Be sure to cover fuel tank inlet with a shop towel prior to
front cab removal.

airbox.
7. Disconnect the wire harness from the ECU by pulling
the black slider out away from the ECU while pulling
down on the connector. Once the slider is fully
extended, pull the connector from the ECU, using
care not to damage the connector or locking
mechanism.
4.22
FUEL SYSTEM
ECU CONNECTOR PINOUT
FUNCTION PIN
EFI Relay Ground
Fan Relay Ground
2
4
4
MAG Fuel Injector Ground 5
TPS 5V Reference 6
T-MAP 5V Reference 7
Key Switch Power 9
TPS Signal 10
Override Signal 11
PTO Fuel Injector Ground 16
AWD Hub Coil Ground 17
Fuel Pump Relay Ground 19
Manifold Pressure Signal 22
Gear Position Signal 23
Air Temp Sensor Signal 24
IAC Signal Pin 3 25
IAC Signal Pin 4 26
CPS Signal In 27
AWD Switch On Signal 28
Thermister / Gear Position / TRS Ground 30
TPS Ground 31
TRS Signal In 32
Temp CAN Low 35
CAN High Signal 36
IAC Signal Pin 1 37
IAC Signal Pin 6 38
CSP Signal Out 39
ATS / T-MAP Ground 42
Thermister Signal 44
Vehicle Speed Sensor Signal 45
Temp CAN High 47
CAN Low Signal 48
Chassis Ground 50
Chassis Ground 51
Chassis Ground 52
EFI Power In 53
MAG Ignition Coil Ground 55
PTO Ignition Coil Ground 56
4.23
FUEL SYSTEM
ELECTRONIC THROTTLE CONTROL

ETC OVERVIEW ETC REPLACEMENT
NOTE 1. Remove the intake air box.Intake Replacement, page
3.25
Only some models will be equipped with ETC, others
will have the standard cable controlled system. 2. Disconnect the wire harness from the ETC.
NOTE
DO NOT attempt to service the ETC. The ETC is a non-
serviceable component and can only be tested using
Digital Wrench®. If the ETC is faulty, the entire
assembly must be replaced.
3. Depressurize the fuel system at the fuel valve.

Disconnect the fuel line fitting from the fuel rail.
4. Remove the 4 bolts retaining the ETC housing to
intake .
5. Reverse these steps for installation. Torque the ETC
housing retaining bolts and intake runner screws to
specification.
Mounted to the intake, the ETC acts as an electronically TORQUE
controlled throttle body. The ETC controls engine throttle
operation to provide the proper air/fuel ratio needed for ETC Housing Retaining Bolts:
engine operation at all RPM ranges. The ETC controls 7 ft-lb (10 Nm)
engine RPM based off input provided by the Throttle Plenum to Throttle Body Fasteners:
Control Sensor (TCS) and Electronic Control Unit (ECU). 7 ft-lbs (10 Nm)
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 under warranty without factory
authorization.
Use Digital Wrench® to perform all troubleshooting of
this component. Use a Volt Ohm meter to test the vehicle
harness continuity between the ETC connector and ECU
connector. Refer to the wire diagram for pin-out details. If
the ETC is faulty, the entire ETC assembly must be
replaced.
4.24
FUEL SYSTEM
ETC LEARN PROCEDURE THROTTLE CONTROL SWITCH

IMPORTANT DRIVE MODE SWITCH DESCRIPTION AND
This procedure MUST be performed on the vehicle OPERATION
whenever the ECU is replaced or reflashed or the Some vehicle models are equipped with a drive mode
throttle body is replaced. selection switch that alters throttle response and engine
power. The switch is located on the center dash.
1. After the reflash / ECU replacement / throttle body If the drive mode switch is improperly functioning, the
change, leave the key on (engine not running) for 60 switch will default to Standard mode.
seconds. Do NOT crank the engine during this time. 1. Disconnect the drive mode switch harness by
2. Turn the key off and wait 3 minutes. During this time, depressing the connector locks and pulling on the
the ECU will write values into memory and then connector. Do not pull on the wiring.
completely shut down. 2. Test the resistance between pins 3 and 11.
3. Turn key back on and start the vehicle. The vehicle
should operate normally.
3. If the resistance is out of specification for any mode,
replace the switch.
4
4. If the procedure was interrupted at any time, start
The Drive Mode Switch is a three way rocker switch with
back at step 1.
internal resistors which allow the ECU to monitor voltage
drop, indicating the selected mode. The modes are:
• PERF – Performance mode. Maximum power output.
Resistor in the switch for this mode is 4 K Ohms.
• STND – Standard mode. Balanced power output.
Resistor in the switch for this mode is 25 K Ohms
• WORK – Work mode. Limited power output, limited
rpm. Resistor in the switch for this mode is 1.5 K Ohms
The drive modes in Digital Wrench data will show Drive

Mode Input and Output Status for 4 Drive Modes. Each
mode uses one of these input/output sets. Both input and
output should show active for the respective number
when operating correctly.
NOTE
Only three of the four available drive modes are used.
Digital Wrench Values
4.25
FUEL SYSTEM
THROTTLE CONTROL SWITCH

REPLACEMENT
The switch is a rocker switch, and will be mounted on
either the dash or in the headlight pod of an ATV.
Remove the component it is mounted to, remove the
connector, and disengage the switch from the panel by
depressing the retention tabs. Reverse to install.
4.26
FUEL SYSTEM
THROTTLE CONTROL SENSOR (TCS)

THROTTLE LEVER POSITION SENSOR 3. Disconnect the throttle control assembly q connector
OVERVIEW w form the wiring harness.
NOTE
DO NOT attempt to service the Throttle Lever Position
Sensor. The Throttle Lever Position Sensor is a non-
serviceable component and can only be tested using
Digital Wrench®. If the Throttle Lever Position Sensor is
faulty, the entire right hand control assembly must be
replaced.
Mounted to the right hand control assembly, the Throttle

Lever Position Sensor acts as a throttle position sensor.
The TCS provides throttle lever position to the Electronic 4
Control Unit (ECU) to increase or decrease engine RPM
using the Electronic Throttle Control (ETC). The Throttle
Lever Position Sensor is the primary input used to control
engine speed during vehicle operation.
4. Remove the screws e clamping the throttle control
assembly to the handle bars.
THROTTLE CONTROL SENSOR TEST 5. loosely fasten the new throttle control assembly to the
The TCS can be tested utilizing Digital Wrench® by handle bars.
verifying that throttle position readout varies as the pedal
6. Adjust the position for the throttle control assembly to
is pressed. Reference the Data Display section and be
a comfortable riding position and evenly tighten the
sure Throttle Position is displayed. With the ignition key
screw to clamp the throttle control assembly to the
on for at least 15 seconds and engine not running, the
handle bars.
Throttle Position will read approximately 9.6% when the
throttle lever is released. NOTE
Verify that the throttle control assembly does not rotate
THROTTLE CONTROL SENSOR on the handle bars.
REPLACEMENT
7. Move the thumb lever through the full range of motion
NOTE to ensure smooth operation.
The Throttle Control Sensor is calibrated to the right 8. Connect the throttle control assembly to the vehicle
hand control. If the Throttle Control Sensor is faulty, the wiring harness.
throttle lever assembly must be replaced.
9. Assemble the headlight pod and re-fasten the wiring
with panduit straps as required.
10. Connect the negative (-) battery cable.
1. Disconnect the negative (-) battery cable.

2. Disassemble the headlight pod.
4.27
FUEL SYSTEM
FUEL INJECTORS
OPERATION OVERVIEW If an injector is not operating, it can indicate either a bad
The fuel injectors mount into the throttle body, and the injector, or a wiring/electrical connection problem. Check
fuel rail attaches to the top end of them. O-rings on both as follows:
ends of the injector prevent external fuel leaks and also Injector leakage is very unlikely, but in rare instances it
insulate it from heat and vibration. 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
injectors include rough idle, hesitation/stumble during
acceleration, or triggering of fault codes related to fuel
delivery. Injector clogging is usually caused by a buildup
of deposits on the director plate, restricting the flow of
fuel, resulting in a poor spray pattern. Some contributing
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
REF. DESCRIPTION should be replaced. Additives and higher grades of fuel
can be used as a preventative measure if clogging has
q Fuel Injectors been a problem.
w Damper
FUEL INJECTOR O-RINGS
e Pressure Valve
1. Any time an injector is removed, you must replace the
upper and lower O-rings.
When the key switch is on, the fuel rail is pressurized,
and the EFI relay provides voltage to the injectors. 2. Always lubricate NEW injector o-rings with clean,
During engine operation, the ECU completes the ground silicone-free motor oil.
circuit, energizing the injectors. The valve needle in the NOTE
injector is opened electromagnetically, and the pressure
in the fuel rail forces fuel down through the inside. The Apply oil sparingly and avoid contaminating the pintle
“director plate” at the tip of the injector contains a series valve / jet surface and upper inlet port.
of calibrated openings which directs the fuel into the
intake port in a cone-shaped spray pattern. 3. Install NEW o-rings onto top and bottom of injector
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.
FUEL INJECTOR SERVICE

Injector problems typically fall into three general
categories: electrical, dirty / clogged, or leakage. An
electrical problem usually causes one or both of the
injectors to stop functioning. Several methods may be
used to check if the injectors are operating.
NOTE
Do not apply voltage directly to the fuel injectors.
Excessive voltage will burn out the injectors. Do not
ground the injectors with the ignition on. The injectors
will open if the EFI relay is energized.
4.28
FUEL SYSTEM
ITEM PART COLOR POSITION CAUTION

NUMBER
Ensure you have a shop rag to clean up the fuel that will
TOP OF spill when removing this line.
q 1500198 Blue
INJECTOR
BOTTOM OF
w 5415066 Brown
INJECTOR 4. Remove the two fasteners o that retain the fuel rail.
IMPORTANT
Always install NEW o-rings when removing the fuel rail
or injectors.
IMPORTANT
Verify that the new top and bottom o-rings are installed
in the correct position and are lubricated with clean,
silicone-free oil.
4
FUEL INJECTOR TEST

If an injector is not operating, it can indicate either a bad
injector, or a wiring/electrical connection problem. Check 5. Gently pull/pry up to disengage the fuel injectors from
as follows: their ports.
• Remove the seat, left-hand side panel, and disconnect 6. Carefully spread the injector to rail retaining clips just
the fuel injector(s). enough to remove the injector.
• Using an ohmmeter, test for continuity by placing the 7. Install is the reverse of removal.
test leads on each pin of the injector.
• Resistance specification is 12Ω ± 5% (20°C, 68°F) 8. Ensure to torque bolts to spec on install.
Fuel Injector Resistance Specification: TORQUE

12Ω ± 5% (20°C, 68°F) Fuel Rail Mounting Screws:
44 in. lbs (5 Nm)
INJECTOR REPLACEMENT TORQUE

1. Remove the intake/plenum. , page 3.25 Plenum to Throttle Body Fasteners:
7 ft-lbs (10 Nm)
2. Thoroughly clean the area on top of the throttle body
and around the injectors.
3. Disconnect the fuel line i by disengaging the quick
disconnect clips.
4.29
FUEL SYSTEM
CRANKSHAFT POSITION SENSOR (CPS)

OPERATION OVERVIEW CPS SERVICE
The crankshaft position sensor r is essential to engine
1. Remove the intake/plenum. , page 3.25
operation, constantly monitoring the rotational speed
(RPM) and position of the crankshaft. 2. To perform a static test on the CPS, disconnect the
CPS electrical connector. Set your digital multimeter
to Ohms, and test the resistance of the internal circuit
of the sensor. The wires in the harness that
correspond/match up with this circuit are the WHITE
(WH) and BLACK (BK) wires. The BROWN (BN) wire
is a shield.
Crankshaft Position Sensor:
860Ω ± 10% (20° C, 68° F)
3. If the sensor static resistance tests in spec, it could

still be dynamically failing (not producing a proper
output). First check for good (under 1 ohm) continuity
on all 3 CPS circuits and for no shorts to ground. If
those circuits check out, trying a known good sensor
even if the static resistance test passes is advisable.
A ferromagnetic 60-tooth ring gear with two consecutive 4. If removing the sensor, torque the fastener to
teeth missing is mounted on the flywheel. The inductive specification.
speed sensor is mounted 1.0 ± 0.26 mm (0.059 ± 0.010
in.) away from the ring gear. During rotation, an AC pulse TORQUE
is created within the sensor for each passing tooth. The CPS Retaining Bolt:
ECU calculates engine speed from the time interval
89 in. lbs (10 Nm)
between the consecutive pulses. The two-tooth gap
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.
4.30
FUEL SYSTEM
TEMPERATURE / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP)

OPERATION OVERVIEW TMAP REPLACEMENT
Mounted on the throttle body, the temperature and
manifold absolute pressure sensor (T-MAP) q performs
two functions in one unit. 2. Thoroughly clean around the TMAP to avoid getting
dirt in the intake.
3. Disconnect the harness t from the T-MAP sensor.
4. Remove the retaining bolt y and sensor.

5. Install the new sensor using a light coating of oil on
Air passing through the intake is measured by the T-MAP the O-ring to aid installation.
and relayed to the ECU. These signals, comprised of
separate air temperature and manifold absolute pressure 6. Torque the T-MAP retaining bolt to specification.
readings, are processed by the ECU and compared to its
TORQUE
programming for determining the fuel and ignition
requirements during operation. T-MAP Retaining Bolt:
30 in. lbs (3.5 Nm)
T-MAP TEST
The temperature and manifold absolute pressure sensor 7. Reverse the previous steps to assemble the vehicle.
(T-MAP) is a non-serviceable item. If it is faulty, it must
be replaced. This sensor requires a 5 Vdc input to
operate, therefore the T-MAP sensor should only be
tested using the Digital Wrench® Diagnostic Software
(dealer only).
4.31
FUEL SYSTEM
IDLE AIR CONTROLLER (IAC)

OPERATION OVERVIEW IAC REPLACEMENT
The Idle Air Control (IAC) is used to stabilize idle quality 1. Remove the seat and upper RH side panel.
of the engine at cold start-up and after warm-up
2. Disconnect the wire harness from the IAC motor
operations.
connector q, remove the two hoses from the IAC
valve tubes w and remove the screw retaining the
IAC valve to the airbox.
Mounted on the RH side of the airbox, the IAC contains 1

stepper motor which receives varying voltage signal
pulses from the ECU. These pulses determine the IAC 3. Remove the IAC assembly from the airbox by pulling
plunger setting, thereby controlling the amount of air the IAC tube out of the airbox grommet.
bypassing the closed throttle body for idle control. If the 4. If removed with the IAC during removal, install the
IAC is disconnected or inoperative, it will remain at it’s rubber grommet back into the airbox.
last operated position.
5. Install the new IAC into the airbox. Lightly lubricate
the IAC tube to aid installation.
IAC TEST
The IAC is a non-serviceable item. If it is faulty, it must be 6. Position the IAC on the airbox and install retaining
replaced. It can be ‘bench tested’ using the following screw.
method: 7. Install the two hoses on the IAC valve.
Set your meter to read Ohms. Check the resistance 8. Reconnect the vehicle harness to the IAC motor.
values at each of the following pin locations of the IAC. If
any of the readings are out of specification, replace the 9. Install upper RH side panel and seat.
IAC.
PINS RESISTANCE PINS RESISTANCE

1-2 30Ω ± 1.2Ω 4-5 30Ω ± 1.2Ω
2-3 30Ω ± 1.2Ω 5-6 30Ω ± 1.2Ω
1-3 60Ω ± 2.4Ω 4-6 60Ω ± 2.4Ω
4.32
FUEL SYSTEM
THROTTLE POSITION SENSOR (TPS)

OPERATION OVERVIEW TPS RESISTANCE TESTS
Mounted on the throttle body and operated directly off The TPS is a non-serviceable item. If it is faulty, it must
the end of the throttle shaft, the TPS works like a be replaced. It can be tested with a Ohm meter using the
rheostat, varying the voltage signal to the ECU in direct following method:
correlation to the angle of the throttle plate. This signal is With the test leads connected and the meter set to read
processed by the ECU and compared to the internal pre-
Ohms, compare the resistance readings with those given
programmed “maps” to determine the required fuel and
in the tables.
ignition settings for the amount of engine load.
NOTE
Resistance readings may vary slightly from vehicle to
vehicle. The important thing to remember when testing
the TPS is to look for a smooth, uninterrupted sweep
between closed and open throttle. Sweep can also be
checked using Digital Wrench® diagnostic software. 4
IMPORTANT
The correct position of the throttle body stop screw is
established and set at the factory.
DO NOT remove the tamper proof cap to adjust the
throttle body stop screw or alter its position in any TPS RESISTANCE READINGS
manner.
THROTTLE
The stop screw controls the air flow calibration of the PINS RESISTANCE
POSITION
throttle body.
1000 - 5000 Ω ± 1kΩ
Resistance value
2—3 Closed to Open should change
smoothly as throttle is
opened and closed.
5000 - 1000Ω ± 1kΩ
Resistance value
2—1 Closed to Open should change
smoothly as throttle is
opened and closed.
5000Ω ± 40%
NOTE: Reading does
1—3 Open or Closed
not change with
throttle position
4.33
FUEL SYSTEM
TPS REPLACEMENT AND ADJUSTMENT 9. Loosen the TPS mounting screw

10. Slowly rotate the TPS until the display reading is
within specification.
2. Thoroughly clean the area around the TPS. Take care
11. After establishing the TPS voltage, torque mounting
not to allow any debris to get into the throttle body.
screws to specification.
3. Note how the TPS wire harness is routed and
secured. Disconnect the TPS from the wire harness. TORQUE
4. Remove the TPS mounting screw and remove the TPS Mounting Screw:
TPS a from the throttle body. 30 in. lbs (3.5 Nm)
12. Reverse the previous steps to assemble the vehicle.
NOTE
New throttle body assembly service parts are equipped
with a TPS. No adjustments are required as the TPS is
set at the time of throttle body assembly. While no
adjustments are required, use Digital Wrench to verify
the TPS is set correctly.
5. Install new TPS and finger tighten the mounting

screw. Reconnect the TPS wire harness.
6. Secure wire harness as noted during disassembly.
7. Assemble SmartLink Module and connect the
diagnostic interface cable to the vehicle to allow
Digital Wrench use (see “Digital Wrench - Diagnostic
Connector”)., page 4.5
8. Turn the ignition key on and open Digital Wrench.
Select the appropriate vehicle and open the data
display grid. Click on the meter icon next to “TPS
Volts”.
4.34
FUEL SYSTEM
ENGINE COOLANT TEMPERATURE SENSOR (ECT)

OPERATION OVERVIEW ECT SENSOR REPLACEMENT
The engine coolant temperature sensor measures 1. Remove the seat and both LH side panels.
coolant temperature. The engine temperature sensor is a
2. Drain coolant to level below the ECT sensor.
Negative Temperature Coefficient (NTC) type sensor, as
the temperature increases the resistance decreases. 3. Disconnect the wire harness from the ECT sensor.
Coolant passes through the cylinder and by the sensor 4. Remove the clamp q from the coolant bypass hose,
probe, varying a resistance reading which is relayed to then pull the hose from the bottom of the thermostat
the ECU. This signal is processed by the ECU and housing to allow enough access for ECT sensor w
compared to its programming for determining the fuel removal.
and ignition requirements during operation. The ECU
also uses this signal to determine when to activate the
fan during operation.
ECT SENSOR TEST 4

To quickly rule out other components and wiring related
to the ECT, disconnect the harness from the ECT sensor
and start the engine. After a few seconds, the fan should
turn on and the “Check Engine” indicator should display
on the instrument cluster. This indicates all other
components are working properly.
Refer to Chapter 4 for additional ECT information. Polaris
dealers can test the sensor by using the Digital Wrench®
Diagnostic Software (dealer only).
TEMPERATURE °F (°C) RESISTANCE 5. Remove and replace the sensor, applying a light
32 °F (0 °C) 5.9kΩ ± 5% coating of thread sealant to aid installation.
68 °F (20 °C) 2.5kΩ ± 5% 6. Torque the ECT sensor to specification.
176 °F (80 °C) 323Ω ± 5% TORQUE
212 °F (100 °C) 186Ω ± 5% ECT Sensor:
17 ft. lbs (23 Nm)
7. Reverse the previous steps to assemble the vehicle.
4.35
FUEL SYSTEM
IGNTION COIL
OPERATION OVERVIEW Secondary Test
The ignition coil is used to provide high voltage to fire the
spark plugs. When the ignition key is on, DC voltage is
present in the primary side of the ignition coil windings.
During engine rotation, an AC pulse is created within the
crankshaft position sensor for each passing tooth on the
flywheel. The two-tooth gap creates an “interrupt” input
signal, corresponding to specific crankshaft position. This
signal serves as a reference for the control of ignition
timing. The ECU then calculates the time interval
between the consecutive pulses, and determines when
to open the ground side of the primary coil circuit. This
triggers the voltage spike that induces the voltage from
the primary to the secondary coil windings to fire the
spark plugs.
IGNITION COIL TESTS

The ignition coil can be tested by using an ohm meter.
Use the following illustrations and specification table to
test the ignition coil.
Remove the seat and upper right-hand side panel to
access the ignition coil.
Ignition Coil Resistance Readings
TEST PIN CONNECTION RESISTANCE
Primary Between 1 & 2
0.4Ω
Between 2 & 3
Secondary Between High MAG: 975Ω ± 15% IGNITION COIL AND HT LEAD
Tension Lead Ends PTO: 1188Ω ± 15% REPLACEMENT
Primary Test NOTE
The plug caps or coil ends are not removable. The high
tension lead (coil wire) must be replaced as an
assembly.
1. Remove the seat and upper right-hand side panel to

access the ignition coil.
2. Disconnect the shift linkage and remove the high
tension lead caps from the spark plugs.
3. Remove the high tension leads from the airbox
retention.
4. Disconnect the wire harness from the ignition coil.
4.36
FUEL SYSTEM
5. Using a T20 driver, remove the screw q retaining

the ignition coil to the airbox.
4
6. Remove the coil assembly and disconnect the high
tension leads by pulling on the coil side end caps.
7. Install the spark plug wires.
NOTE
Be sure to install the PTO (long) wire e on the coil
terminal nearest the airbox.
8. Install the coil assembly and securely tighten the

mounting screw.
9. Upon assembly, make sure the spark plug wires are
retained by the airbox.
10. Reinstall shift linkage, upper right-hand side panel
and seat.
4.37
FUEL SYSTEM
EFI DIAGNOSTICS
INSTRUMENT CLUSTER TROUBLE CODE 2. If the trouble code (s) are not displayed, use the
DISPLAY MODE button to toggle until “CK ENG” displays on
the information display area.
NOTE
The diagnostic mode is accessible only when the check
engine MIL has been activated.
Use the following procedure to display diagnostic trouble

codes that were activated during current ignition cycle
causing the MIL to illuminate. Diagnostic trouble codes
will remain stored in the gauge (even if MIL turns off) until
the key is turned off.
NOTE
If there is a diagnostic problem with the power steering
system, the power steering MIL will illuminate and blink 3. Press and hold the MODE button to enter the
in place of the check engine MIL. diagnostics code menu.
4. A set of three numbers will appear in the display area.
Use the “Diagnostic Trouble Code Table” as a reference • The first number (located far left) can range from 0 to
(refer to the following pages). 9. This number represents the total number of trouble
Digital Instrument Cluster code present (example: 2 means there are 3 codes
present).
1. If the trouble code (s) are not displayed, toggle
• The second number (located top right) can be 2 to 6
through the LCD display using the “SELECT” button
digits in length. This number equates to the suspected
until the Check Engine (MIL) icon begins flashing.
area of fault or the Suspect Parameter Number (SPN).
2. When the Check Engine (MIL) icon is flashing, a set • The third number (located bottom right) can be 1 to 2
of two numbers will appear on the LCD. digits in length. This number equates to the fault mode
• The first number can be 2 to 6 digits in length. This (FMI).
number equates to the suspected area of fault or the
Suspect Parameter Number (SPN).
• The second number can be 1 to 2 digits in length. This
number equates to the fault mode or the Failure Mode
Identifier (FMI).
3. If more than one code exists, press the MODE button

to advance to the next trouble code.
4. To exit the diagnostic mode, press and hold the
MODE button or turn the ignition key “OFF” once the
codes are recorded.
Analog/Digital Instrument Cluster
1. The reverse override button on the LH control acts as
the MODE button when pressed and released
quickly.
5. If more than one code exists, press the MODE button
to advance to the next trouble code.
6. To exit diagnostic mode, press and hold MODE
button or turn ignition key “OFF” once codes are
recorded.
4.38
FUEL SYSTEM
DIAGNOSTIC TROUBLE CODES (DTCS)

DIAGNOSTIC TROUBLE CODES
DIGITAL
COMPONENT CONDITION SPN FMI WRENCH® P-
CODE
Voltage Too High 3 P0123
Throttle Position Sensor (TPS) 51
Voltage Too Low 4 P0122
Data Erratic, Intermittent or Missing 2 P0503
Vehicle Speed Signal 84
Received Vehicle Speed Has Error 19 C1069
Manifold Absolute Pressure Sensor (T-
Voltage Too Low 102 4 P0107
MAP)
Signal Out of Range 2 P0106
4
Intake Air Temperature (T-MAP) 105
Engine Temperature Sensor (ECT) 110
Temperature Too High 16 P0217
Engine Overheat Shutdown 0 P1217
P0563
Voltage Too High 3
C1063
System Power 168
P0562
Voltage Too Low 4
C1064
Engine Speed Too High 0 C1059
Engine Speed 190
Received Engine Speed Has Error 19 C1066
Gear Sensor Signal Voltage Too Low 523 4 P0916
Signal Fault 2 P0914
ECU Memory EEProm: Read/Write Failure 628 12 C1073
Calibration Checksum/CRC Error 630 13 C1074
Driver Circuit Open / Grounded 5 P0505
Driver Circuit Short to B+ 3 P0509
Idle Air Control (IAC) 634
Driver Circuit Grounded 4 P0508
Position Out of Range 7 P0519
Circuit Fault 8 P0336
Crankshaft Position Sensor (CPS) 636
Plausibility Fault 2 P0335
Fuel Injector 1 (MAG) Driver Circuit Short to B+ 651 3 P0262
Fuel Injector 2 (PTO) Driver Circuit Short to B+ 652 3 P0265
Rear Differential Output Driver Circuit Short to B+ 746 3 P1692
Fan Relay Driver Circuit 1071
Driver Circuit Short to B+ 3 P1482
4.39
FUEL SYSTEM
DIAGNOSTIC TROUBLE CODES

DIGITAL
COMPONENT CONDITION SPN FMI WRENCH® P-
CODE
Starter Enable Circuit Driver Circuit Short to B+ 1321 3 P1617
Fuel Pump Driver Circuit Driver Circuit Short to B+ 1347 3 P0232
Throttle Release Signal 520194
Signal Out of Range 2 P1553
Throttle Stuck 7 P1552
Active Descent Control (ADC) Driver Circuit Short to B+ 520203 3 P1686
Reverse Alarm Driver Circuit Short to B+ 520206 3 P1682
All Wheel Drive Control (AWD) Driver Circuit Short to B+ 520207 3 P1835
Chassis Relay Driver Circuit Short to B+ 520208 3 P1614
Speed Too High 3 P0507
Idle Speed 520211
Speed Too Low 4 P0506
Steering Over Current Shut Down Current Above Normal or Grounded 520221 6 C1050
Steering Excessive Current Error Current Above Normal or Grounded 520222 6 C1051
Steering Torque Partial Failure Condition Exists 520223 31 C1052
Steering Torque Full Failure Condition Exists 520224 31 C1053
Greater than 110° C (230° F) 16 C1054
EPS Inverter Temperature 520225
Greater than 120° C (248° F) 0 C1055
EPS CAN Communications No RX Message for 2 Seconds 520226 2 U0100
Receive Error
EPS CAN Communications No TX Message for 2 Seconds 520227 2 U1100
Transmit Error
Position Encoder Error 520228 11 C1065
EPS Software Error Software Error 520229 12 C1070
IC CAN Communication with EPS EPS Off Line (EPS DM1 not seen) 520230 31 U0131
4.40
FUEL SYSTEM
DIGITAL WRENCH
DIGITAL WRENCH® DIAGNOSTIC • View or clear trouble codes
SOFTWARE OVERVIEW • Analyze real-time engine data
• Reflash ECU calibration files
NOTE • Perform guided diagnostic procedures
• Create customer service account records
Refer to Section 2, 3 and 4 in the Instruction Manual • Perform output state control tests (some models)
provided in the Digital Wrench® Diagnostic Kit to install
the Polaris Digital Wrench® diagnostic software on your
computer.
The Digital Wrench® diagnostic software allows the

technician to perform the following tests and
observations:
SPECIAL TOOLS (DIGITAL WRENCH) 4

DIGITAL WRENCH® DIAGNOSTIC SOFTWARE PART NUMBER
Digital Wrench® Diagnostic Kit PU-47063-B
Digital Wrench® Software: PU-48731
Standard Interface Cable: PU-47151
PU-47063-B (listed above) INCLUDES:
SmartLink Module Kit: PU-47471
USB-Serial Adapter Cable: PU-50621
Fluke 73 Digital Multi-Meter or Fluke 77 DMM PV-43546 (Fluke 77: PV-43568)
Commercially Available (refer to diagnostic software
Laptop or Desktop Computer user manual or HELP section for minimum
requirements)
4.41
FUEL SYSTEM
DIGITAL WRENCH SOFTWARE VERSION DIGITAL WRENCH® UPDATES

AND UPDATE ID Updates are released for Digital Wrench® via the
Always use the most current version of the Digital Internet at: http://polaris. diagsys. com. The Digital
Wrench® software to ensure you have the latest updates Wrench® website can also be accessed through the
or enhancements. New reprogramming files and guided dealer website at: www.polarisdealers.com.
diagnostic procedures are added to these updates as
they become available. NOTE
Knowing what Digital Wrench® version and update is Only authorized Polaris dealers and distributors can
installed will help determine which updates are required. access the dealer website.
NOTE 1. Log on to www.polarisdealers.com.

Versions and updates are subject to change. 2. Locate the “Service and Warranty” drop-down
menu.
1. Open the Digital Wrench® software. Locate the 3. Click on “Digital Wrench Updates”.
version ID shown on the lower right side of the Digital
Wrench® start-up screen.
4. The Digital Wrench® portal website should appear in

a new web browser.
5. Click on “Digital Wrench Version Updates”.
2. Proceed to http://polaris. diagsys. com to see if a

newer update is available.
NOTE
You must already have the current version installed
before adding an update. Updates will not install if you
are using an older version loaded on your PC.
3. If a newer update is available, it should be
downloaded before using Digital Wrench® (see 6. If the update file date listed is newer than your
Chapter 4). current version and update (see Chapter 4 to
download the file.
4.42
FUEL SYSTEM
7. Click on the link shown above, save the file to your DIGITAL WRENCH® - CONNECTING
hard disk and then double-click the icon to start the Follow these steps to connect the diagnostic interface
update process. cable to the vehicle to allow Digital Wrench® use:
NOTE 1. Assemble the SmartLink Module and attach the PC
Do not "run" or "open" the file from where they are. Interface Cable to your laptop (see page 3.3).
Select "save" and download them to your PC before 2. Remove the protective cap from the Digital Wrench®
running the install. connector.
3. Connect the Vehicle Interface Cable to the Digital
8. When the update is complete, the version shown on
Wrench® diagnostic connector.
the right side of the Digital Wrench® start-up screen
should match the update you just downloaded. 4. Turn the ignition key to the ‘ON’ position, select the
appropriate vehicle and wait for the status to display
‘Connected’ in the lower left corner of the screen.
5. Once connected, proceed with using Digital
Wrench®. 4
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.
Diagnostic procedures are added to subsequent versions
NOTE of Digital Wrench® as they become available. Check
your release version often and upgrade when available
Versions and updates are subject to change. to be sure you are using the most current software
available.
DIGITAL WRENCH® COMMUNICATION DIGITAL WRENCH® SERIAL NUMBER

ERRORS LOCATION
If you experience problems connecting to a vehicle or Open the configuration screen by clicking on the wrench
any Digital Wrench® related problem, visit the Digital icon. The serial number is located on the right side of the
Wrench® Knowledge Base for the most current screen.
troubleshooting information, FAQs, downloads and
software updates at: http://polaris.diagsys.com/.
4.43
FUEL SYSTEM
DIGITAL WRENCH® FEATURE MAP
View, or clear trouble codes

in the Engine Controller Enter / Edit / Change
Memory. Vehicle Information
This is the most viewed

screen. View sensor and Enter customer and vehicle
ECU information in a grid, information and view ECU
meter, or chart format. Identification.
View information from the Load the Vehicle Home

main ECU sensors. Page.
Set up data capture and Open the Software

record functions. Configuration Screen.
Perform specialized testing

and adjustment functions Run the Help System.
service reports.
Open the ASSERT ASK Prints the current screen as

form. a formatted printout.
4.44
FUEL SYSTEM
ECU REPLACEMENT • BATTERY VOLTAGE: The majority of problems with

Although the need for ECU replacement is unlikely, a reprogramming can be attributed to a low battery. Be
specific replacement procedure is required to ensure that sure the battery voltage (no load) is at least 13 volts
all essential data contained within the original ECU is and at least 12.5 volts with the key ‘ON’. Connect a
transferred to the replacement ECU. battery charger if necessary to bring voltage level
above minimum. Fully charge the battery before you
Refer to procedure and carefully follow all instructions attempt to reprogram.
provided in Digital Wrench®. • DEDICATED LAPTOP: Best results are obtained using
a laptop computer that is “dedicated to Digital
ETC LEARN PROCEDURE Wrench®”. A laptop that is used by a variety of people
and in several applications around the dealership is
IMPORTANT more likely to cause a reprogramming problem than
one dedicated to Digital Wrench® diagnostics only.
This procedure MUST be performed on the vehicle • OBTAINING THE LATEST UPDATE: Reprogramming
whenever the ECU is replaced or reflashed or the updates are provided periodically and contain the most
throttle body is replaced. recent calibrations (see Chapter 4 – , page 4.42.
• CLOSE NON-ESSENTIAL PROGRAMS: Polaris 4
1. After the reflash / ECU replacement / throttle body recommends that you DO NOT install non-essential
change, leave the key on (engine not running) for 60 programs on a Service Department laptop. Camera
seconds. Do NOT crank the engine during this time. detection software, Virus Scanners, Tool Bars, etc.
may clog up memory if running in the background and
2. Turn the key off and wait 3 minutes. During this time, make it harder for the diagnostic software to operate.
the ECU will write values into memory and then • KNOW THE PROCESS: If you are not familiar with the
completely shut down. entire reprogramming process, review the HELP
3. Turn key back on and start the vehicle. The vehicle section of the diagnostic software before you attempt
should operate normally. reprogramming. Click on the ? on the tool bar or press
4. If the procedure was interrupted at any time, start F11. The information in the on-line help is the most
back at step 1. current and complete information available. This
should be your first step until you are familiar with the
process.
ECU REPROGRAMMING (REFLASH) • COMMUNICATION PROBLEMS: If you have had
Process Overview problems communicating with a vehicle while
performing diagnostic functions, do not attempt
The reprogramming feature is in the Special Tests menu
reprogramming until the cause has been identified and
on the Digital Wrench® screen. Start Digital Wrench®
fixed. Check all connections, and be sure battery
and click on the Special Tests menu icon (red tool box). A
voltage is as specified.
technician should be familiar with the process and with
computer operation in general before attempting to
• Proceed to http://polaris.diagsys.com for specific
reprogram an ECU.
information and FAQs on how to troubleshoot
The Digital Wrench® Engine Controller Reprogramming communication problems.
(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 box provided on the Reflash
Authorization site. The Request Code is automatically
generated by Digital Wrench® during the reprogramming
process. The Reflash Authorization site is located under
the “Service and Warranty” drop down menu on the
dealer website at: www.polarisdealers.com.
NOTE
Failure to follow the reprogramming instructions
completely and correctly can result in an engine that
does not run! Replacement ECUs are programmed as • DON’T DISTURB THE PC: While reprogramming is in
“no-start” and require a reflash for them to work. progress, don’t move the mouse and don’t touch the
keyboard. The process only takes a few minutes, and
Reprogramming (Reflash) Tips: is best left alone until complete.
Reprogramming (Reflash) Procedure:
4.45
FUEL SYSTEM
If you are not familiar with the reprogramming process, 7. Select the file you want to load into the ECU then
review the “Reprogramming (Reflash) Tips” before you click the “Continue” icon to proceed to the Integrity
begin. Follow the on-screen instructions as you progress Check and obtain a Request Code.
through the steps. If you encounter a problem, always
check the On-Line help for current tips and information.
1. Verify the most current update has been downloaded
and loaded into Digital Wrench®. , page 4.42
2. Connect SmartLink Module cables to PC and
vehicle.
3. Open the Digital Wrench® program.
4. Select the model year, product line and vehicle
description by selecting the “Change Vehicle Type”
8. Copy (CTRL +C) the Request Code that will be
icon.
required on the dealer website in the next step. DO
NOT CLOSE Digital Wrench® or the Request Code
will be invalid. NOTE: All characters are letters;
there are no numbers in a request code.
5. Select the “Special Tests” icon.
6. Select “Engine Controller Reprogramming”. NOTE

Request Codes and Authorization Keys must be
entered EXACTLY as they appear on the screen.
9. Go to www.polarisdealers.com and click on “ReFlash

Authorization” from the “Service and Warranty” drop-
down menu.
4.46
FUEL SYSTEM
10. Enter or paste the Request Code into the box. 13. Enter or paste the Authorization Key in the box
located on the Digital Wrench® screen. Click the
‘Continue’ button and follow instructions provided on
the screen to complete reprogramming procedure.
11. Select the same file type from the list that you
14. At this point the reflash process will begin. Do not
selected previously while in Digital Wrench®. Enter
the VIN along with the customer’s name and touch the vehicle or PC during the process. 4
address. When completed, click the Authorize button
once to proceed.
15. Once the ECU reprogramming procedure is

complete, click the ‘Finish’ button on the screen.
Verify the reflash was a success by starting the
vehicle.
12. An “Authorization Key” will appear in the upper left

corner of the screen. Copy this key exactly as it
appears.
4.47
FUEL SYSTEM
POLARIS MOBILE DIGITAL WRENCH • An electronic user’s guide is provided within the app.
(PMDW) To access the user’s guide, launch the app, and then
click on the “Help” button in the Settings/Preferences
Polaris Mobile Digital Wrench (PMDW) is a diagnostic menu.
software application (app) designed specifically for • Only CAN-based vehicles are compatible with PMDW
Android™ devices. When paired with the Wireless and the WVL. A complete list of compatible vehicles
Vehicle Link (WVL), part number PU-51435, PMDW can be found in the user’s guide.
provides Polaris service technicians with many of the
features and functions found in Digital Wrench.
PMDW Main Page:
Wireless Vehicle Link (WVL) – Part Number PU-

51435:
To download the PMDW app, navigate your Android

device to www. polarisdealers. com. Locate the Service
and Warranty drop-down menu. Select: “Mobile Digital
Wrench App Download”. Tap on the link to download the
app.
Android Device Minimum Specifications:
• Minimum operating system: Android 3.1 “Honeycomb”
or higher (Android 4.0 or higher preferred)
• Dual core processor / 2 GB internal memory / external
microSD (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
PMDW App Notes:

• PMDW will not work on Microsoft Windows 8™ or
Apple IOS™ products
• Device must be set to allow the installation of non-
market applications
4.48
FUEL SYSTEM
FUEL SYSTEM TROUBLESHOOTING

The correct position of the throttle body stop screw is POOR IDLE
established and set at the factory. Symptom: Idle Too High (If greater than 1400 RPM when
DO NOT remove the tamper proof cap to adjust the engine is warm)
throttle body stop screw or alter its position in any
manner. • Throttle stop screw tampering
The stop screw controls the air flow calibration of the • Throttle cable sticking, improperly adjusted, routed
throttle body. incorrectly
• Failed sensor or disconnected wiring
• IAC stuck or inoperative
FUEL STARVATION / LEAN MIXTURE • Intake air leak
Symptoms: Hard start or no start, bog, backfire, popping
through intake / exhaust, hesitation, detonation, low Symptom: Idle Too Low (if less than 1100 RPM when
power, spark plug erosion, engine runs hot, surging, high engine is warm)
idle, idle speed erratic. • Dirty throttle body (damaged or improper air filter)
• Plugged air filter
4
• No fuel in tank • Leaking injector (rich condition)
• Restricted tank vent, or routed improperly • Belt dragging
• Fuel lines or fuel injectors restricted • Throttle stop screw tampering
• Fuel pump inoperative • Failed sensor or disconnected wiring
• Air leak in system
• Intake air leak (throttle shaft, intake boot, gasket or Symptom: Erratic Idle
grommet)
• Throttle stop screw tampering • Throttle cable incorrectly adjusted
• Failed sensor or disconnected wiring • Air Leaks, dirty injector
• TPS damaged or misadjusted
• Tight valves
RICH MIXTURE • Belt dragging
• Dirty air cleaner
Symptoms: Fouls spark plugs, black, sooty exhaust • Engine worn
smoke, rough idle, poor fuel economy, engine runs • Spark Plug fouled
rough/ misses, poor performance, bog, engine loads up, • Throttle stop screw tampering
backfire. • Failed sensor or disconnected wiring
• Air intake restricted (inspect intake duct)
• Air filter dirty/plugged
• Poor fuel quality (old fuel)
• Fouled spark plug
• TPS setting incorrect
• Injector failure
• Failed sensor or disconnected wiring
• Throttle stop screw tampering
4.49
FUEL SYSTEM
NOTES
4.50
PVT SYSTEM
CHAPTER 5
PVT SYSTEM
PVT GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
PVT SYSTEM FASTENER TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
SPECIAL TOOLS AND SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
GENERAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
DRIVE CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
DRIVEN CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
SHIFT WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
PVT BREAK-IN (DRIVE BELT / CLUTCHES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
MAINTENANCE / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
OVERHEATING / DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
PVT SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 5
PVT SEALING AND DUCTING COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
PVT DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
PVT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.10
PVT BREAK-IN (DRIVE BELT / CLUTCHES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.10
DRIVE BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.10
BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
DRIVE BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
DRIVE CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.13
DRIVE CLUTCH EXPLODED VIEW (ALL MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.13
DRIVE CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.15
DRIVE CLUTCH SPRING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.16
SHIFT WEIGHT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.16
SPIDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.17
ROLLER, PIN, AND THRUST WASHER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.18
BUTTON TO TOWER CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.18
BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.18
DRIVE CLUTCH INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.19
BUSHING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.20
DRIVE CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.22
DRIVEN CLUTCH SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.24
DRIVEN CLUTCH SLIDER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.24
DRIVEN CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.24
DRIVEN CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.26
BEARING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.26
CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.27
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.29
5.1
PVT SYSTEM
PVT GENERAL INFORMATION

PVT SYSTEM FASTENER TORQUES GENERAL OPERATION
ITEM TORQUE VALUE WARNING
Drive Clutch
200 ft-lbs (271 Nm) All PVT maintenance or repairs should be performed by
Spider
a certified Polaris Master Service Dealer (MSD)
Drive Clutch 47 ft-lbs (64 Nm) technician who has received the proper training and
Retaining Bolt Left Hand Thread understands the procedures outlined in this manual.
Driven Clutch Because of the critical nature and precision
37 ft-lbs (50 Nm) balance incorporated into the PVT components, it is
Retaining Bolt
absolutely essential that no disassembly or repair
Drive Clutch 100 in-lbs (11 Nm) be made without factory authorized special tools
Cover Bolts
and service procedures.
Inner PVT Cover 6-8 ft-lbs (8-11 Nm)
Screws
The Polaris Variable Transmission (PVT) consists of
Outer PVT Cover 45-50 in-lbs (5-5.6 Nm) three major assemblies:
Screws
1) The Drive Clutch
Drive Clutch
15-25 in-lbs (2-3 Nm) 2) The Driven Clutch
Weight Pins
Worm Clamps 14 in-lbs (1.6 Nm) 3) The Drive Belt
The internal components of the drive clutch and driven
clutch control engagement (initial vehicle movement),
SPECIAL TOOLS AND SUPPLIES clutch upshift and backshift. During the development of a
Polaris ATV, the PVT system is matched first to the
PART NUMBER TOOL DESCRIPTION engine power curve; then to average riding conditions
PA-48595 Drive Clutch Puller (Short) and the vehicle’s intended usage. Therefore,
modifications or variations of components at random are
9314177-A Clutch Holding Wrench never recommended. Proper clutch setup and careful
2871358-A Clutch Holding Fixture inspection of existing components must be the primary
objective when troubleshooting and tuning.
Drive Clutch Spider Removal and
2870341
Installation Tool
2870910 Roller Pin Tool
Clutch Bushing Replacement
2871226
Tool Kit
2870386 Piston Pin Puller
PU-50518 Universal Clutch Compressor
Clutch Bushing Replacement
2871025
Tool Kit
PART NUMBER SPECIAL SUPPLIES

N/A Loctite™ 242 Blue
N/A Loctite™ 609 Green
8560054 RTV Silicone Sealer
5.2
PVT SYSTEM
DRIVE CLUTCH OPERATION SHIFT WEIGHTS

Drive clutches primarily sense engine RPM. The two Shift weights have many factors designed into them for
major components which control its shifting function are controlling engagement RPM and shifting patterns. Shift
the shift weights and the coil spring. Whenever engine weights should not be changed or altered without first
RPM is increased, centrifugal force is created, causing having a thorough understanding of their positioning and
the shift weights to push against rollers on the moveable the effects they may have on belt to sheave clearance,
sheave, which is held open by coil spring preload. When clutch balance and shifting pattern.
this force becomes higher than the preload in the spring,
the outer sheave moves inward and contacts the drive
belt. This motion pinches the drive belt between the
PVT BREAK-IN (DRIVE BELT / CLUTCHES)
spinning sheaves and causes it to rotate, which in turn A proper break-in of the clutches and drive belt will
rotates the driven clutch. ensure a longer life and better performance. Break in the
clutches and drive belt by operating at slower speeds
At lower RPM, the drive belt rotates low in the drive during the 10 hour break-in period as recommended. Pull
clutch sheaves. As engine RPM increases, centrifugal only light loads. Avoid aggressive acceleration and high
force causes the drive belt to be forced upward on drive speed operation during the break-in period.
clutch sheaves.
DRIVEN CLUTCH OPERATION MAINTENANCE / INSPECTION

Driven clutches primarily sense torque, opening and Under normal use the PVT system will provide years of
closing according to the forces applied to it from the drive trouble free operation. Periodic inspection and
maintenance is required to keep the system operating at
5
belt and the transmission input shaft. If the torque
resistance at the transmission input shaft is greater than peak performance. The following list of items should be
the load from the drive belt, the drive belt is kept at the inspected and maintained to ensure maximum
outer diameter of the driven clutch sheaves. performance and service life of PVT components. Refer
to the troubleshooting checklist at the end of this chapter
As engine RPM and horsepower increase, the load from for more information.
the drive belt increases, resulting in the belt rotating up
toward the outer diameter of the drive clutch sheaves • Belt Inspection
and downward into the sheaves of the driven clutch. This • Drive and Driven Clutch Buttons and Bushings
action, which increases the driven clutch speed, is called • Drive Clutch Shift Weights and Pins
upshifting. • Drive Clutch Spider Rollers and Roller Pins
• Drive and Driven Clutch Springs
Should the throttle setting remain the same and the • Sheave Faces (clean and inspect for wear)
vehicle is subjected to a heavier load, the drive belt • PVT System Sealing. Refer to appropriate illustrations
rotates back up toward the outer diameter of the driven on the following pages. The PVT system is air cooled
clutch and downward into the sheaves of the drive clutch. by fins on the drive clutch stationary sheave. The fins
This action, which decreases the driven clutch speed, is create a low pressure area in the crankcase casting,
called backshifting. drawing air into the system through an intake duct. The
In situations where loads vary (such as uphill and opening for this intake duct is located at a high point on
downhill) and throttle settings are constant, the drive and the vehicle (location varies by model). The intake duct
driven clutches are continually shifting to maintain draws fresh air through a vented cover. All connecting
optimum engine RPM. At full throttle a perfectly matched air ducts (as well as the PVT cover) must be properly
PVT system should hold engine RPM at the peak of the sealed to ensure clean air is being used for cooling the
power curve. This RPM should be maintained during PVT system and also to prevent water and other
clutch upshift and backshift. In this respect, the PVT contaminants from entering the PVT area. This is
system is similar to a power governor. Rather than vary especially critical on units subjected to frequent water
throttle position, as a conventional governor does, the fording.
PVT system changes engine load requirements by either
upshifting or backshifting.
5.3
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 truck or tall Shift transmission to Low during loading of the vehicle to prevent belt
trailer when in high range. burning.
Starting out going up a steep incline When starting out on an incline, use Low, or dismount the vehicle after first
from a stopped position. applying the park brake and perform the “K” turn.
Driving at low RPM or low ground speed Drive at higher speed or use Low. The use of Low is highly recommended
(at approximately 3-7 MPH). for cooler PVT operating temperatures and longer component life.
Warm engine at least 5 min., then with transmission in neutral, advance
Insufficient engine warm-up when
throttle to approx. 1/8 throttle in short bursts, 5 to 7 times. The belt will
exposed to low ambient temperatures.
become more flexible and prevent belt burning.
Slow and easy clutch engagement. Fast, effective use of the throttle for efficient engagement.
Towing/Pushing at low RPM/low ground
Use Low only.
speed.
Plowing snow, dirt, etc./utility use. Use Low only.
Shift the transmission to Low, carefully use fast, aggressive throttle
Stuck in mud or snow. application to engage clutch. WARNING: Excessive throttle may cause
loss of control and vehicle overturn.
Climbing over large objects from a Shift the transmission to Low, carefully use fast, aggressive, brief throttle
stopped position. application to engage clutch. WARNING: Excessive throttle may cause
loss of control and vehicle overturn.
Shift the transmission to neutral. Using the throttle, vary the engine rpm
from idle to full throttle. Repeat several times as required. During this
Belt slippage from water or snow
procedure, the throttle should not be held at the full position for more than
ingestion into the PVT system.
10 seconds. Clutch seals should be inspected for damage if repeated
leaking occurs.
For inspection of clutch components, please contact your Polaris dealer.
Clutch malfunction. Shift transmission to Low during loading of the vehicle to prevent belt
burning.
Fouled plugs, foreign material in gas tank, fuel lines, or carburetor. Contact
Poor engine performance.
you dealer for further service information.
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, speeds above 7 MPH.
NOTE
Using High Gear when pulling heavy loads, operating on hilly terrain, or in wet, muddy conditions will increase the
chance of drive belt damage.
5.4
PVT SYSTEM
PVT SYSTEM SERVICE

PVT SEALING AND DUCTING
COMPONENTS
PVT DUCTING ASSEMBLY VIEW

q AIR INTAKE BOOTS
w SCREW
e CLUTCH DUCT BOOT
r WORM DRIVE CLAMPS 14 in-lbs (1.6 Nm)
t INNER CLUTCH COVER Apply RTV silicone sealant to the outside edge of the inner PVT
cover to ensure a water tight fit between the cover and the
transmission.
y SCREW 7 ft-lbs (10 Nm)
u CLUTCH COVER SEAL
i OUTER CLUTCH COVER
o O-RING
a PLUG
s SCREW 48 in-lbs (5.3 Nm)
PVT DISASSEMBLY
Some fasteners and procedures will vary. Refer to the
appropriate parts manual for proper fastener placement.
1. Remove the seat.
5.5
PVT SYSTEM
2. Remove the fasteners securing the side panels. 9. Loosen the clamp q retaining the PVT Duct w to the
PVT Housing.
3. Remove the upper side panels.

4. Remove the fasteners securing the rear cab rack and 10. Loosen the clamp securing the rubber duct w to the
storage assembly to the chassis. plastic ducte.
5. Remove the fastener retaining the PVT duct. 11. Remove the rubber bootw between the PVT housing
and plastic duct.
6. Remove the Left Rear wheel.
12. Lift the rear cab and storage compartment and
7. Remove the left rear wheel. support them with a block of wood or similar non
8. Remove the lower LH frame support. marring material.
13. Remove the plastic PVT duct.
14. Remove the outer PVT cover and drive belt.
5.6
PVT SYSTEM
15. With the belt removed, completely remove the 18. Insert the Drive Clutch Puller (PA-48595) into the
retaining bolt and driven clutchr. drive clutch and use it to remove the clutch from the
shaft.
16. Install the Drive Clutch Holder (PN 9314177-A) onto

the drive clutch. Drive Clutch Puller:
Drive Clutch Holder:
PA-48595 5
9314177-A
19. If removing the inner PVT cover, continue with this
procedure.
17. Remove the drive clutch retaining boltt by turning
the bolt in a clockwise direction. a. Remove the (10) screws that retain the inner PVT
cover to the transmission case and remove the
cover.
NOTE
The drive clutch retaining bolt has left-hand threads. b. Remove the old silicone material from the inner
Turn the bolt clockwise to remove it. PVT cover and transmission case using a wire
brush. Clean both surfaces thoroughly in
preparation for assembly.
5.7
PVT SYSTEM
PVT ASSEMBLY 4. Install the cover i and torque the inner PVT cover
screwsu to specification.
1. Inspect the inner PVT cover. Replace if cracked or
damaged. The mating surface must be clean to
ensure adhesion of new silicone sealant.
2. Be sure to “flame treat” the inner PVT cover prior to
applying silicone to ensure good adhesion. Pass the
flame of a propane torch back and forth quickly over
the area where the silicone is to be applied (2-3
inches from the flame tip is recommended). Do not
hold the torch too close to the surface. Keep the torch
moving to prevent damage.
3. Apply RTV silicone sealant to the outside edge of the
inner PVT cover to ensure a water tight fit between
the cover and the transmission.
TORQUE
Inner Clutch Cover Fasteners:
5 ft. lbs (7 Nm)
5. Wipe away any excess silicone sealant.

6. Clean end of taper on crankshaft and the taper bore
inside drive clutch using a tapered reamer.
7. Install the drive clutchy , bushing, washer, lock
washer, and the left-hand threaded retaining boltt.
Torque retaining bolt to specification.
TORQUE
Drive Clutch Retaining Bolt:
47 ft. lbs (64 Nm)
8. Clean the splines on the transmission input shaft and

apply a light film of grease to the splines on the shaft.
9. Install the washer, driven clutch, flat washers and
retaining bolt.
10. Install drive belt noting direction of rotation if the belt
is being reused. Refer to “Belt Installation”.
11. Torque the driven clutch retaining bolt to specification
5.8
PVT SYSTEM
TORQUE
Driven Clutch Retaining Bolt:
37 ft. lbs (50 Nm)
12. Install the PVT outlet duct and align it with the inner
PVT cover. Install the push rivet and tighten the hose
clamps to specification.
NOTE
PVT Duct Clamp:
24 in-lbs (3 Nm)
13. Replace the outer PVT cover seal.

14. Reinstall outer PVT cover and secure with screws.
Torque screws to specification.
TORQUE
Outer PVT Cover Screws:
30 in. lbs (3.5 Nm)
5
15. Reinstall the rear cab, tail light bulbs, and fasteners.
16. Reinstall the lower left-hand frame support and
torque bolts to specification.
TORQUE
Lower Left-Hand Frame Support Bolts:
36 ft. lbs (49 Nm)
17. Install the left rear wheel and torque wheel nuts to
specification.
TORQUE
Wheel Nuts:
Steel: 45 ft. lbs (61 Nm)
Aluminum: 75 ft. lbs (102 Nm)
18. Reinstall the seat, lower the ATV, start the engine and
test the operation of the PVT system.
5.9
PVT SYSTEM
DRIVE BELT
PVT BREAK-IN (DRIVE BELT / CLUTCHES) 8. Using care, pull the outer PVT cover out the left-hand
A proper break-in of the clutches and drive belt will wheel well.
ensure a longer life and better performance. Break in the TIP
clutches and drive belt by operating at slower speeds
during the 10 hour break-in period as recommended. Pull Flexing the PVT outlet duct aids PVT cover removal.
only light loads. Avoid aggressive acceleration and high
speed operation during the break-in period.
NOTE
TOURING MODELS: remove the clutch cover throught
DRIVE BELT REMOVAL the bottom of the chassis.
1. Position the vehicle on a level surface and place the
transmission in Park. 9. Note the orientation of the drive belt so that it can be
2. Elevate and safely support the rear of the vehicle. installed in the same direction.
3. Remove the left rear wheel from the vehicle. 10. Insert the provided clutch tool between the slides and
rotate the tool to spread the sheaves.
4. Remove the (4) bolts retaining the lower left-hand
frame support and remove it from the frame.
Clutch Spreader Tool:

5. TOURING MODELS: Remove the rear skid plate. 2877408
6. Remove the seat.
7. Remove the (11) screws retaining the PVT cover. NOTE
Make sure the tool is square with the moveable sheave
surface of the driven clutch.
5.10
PVT SYSTEM
11. Once the sheaves have been spread, walk the drive DRIVE BELT INSTALLATION
belt out of the driven clutch and drive clutch, and
remove it from the vehicle. IMPORTANT
Orient the Belt as it was removed or orient the new belt
so you may read the text.
1. Spread the sheaves and walk the drive belt on to the

drive clutch and driven clutch.
BELT INSPECTION 5
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.
Clutch Spreader Tool:
2. Inspect belt for loose cords, missing cogs, cracks,
2877408
abrasions, thin spots, or excessive wear. Compare
belt measurements with a new drive belt. Replace if
necessary. NOTE
3. Belts with thin spots, burn marks, etc., should be Make sure the tool is square with the moveable sheave
replaced to eliminate noise, vibration, or erratic PVT surface of the driven clutch.
operation. See the Troubleshooting Chart at the end
of this chapter for possible causes. Troubleshooting,
2. Release the sheaves and rotate the driven clutch
page 5.29
counter-clockwise to ensure the sheaves have
spread.
3. Replace the outer PVT cover seal.

4. Reinstall outer PVT cover and secure with screws.
Torque to specification.
5.11
PVT SYSTEM
TORQUE
Outer PVT Cover Screws:
30 in. lbs (3.5 Nm)
5. Reinstall the lower left-hand frame support. Torque to

specification.
TORQUE
Lower Left-Hand Frame Support Bolts:
36 ft. lbs (49 Nm)
6. Install rear wheel and torque wheel nuts. Torque to

specification.
TORQUE
Wheel Nuts:
Steel: 45 ft. lbs (61 Nm)
Aluminum: 75 ft. lbs (102 Nm)
7. Install the seat.

8. TOURING MODELS: Reinstall the rear skid plate and
the (6) T40 Torx-headed screws.
9. Safely lower the ATV.
10. Test the operation of the PVT system.
5.12
PVT SYSTEM
DRIVE CLUTCH SERVICE

DRIVE CLUTCH EXPLODED VIEW (ALL MODELS)
5.13
PVT SYSTEM

q Stationary Sheave
w Washers
e Needle Bearing (non-EBS models)

One Way Clutch (EBS models)
r Spacer
t Bushing
y Moveable Sheave
u Spider 225 ft-lb (305 Nm)

(Apply 0.4 mL Loctite® 7088 Primer and 0.4 mL
Loctite® 620™)
i Shift Weight
o Shift Weight Bolt 20 in-lb (2 Nm)
a Pin
s Washer
d Button
f Limiter Spacer
g Clutch Spring
h Cover Bushing
j Cover
k Cover Bolt 100 in-lb (12 Nm)
5.14
PVT SYSTEM
DRIVE CLUTCH DISASSEMBLY 4. Inspect cover bushing q. The outer cover bushing is
manufactured with a Teflon™ coating. Wear is
CAUTION determined by the amount of Teflon™ remaining on
The clutch assembly is a precisely balanced unit. Never the bushing.
replace parts with used parts from another clutch
assembly!
1. Using a permanent marker, mark the cover, spider,

moveable and stationary sheaves for reference, as
the cast in X's may not have been in alignment before
disassembly.
Cover Bushing Inspection:Replace the cover bushing if 5

more brass than Teflon™ is visible on the bushing.
Refer to bushing replacement in this chapter.
5. Inspect area on shaft where bushing rides for wear,

galling, nicks, or scratches. Replace clutch assembly
if worn or damaged.
2. Mark the stationary sheave and clutch shaft to verify 6. Remove and inspect the clutch spring w. Refer to
the shaft has not rotated in the sheave after “Drive Clutch Spring Inspection”.
tightening the spider during clutch assembly.
7. Remove and inspect limiter spacer (s) e. Replace if

NOTE necessary.
Upon reassembly, if the reference marks created in CAUTION
step 2 are not in alignment, the clutch will not be in
balance and the assembly MUST be replaced. DO NOT reassemble the drive clutch without the limiter
spacer. Belt life will be greatly reduced.
3. Remove cover bolts evenly in a cross pattern and

remove cover plate.
5.15
PVT SYSTEM
DRIVE CLUTCH SPRING INSPECTION SHIFT WEIGHT INSPECTION

Remove shift weight bolts and weights. Inspect the
CAUTION contact surface of the weight q. The surface should be
Never shim a drive clutch spring to increase its smooth and free of dents or gall marks. Inspect the
compression rate. This may result in complete stacking weight pivot bore and bolts w for wear or galling. If
of the coils and subsequent clutch cover failure. weights or bolts are worn or broken, replace in sets of
three with new bolts and nuts.
The drive clutch spring is one of the most critical
components of the PVT system. It is also one of the
easiest to service. Due to the severe relaxation the
spring is subject to during operation, it should always be
inspected for tolerance limits during any clutch operation
diagnosis or repair.
Check to see that spring coils are parallel to one another
using a straight-edge. Distortion of the spring indicates
stress fatigue, requiring replacement.
CAUTION
The clutch assembly is a precisely balanced unit. Never
replace parts with used parts from another clutch
assembly!
NOTE
A damaged shift weight is usually caused by a
damaged or stuck roller in the spider assembly. See,
page 5.18
5.16
PVT SYSTEM
SPIDER REMOVAL 2. Inspect the Teflon™ coating on the moveable sheave

bushing.
1. Install clutch in holding fixture q in a vise. Loosen the
spider (clockwise) using Clutch Spider Removal Tool
w with a breaker bar. Threads are left-handed.
ITEM DESCRIPTION
2871358–B
Clutch Holding Fixture
Moveable Sheave Bushing Inspection:

Replace the cover bushing if more brass than Teflon is
2870341 visible on the bushing. Refer to bushing replacement in 5
Spider Removal Tool this chapter.
NOTE
It is important that the same number and thickness of
washers are reinstalled beneath the spider during
assembly. Be sure to note the number and thickness of
these washers.
5.17
PVT SYSTEM
ROLLER, PIN, AND THRUST WASHER 2. Inspect sheave surfaces. Replace the entire clutch if
INSPECTION worn, damaged or cracked.
Inspect all rollers, bushings and roller pins by pulling a
flat metal rod across the roller. Turn roller with your BEARING INSPECTION
finger. If you notice resistance, galling, or flat spots,
replace rollers, pins and thrust washers in sets of three. 1. Rotate the clutch bearing in both clockwise and
Also inspect to see if roller and bushing are separating. counter-clockwise directions.
Bushing must fit tightly in roller. Use the Roller Pin Tool • Non-EBS: The non-braking bearing should rotate
both directions on the shaft with only a slight
e to replace rollers and pins. Take care not to damage amount of drag.
roller bushing or bearing surface of the new pin during
installation. • EBS: The one-way bearing should rotate clockwise
(when viewed from cover plate side) with only a
2870910 slight amount of drag. When rotated counter-
Roller Pin Tool clockwise the one-way bearing should lock to the
shaft without slipping.
2. Verify there is no binding or rough spots. If problems
are noted continue with disassembly.
e
BUTTON TO TOWER CLEARANCE

INSPECTION
1. Inspect for any clearance between spider button to
tower. If clearance exists, replace all buttons and
inspect surface of towers.
Button to Tower Clearance:

.000-.012”
5.18
PVT SYSTEM
DRIVE CLUTCH INSPECTION 3. Lift bearing e and thrust washers r off shaft.
Replace as an assembly if worn, damaged, or if
NOTE problems were noted.
Remove cover, spring, and spider following instructions
for drive clutch removal, then proceed as follows:
1. Remove the moveable sheave spacer sleeve q .

Inspect for damage and wear.
4. Inspect surface of shaft for pitting, grooves, or

damage. Measure the outside diameter and compare
to specifications. Replace the drive clutch assembly if
5
shaft is worn or damaged.
2. Remove the moveable clutch sheave w . Inspect for

damage and wear.
MEASUREMENT
Shaft Diameter:
Standard: 1.3745” - 1.375” (34.91 - 34.93 mm)
Service Limit: 1.3730” (34.87 mm)
5. Visually inspect PTFE thrust washers for damage.

Measure the thickness and compare to specification.
Replace if worn or damaged.
MEASUREMENT
PTFE Washer Thickness:
Standard: .030” (.76 mm)
Service Limit: .025” (.64 mm)
5.19
PVT SYSTEM
BUSHING SERVICE
NOTE
Special Tools Required
EBS Clutch Bushing Tool Kit - 2201379-A

ITEM QTY. PART DESCRIPTION PART #
A, B 1 EBS Puller Tool 5132027
C 1 EBS Puller Nut 5132501
D 1 EBS Main Adapter 5132029
EBS Bushing Removal
E 1 5132028
Tool Instructions
– 1 Bushing Tool PA-47336 NOTE
Bushings are installed at the factory using Loctite® 648.
In order to remove bushings it will be necessary to
Additional Special Tools apply heat evenly to the area around each bushing.
Clean all residual Loctite® from bushing bore prior to
QTY. PART DESCRIPTION PART # installing new bushing.
Clutch Bushing Replacement Tool
1 2871226
Kit
CAUTION
1 Piston Pin Puller 2870386
Clutch components will be hot! In order to avoid serious
*Clutch Bushing Replacement Tool Kit (PN 2871226) burns, wear insulated gloves during the removal
process.
ITEM QTY. PART DESCRIPTION PART #
P-90 Drive/Driven Moveable Sheave - Bushing Removal
#2 1 Clutch Bushing Install 5020628
1. Remove clutch as outlined previously in this chapter.
Tool
2. Install handle end of the Piston Pin Puller securely
Drive Clutch Cover into bench vise and lightly grease puller threads.
Bushing Removal/
#3 1 Installation Tool (all 5020629
clutches)
P-90 Driven Clutch
#5 1 Cover Bushing 5020631
Removal Tool
#8 1 Main Puller Adapter 5020632
#9 1 Adapter Reducer 5010279
Number Two Puller
#10 1 Adapter 5020633
Piston Pin Puller:

2870386
3. Remove nut from puller rod and set aside.

4. Install puller adapter from kit PN 2871226).
5.20
PVT SYSTEM
5. Install main adapter (D) onto puller. 20. Remove installation tool.
Cover Bushing Removal

21. Install main adapter (8) on puller.
6. With towers pointing toward the vise, slide sheave

onto puller rod. 5
7. Install bushing removal tool into center of sheave with
small side toward sheave.
22. Install adapter reducer (9).
NOTE
23. From outside of clutch cover, insert removal tool (3)
Bushing Tool: into cover bushing.
PA-47336
24. With inside of cover toward vise, slide cover onto
puller. With inside of cover toward vise, slide cover
8. Install nut (C) onto end of puller rod and hand tighten. onto puller.
Turn puller barrel to increase tension on sheave if
needed. Using a hand held propane torch, apply heat 25. Install nut onto puller rod and hand tighten. Turn
around outside of bushing until tiny smoke tailings puller barrel to increase tension as needed.
appear. 26. Turn clutch cover counterclockwise on puller rod until
9. Turn sheave counterclockwise on puller rod until it bushing is removed and cover comes free.
comes free. Lift sheave off puller. 27. Remove nut from puller rod and set aside.
10. Remove nut from puller rod and set aside. 28. Remove bushing and bushing removal tool from
11. Pull bushing removal tool and adapter from puller rod. puller. Discard bushing.
Remove bushing from tool and discard.
Cover Bushing Installation
Moveable Sheave - Bushing Installation 29. Apply Loctite® 648 evenly to bushing bore in cover.
12. Apply Loctite® 648 evenly to bushing bore inside 30. Working from inside of cover, insert new bushing and
moveable sheave. bushing installation tool into center of clutch cover.
13. Set bushing in place on sheave. 31. With main adapter on puller, insert cover onto puller
14. Insert bushing tool (PA-47336) with small side down, rod, placing outside of cover toward vise.
into center of bushing. 32. Install nut on rod and hand tighten. Turn puller barrel
15. With towers pointing upward, slide sheave, bushing to apply more tension if needed.
and tool onto puller rod. 33. Turn clutch cover counterclockwise on puller rod until
16. Install nut on puller rod and hand tighten. Turn barrel bushing is seated.
to apply additional tension if needed. 34. Remove nut from puller rod. Take installation tool and
17. Turn sheave counterclockwise, making sure bushing clutch cover off rod.
is drawn straight into bore. Continue until bushing is
seated.
18. Remove nut from puller rod and set aside.
19. Remove sheave from puller.
5.21
PVT SYSTEM
DRIVE CLUTCH ASSEMBLY 5. Install the spider assembly onto the shaft threads. Be
sure all of the alignment marks u are in alignment.
CAUTION
Do not apply oil or grease to the bushings.
Reassemble the drive clutch in the following sequence.

Be sure the marks that were made during disassembly
are aligned during each phase of assembly.
ITEM DESCRIPTION
t Moveable Sheave
y Spider
u Alignment Marks
1. Install the shift weights, bolts and nuts onto the
movable sheave. Torque shift weight bolts to 6. Install clutch onto holding fixture (PN 2871358-A) and
specification. secure in a bench vice. Torque spider o to
specification using the holding fixture and spider tool
TORQUE i. Torque spider to specification
Shift Weight Bolt:
20 in-lb (2 Nm)
2. Install the non-braking needle bearing q, the two

washers w and the spacer r onto the stationary
sheave e.
TORQUE
Spider:
225 ft-lb (305 Nm)(Apply 0.4 mL Loctite® 7088
Primer and 0.4 mL Loctite® 620™)
3. Install movable sheave onto stationary sheave shaft. 7. Install shift weights using new lock nuts on the bolts.
Be sure the movable sheave slides freely on the
spacer.
4. Apply 0.4 mL of Loctite® 620™ and 0.4 mL of
Loctite® 7088™ Primer in 90º apart in vertical stripes
to the shaft threads.
5.22
PVT SYSTEM
8. Reinstall clutch spring a and limiter spacer s.
9. Reinstall cover f, aligning “X” mark with other marks.
IMPORTANT
If the aligning marks are not in alignment, the clutch will 5
not be in balance. The drive clutch assembly must be
replaced.
10. Torque cover bolts d evenly to specification.
TORQUE
Drive Clutch Cover Bolt:
100 in-lb (12 Nm)
5.23
PVT SYSTEM
DRIVEN CLUTCH SERVICE

DRIVEN CLUTCH SLIDER INSPECTION DRIVEN CLUTCH DISASSEMBLY
The square sliders can be inspected with the driven
1. Remove driven clutch from the transmission input
clutch installed on the vehicle.
shaft. Do NOT attempt disassembly of the driven
Using a feeler gauge, measure the distance between the clutch from the outside snap ring q. The driven
slider and the stationary sheave at the widest point q. If clutch must be disassembled from the helix side.
the measurement is over the service limit, the sliders or
driven clutch will need to be replaced. Also measure the
width of the slider block w. Replace the sliders if they are
smaller than the service limit.
NOTE
If driven clutch is difficult to remove, use 2871056
Driven clutch puller to remove driven clutch.
MEASUREMENT
2. It is important to mark the position of the shaft, cam
Slider to Sheave Clearance q:
cover and sheave before disassembly or use the X’s
Service Limit: 0.175″ (4.5 mm) on the components for reference. This will aid in
assembly and maintains clutch balance.
Slider Width w:
Service Limit: 0.975″ (24.8 mm)
5.24
PVT SYSTEM
3. Remove the four screws w that secure the cam 6. Remove the spider assembly and spring.
(helix) assembly using a T25 Torx driver.
NOTE
4. Place the driven clutch into the Universal Clutch
Compressor. Spring is compression only and has no torsional wind.
5
7. Remove the E-clips, washers, and the clutch rollers.
Inspect the rollers for wear; replace if worn.
8. Press out the spring pins o in the inner sheave.
Universal Clutch Compressor:

PU-50518-A
5. Press down on the top of the spider assembly,

pushing the spider onto the shaft. Remove snap ring 9. Pull out the clutch slider pins a and sliders s.
e and slowly release the assembly.
5.25
PVT SYSTEM
10. Press the shaft and bearing out of the outer sheave DRIVEN CLUTCH ASSEMBLY
using an arbor press.
BEARING INSTALLATION
1. Install a new bearing q onto the clutch shaft using an
arbor press. Once bearing is fully seated, install a
new snap ring w.
11. Inspect the bearing d for wear. Spin the bearing, if

the bearing does not spin smoothly, replace it. To
replace the bearing, remove the snap ring f from the
end of the shaft and press the bearing off the shaft.
2. Install the shaft and bearing assembly into the outer
sheave using an arbor press.
12. Inspect the cam (helix) assembly bushing g for wear.

If the bushing is worn or the shaft does not fit snug
into the bushing, replace the cam (helix) assembly. NOTE
Press only on the outer race of the bearing during
installation to prevent damaging the bearing.
13. Inspect the sheaves for excessive wear or damage.
5.26
PVT SYSTEM
CLUTCH ASSEMBLY 4. If removed, install the rollers t, washers y and E-

clips u onto the spider.
1. Align the X’s q on the moveable and stationary
sheaves.
5. Install the spring so the arm i rests into the notch in

2. Install the square sliders w and slider pins e. the moveable sheave.
5
6. Align the X’s o on the spider and moveable sheave.

3. Install the spring pins r to retain the slider pins.
7. Install the universal clutch compressor on the clutch

and compress the helix cover.
5.27
PVT SYSTEM
CAUTION
The helix cover is loaded by the spring. Not using a
proper compressor may result in personal injury or
damage to the clutch.
8. Align the marks previously made on the helix cover

and moveable sheave. Install the helix/cover and the
four fasteners a. Torque fasteners to specification.
TORQUE
Helix Retaining Screws:
48 in-lb (5 Nm)
9. Once back together, verify the grease / tape marks

made during disassembly are properly aligned.
10. Install the drive clutch on the vehicle.
5.28
PVT SYSTEM
TROUBLESHOOTING
SITUATION PROBABLE CAUSE REMEDY
-Wrong or broken drive clutch spring -Replace with recommended spring
Engine RPM
below specified -Drive clutch shift weight too heavy -Install correct shift weight kit to match engine
operating range, application
although engine is -Driven clutch spring broken or installed in
properly tuned wrong helix location -Replace spring; refer to proper installation
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
Erratic engine problem area
operating RPM
during acceleration -Belt worn unevenly - thin / burnt spots Replace belt
or load variations
-Driven clutch malfunction Inspect movable sheave for excessive bushing
clearance
-Sheave face grooved 5
-Replace the clutch
-Incorrect drive clutch spring (too high of rate) -Install correct recommended spring
-Drive clutch shift weights incorrect for -Install correct recommended shift weights
application (too light)
-Drive clutch binding -Disassemble and clean clutch, inspecting shift

Engine RPM
weights and rollers. Reassemble without the
above specified
spring and move sheaves through entire range to
operating range
further determine probable cause
-Driven clutch binding -Disassemble, clean, and inspect driven clutch
-Clutch 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 -Vehicle operated with parking brake on. Inspect
spots -Slow, easy clutch engagement brake system
-Fast, effective use of throttle for efficient

engagement
-Plugged air intake or outlet -Clear obstruction
PVT cover -Belt slippage due to water, oil, grease, etc., -Inspect system. Clean , repair or replace as
overheating rubbing on cover necessary.
(melting) Seal PVT system ducts
-High vs. low range
5.29
PVT SYSTEM
SITUATION PROBABLE CAUSE REMEDY

-Instruct operator on guidelines for operation in
proper driving range for different terrain as
outlined in Owner’s Safety and Maintenance
Manual
-Cover seal 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
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
5.30
TRANSMISSION
CHAPTER 6
TRANSMISSION
TRANSMISSION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
SHIFT LINKAGE / GEAR SELECTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
GEAR SELECTOR REMOVAL (SPORTSMAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
TRANSMISSION SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
TRANSMISSION VENT ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
TRANSMISSION SHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.10
TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.13
TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.18
TRANSMISSION EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.20
TRANSMISSION TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.22
TROUBLESHOOTING CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.22 6
6.1
TRANSMISSION
TRANSMISSION SPECIFICATIONS
LUBRICATION SPECIFICATIONS
TRANSMISSION CAPACITY
AGL
Gearcase Lubricant 37 oz. (1100 ml)
(PN 2878068) (Quart)
6.2
TRANSMISSION
SHIFT LINKAGE / GEAR SELECTOR

GEAR SELECTOR REMOVAL
(SPORTSMAN)
1. Remove the seat and upper RH side panel.
2. Push linkage rod out of the snap linkage at the gear
selector.
3. Remove the retaining screw from the back side and
pull the gear selector out from the frame support as
an assembly.
NOTE
Remove RH frame support to ease removal.
6.3
TRANSMISSION
TRANSMISSION SERVICE
TRANSMISSION VENT ROUTING
There are two vents for the transmission, they terminate with all other vent lines in the headlight pod. The upper vent
pictured tees into the vent for the rear gear case. The lower vent pictured, located near the starter, vents the bell
housing. If there is oil present in the bell housing vent, either the engine or transmission seals are leaking, and service
is required.
NOTE
Clutch intake removed for visibility of vents.
6.4
TRANSMISSION
TRANSMISSION REMOVAL 12. Disconnect the linkage rod from the gear selector.
2. Remove the seat and side panels.
3. Disconnect negative (-) battery cable.
4. Remove rear cab and both footwells.
5. Thoroughly clean the engine, transmission and
chassis.
6. Drain the transmission fluid.
7. Remove the outer PVT cover:
• SPORTSMAN / SCRAMBLER MODELS: Remove the
left rear wheel and lower left-hand frame support.
• TOURING MODELS: Remove the rear skid plate.
8. Remove the PVT intake duct from the transmission,
and the PVT outlet duct from the inner PVT cover.
13. Remove the high tension leads from the engine and
9. Using a 6 mm Ball Allen, remove the (4) bolts remove the (2) nuts from each exhaust flange at the
retaining the rear propshaft to the rear gearcase engine.
input shaft. Slide the shaft off the transmission output
shaft and out from the vehicle.
10. Disconnect the wheel speed sensor located on the 14. Remove the exhaust springs retaining the exhaust
lower right-hand side of the transmission. pipe to the silencer and remove the pipe from the
11. Disconnect the gear selector switch from the top of vehicle.
the transmission.
6.5
TRANSMISSION
15. Remove the (7) bolts retaining the transmission to 19. Remove the (3) screws retaining the rear right-hand
the engine. footwell support and remove the support from the
frame (TOURING Models Only).
16. Remove the (2) vent lines from the top left portion of
the transmission. 20. Remove the (2) through-bolt fasteners that mount
the transmission to the isolator mount on the lower
LH side.
17. Remove the lower right airbox retaining screw.

18. Remove the (4) bolts securing the right-hand frame
21. Using a T45 driver, remove the screw from the top of
support and remove the support from the vehicle.
the isolator mount on the lower RH side.
6.6
TRANSMISSION
22. Carefully slide the transmission away from the

engine and remove the front propshaft from the
transmission shaft.
23. Once you have disengaged the transmission input
shaft from the engine coupler, carefully lift the
transmission assembly out the right side the of
vehicle.
6.7
TRANSMISSION
TRANSMISSION DISASSEMBLY 5. Carefully lift up on the cover. Use a soft-faced

1. Remove the drive belt, drive clutch and driven clutch. hammer to tap on the input shaft and rear output
shaft to ease cover removal.
2. Remove the (10) screws that secure the inner PVT
cover to the transmission case and remove the
cover.
6. Lift up on the rear output shaft assembly and remove

the front output shaft assembly.
3. Place the transmission in neutral by moving the

bellcrank.
4. Lay the transmission down with the cover facing up
and remove the bolts retaining the transmission
cover.
7. Remove the rear output shaft assembly and silent

chain from the transmission.
NOTE
Take note of any shims that may have fallen into the
case during cover removal. Be sure to reinstall during
“Transmission Assembly”.
6.8
TRANSMISSION
8. Remove the four bolts for the coupler shaft retainer 11. Remove the springs, shift shaft rail and park shaft
plate. rail.
9. Lift up on the coupler input shaft assembly and 12. Lift up on each end of the shift fork and rotate the
remove it from the transmission. fork out of the shift shaft cam.
10. Remove the (2) screws retaining the oil deflector 13. Repeat the previous step to remove the lower shift
plate. fork.
6.9
TRANSMISSION
14. Remove the input shaft assembly and reverse shaft 18. Remove the retaining ring and washer from the cam
assembly together from the transmission. shift shaft. Remove the nut, bellcrank and washer
from the bellcrank shift shaft.
15. If servicing either shaft assembly, remove the

reverse silent chain and separate the shaft 19. Remove both shift shafts from the transmission as
assemblies. an assembly. Lightly tap on each shaft to ease
removal.
16. Inspect all bearings, gear teeth, engagement dogs
and silent chain.
TRANSMISSION SHAFT SERVICE
Use the exploded views within this section when
servicing the transmission shafts.
Shaft bearings can be serviced using an arbor press.
Clutch Input Shaft
17. Remove the detent plug, snap ring, washer and gear
selector switch.
6.10
TRANSMISSION
Primary Shaft Reverse Shaft
6
Rear Output Shaft
Coupler Input Shaft
6.11
TRANSMISSION
Cam Shift Shaft
Bellcrank Shift Shaft
6.12
TRANSMISSION
TRANSMISSION ASSEMBLY
1. Thoroughly clean the transmission case halves and 3. If the cam shift shaft was disassembled, install the
shafts. detent gear with the step facing the O-ring.
2. Inspect all seals and O-rings for damage. If
transmission was disassembled, seal and O-ring
replacement is recommended (see exploded view
above).
NOTE
Both shift shafts have skip-tooth keyed splines for
assembly purposes.
6.13
TRANSMISSION
4. If the bellcrank shift shaft was disassembled, install 7. Place the two shafts into the transmission as an
the gear sector with the step facing the O-ring. assembly.
5. Install new O-rings on both shift shafts and lubricate

prior to installation. NOTE
Gently rock or twist the shift shafts upon installation to
6. Align the timing marks on the cam shift shaft and
prevent from damaging the new O-rings. Forcing the
bellcrank shift shaft.
shift shafts straight into the transmission housing may
cut the O-rings.
8. Install the washer over the bellcrank shift shaft and

install the bellcrank by aligning the skip-tooth splines.
9. Install the retaining nut and torque to specification.
TORQUE
Bellcrank Retaining Nut:
15 ft. lbs (20 Nm)
10. Install the washer and a new retaining ring onto the
cam shift shaft. The retaining ring should be tight on
the shaft.
6.14
TRANSMISSION
11. Install the transmission switch, washer and snap 15. Lift up on the lower shift fork and rotate the end into
ring. the cam.
12. Install the detent plug and torque to specification. 16. Install the upper shift fork and rotate the end into the
cam.
TORQUE
Detent Plug:
20 ft. lbs (27 Nm)
6
13. Assemble the input shaft and reverse shaft with the
lower shift fork and park pawl installed.
14. Place the assembly into the transmission housing

making sure to move the park pawl arm behind the
shift shaft cam during installation.
6.15
TRANSMISSION
17. Install both rails and springs. 24. Apply grease to the primary shaft and coupler input
shaft shim (s) (if found during removal), and place
them into the transmission cover for assembly.
25. Apply Crankcase Sealant (PN 2871557) to mating
surfaces.
26. Carefully install the transmission cover onto the
transmission. Apply even pressure to cover while
setting into place. A soft-faced hammer can be used
once the cover is started and aligned.
NOTE
Take care not to damage seals during cover installation.
27. Install the retaining bolts and torque to specification.
TORQUE
Transmission Cover Bolts:
NOTE 18 ft. lbs (25 Nm)
Make sure the spring is flush with the top of the shift
shaft rail. If not flush, the rail may not be fully seated. 28. Remove the old silicone material from the inner PVT
cover and transmission case using a wire brush.
Clean both surfaces thoroughly in preparation for
18. Install the oil deflector plate and install new retaining assembly.
screws. Torque screws to specification.
29. Inspect the inner PVT cover. Replace if cracked or
TORQUE damaged. The mating surface must be clean to
Deflector Plate Retaining Screws: ensure adhesion of new silicone sealant.
8 ft. lbs (11 Nm) 30. Be sure to “flame treat” the inner PVT cover prior to
applying silicone to ensure good adhesion. Pass the
19. Lubricate all seal lips to prevent damage upon flame of a propane torch back and forth quickly over
assembly. the area where the silicone is to be applied (2-3
inches from the flame tip is recommended). Do not
20. Install the coupler input shaft assembly. hold the torch too close to the surface. Keep the
21. Install the rear output shaft assembly and silent torch moving to prevent damage.
chain.
22. Lift up slightly on the rear output shaft and install the
front output shaft assembly.
23. If primary shaft was serviced, reinstall shaft
assembly into the transmission case.
6.16
TRANSMISSION
31. Apply RTV silicone sealant to the outside edge of the

inner PVT cover to ensure a water tight fit between
the cover and the transmission.
32. Install the cover and torque the inner PVT cover
screws to specification.
TORQUE
Inner PVT Cover Screws:
5 ft. lbs (7 Nm)
33. Wipe away any excess silicone sealant.

34. Install the drive clutch, driven clutch and drive belt
(see Chapter 7 “PVT SYSTEM SERVICE -
Disassembly”).
6.17
TRANSMISSION
TRANSMISSION INSTALLATION 8. Install the (2) through-bolt fasteners on the lower LH

1. Install a new gasket onto the engine mounting side and torque to specification.
surface.
TORQUE
Transmission Through-Bolt Fasteners:
19 ft. lbs (26 Nm)
2. Carefully place the transmission assembly into the

chassis.
3. Grease the transmission front output shaft and slide
the propshaft onto the transmission shaft.
4. Line up the splines on the transmission input shaft
with the engine coupler. Apply anti-seize compound
to the coupler shaft splines. 9. Install a new T45 mounting screw in the isolator
5. Slide the transmission forward to engage the mount on the lower RH side and torque to
coupler. specification.
NOTE TORQUE
Be sure the front propshaft is still attached to the Transmission Torx-Head Mounting Screw:
transmission shaft before installing the bolts. 36 ft. lbs (49 Nm)
6. Start the (7) bolts that retain the transmission to the

engine.
10. Install the rear right-hand footwell support with the

(3) retaining screws (TOURING Models Only).
7. Torque transmission to engine bolts to the specified 11. Install the upper RH frame support and torque
torque value using a criss-cross pattern. fasteners to specification.
TORQUE TORQUE
Transmission-to-Engine Retaining Bolts: Upper Right-Hand Frame Support Bolts:
19 ft. lbs (26 Nm) 36 ft. lbs (49 Nm)
6.18
TRANSMISSION
12. Install the rear propshaft and torque the retaining

bolts to specification.
TORQUE
Rear Propshaft Bolts:
18 ft. lbs (25 Nm)
13. Reverse the transmission removal procedure to

complete the installation.
15. Reinstall drain plug with a new O-ring and torque to
specification.
16. Add the recommended amount of lubricant through
the fill plug hole. Maintain the lubricant level at the
bottom of the fill plug hole when filling the
transmission. Do not overfill.
FLUID CAPACITY
Recommended Transmission Lubricant:
(PN 2878068) (Quart)
Capacity: 37 oz. (1100 ml)

specification.
TORQUE
Drain/Fill Plug Torque:
14 ft. lbs (19 Nm)
6.19
TRANSMISSION
TRANSMISSION EXPLODED VIEW
6.20
TRANSMISSION
REF. QTY. DESCRIPTION REF. QTY. DESCRIPTION

1. 1 Fill Plug, M18 41. 1 Park Pawl
2. 1 Drain Plug w/Magnet, M18 42. 1 Gear, Sector (See Parts Book)
3. 2 Torx Screw, M6 43. 1 Detent Bullet
4. 19 Screw, M8 44. 1 Sprocket (See Parts Book)
5. 4 Screw, M10 45. 1 Reverse Shaft (See Parts Book)
6. 1 Nut, Nylon Lock, 5/16-24 46. 1 Ball Bearing
7. 1 Washer, Thrust 47. 1 Gear, Helical (See Parts Book)
8. 1 Washer, Thrust 49. 1 Input Shaft (See Parts Book)
9. 2 Dowel Pin 50. 1 Input Shaft
10. 1 Retaining Ring 51. 1 Output Shaft
11. 1 E-Ring 52. 2 Vent Tube
12. 1 Retaining Ring 53. 1 Gear (See Parts Book)
13. 1 Retaining Ring 54. 1 Sprocket (See Parts Book)
14. 1 Retaining Ring 55. 1 Sprocket (See Parts Book)
15. 1 Retaining Ring 56. 1 Shift Shaft, Bellcrank
16. 1 Retaining Ring 57. 1 Rail, Shift Shaft
17. 1 Retaining Ring 58. 1 Detent Plug
18. 1 Washer, Thrust 59. 1 Rail, Park Shaft 6
19. 1 Shim 60. 1 Engagement Dog, Low
20. 1 Washer, Thrust 61. 1 Engagement Dog, Reverse/Low
21. 2 Shim 62. 1 Shift Fork
22. 1 Shim 63. 2 Pipe, Knock
23. 1 Washer, Thrust 64. 1 Shift Fork
24. 1 Washer, Thrust 65. 1 Engagement Dog, High
25. 2 Ball Bearing 66. 1 Switch Shaft
26. 3 Ball Bearing 69. 1 Shim Pack, Primary
27. 1 Ball Bearing 70. 1 Bellcrank, Spline (See Parts Book)
28. 1 Ball Bearing 71. 1 Oil Deflector
29. 1 Ball Bearing 72. 1 Bearing Cover
30. 1 Needle Bearing 74. 1 Silent Chain
31. 1 Ball Bearing 75. 1 Silent Chain
32. 1 Needle Bearing 76. 1 Switch, Rotary
33. 1 Needle Bearing 77. 1 O-Ring
34. 1 Compression Spring 78. 1 O-Ring
35. 1 Wave Spring 79. 1 O-Ring
36. 1 Torsion Spring, Park Pawl 80. 1 O-Ring
37. 1 Compression Spring 81. 1 Seal
38. 1 Gearcase, Cover 82. 4 Seal, Triple Lip
39. 1 Bell Housing 84. 1 Speed Sensor
40. 1 Gearcase, Main
6.21
TRANSMISSION
TRANSMISSION TROUBLESHOOTING
TROUBLESHOOTING CHECKLIST
Check the following items when shifting difficulty is
encountered.
• Engine idle speed is above specification
• Transmission fluid type/quality
• Loose or worn snap linkage bushings
• Worn linkage rod pivot end at the transmission
bellcrank
• Bent bellcrank
• Worn, broken or damaged internal transmission
components
• Drive clutch one-way bearing
• Worn drive belt
• Clutch alignment
NOTE
To determine if shifting difficulty is caused by an internal
transmission problem, isolate the transmission by
disconnecting linkage rod from transmission bellcrank.
Manually select each gear range at the transmission
bellcrank and test ride vehicle. If it functions properly,
the problem is outside the transmission.
If transmission problem remains, disassemble
transmission and inspect all gear dogs for wear
(rounding), or damage. Inspect all bearings, circlips,
thrust washers and shafts for wear.
6.22
FINAL DRIVE
CHAPTER 7
FINAL DRIVE
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
WHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
WHEEL STUDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
WHEEL STUD SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
WHEEL HUBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
FRONT HUB ASSEMBLY VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
REAR HUB ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
FRONT BEARING CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
INSPECTION / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
FRONT DRIVESHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.14
FRONT PROPSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.15 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.15
PROPSHAFT U-JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.16
PROPSHAFT U-JOINT DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.16
PROPSHAFT U-JOINT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.17
FRONT GEARCASE REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.19
NON-EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.19
FRONT GEARCASE REMOVAL (NON-EPS MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.19
FRONT GEARCASE INSTALLATION (NON-EPS MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.20
EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.22
FRONT GEARCASE REMOVAL (EPS MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.22
FRONT GEARCASE INSTALLATION - EPS MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.23
HIGHLIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.26
FRONT GEARCASE REMOVAL (HIGHLIFTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.26
FRONT GEARCASE INSTALLATION (HIGHLIFTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.26
FRONT GEARCASE - NON-ADC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.29
FRONT GEARCASE ASSEMBLY VIEW - NON-ADC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.29
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.30
AWD DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.31
GEARCASE DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.32
GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.35
FRONT GEARCASE (ADC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.38
7.1
FINAL DRIVE
FRONT GEARCASE ASSEMBLY VIEW - 4WDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.38

OPERATION, FRONT GEARCASE (4WDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.39
DISASSEMBLY / INSPECTION, FRONT GEARCASE (ADC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.40
REASSEMBLY, FRONT GEARCASE (ADC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.43
TROUBLESHOOTING, FRONT GEARCASE (ADC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.46
REAR BEARING CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.49
INSPECTION / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.49
BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.50
BUSHING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.51
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.52
REAR DRIVESHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.54
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.54
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.55
DRIVESHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.56
DRIVE SHAFT / CV JOINT HANDLING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.56
OUTER CV JOINT / BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.56
INNER PLUNGING JOINT / BOOT REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.58
REAR PROPSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.61
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.61
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.61
REAR GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.62
GEARCASE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.62
GEARCASE REMOVAL - TOURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.64
GEARCASE DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.66
GEARCASE BEARING AND SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.67
GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.69
REAR GEARCASE ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.70
REAR GEARCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.71
REAR GEARCASE INSTALLATION - TOURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.73
7.2
FINAL DRIVE
GENERAL INFORMATION
SPECIAL TOOLS
2872608 Roller Pin Removal Tool
PU-48951 Axle Boot Clamp Tool
8700226 CV Boot Clamp Pliers (Ear)

7.3
FINAL DRIVE
WHEELS
WHEEL REMOVAL
2. Stop the engine, place the transmission in PARK and
lock the parking brake. Loosen the wheel nuts
slightly.
3. Elevate the appropriate side of the vehicle by placing
a suitable stand under the footrest frame.
4. Remove the wheel nuts and remove the wheel.
WHEEL INSTALLATION
1. Verify the transmission is still in PARK and the
parking brake is locked.
2. Place wheel in correct position on the wheel hub. Be
sure the valve stem is toward the outside and
rotation arrows on the tire point toward forward
rotation.
3. Install wheel nuts and finger tighten them. Align the
center of wheel holes with center of the tapered nuts.
NOTE
It is possible to torque the wheel nut on a steel rim
without the nut being centered in the hole. Be sure to
center the wheel nuts before applying torque to prevent
wheel nuts from coming loose.
4. Carefully lower the vehicle to the ground.

5. Torque wheel nuts to the proper torque specification.
TORQUE
Lug Nuts
Aluminum Wheels: 75 ft. lbs (102 Nm)
Steel Wheels: 45 ft. lbs (61 Nm)
CAUTION
Improperly installed wheels could affect vehicle
handling and tire wear. On vehicles with tapered rear
wheel nuts, make sure tapered end of nut goes into
taper on wheel. Be sure to properly torque and install all
wheel nuts.
7.4
FINAL DRIVE
WHEEL STUDS
WHEEL STUD SERVICE 5. Obtain new wheel stud (s) t. Thoroughly clean stud
To ensure proper wheel stud replacement, follow the pro- t to remove all oil.
cedure outlined below. 6. Clean brake disc y / hub r.
IMPORTANT 7. Mount wheel to hub and torque lug nuts to
specification.
Use a calibrated torque wrench when servicing wheel
studs.
IMPORTANT
All parts must be clean, dry and free of oils / lubricants.
Wheel studs / lug nuts must be dry to ensure proper

torque.
1. Stop engine, place machine in Park and set parking

brake.
2. Properly raise and support vehicle.
TORQUE
CAUTION Lug Nuts
Serious injury may result if machine tips or falls. Be Aluminum Wheels: 75 ft. lbs (102 Nm)
sure machine is secure before beginning this service Steel Wheels: 45 ft. lbs (61 Nm)
procedure. Wear eye protection when removing and
installing bearings and seals.
3. Remove the wheel nuts q, wheel w, and tire e from 7

the hub r.
8. Install new wheel stud by hand.
NOTE
Front Hub: Insert the stud in to the hub.
4. Remove any damaged stud (s) t from hub r and Rear Hub: Insert the stud in the rotor and hub.
discard.
7.5
FINAL DRIVE
9. Install the lug nut for the corresponding new stud(s).
10. Using a calibrated torque wrench, torque lug nut to

specification to set the stud in the brake disc.
TORQUE
1st Torque Application:
5 ft-lbs (6.7 Nm)
NOTE
Failure to properly set the stud in the hub may damage
the knurling seat in the hub.
11. Without backing off the lug nut, continue to torque the
lug nut to specification to properly seat the stud in the
brake disc.
TORQUE
2nd Torque Application:
50 ft-lbs (68 Nm)
12. Without backing off the lug nut, continue to torque the
lug nut to specification.
TORQUE
3rd Torque Application:
75 ft-lbs (101 Nm)
13. Properly lower vehicle and verify proper operation.
7.6
FINAL DRIVE
WHEEL HUBS
FRONT HUB ASSEMBLY VIEW
7
q Bearing Carrier
w Bearing
e Snap (Retaining) Ring Install with sharp edge out.
r Wheel Stud
t Brake Disc
y Hub
u Cone Washers
i Castle Nut 80 ft-lbs (108 Nm)
o Cotter Pin
a Air Valve
s Hub Cover
d Dust Cover
f Wheel Nuts 75 ft-lbs (102 Nm)
7.7
FINAL DRIVE
REAR HUB ASSEMBLY VIEW

q Bearing Carrier
w Bearing
e Snap (Retaining) Ring Install with sharp edge out.
r Wheel Stud
t Brake Disc
y Hub
u Cone Washers
i Castle Nut 80 ft-lbs (108 Nm)
o Cotter Pin
a Air Valve
s Hub Cover
d Dust Cover
f Wheel Nuts 75 ft-lbs (102 Nm)
7.8
FINAL DRIVE
FRONT BEARING CARRIER

INSPECTION / REMOVAL 6. Remove the front wheel hub assembly.
1. Elevate front of vehicle and safely support machine 7. Remove cotter pin from the bottom of the tie rod end.
under the frame area.
8. Hold the top of the rod end with a 13 mm open-end
CAUTION wrench and remove the nut from the bottom.
Serious injury may result if machine tips or falls. Be
sure machine is secure before beginning this service
procedure. Always wear eye protection.
2. Check bearings for side play by grasping the top and

bottom of the tire firmly and checking for movement.
The tire should rotate smoothly without binding or
rough spots.
3. Remove the (4) wheel nuts and remove the front
wheel.
4. Remove the cotter pin and loosen the front wheel
hub castle nut. Remove the nut and (2) cone
washers from the front wheel hub assembly.
9. Remove the steering tie rod from the bearing carrier.

10. Remove the upper and lower ball joint pinch bolts.
5. Remove the (2) brake caliper mounting bolts and

caliper. CAUTION: Do not hang the caliper by the
brake line. Use wire to hang caliper to prevent
damage to the brake line.
11. Using a soft faced hammer, lightly tap on the bearing

carrier while removing the upper and lower ball joint
ends.
7.9
FINAL DRIVE
12. Remove the bearing carrier from the front drive shaft. BEARING REPLACEMENT
Bearing Removal
1. Remove the outer retaining ring from the bearing
carrier.
13. Rotate bearing by hand and check for smooth

rotation. Visually inspect bearing for moisture, dirt, or
corrosion.
NOTE
2. Support the bearing carrier in an arbor press and
Due to extremely close tolerances and minimal wear, remove the bearing by pressing it out from the back
the bearings must be inspected visually, and by feel. side.
While rotating bearings by hand, inspect for rough
spots, discoloration, or corrosion. The bearings should
turn smoothly and quietly, with no detectable up and
down movement and minimal movement sideways
between inner and outer race.
14. Replace bearing if moisture, dirt, corrosion, or

roughness is evident.
3. Inspect the bearing carrier housing for scratches,

wear or damage. Replace front bearing carrier if
damaged.
Bearing 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.
2. Support the bottom of the bearing carrier housing.
CAUTION
Use an arbor and press only on the outer race or
bearing damage may occur.
7.10
FINAL DRIVE
3. Apply Loctite 603 retaining compound to the outer 3. Install new pinch bolts and fastener hardware.
circumference of the new bearing race and carefully Torque new pinch bolts to specification.
press the new bearing into the bearing carrier
housing. NOTE
Refer to the Polaris Electronic Parts Catalog for
replacement pinch bolts and fastener hardware.
NOTE
Use care to not allow any of the Loctite compound to
get in the bearing.
4. Wipe the housing clean of any excess compound and

install the snap ring. 7
INSTALLATION TORQUE
1. Install the drive shaft axle through the backside of Pinch Bolts:
the bearing carrier. 17 ft. lbs (24 Nm) Plus 90 Degrees
2. Install the upper and lower ball joint ends into the
bearing carrier. 4. Apply grease to drive shaft axle splines.
5. Install the front wheel hub assembly, cone washers,
and hand tighten the castle nut. Install washers with
domed side facing out toward the castle nut.
7.11
FINAL DRIVE
6. Install the brake caliper and torque the new mounting 8. Torque the wheel hub castle nut to specification and
bolts to specification. install a NEW cotter pin. Tighten nut slightly if
necessary to align cotter pin holes.
TORQUE
Front Caliper Mounting Bolts:
37 ft. lbs (50 Nm)
CAUTION
New bolts have a pre-applied locking agent which is
destroyed upon removal. Always use new brake caliper
mounting bolts upon assembly.
7. Install the steering tie rod end onto the front bearing
carrier. Torque fastener to specification and install a
new cotter pin.
TORQUE
Wheel Hub Castle Nut:
80 ft. lbs (108 Nm)
9. Install the front wheel and (4) wheel nuts. Torque

wheel nuts to specification.
TORQUE
Lug Nuts
10. Rotate wheel and check for smooth operation. Bend

both ends of cotter pin around end of spindle in
different directions.
TORQUE
Tie Rod End Fastener:
42 ft. lbs (58 Nm)
7.12
FINAL DRIVE
FRONT DRIVESHAFT
REMOVAL 5. Remove the front wheel hub assembly.
1. Elevate front of vehicle and safely support machine 6. Remove the upper ball joint pinch bolt.
7. Using a soft faced hammer, lightly tap on the upper
CAUTION A-arm to remove it from the bearing carrier.
Serious injury may result if machine tips or falls. Be 8. Remove the drive shaft from the front bearing carrier.
2. Remove the (4) wheel nuts and remove the front

wheel (see “Wheel Removal”).
3. Remove the cotter pin and loosen the front wheel
hub castle nut. Remove the nut and (2) cone
washers from the front wheel hub assembly.
9. With a short, sharp jerk, remove drive shaft from the

front gearcase.

caliper.
CAUTION
Do not hang the caliper by the brake line as it mar result
in brake line damage. Use wire to hang caliper to
prevent damage to the brake line.
10. Refer to the “DRIVE SHAFT SERVICE” procedure if

repairing the drive shaft.
7.13
FINAL DRIVE
INSTALLATION
1. Install a new spring ring on the end of the drive shaft
and apply an anti-seize compound to the splines.
2. Align the splines of the drive shaft with the front

gearcase and reinstall the drive shaft. Use a rubber
mallet to tap on the outboard end of the drive shaft if
necessary.
3. Install the drive shaft into the front bearing carrier.
4. Refer to the “FRONT BEARING CARRIER -
Installation” procedure within this chapter to properly
reassemble the vehicle.
7.14
FINAL DRIVE
FRONT PROPSHAFT
REMOVAL INSTALLATION
1. Locate front propshaft roll pin through the right front 1. Apply anti-seize compound to all splines. Slide
wheel well. Position the vehicle for roll pin removal. propshaft back onto the transmission output shaft,
then slide it up onto the front gearcase input shaft,
2. Use the Roll Pin Removal Tool (PN 2872608), to
verify pin holes are aligned.
drive out the roll pin from the front propshaft.
2. Using Roll Pin Tool (PN 2872608), install a NEW roll
pin (spring pin) into the propshaft.
3. Reinstall footwell, side panel and seat.
Roll Pin Removal Tool (PN 2872608)
3. Remove seat, upper RH side panel and RH footwell.

4. Pull shaft back towards the transmission to remove it
from the front gearcase input shaft, then pull it
7
forward to remove it from the transmission output
shaft.
7.15
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.
NOTE
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.
5. Tighten clamp with hand tools to force U-joint cups

out of yoke.
7.16
FINAL DRIVE
6. Discard and replace all U-joint parts that were 5. Place clamp and installer adapters r with smaller
removed from the yoke. OD than caps over each cap.
PROPSHAFT U-JOINT ASSEMBLY

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.
7.17
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

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.
7.18
FINAL DRIVE
FRONT GEARCASE REMOVAL / INSTALLATION

NON-EPS 7. Remove the (2) bolts retaining the lower steering
post bracket to the front gearcase.
FRONT GEARCASE REMOVAL (NON-EPS
MODELS)
1. Stop engine and place gear selector in Park.
CAUTION
2. Raise and support the front of the vehicle. Remove

the front wheels.
3. Remove both front drive shafts from the front
gearcase.
8. Remove the bolts and flange nuts retaining the
4. Remove the front propshaft from the front gearcase steering post assembly plate to both sides of the
input shaft. frame.
5. Disconnect the wire harness above the front
gearcase and remove the plastic tie strap retaining
the wires to the frame.
9. Remove the front cover and remove the (2) fasteners

retaining the upper steering post bushing bracket.
6. Remove and discard the cotter pins q and nuts w

from each tie rod end at the steering post frog.
10. Lift the steering post assembly up from the front

gearcase. Position the steering post toward the
center of the vehicle to allow enough room for
gearcase removal.
7.19
FINAL DRIVE
11. Remove the vent line and the (4) bolts securing the 2. Install the vent line and the (4) bolts that secure the
front gearcase to frame. front gearcase to frame. Torque bolts to specification.
12. Lay the gearcase on its side and rotate it in the frame
so the input shaft is facing you.
13. Remove the gearcase from the front RH wheel well
area and carefully slide it between the upper and
lower A-arms. TORQUE
Front Gearcase Mounting Bolts:
36 ft. lbs (49 Nm)
FRONT GEARCASE INSTALLATION (NON-EPS
MODELS) 3. Connect and route the AWD wire harness along the
1. Install the gearcase between the A-arms as shown. frame and install a plastic tie strap to attach it to the
frame.
4. Place the lower steering post assembly into the front

gearcase.
7.20
FINAL DRIVE
5. Secure the steering post to the frame by installing 8. When all of the fasteners for the lower steering post
the upper steering post bracket and bushings. are installed, torque all to specification.
Torque fasteners to specification.
TORQUE
Front Gearcase to Post Fasteners:
18 ft. lbs (24 Nm)
Bracket-to-Frame Fasteners:
18 ft. lbs (24 Nm)
9. Install the steering tie rod ends into the steering frog
plate. Torque the tie rod end fasteners to
specification and install new cotter pins.
TORQUE
Upper Steering Post Bracket:
18 ft. lbs (24 Nm)
6. Loosely install the two screws that attach the lower

steering post assembly to the front gearcase..
TORQUE 7
Tie Rod to Steering Frog:
42 ft-lbs (57 Nm)
10. Install the front cover and front rack (see Chapter 9).
11. Install the front propshaft onto the front gearcase
input shaft (see “FRONT PROPSHAFT -
Installation”).Installation, page 7.15
12. Install both front drive shafts into the front gearcase
7. Loosely install the two screws and flange nuts that (see “FRONT DRIVE SHAFT - Installation”).
attach the lower steering post assembly to the frame. Installation, page 7.14
13. Reinstall the front gearcase drain plug with a new O-
ring and torque to specification.
7.21
FINAL DRIVE
14. Add the recommended amount of fluid. Maintain fluid 4. Disconnect the gearcase wiring harness.
level even with the bottom threads of the fill plug
hole.

from each tie rod end at the steering post frog.
FLUID CAPACITY
Recommended Front Gearcase Fluid:
(PN 2877922) (Quart)
Capacity: 9.3 oz. (275 ml)

specification.
TORQUE
Drain / Fill Plug:
10 ft-lbs (14 Nm)
6. Remove the power steering unit from the vehicle.
16. Check for external leaks. See: EPS Unit Removal, page 8.11
7. Remove the bolts retaining the lower steering post
assembly to the front gearcase.
EPS
FRONT GEARCASE REMOVAL (EPS MODELS)

1. Stop engine and place gear selector in Park.
CAUTION
2. Remove both front drive shafts from the front

gearcase. See: , page 7.13
3. Remove the front propshaft from the front gearcase
input shaft. See: , page 7.15
7.22
FINAL DRIVE
8. Remove the bolts and flange nuts retaining the lower 12. Remove the gearcase from the front LH wheel well
steering post assembly to the frame on each side. area and carefully slide it between the upper and
lower A-arms.
9. Lift the lower steering post assembly from the front

gearcase and out from the vehicle.
FRONT GEARCASE INSTALLATION - EPS

MODELS
1. Install the gearcase between the A-arms as shown.
10. Remove the vent line and the (4) bolts securing the
front gearcase to frame.
11. Lay the gearcase on its side and rotate it in the frame
so the input shaft is facing you.
7.23
FINAL DRIVE
2. Install the vent line and the (4) bolts that secure the 4. Place the lower steering post assembly into the front
front gearcase to frame. Torque bolts to specification. gearcase.
5. Loosely install the two screws and flange nuts that

attach the lower steering post assembly to the frame.
TORQUE
Front Gearcase Mounting Bolts:
36 ft. lbs (49 Nm)
3. Connect and route the AWD wire harness along the

frame and install a plastic tie strap to attach it to the
frame.
6. Loosely install the bolts retaining the lower steering

post assembly to the front gearcase.
TORQUE
Steering Post to Gearcase Fasteners:
18 ft. lbs (24 Nm)
Lower Steering Post-to-Frame Fasteners:

18 ft. lbs (24 Nm)
7.24
FINAL DRIVE
7. Reinstall the power steering unit, attach the upper 13. Add the recommended amount of fluid. Maintain fluid
steering post and install the fuel tank. See:EPS Unit level even with the bottom threads of the fill plug
Installation, page 8.12 hole.
8. Install the steering tie rod ends into the steering frog.
Torque the tie rod end fasteners q and w to
TORQUE FLUID CAPACITY

Tie Rods to Steering Frog: Recommended Front Gearcase Fluid:
42 ft. lbs (58 Nm) Polaris Demand Drive Fluid
(PN 2877922) (Quart)
9. Install the front cover and front rack. Capacity: 9.3 oz. (275 ml)
10. Install the front propshaft onto the front gearcase
input shaft. See: Installation, page 7.15 14. Reinstall fill plug with a new O-ring and torque to
specification.
7
11. Install both front drive shafts into the front gearcase.
See: Installation, page 7.14 TORQUE
12. Reinstall the front gearcase drain plug with a new O- Drain / Fill Plug:
ring and torque to specification. 10 ft-lbs (14 Nm)
7.25
FINAL DRIVE
HIGHLIFTER FRONT GEARCASE INSTALLATION

(HIGHLIFTER)
FRONT GEARCASE REMOVAL (HIGHLIFTER)
1. Install the gearcase on the right side of the unit as
1. Remove the fan/snorkel cover (lock and ride shown.
fasteners)
2. Remove six screws holding on the front cover.
3. Disconnect both fans and remove the radiator cover.
4. Remove both fuel tank guards.
5. Remove seat and side panels.
6. Remove cover on front side of upper steering shaft.
7. Remove front cab.
8. Disconnect fuel lines and pump harness.
9. Remove fuel tank (two hidden upper mounting
fasteners)
10. Remove upper steering shaft from EPS unit.
11. Remove steering shaft / handlebar mounting
fasteners.
12. Remove lower steering shaft fasteners to EPS unit.
2. Install the driveshaft.
13. Disconnect two EPS wiring harnesses.
3. Place the lower steering post assembly into the front
14. Remove EPS fasteners and remove EPS unit. gearcase.
15. Remove prop shaft roll pin from the yoke to front
gearcase using special tool. NOTE
16. Remove lower steering shaft frog/mount from the Bearing is a snug fit to the front gearcase.
front gearcase. Bearing is a snug fit to the front
gearcase and it should wiggle loose.
17. Remove four front gearcase mounting bolts.
18. Remove right side driveshaft and pop the left
driveshaft from the gearcase.
19. Remove the gearcase out the right side of the unit.
7.26
FINAL DRIVE
4. Loosely install the two screws and flange nuts that TORQUE
attach the lower steering post assembly to the frame.
Tie Rods to Steering Frog:
42 ft. lbs (58 Nm)
5. Loosely install the bolts retaining the lower steering

post assembly to the front gearcase.
7. Install the vent line and the (4) bolts that secure the
front gearcase to frame. Torque bolts to specification.
TORQUE
Steering Post to Front Gearcase Fasteners:
18 ft. lbs (24 Nm)
Lower Steering Post-to-Frame Fasteners:

18 ft. lbs (24 Nm)
TORQUE
6. Install the steering tie rod ends into the steering frog. Front Gearcase Mounting Bolts:
Torque the tie rod end fasteners q and w to 36 ft. lbs (49 Nm)
7.27
FINAL DRIVE
8. Connect and route the AWD wire harness along the 16. Add the recommended amount of fluid. Maintain fluid
frame and install a plastic tie strap to attach it to the level even with the bottom threads of the fill plug hole.
frame.
9. Install the prop shaft roll pin at the front gearcase. FLUID CAPACITY
10. Reinstall the power steering unit, attach the upper Recommended Front Gearcase Fluid:
steering post.. Polaris Demand Drive Fluid
11. Connect the EPS wiring harnesses. (PN 2877922) (Quart)
12. Install the EPS Unit. See EPS Unit Installation Capacity: 9.3 oz. (275 ml)
13. Install the upper steering shaft.
14. Install the steering shaft / handlebar mounting 17. Reinstall fill plug with a new O-ring and torque to
fasteners. specification.
15. Reinstall the front gearcase drain plug with a new O- TORQUE
ring and torque to specification.
Drain / Fill Plug:
10 ft-lbs (14 Nm)
18. Install the fuel tank

NOTE
There are two hidden upper mounting fasteners

20. Install the front cab.
21. Install the cover on front side of upper steering shaft.
22. Install the seat and side panels.
23. Install the fuel tank guards.
24. Connect both fans and install the radiator cover.
25. Install the six screws holding on the front cover.
26. Install the fan/snorkel cover (lock and ride fasteners)
7.28
FINAL DRIVE
FRONT GEARCASE - NON-ADC

FRONT GEARCASE ASSEMBLY VIEW -
NON-ADC
7
REF# DESCRIPTION QTY REF# DESCRIPTION QTY
1 Square o-ring 1 22 H-clip 20
2 O-ring 1 28 Coil insert 1
3 Dowel pin 1 29 Thrust button 1
4 Bearing 2 30 Thrust plate 1
5 Open bearing 1 31 Spring retainer 1
6 Needle roller bearing 1 32 Nylon spacer 2
7 Bushing 1 33 Pinion gear 1
8 Bushing 1 34 Armature plate 1
9 Oil seal 1 35 4WD coil 1
10 Oil seal 2 36 Grommet 1
11 Shaft ring 1 37 Vent tube 1
12 T30 Torx screw 10 38 Fill plug 1
13 Set screw 1 39 Magnetic drain plug 1
14 Cover 1 40 Clip 1
15 Input cover 1 41 Connector 1
16 Gearcase housing 1
17 Ring gear 1
18 Roll cage 1
19 Hub assembly 2
20 Roller 20
21 Torsion spring 1
7.29
FINAL DRIVE
OPERATION
The AWD switch may be turned on or off while the
vehicle is moving, however, AWD will not enable until the
engine RPM drops below 3100. Once the AWD is
enabled, it remains enabled until the switch is turned off.
Engage the AWD switch before getting into conditions
where the front wheel drive may be needed. If the rear
wheels are spinning, release the throttle before switching
to AWD.
CAUTION
Switching to AWD while the rear wheels are spinning
may cause severe drive shaft and gearcase damage.
Always switch to AWD while the rear wheels have
traction or are at rest.
With the AWD switch off, the vehicle drives through the
rear wheels only (2 wheel drive). When the AWD is CAUTION
enabled, the front drive acts as an on-demand AWD If the rear wheels are spinning, release the throttle
system. This means, the front drive will engage once the before turning the AWD switch on. If AWD is engaged
rear wheels have lost traction, and will remain engaged while the wheels are spinning, severe drive shaft and
until the torque requirement goes away (i.e. rear wheels clutch damage could result.
regain traction).
AWD Disengagement: Once the rear wheels regain

traction, the front wheels will return to the “over-running”
condition. The vehicle is now back to rear wheel drive
until the next loss of rear wheel traction occurs.
AWD Engagement: When the AWD switch is activated,

the AWD coil is powered by a 12 Vdc input which creates
a magnetic field. This magnetic field attracts an armature
plate that is keyed to the roll cage. When the ring gear
and roll cage are spinning (vehicle is moving), the
energized coil and armature plate will apply drag to the
roll cage that indexes the rollers inside the ring gear to an
engagement position. While in the engagement position,
the front drive will be in an “over-running” condition (not
engaged), until the rear wheels lose traction. Once the
rear wheels begin to lose traction, the front drive will
engage by coupling the output hubs to the ring gear via
the rollers. The front drive will remain engaged until the
torque requirement goes away (i. e. rear wheels regain
traction).
7.30
FINAL DRIVE
AWD DIAGNOSIS 4. Inspect the armature plate for a consistent wear

Symptom: AWD Will Not Engage pattern. There should be two distinct wear bands
(one band inside the other). If only one band of wear
1. Check the gearcase AWD coil resistance. Measure is present or if there is wear between the two bands,
between the Grey (C) and Brown/White (B) wires. inspect the coil area as indicated in Step 5. A wear
The resistance value should be within specification. band with an interrupted wear mark may indicate a
warped plate, which may cause intermittent
operation.
5. Check to make sure the AWD coil is seated in the U-

shaped insert that is pressed into the gearcase
Front Gearcase Coil Resistance: cover. The top of the coil should be seated below the
AWD (Pin B to Pin C): 24Ω U-shaped insert. If the top of the coil is above the
ADC (Pin A to Pin D: 12.49Ω surface of the U-shaped insert it raises the armature
plate, thereby increasing pole gap. If the pole gap
7
2. For in depth electrical diagnostics, refer to the AWD increases, the coil will not be strong enough to
section in the electrical chapter. engage the AWD system. If this is found, replace
cover plate assembly.
3. If electrical tests are within specification, remove the
front gearcase and inspect the internal components.
7.31
FINAL DRIVE
6. Inspect the rollers for nicks and scratches. The 3. Remove the cover plate assembly from the
rollers must slide freely within the roll cage and H- gearcase.
springs.
4. Remove the female (LH) output hub assembly.

Inspect the thrust bearing (A) for wear. Inspect the
output hub ball bearings, contact surfaces and
splines for signs of wear or damage.
NOTE
7. Inspect the roll cage assembly for cracks or Excessive noises coming from the front drive on
excessive wear. If damaged, replace the roll cage deceleration are key indicators of burnt or broken down
assembly. front drive fluid.
GEARCASE DISASSEMBLY / INSPECTION 5. Remove and inspect the armature plate. Refer to
1. Drain and properly dispose of used lubricant. “AWD Diagnosis” for detailed inspection process.
Remove any metal particles from the drain plug
magnet.
2. Remove the (6) screws retaining the cover plate
assembly and open the wire retaining clip.
7.32
FINAL DRIVE
6. Remove the torsion spring retainer and torsion 8. Remove the male (RH) output hub assembly. Inspect
spring from the top of the ring gear. the bearings, contact surfaces and splines for signs
of wear or damage. Visually inspect the clutch plate
area. If plates are steel-on-steel, or if the friction
material is worn, the assembly must be replaced.
9. Place a shop towel over the ring gear assembly and

slowly remove the roll cage and rollers from the ring
gear.
NOTE
Rollers are spring loaded. Take care not to allow them
to fall out or lose them upon removal of the roll cage.
7
10. Inspect the rollers (B) for nicks, scratches and flat
spots. Inspect the roll cage (C) for damage or cracks.
The rollers must slide up and down freely within the
roll cage surfaces. Inspect the ring gear (D) for
consistent wear patterns. Surfaces should be free of
nicks or burrs.
7. Remove the ring gear and roll cage assembly from
the gearcase housing.
11. Inspect roll cage sliding surfaces. These surfaces

must be clean and free of nicks, burrs or scratches.
7.33
FINAL DRIVE
12. Remove and inspect the H-springs (E). If the spring 14. Inspect the magnetic coil (F) in the cover plate
legs appear to be flattened or damaged, replace the assembly (refer to “AWD Diagnosis” for inspection).
roll cage and H-springs as an assembly.
15. Inspect the backlash thrust button (G) and thrust

plate for excessive wear.
NOTE
Refer to the “Electronic Parts Catalog” for individual NOTE
part availability. Most parts are to be replaced as an Ring gear backlash is set at the factory. No adjustment
assembly or as a complete kit. is required unless the front cover is replaced or the
backlash thrust pad screw is removed. Refer to “Setting
13. Inspect the armature plate for a consistent wear Ring Gear Backlash” later in this chapter for details on
pattern. Uneven wear of the armature plate indicates backlash setting.
a warped plate, which may cause intermittent
operation (refer to “AWD Diagnosis” for inspection). 16. Remove the (4) bolts retaining the input cover.
7.34
FINAL DRIVE
17. Remove the input shaft assembly from the main GEARCASE ASSEMBLY
gearcase.
NOTE
Refer to the photos used in the “Gearcase Disassembly
/ Inspection” procedure when needed, while assembling
the front gearcase.
1. Thoroughly clean all gearcase components before

beginning reassembly.
2. Install new seals and O-rings as shown (included in
the Seal Repair Kit).
3. Apply assembly grease to the seal lips to prevent
from damaging the seals upon assembly.
4. Install the input shaft assembly.
5. Torque the input cover screws to specification.
TORQUE
18. Inspect the pinion gear (N) for chipped, broken, or
missing teeth. Inspect the input shaft bearing (P) for Input Cover Screws:
signs of wear. The bearing can be replaced separate 8 ft. lbs (11 Nm)
from the input shaft.
6. Install the roll cage and rollers into the ring gear.
NOTE Insert the rollers as the roll cage is installed.
Refer to the “Electronic Parts Catalog” for individual
part availability. Most parts are to be replaced as an
assembly or as a complete kit.
7. Hold the roll cage assembly in the ring gear and turn
it over to install the torsion spring.
7.35
FINAL DRIVE
8. Install the torsion spring by wrapping each leg of the 11. Install the male (RH) output hub assembly into the
spring around the dowel pin on the ring gear. main gearcase.
NOTE
Take care not to damage the seal lip or seal spring
while installing the output hub.
9. Align the spring retainer dowel pin with the ring gear
dowel pin and install the retainer on top of the torsion
spring.
12. Carefully install the ring gear and roll cage assembly
into the gearcase housing.
10. Check the action of the torsion spring by rotating in

both directions to ensure the spring and retainer are
installed properly.
7.36
FINAL DRIVE
13. Install the armature plate on top of the roll cage / ring TORQUE
gear assembly. Be sure that the armature plate tabs
are fully engaged into the roll cage assembly and are Cover Plate Screws:
resting on the cut-out grooves of the ring gear. 8 ft. lbs (11 Nm)
NOTE
If the cover plate was replaced or if the backlash set
screw was repositioned, proceed to the “Setting Ring
Gear Backlash” procedure.
NOTE
Install the female (LH) output hub assembly into the roll
cage / ring gear assembly.
14. Install the large O-ring onto the cover plate.

15. Lightly crimp the thrust pad to hold the pad on the
cover plate during installation.
7
16. Place the cover plate assembly on the main

gearcase and install the (6) screws. Torque screws
to specification.
NOTE
Take care not to damage the seal lip or seal spring
while installing the cover plate.
7.37
FINAL DRIVE
FRONT GEARCASE (ADC)

FRONT GEARCASE ASSEMBLY VIEW - 4WDC
REF. PART DESCRIPTION NOTES

q ASM., GEARCASE, RH, ADC, 4WDC [INCL. ALL]
w ASM., COVER, OUTPUT
e ASM., OUTPUT HUB
r KIT, FASTENERS Torque: 7-11 ft-lbs
t KIT, SEAL REPAIR
y PLATE, ARMATURE
u PLATE, ARMATURE, BD
i BEARINGS
o KIT, ROLLER [SET OF 24]
a ASM., ROLL CAGE [INCL. CAGE, 24 CLIPS]
s ASM., GEARCASE
d ASM., PLUG, DRAIN Torque: 8-30 ft-lbs (11-40 Nm)
f PLUG, OIL FILL Torque: 8-30 ft-lbs (11-40 Nm)
g ASM, GEAR HOUSING / PINION GEAR
h KIT, SPRING
j INPUT COVER
7.38
FINAL DRIVE
OPERATION, FRONT GEARCASE (4WDC)

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.
7.39
FINAL DRIVE
DISASSEMBLY / INSPECTION, FRONT

GEARCASE (ADC)
1. Drain and properly dispose of used oil. Remove any
metal particles from the drain plug magnet q.
4. Remove the output hub assembly e.
2. Remove bolts w retaining the outer cover plate

assembly.
5. Inspect the bearing and contact surfaces of the output

hub for signs of wear or damage. Replace component
if found to be worn or damaged.
3. Remove the outer cover plate assembly.
NOTE
Press on the output hub assembly e while lifting up on
the outer cover plate(4) to prevent removing more than
the cover plate.
6. Remove and inspect the armature plates t. Refer to

“AWD Diagnosis” for detailed inspection process.
7.40
FINAL DRIVE
7. Remove the torsion spring retainer y. 10. Remove the LH output hub s.
7
8. Remove the torsion spring u from the top of the ring 11. Inspect the bearing and contact surfaces of the output
gear i. hub for signs of wear or damage. Replace component
if found to be worn or damaged.
9. Remove the roll cage assembly o, rollers a, and

ring gear i. Inspect for wear. 12. Thoroughly clean all parts. Inspect the bearing
surfaces of the output hub. Inspect the rollers a for
nicks, scratches and flat spots. Inspect the roll cage
o for damage or cracks. The rollers must slide up
and down freely within the roller cage surfaces.
7.41
FINAL DRIVE
13. Inspect the ring gear i for inconsistent wear patterns

or damage. The surfaces should be free of nicks or 16. Drill a hole in the input shaft seal d and remove the
burrs. seal using a pry bar or seal puller.
14. Inspect roll cage (B) sliding surface. This surface
must be clean and free of nicks, burrs or scratches.
Inspect the H-springs, but do not remove them
from the roll cage.
17. Remove the snap ring retaining the input shaft

assembly.
15. Inspect the armature plate for a consistent wear

pattern. Uneven wear of the armature plate indicates
a warped plate, which may cause intermittent
operation.
NOTE
See “FRONT GEARCASE DIAGNOSIS” later in this
chapter for more details.
18. Remove the input shaft assembly. Inspect the pinion

gear g for chipped, broken, or missing teeth. Inspect
the input shaft bearing h for signs of wear. Replace
the input shaft cover O-ring prior to reassembly.
7.42
FINAL DRIVE
REASSEMBLY, FRONT GEARCASE (ADC)

1. Clean the gearcase housing of debris.
2. Replace all O-rings, seals, and worn components.
3. Inspect bearings on output and pinion shafts. To
replace, press new bearing onto shaft.
NOTE
Due to extremely close tolerances and minimal wear,
the bearings must be inspected visually, and by feel.
down movement and minimal movement side to side.
19. Inspect the input shaft bushing j for wear.

4. Install input shaft, bearing, and snap ring.
7
20. Thoroughly clean the gearcase components before
beginning reassembly. 5. Press the pinion shaft seal into the gearcase, until the
seal is flush.
6. Install the LH output hub s into the gearcase

housing. The output hub should spin freely.
7.43
FINAL DRIVE
7. Install the torsion spring by wrapping each leg of the 11. Check the action of the torsion spring by rotating in
spring around the dowel pin on the ring gear. both directions to ensure the spring and retainer are
8. Install the rollers and roll cage into the ring gear. installed properly.
Insert the rollers as the roll cage is installed. 12. Install the armature plates t. Be sure the armature
plate tabs are fully engaged into the roll cage
assembly.
9. Install the pins a, roll cage o, and ring gear

assembly i into the gearcase housing.
NOTE
Verify armature plate tabs are in the slots on the roll
cage and are resting in the ring gear grooves.
13. Install the RH output hub e into the gearcase

housing. The output hub should spin freely.
10. Align the spring retainer dowel pin with the ring gear
dowel pin and install the retainer y on top of the
torsion spring.
7.44
FINAL DRIVE
TORQUE
Fill Plug:
8-10 ft-lbs (11-14 Nm)
Drain Plug:
11 ft-lbs (15 Nm)
14. Install the cover plate assembly with a new o-ring

onto the gearcase.
NOTE
Verify the square O-ring is placed flat on the cover
surface. If the O-ring is twisted, fluid leaks may occur.
15. Torque the cover plate bolts w to specification.
TORQUE
AWD Cover Screws:
8 ft-lbs (11 Nm)
16. Fill the gearcase with fluid.
FLUID CAPACITY
Demand Drive
Hub Fluid
8.97 oz. (265 ml)
17. Install the drain plug. Torque to specification.
7.45
FINAL DRIVE
TROUBLESHOOTING, FRONT GEARCASE

(ADC)
Customer Complaint: 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 on handle
bar 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.
POTENTIAL DIAGNOSIS PROBLEM REPAIR REPAIR

PROBLEM PROCEDURE DIAGNOSIS PROCEDURE VERIFICATION
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
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
7.46
FINAL DRIVE
POTENTIAL DIAGNOSIS PROBLEM REPAIR REPAIR

PROBLEM PROCEDURE DIAGNOSIS PROCEDURE VERIFICATION
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
engage.
spring, replace one or both
and retest.
additional problems listed. 7
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.
7.47
FINAL DRIVE
Symptom: AWD Will Not Engage 4. Check to make sure the coil t is seated in the U-
shaped y insert that is pressed into the gearcase
1. Check the gearcase coil resistance. To test the
cover u. The top of the coil should be seated below
gearcase coil resistance, use the coil harness (Grey
the U-shaped insert. The U-shaped insert controls the
& Brown/White).
pole gap. If the top of the coil is above the surface of
NOTE the U-shaped insert it raises the armature plate,
thereby increasing pole gap. If the pole gap increases
To test the gearcase coil resistance, use the coil the coil will not be strong enough to engage the AWD
harness. The gearcase coil should measure between system. If this is found, replace the cover plate
22.8 ohms and 25.2 ohms. assembly.
ADC Front Gearcase Coil Resistance

B-C (4X4): 23 Ω ±4Ω 5. Inspect the rollers for nicks, scratches, and flat spots.
A–D (4X4 ADC): 12.49 Ω ±4Ω Also inspect the roll cage o for cracks and ensure
the rollers a are able to slide up and down and in and
out freely within the roll cage sliding surfaces.
2. Check the minimum battery voltage at the Grey &
Brown/White wires that feed the hub coil wires.
AWD Coil Applied Battery Voltage:
11.80-12.0 Vdc
3. Inspect the armature plate e for a consistent wear

pattern. There should be two distinct wear bands r
(one band inside the other). If only one band of wear
is present (or if there is wear between the two bands,
inspect the coil area as indicated in Step 4. A band
with an interrupted wear mark may indicate a warped
plate, which may cause intermittent operation.
7.48
FINAL DRIVE
REAR BEARING CARRIER

INSPECTION / REMOVAL 6. Remove the rear wheel hub assembly.
1. Elevate rear of vehicle and safely support machine
CAUTION
2. Check bearings for side play by grasping the top and

bottom of the tire firmly and checking for movement.
The tire should rotate smoothly without binding or
rough spots.
3. Remove the (4) wheel nuts and the rear wheel.
4. Remove the cotter pin and loosen the rear wheel hub
castle nut. Remove the nut, and (2) cone washers
from the rear wheel hub assembly.
7. Remove the bolts that attach the rear bearing carrier
to the upper and lower A-arms.
5. Remove the two brake caliper mounting bolts.

CAUTION: Do not hang the caliper by the brake line.
Use wire to hang caliper to prevent damage to the 8. Remove the bearing carrier from the rear drive shaft.
brake line.
7.49
FINAL DRIVE
9. Rotate bearing by hand and check for smooth BEARING REPLACEMENT

rotation. Visually inspect bearing for moisture, dirt, or Bearing Removal
corrosion.
1. Remove outer retaining ring from the bearing carrier.
NOTE
Due to extremely close tolerances and minimal wear,
the bearings must be inspected visually, and by feel.
down movement and minimal movement sideways
between inner and outer race.
10. Replace bearing if moisture, dirt, corrosion, or

roughness is evident.
2. Support the bearing carrier in an arbor press and

remove the bearing by pressing it out from the back
side.
3. Inspect the bearing carrier housing for scratches,

wear or damage. Replace rear bearing carrier if
damaged.
Bearing Installation
1. 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.
2. Support the bottom of the bearing carrier housing.
CAUTION
Use an arbor and press only on the outer race or
bearing damage may occur.
7.50
FINAL DRIVE
3. Apply Loctite 603 retaining compound to the outer BUSHING REPLACEMENT

circumference of the new bearing race and carefully 1. Check bearing carrier bushings and shafts for
press the new bearing into the bearing carrier excessive wear or damage.
housing.
2. If replacement is required, slide shafts out and
remove the bushings with a drift punch.
3. Thoroughly clean the bearing carrier and inspect for

excessive wear or damage. Replace rear bearing
carrier if damaged.
NOTE 4. Install new shafts and bushings. Press the bushings
Use care to not allow any of the Loctite compound to into the bearing carrier until they are flush with the
mating surface.
get in the bearing. 7
5. Grease the rear bearing carrier fittings after it has
4. Wipe the housing clean of any excess compound and been installed and the rear A-arms have been
install the snap ring. attached.
7.51
FINAL DRIVE
INSTALLATION 4. Install rear wheel hub assembly, cone washers, and

1. Install drive shaft axle through the backside of the hand tighten the castle nut. Install washers with
bearing carrier. Be sure bushings and pivot tubes are domed side out.
installed.
5. Install the brake caliper and torque the new mounting

CAUTION
2. Install the fasteners that attach the rear bearing destroyed upon removal. Always use new brake caliper
carrier to the upper and lower A-arms. Torque bolts mounting bolts upon assembly.
to specification.
TORQUE TORQUE
Rear Bearing Carrier Bolts: Rear Caliper Mounting Bolts:
37 ft. lbs (50 Nm) 37 ft. lbs (50 Nm)
3. Apply grease to drive shaft axle splines.
7.52
FINAL DRIVE
6. Torque wheel hub nut to specification and install a

new cotter pin. Tighten nut slightly if necessary to
align cotter pin holes.
TORQUE
80 ft. lbs (108 Nm)
7. Install the rear wheel and (4) wheel nuts. Torque

TORQUE
Wheel Nuts: 7
8. Rotate wheel and check for smooth operation. Bend

both ends of cotter pin around end of spindle in
different directions.
7.53
FINAL DRIVE
REAR DRIVESHAFT
REMOVAL 6. Remove the rear wheel hub assembly.
CAUTION
Serious injury may result if machine tips or falls.
Be sure machine is secure before beginning this
service procedure.
Always wear eye protection.
2. Remove the (4) wheel nuts and remove the rear

wheel.
3. Remove the cotter pin and loosen the rear wheel hub
castle nut. Remove the nut, and (2) cone washers
from the rear wheel hub assembly.
7. Remove the bolt that attaches the upper A-arm to the

rear bearing carrier.

5. CAUTION: Do not hang the caliper by the brake line.
Use wire to hang caliper to prevent damage to the
brake line.
8. Tilt the top portion of the bearing carrier down and
pull the rear drive shaft out from the bearing carrier.
7.54
FINAL DRIVE
9. Grasp the rear drive shaft and pull sharply outward INSTALLATION
on the shaft to disengage it from the rear gearcase. 1. Install a new spring ring on the end of the drive shaft
and apply an anti-seize compound to the splines.
10. Inspect the axle splines and CV boots for any

damage.
2. Align the splines of the drive shaft with the rear
11. Refer to the “DRIVE SHAFT SERVICE” procedure if gearcase and reinstall the drive shaft. Use a rubber
repairing the drive shaft. mallet to tap on the outboard end of the drive shaft if
necessary.
3. Install the drive shaft into the rear bearing carrier.

4. Refer to the “REAR BEARING CARRIER -
Installation” procedure within this chapter to properly
reassemble the vehicle.
7.55
FINAL DRIVE
DRIVESHAFT SERVICE
DRIVE SHAFT / CV JOINT HANDLING TIPS OUTER CV JOINT / BOOT 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 q.
precision parts.
Cleanliness and following these instructions is very
important to ensure proper shaft function and a normal
service life.
• The complete drive shaft and joint should be handled
by getting hold of the interconnecting shaft to avoid dis-
assembly or potential damage to the drive shaft joints.
• Over-angling of joints beyond their capacity could re-
sult in boot or joint damage.
• Make sure surface-ground areas and splines of shaft
are protected during handling to avoid damage.
• Do not allow boots to come into contact with sharp
edges or hot engine and exhaust components.
• The drive shaft is not to be used as a lever arm to posi-
tion other suspension components.
• Never use a hammer or sharp tools to remove or to in- 2. Remove the large end of the boot from the CV joint
stall boot clamps. and slide the boot down the shaft.
• 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.
7.56
FINAL DRIVE
4. Place the drive shaft in a soft-jawed vise. Using a 7. Thoroughly clean the joint with an appropriate
soft-faced hammer, or brass drift, strike the inner solvent and dry the joint to prevent any residual
race of the joint to drive the joint off the drive shaft. solvent from being left in the joint upon reassembly.
Be sure to tap evenly around the joint to avoid
binding.
8. Visually inspect the joint by tilting the inner race to

one side to expose each ball. Severe pitting, galling,
play between the ball and its cage window, any
IMPORTANT cracking or damage to the cage, pitting or galling or
Tap on inner race only! chips in raceways call for joint replacement.
5. Make sure circlip w is on the shaft and not left in the

NOTE
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.
7
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 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
inner race. Pack the ball tracks and outer face flush
6. Remove the CV boot from the shaft. with grease. Place any remaining grease into the
boot.
CAUTION
CAUTION
Complete disassembly of the CV joint is NOT
recommended. The internal components are precision The grease provided in the replacement kit is specially
fit and develop their own characteristic wear patterns. formulated for wear resistance and durability. DO NOT
Intermixing the internal components could result in use substitutes or mix with other lubricants.
looseness, binding, and/or premature failure of the joint.
NOTE
IMPORTANT The amount of grease provided in the boot kit is pre-
If the grease in the joint is obviously contaminated with measured. Use entire contents of package.
water and/or dirt, the joint should be replaced.
7.57
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
sure the boot is not dimpled or collapsed. or
CV Boot Clamp Pliers: 8700226
18. Install and tighten the large clamp e using the
appropriate clamp tool.
INNER PLUNGING JOINT / BOOT
REPLACEMENT
1. Use a side cutters to cut and discard the boot clamps
q.

or
7.58
FINAL DRIVE
2. Remove the large end of the boot from the plunging 6. Remove the joint/cage from the shaft. Use a brass
joint and slide the boot down the shaft. drift on the inner race only.
3. Clean the grease from the face of the joint. NOTE

4. Remove the circlip w retaining the plunging joint.
The joint/cage asm will be held in place by a circlip e.
7. Remove the boot from the shaft.

IMPORTANT
If the grease in the joint is obviously contaminated with
water and/or dirt, the joint should be replaced.
8. Thoroughly clean the joint with an appropriate solvent

and dry the joint to prevent any residual solvent from
7
being left in the joint upon reassembly.
9. Visually inspect the joint for damage. Replace if
needed.
10. Clean the splines on the end of the shaft and apply a
light coat of grease prior to reassembly.
5. Remove the shaft and plunging joint from the
housing. 11. Slide the small boot clamp and boot (small end first)
onto the drive shaft and position the boot in its groove
machined in the shaft.
12. Install a new circlip on the end of the shaft.
13. Grease the joint with the special joint grease provided
in the boot replacement kit. Fill the cavity behind the
balls and the splined hole in the joint’s inner race.
Pack the ball tracks and outer face flush with grease.
Place any remaining grease into the boot.
CAUTION
The grease provided in the replacement kit is specially
formulated for wear resistance and durability. DO NOT
use substitutes or mix with other lubricants.
NOTE
The amount of grease provided in the boot kit is pre-
measured. Use entire contents of package.
7.59
FINAL DRIVE
14. Fully compress the joint and push the drive shaft 22. Position the boot lip in its groove. Install and tighten
firmly into the inner race. the small clamp t using the appropriate clamp tool.
15. Pull on the joint to test that the circlip is seated and
that the joint is securely fastened to the shaft.
16. Install the shaft/joint/cage asm into the housing.
17. Install the large circlip w and pull on the joint to
ensure the circlip is fully engaged.

or
18. Remove excess grease from the plunging joint’s

external surfaces and place the excess grease in the
boot.
19. Pull the boot over the joint and position the boot lips
into the grooves on the joint housing and shaft. Make
sure the boot is not dimpled or collapsed.
20. Install and tighten the large clamp r using the
appropriate clamp tool.
21. Pull out on the drive shaft to center the joint in the
housing. Slide a straight O-ring pick or a small slotted
screw driver between the large end of the boot and
the joint housing and lift up to equalize the air
pressure in the boot.
7.60
FINAL DRIVE
REAR PROPSHAFT
REMOVAL INSTALLATION
1. Locate the rear propshaft through the right rear 1. Apply anti-seize compound to all splines. Slide
wheel well. propshaft back onto the transmission output shaft,
and then lift it up and align it with the rear gearcase
input shaft coupler.
2. Install (4) new bolts and torque to specification.
TORQUE
18 ft. lbs (25 Nm)
NOTE
If needed, remove the right rear wheel to gain better
access to the rear propshaft bolts.
2. Remove the (4) bolts retaining the rear propshaft to

the rear gearcase input shaft coupler and discard the
bolts. 7
3. Slide the shaft towards the transmission and pivot

the propshaft down. Slide the propshaft off the
transmission output shaft and out from the vehicle.
7.61
FINAL DRIVE
REAR GEARCASE
GEARCASE REMOVAL 11. Remove the left rear suspension and drive shaft from
1. Position vehicle on a level surface and remove seat. the vehicle as an assembly.
2. Drain the rear gearcase lubricant.

3. Remove the rear cab.
4. Remove the left rear wheel, lower left-hand frame
support and outer PVT cover.
5. Remove the (4) bolts retaining the rear propshaft to
the rear gearcase input shaft.
12. Remove the through-bolt fastener retaining the right

rear upper A-arm to the bearing carrier. Pivot the
wheel hub and bearing carrier down to remove the
drive shaft from the gearcase.

7. Remove the drive belt, drive clutch and driven clutch.
8. Remove the stabilizer bar linkage rod and rotate the
stabilizer bar out of the way.
9. Remove upper shock mounting bolts from each side.
10. Remove the (3) through-bolt fasteners retaining the
left rear upper and lower A-arms to the frame.
NOTE
Take care not to stretch the brake line while removing
the drive shaft.
13. Remove the drive shaft from the rear gearcase by

pulling sharply.
7.62
FINAL DRIVE
14. Remove the (4) through-bolts retaining the rear 17. Using your hand, press down on the inner PVT cover
gearcase to the frame. and continue to rotate the gearcase down and
forward until it is removed from the frame.
15. Lift up on the gearcase and move it forward in the NOTE

frame. Do not use a pry bar to flex the inner PVT cover as
damage to the cover will occur.
18. Rotate the gearcase so the input shaft is facing down

and remove the rear gearcase from the vehicle.
16. Begin to rotate the gearcase down and remove the

vent line.
7.63
FINAL DRIVE
GEARCASE REMOVAL - TOURING 10. Remove the (3) through-bolt fasteners retaining the
1. Position the vehicle on a level surface, remove the left rear upper and lower A-arms to the frame.
passenger seat and driver’s seat.
2. Remove the (6) T40 Torx-headed screws retaining
the rear skid plate and remove the skid plate from
the frame.
3. Drain the rear gearcase lubricant.
CAUTION
5. Remove the (4) wheel nuts retaining each wheel and

remove both rear wheels.
11. Remove the left rear suspension and drive shaft from
6. Remove the (4) bolts retaining the rear propshaft. the vehicle as an assembly.

8. Remove the stabilizer bar linkage and rotate the
stabilizer bar back out of the way.
9. Remove the upper shock mounting bolts from each
side.
7.64
FINAL DRIVE
12. Remove the through-bolt fastener retaining the right 15. Move the gearcase forward in the frame and remove
rear upper A-arm to the bearing carrier. Pivot the the vent line from the gearcase.
wheel hub and bearing carrier down to remove the
drive shaft from the gearcase.
16. Using care, remove the rear gearcase through the

bottom of the frame.
NOTE NOTE
Take care not to stretch the brake line while removing Be sure to move the rear brake line out of the way upon
the drive shaft. removal to prevent from damaging it.
13. Remove the drive shaft from the rear gearcase by

pulling sharply.
14. Remove the (4) through-bolts retaining the rear
gearcase to the frame. 7
7.65
FINAL DRIVE
GEARCASE DISASSEMBLY AND 5. Inspect the ring gear teeth for chipped, worn, or
INSPECTION broken teeth.
NOTE
Pinion and ring gear shimming information is NOT
provided. The components are matched at the factory,
which requires special OEM tooling in order to properly
assemble and shim the gears.
In the event damage to the gears or housing requires

replacement, the entire assembly must be replaced.
1. Drain and properly dispose of used gearcase

lubricant.
2. Remove the (8) screws from the rear gearcase
cover.
6. Inspect the pinion shaft by rotating the assembly in

the gearcase housing while checking for any
looseness or roughness. Inspect the pinion gear
teeth for chipped, worn, or broken teeth.
3. Lift the gearcase cover off the main gearcase half

and note the shim between the cover and the ring
gear.
4. Remove the ring gear from the main gearcase half.
NOTE
In the event damage to the gears or housing requires
replacement, the entire assembly must be replaced.
7. Inspect the gearcase bearings and seals. Proceed to

“Gearcase Bearing and Seal Replacement” if
components require service. Gearcase Bearing and
Seal Replacement, page 7.67
7.66
FINAL DRIVE
GEARCASE BEARING AND SEAL 3. Remove the seal above the pinion shaft using a seal
REPLACEMENT puller or other suitable method (see Figure 8-27).
NOTE
If the gearcase is assembled, perform the “Gearcase
Disassembly and Inspection” procedure.
1. Remove the nut and lock washer from the pinion

shaft (if necessary, hold the coupler in a vise to
remove the nut).
4. Remove the retaining ring and lift the pinion shaft

and bearing from the main gearcase (see Figure 8-
27).
NOTE
If the pinion shaft will not lift out of the gearcase,
reinstall the coupler and finger tighten the retaining nut.
Use two pry bars to lift the pinion shaft assembly out.
2. Remove the coupler from the pinion shaft by using
two pry bars in the areas shown. If the coupler is 5. Support the pinion shaft and press the bearing off the
difficult to remove, use a universal bolt-grip puller to shaft (see Figure 8-27). 7
prevent any damage. 6. Thoroughly clean the pinion shaft.
WARNING
Wear appropriate safety equipment while installing
bearings to reduce the risk of injury.
7. Support the pinion shaft and carefully press the new

bearing on the shaft and install a new O-ring (see
Figure 8-27).
NOTE
Carefully inspect the pinion shaft gear before replacing
the bearing. If the gear teeth are damaged, the shaft
must be replaced as an assembly.
7.67
FINAL DRIVE
8. Remove the seals from each case half using a seal 12. Install the seals into the case halves using a
puller or other suitable method (see Figure 8-28). standard seal installer or other suitable method. Seal
depth should be approximately .110 in. (2.79 mm)
from the main surface.
9. Support the gearcase cover and press the bearing 13. Install pinion shaft and a new retaining ring. Install
out. Repeat this procedure on the main gearcase the retaining ring with the straight edge facing the
half, unless the bearing came out with the ring gear bearing.
(see Figure 8-28).
NOTE
If the main gearcase bearing is installed on the ring
gear, heat the bearing to remove it.
10. Thoroughly clean the gearcase halves.
WARNING
Wear appropriate safety equipment while installing
bearings to reduce the risk of injury.
11. Support the gearcase cover and carefully press in

the new cover bearing (see Figure 8-28). Support the
ring gear and carefully press on the new main
gearcase bearing.
7.68
FINAL DRIVE
14. Install the seal into the main gearcase half using a 7. Install the cover screws and torque to specification.
standard seal installer or other suitable method.
Press seal into the gearcase until it bottoms out in
the housing.
TORQUE
Cover Screws:
GEARCASE ASSEMBLY
18 ft. lbs (25 Nm)
1. Grease all seals with Polaris All Season Grease
(PN 2871322) upon assembly to prevent from
8. Proceed to “Gearcase Installation” before installing
damaging seals.
the coupler, lock washer and retaining nut. Doing so
2. Install the ring gear into the main gearcase. will allow you to properly torque the coupler retaining
nut. See: Gearcase Installation (XP Models), page
3. Install the shim previously removed onto the ring
gear.
7.71 or Gearcase Installation (TOURING Models),
page 7.73
7
4. Thoroughly clean the gearcase mating surfaces and

be sure the alignment pins are in place.
5. Apply Crankcase Sealant (PN 2871557) to mating
surfaces.
6. Install the gearcase cover onto the main gearcase
half.
7.69
FINAL DRIVE
REAR GEARCASE ASSEMBLY VIEW
REF# DESCRIPTION QTY REF# DESCRIPTION QTY

1 Fill Plug with O-ring 1 11 Ball Bearing 2
2 Drain Plug with O-ring, Magnetic 1 12 Main Case, Machined 1
3 Screw 8 13 Cover, Machined 1
4 Nut 1 14 Pinion Shaft, 10T Straight Bevel 1
5 Lock Washer 1 15 Ring Gear, 37T Straight Bevel 1
6 Dowel Pin 2 16 Vent Tube 1
7 Retaining Ring 1 17 Coupler 1
8 Shim 1 18 Triple Lip Seal 2
9 Needle Bearing 1 19 Triple Lip Seal 1
10 Ball Bearing 1 20 O-Ring 1
7.70
FINAL DRIVE
REAR GEARCASE INSTALLATION 5. Inspect the inner PVT cover for any signs of damage
1. Place the gearcase in the frame as shown by starting caused during removal or installation. If any burs are
the lower portion first. present, carefully clean them up with a flat hand file.
2. Using your hand, press down on the inner PVT cover

and position the gearcase back into the frame while
taking care not to damage the inner PVT cover.
6. Continue the installation procedure by reversing the

“Gearcase Removal” procedure at the beginning of
this section. Refer to the following installation steps
NOTE for torque specifications. Gearcase Removal (XP
Models), page 7.62
Do not use a pry bar to flex the inner PVT cover as
damage to the cover will occur. 7. Install the gearcase through-bolt mounting fasteners
3. Continue to position the gearcase back into the
frame until the top portion clears the frame. NOTE
Use the longer bolts (150 mm) in the top and the 7
shorter bolts (125 mm) in the bottom.
TORQUE
Gearcase Mounting Fasteners:
40 ft. lbs (54 Nm)
8. Install the right rear drive shaft into the gearcase and
the upper A-arm onto the bearing carrier. Torque the
bearing carrier through-bolt fastener to specification.
TORQUE
Rear Upper A-arm to Bearing Carrier:
37 ft. lbs (50 Nm)
4. Position the gearcase in the frame and align the 9. Install the left rear drive shaft and suspension
mounting holes of the gearcase to those in the assembly. Torque the upper and lower A-arms to
frame. specification.
TORQUE
Rear Upper & Lower A-arms to Frame:
37 ft. lbs (50 Nm)
7.71
FINAL DRIVE
10. Install the rear upper shock through-bolts. Torque 17. Install the rear wheels and torque wheel nuts to
bolts to specification. specification (see Page 8.2).
TORQUE TORQUE
Rear Upper Shock Bolts: Wheel Nuts:
37 ft. lbs (50 Nm) Steel Wheels: 45 ft. lbs (61 Nm)
11. Install the rear stabilizer bar onto the linkage rods.
Torque the linkage retaining nuts to specification. 18. Add Polaris ATV Angle Drive Fluid to rear gearcase.
Torque drain and fill plugs to specification.
TORQUE
Stabilizer Bar Linkage Bolts: FLUID CAPACITY
37 ft. lbs (50 Nm) Rear Gearcase Capacity:
7.1 fl. oz. (210 ml) or to bottom of fill plug hole threads
12. Install the propshaft coupler onto the rear gearcase
pinion shaft splines. Install the lock washer and
retaining nut. TORQUE
Drain / Fill Plug:
NOTE 14 ft. lbs (19 Nm)
Orient the lock washer as shown with the tooth surfaces
contacting the nut and coupler.
13. Lock the brake lever and torque the propshaft

coupler retaining nut to specification.
TORQUE
Coupler Retaining Nut:
100 ft. lbs (136 Nm)
14. Install the rear propshaft and torque bolts to

specification.
TORQUE
18 ft. lbs (25 Nm)
15. Install the drive clutch, driven clutch and drive belt.
16. Install the outer PVT cover, lower left-hand frame
support and the left rear wheel.
7.72
FINAL DRIVE
REAR GEARCASE INSTALLATION - 7. Install the propshaft coupler onto the rear gearcase
TOURING pinion shaft splines. Install the lock washer and
retaining nut.
1. Install the rear gearcase by reversing the “Gearcase
Removal” procedure at the beginning of this section. NOTE
Refer to the following installation steps for torque
specifications. Gearcase Removal (TOURING Orient the lock washer as shown with the tooth surfaces
Models), page 7.64 contacting the nut and coupler.
2. Install the gearcase through-bolt mounting fasteners

NOTE
Use the longer bolts (150 mm) in the top and the
shorter bolts (125 mm) in the bottom.
TORQUE
Gearcase Mounting Fasteners:
40 ft. lbs (54 Nm)
3. Install the right rear drive shaft into the gearcase and 8. Lock the brake lever and torque the propshaft
the upper A-arm onto the bearing carrier. Torque the coupler retaining nut to specification.
bearing carrier through-bolt fastener to specification.
TORQUE
TORQUE Coupler Retaining Nut:
Rear Upper A-arm to Bearing Carrier: 100 ft. lbs (136 Nm)
37 ft. lbs (50 Nm)
9. Install the rear propshaft and torque bolts to
4. Install the left rear drive shaft and suspension
assembly. Torque the upper and lower A-arms to
specification. 7
specification. TORQUE
TORQUE 18 ft. lbs (25 Nm)
Rear Upper & Lower A-arms to Frame:
37 ft. lbs (50 Nm) 10. Install the rear wheels and torque wheel nuts to
specification.
5. Install the rear upper shock through-bolts. Torque 11. Add Polaris ATV Angle Drive Fluid to the rear
bolts to specification. gearcase. Torque drain and fill plugs to specification.
TORQUE FLUID CAPACITY
Rear Upper Shock Bolts: Rear Gearcase Capacity:
30 ft-lbs (54 Nm) 7.1 fl. oz. (210 ml) or to bottom of fill plug hole threads
6. Install the rear stabilizer bar onto the linkage rods.

Torque the linkage retaining nuts to specification. TORQUE
TORQUE Drain / Fill Plug:
14 ft. lbs (19 Nm)
Stabilizer Bar Linkage Bolts:
37 ft. lbs (50 Nm)
7.73
FINAL DRIVE
NOTES
7.74
CHAPTER 8
HANDLEBAR REMOVAL / REPLACMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
REMOVAL / REPLACEMENT (SPORTSMAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
STEERING - NON-EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
STEERING ASSEMBLY VIEW - NON-EPS MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
STEERING POST REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
STEERING POST INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
STEERING - EPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
STEERING ASSEMBLY VIEW - EPS MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
UPPER STEERING POST REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.10
UPPER STEERING POST INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.10
EPS UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
EPS UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.12
EPS UNIT REMOVAL (HIGHLIFTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.13
EPS UNIT INSTALLATION (HIGHLIFTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.14
STEERING TIE RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.16
TIE ROD / TIE ROD END REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.16
FRONT CONTROL ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.17
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.17
REMOVAL / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.18
BALL JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.20
8
SERVICE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.20
TO SERVICE THE UPPER BALL JOINT: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.20
TO SERVICE THE LOWER BALL JOINT:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.20
BALL JOINT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.20
BALL JOINT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.21
REAR CONTROLS ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.23
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.24
REAR STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.26
ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.26
LINKAGE REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.27
STABILIZER BAR REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.27
SHOCKS / SPRINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.29
SHOCK EXPLODED VIEW - BASE MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.29
SHOCK REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.29
SHOCK / SPRING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.29
SHOCK REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.30
SHOCK REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.30
8.1
FOX™ SHOCK SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.31

7044135 SHOCK ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.31
7044080 / 7044081 SHOCK ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.32
7044135 SHOCK SERVICE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.33
7044080 / 7044081 SHOCK SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.33
GENERAL SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.34
FOX™ SHOCK REBUILD INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.34
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.34
FOX™ SHOCK DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.34
FOX™ SHOCK BODY AND RESERVOIR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.36
FOX™ SHOCK COMPONENT REBUILD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.36
FOX™ SHOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.38
8.2
GENERAL INFORMATION
HANDLEBAR REMOVAL / REPLACMENT
REMOVAL / REPLACEMENT (SPORTSMAN) INSTALLATION
1. Remove the upper and lower headlight pods from 1. Locate the alignment pin on the bottom side of the
the handlebar bracket. upper block. The pin should line up with the
alignment hole in the lower block and should face the
NOTE front.
It is recommended to take a photo prior to disassembly
to note the routing of lines, wires and cables upon
reassembly. Take note of vent line, wire harness and
throttle cable routing for reassembly purposes.
2. Mark the handlebar and block for proper positioning

upon reassembly.
3. Remove the (4) fasteners retaining the handlebar
bracket and block to the steering post.
4. Remove the handlebar assembly from the steering 8

post.
2. Position handlebar properly and install the (4) bolts.
NOTE 3. Evenly tighten the pin side (front) bolts first. Torque
Take care not to bend the throttle cable or brake line the (2) front bolts to specification.
while the handlebar is removed.
TORQUE
5. If replacing the handlebar: Handlebar Bolts:
• Remove the RH and LH controls 14 ft. lbs (19 Nm)
• Remove the hand grips
• Pry open the upper and lower handlebar blocks and 4. Install the rear bolts and tighten evenly. Torque the
remove them from the handlebar (2) rear bolts to specification.
NOTE
There will be a slight gap on the backside of the
handlebar blocks after installation.
5. If handlebar was replaced:

• Install the hand grips
• Install the RH and LH controls
8.3
6. Reassemble the headlight pod.
NOTE
Make sure to route all vent lines, wire harness and
throttle cable correctly into the lower headlight pod.
8.4
STEERING - NON-EPS
STEERING ASSEMBLY VIEW - NON-EPS MODELS
STEERING ASSEMBLY VIEW - NON-EPS

q Tie Rod Assembly Jam Nut Torque: 12 ft-lbs (16 Nm)
w Cotter Pin Replace with new when removed.
e Tie Rod Flange Nuts 42 ft-lbs (57 Nm)
r Washers
t Flange Nuts 18 ft-lbs (24 Nm)
y Upper Steering Bushings
u Upper Steering Bracket
i Carriage Bolts
o Flange Bolts Front Gearcase Bolts: 18 ft-lbs (24 Nm)
a Steering Post Assembly Bearing not serviceable.
8.5
STEERING POST REMOVAL 6. Remove the (2) bolts retaining the lower steering
1. Remove front rack and front cover. post bracket to the front gearcase.
2. Remove the headlight pods from the handlebar

bracket.
NOTE
Take note of all vent line, wire harness and throttle
cable routing for reassembly purposes.
3. Remove the fasteners retaining the handlebar

7. Remove the bolts and flange nuts retaining the

steering post assembly plate to both sides of the
frame.
4. Carefully remove the handlebar assembly from the

steering post and place it on the front cab.
NOTE
Take care not to bend the throttle cable or brake line
8. Remove the (2) fasteners retaining the upper
steering post bushing bracket.
from each tie rod end at the steering post frog..
9. Lift the steering post assembly up from the front

gearcase and carefully remove it from the chassis.
8.6
STEERING POST INSTALLATION

1. Reverse the “Steering Post Removal” procedure to
reinstall the steering post. See:
NOTE
2. When installing the headlight, be sure to install the

O-rings q prior to installing the headlight.
3. Place the headlight into the bracket mounting tabs
and press firmly until the headlight snaps into place.
4. Lift the O-ring up and over the headlight mounting
tab to secure it.
5. Reinstall the adjustment screw w and be sure to

adjust the upper headlight after reassembly.
8.7
STEERING - EPS
STEERING ASSEMBLY VIEW - EPS MODELS
8.8
STEERING ASSEMBLY VIEW - EPS

q Tie Rod Assembly
w Upper Steering Post
e Rod End
r Jam Nut 12 ft-lbs (16 Nm)
t Tie Rod
y Jam Nut 12 ft-lbs (16 Nm)
u Rod End
i Washers
o Cotter Pin Replace with new when removed.
a Flange Nuts 42 ft-lbs (57 Nm)
s Upper Steering Bracket
d Upper Steering Bushings
f Carriage Bolts
g Flange Nuts 20 ft-lbs (27 Nm)
h Bolts Front Gearcase Bolts: 18 ft-lbs (24 Nm)
j Lower Steering Post Assembly Not Serviceable.
k Power Steering Unit
l Power Steering Bracket
1( Flange Nuts 20 ft-lbs (27 Nm)
2) Bolts
2! Bolts
8.9
UPPER STEERING POST REMOVAL 7. Remove the (2) fasteners retaining the upper
1. Remove front rack and front cover. steering post bushing bracket.
2. Remove the upper and lower headlight pods from

the handlebar bracket.
NOTE
Take note of all vent line, wire harness and throttle
cable routing for reassembly purposes.
3. Remove the fasteners retaining the handlebar

8. Lift the upper steering post up from the power

steering unit remove it from the chassis.
UPPER STEERING POST INSTALLATION

1. Reverse the “Upper Steering Post Removal”
procedure to reinstall the steering post.
2. Apply anti-seize to the shaft splines to aid assembly.
3. Align the mark on the upper steering post (nut side)
with the skip tooth spline on the upper power
steering shaft upon installation.
4. Carefully remove the handlebar assembly from the
steering post and place it on the front cab. 4. Carefully slide the upper steering post onto the upper
power steering shaft and install the pinch bolts.
NOTE
Take care not to bend the throttle cable or brake line
5. Disconnect and remove the battery to access the

upper steering post pinch bolts. See: Battery
Removal (Non-High Lifter), page 11.73
6. Remove the pinch bolts retaining the upper steering
post to the power steering unit.
CAUTION
Striking the steering post can permanently damage the
EPS unit and cause a Power Steering Fault.
8.10
5. Refer to “Steering Exploded View (EPS Models)”. 7. Remove the (2) fasteners retaining the upper
See: steering post bushing bracket.
TORQUE
Upper Steering Post Pinch Bolts:
14 ft. lbs (19 Nm)
NOTE
EPS UNIT REMOVAL

1. Remove the front rack or front storage box and front
cover.
2. Remove the right front wheel and shock assembly. steering unit.
3. Remove both front mud guards, upper side panels, 9. Remove the lower steering post pinch bolt and nut.
front cab and right-hand footwell.
4. Remove the fuel tank.
post to the power steering unit.
8
10. Remove the mounting fasteners and nuts that retain
the power steering unit and mount plate to the frame.
6. Disconnect the (2) electrical harnesses from the

power steering unit.
11. Carefully lift the power steering unit up to disengage

the lower steering coupler and remove it from the
chassis.
8.11
EPS UNIT INSTALLATION 8. Position the upper steering post on the shaft so the
1. Position the vehicle so the front hubs/brake discs are pinch bolts are aligned with the recess in the power
pointing straight forward. steering shaft.
2. Clean the lower steering post so the alignment mark

is visible. Mark the skip tooth spline on the lower
power steering shaft.
4. Align the two marks and install the power steering
unit onto the lower steering post assembly.
CAUTION
• q Upper Steering Post
• w Lower Steering Post Striking the steering post can permanently damage the
• e Power Steering Unit EPS unit and cause a Power Steering Fault.
• A = Alignment Marks (Skip Tooth)
5. Install the (4) mount plate fasteners by hand, but do 9. Install the pinch bolts and torque to specification.
not torque fasteners at this time. Refer to “Steering Exploded View (EPS Models)”.
6. Reconnect the (2) electrical harnesses to the power TORQUE

steering unit. Upper / Lower Steering Post Pinch Bolts:
7. Align the mark on the upper steering post (nut side) 14 ft. lbs (19 Nm)
with the skip tooth spline on the upper power
steering shaft upon installation. 10. Torque the power steering mount plate fasteners to
specification. Refer to “Steering Exploded View (EPS
Models)”.
11. Install the fuel tank assembly, fuel line and reconnect
the fuel pump harness.
NOTE
Apply anti-seize to the shaft splines to aid assembly.
8.12
12. Reinstall the upper steering post bushing bracket 2. Remove six screws holding on the front cover.
and torque the (2) fasteners to specification. 3. Disconnect both fans and remove the radiator cover.
4. Remove both fuel tank guards.
5. Remove seat and side panels.
6. Remove cover on front side of upper steering shaft.
7. Remove front cab.
9. Remove fuel tank.
NOTE

post to the power steering unit and remove upper
steering shaft from EPS unit.
TORQUE
Steering Post to Bulkhead Bolts:
18 ft. lbs (24 Nm)
13. Reinstall the right front shock and wheel. Torque

shock fasteners and wheel lug nuts to specification.
TORQUE
Shock Bolts:
37 ft. lbs (50 Nm)
TORQUE
Wheel Nuts:
Aluminum Wheels: 75 ft. lbs (102 Nm) 8
11. Remove the (2) fasteners retaining the upper steering
14. Place the vehicle on the ground. post bushing bracket.
15. Turn the ignition key to the “ON” position and move
the handlebar from left to right several times to
ensure the power steering doesn’t bind. If binding
occurs:
• Loosen the (4) mounting fasteners
• Move handlebars from left to right several times to
position the power steering unit
• Torque the (4) mounting fasteners to specification.
Refer to “Steering Exploded View (EPS Models)”. See:
• Check the steering operation for binding again
• If no binding is present, proceed; if binding is still
present, repeat this procedure
16. Install front mud guards, upper side panels, front cab
(if removed) and right-hand footwell.
17. Install the front rack cover. 12. Disconnect two EPS wiring harnesses.
EPS UNIT REMOVAL (HIGHLIFTER) steering unit.
1. Remove the fan/snorkel cover (lock and ride

fasteners)
8.13
14. Remove the lower steering post pinch bolt and nut. 4. Align the two marks and install the power steering
unit onto the lower steering post assembly.
15. Remove the mounting fasteners and nuts that retain

the power steering unit and mount plate to the frame. • q Upper Steering Post
• w Lower Steering Post
• e Power Steering Unit
• A = Alignment Marks (Skip Tooth)
5. Install the (4) mount plate fasteners by hand, but do
not torque fasteners at this time.
6. Reconnect the (2) electrical harnesses to the power
steering unit.
7. Align the mark on the upper steering post (nut side)
with the skip tooth spline on the upper power steering
shaft upon installation.
16. Carefully lift the power steering unit up to disengage

the lower steering coupler and remove it from the
chassis.
EPS UNIT INSTALLATION (HIGHLIFTER)

1. Position the vehicle so the front hubs/brake discs are
pointing straight forward.
2. Clean the lower steering post so the alignment mark
is visible. Mark the skip tooth spline on the lower
power steering shaft.
NOTE
Apply anti-seize to the shaft splines to aid assembly.
CAUTION
Striking the steering post can permanently damage the
EPS unit and cause a Power Steering Fault.
8.14
8. Position the upper steering post on the shaft so the TORQUE

pinch bolts are aligned with the recess in the power
steering shaft. Steering Post to Bulkhead Bolts:
18 ft. lbs (24 Nm)
13. Turn the ignition key to the “ON” position and move
the handlebar from left to right several times to
ensure the power steering doesn’t bind. If binding
occurs:
• Loosen the (4) mounting fasteners
9. Install the pinch bolts and torque to specification. • Move handlebars from left to right several times to
Refer to “Steering Exploded View (EPS Models)”. position the power steering unit
• Torque the (4) mounting fasteners to specification.
TORQUE Refer to “Steering Exploded View (EPS Models)”.
See:
Upper / Lower Steering Post Pinch Bolts: • Check the steering operation for binding again
14 ft. lbs (19 Nm) • If no binding is present, proceed; if binding is still
present, repeat this procedure
10. Torque the power steering mount plate fasteners to 14. Install the front cab.
specification. Refer to “Steering Exploded View (EPS 15. Install the cover on front side of upper steering shaft.
8
Models)”.
16. Install the seat and side panels.
11. Install the fuel tank assembly, fuel line and reconnect
the fuel pump harness. 17. Install the fuel tank guards.
18. Connect both fans and install the radiator cover.
NOTE
19. Install the six screws holding on the front cover.
20. Install the fan/snorkel cover (lock and ride fasteners)
12. Reinstall the upper steering post bushing bracket and

torque the (2) fasteners to specification.
8.15
STEERING TIE RODS

TIE ROD / TIE ROD END REPLACEMENT • If replacing just the tie rod end, loosen the jam nut and
Use the following procedure to replace the tie rod remove the rod end
assembly or tie rod ends. • Install new rod end and torque jam nuts to
specification
1. Elevate front of vehicle and safely support machine
under the frame area. TORQUE
Tie Rod Jam Nuts:
CAUTION
14 ft-lbs (19 Nm)
procedure. Always wear eye protection. 5. Install the new tie rod assembly q.
6. Install the rod ends and fasteners in the proper
2. Remove the wheel nuts and the front wheel(s). orientation (see illustration).
3. Remove cotter pins w and tie rod end fasteners e. 7. Torque the tie rod end fasteners to specification and
4. Remove the tie rod assembly q. install new cotter pins.
TORQUE
42 ft-lbs (57 Nm)
8. Install the front wheel (s) and wheel nuts. Torque

TORQUE
Wheel Nuts:
Steel Wheel: 45 ft. lbs (61 Nm)
Aluminum Wheel: 75 ft. lbs (102 Nm)
9. Check wheel toe alignment and adjust as necessary.
• q Tie Rod Assembly

• w Cotter Pin - Replace with new when removed.
• e Flange Nuts - Replace with new when removed.
• r Washers
• t Steering Post
• y Bearing Carrier
8.16
FRONT CONTROL ARMS

EXPLODED VIEW
NOTE 8
Image for Reference Only

1 Upper A-arm
2 Lower A-arm
3 Retaining Ring
4 Ball Joint
5 Nut 28 ft-lbs
6 Bolt Replace if loosened or removed.
7 Grease Fitting
8 Bushing
9 Pivot Shaft
10 Bolt
11 Nut 37 ft-lbs
12 CV Shield
13 Screw
14 Washer
15 Steering Knuckle
8.17
REMOVAL / REPLACEMENT 7. Examine A-arm bushings and pivot shafts. Replace if

The following procedure details upper and lower A-arm worn and discard the hardware.
removal and replacement on one side of the vehicle.
CAUTION
1. Elevate and safely support the front of the vehicle
The locking agent on the existing bolts was destroyed
and remove the front wheel.
during removal. DO NOT reuse old hardware. Serious
2. Remove the lower shock fastener from upper A-arm. 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 shafts.
9. Install new ball joint into A-arm. Refer to “Ball Joint
Replacement” section., page 8.21
10. Insert new bushings and pivot shafts into new A-arm.
11. Install new upper A-arm assembly onto vehicle
frame. Torque new bolts to specification.
TORQUE
42 ft. lbs (58 Nm)
3. Remove the upper ball joint pinch bolt from the front 12. Insert upper A-arm ball joint end into bearing carrier.
bearing carrier (see Figure 10-2). Install new pinch bolt and fastener hardware. Torque
new pinch bolt to specification.
TORQUE
New Pinch Bolt:
17 ft. lbs (24 Nm) Plus 90 Degrees
13. Attach shock to A-arm with new fastener. Torque

lower shock bolt to specification.
TORQUE
A-Arm Fastener:
37 ft. lbs (50 Nm)
14. Remove the lower ball joint pinch bolt from the front
bearing carrier (see Figure 10-2).
15. Using a soft face hammer, tap on bearing carrier to
loosen the lower A-arm ball joint end while pushing
downward on the lower A-arm. Completely remove
the ball joint end from the bearing carrier.
4. Remove the brake line retainer from the upper A-
16. Remove the lower A-arm through-bolt fasteners and
arm.
remove the lower A-arm from the vehicle.
5. Using a soft face hammer, tap on bearing carrier to
17. Examine A-arm bushings and pivot shafts. Replace if
loosen the upper ball joint end while lifting upward on
worn and discard the hardware.
the upper A-arm. Completely remove the ball joint
end from the bearing carrier. 18. If not replacing the A-arm, thoroughly clean the A-
arm and pivot shafts.
6. Remove the upper A-arm through-bolt fasteners and
remove A-arm from vehicle. 19. Install new ball joint into A-arm. Refer to “Ball Joint
Replacement” section.
20. Insert new bushings and pivot shafts into new A-arm.
8.18
21. Install new lower A-arm assembly onto vehicle

frame. Torque new bolts to specification.
TORQUE
A-Arm Assembly Bolts:
37 ft. lbs (50 Nm)
22. Insert lower A-arm ball joint end into bearing carrier.
Install new pinch bolt and fastener hardware. Torque
new pinch bolt to specification.
TORQUE
New Pinch Bolt Fastener:
23. Grease all (4) A-arm grease fittings after reassembly.
CAUTION
Upon A-arm installation completion, test vehicle at low
speeds before putting into service.
8.19
BALL JOINT SERVICE

SERVICE PREPARATION BALL JOINT REMOVAL
Service Preparation 1. Remove the retaining ring from the ball joint.
NOTE
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 tool PU-50506 will allow the upper and lower
ball joints to be replaced with the A-arm installed on the
vehicle.
2. Install Spacer q over the top of the ball joint face.
1. Properly lift and support the vehicle by the frame.

2. Remove the appropriate front wheel.
TO SERVICE THE UPPER BALL JOINT:
1. Remove and discard the two front brake caliper 3. Place Removal Adaptor w over the ball joint shaft.
mounting bolts and remove the caliper from the brake
disc. 4. Install the Press Asm. e onto the A-arm to engage
the ball joint Removal Adapter.
2. Remove and discard the upper ball joint pinch bolt.
3. If necessary, remove the lower front shock fastener NOTE
from the A-arm to gain enough clearance to install Be sure the Press Asm. opening is only contacting the
ball joint tool (PU-50506) on the upper ball joint. Spacer q and not the ball joint face.
TO SERVICE THE LOWER BALL JOINT:
1. Remove and discard the lower ball joint pinch bolt.
2. If necessary, remove the lower front shock fastener
from the A-arm to gain enough clearance to install
ball joint tool (PU-50506) on the lower ball joint.
8.20
5. Tighten the Press Asm. screw and fully remove the 5. Tighten the Press Asm. screw and fully install the
ball joint from the A-arm. ball joint into the arm.
BALL JOINT INSTALLATION 6. After the new ball joint is fully installed into the A-
1. By hand, install the NEW ball joint into the A-arm. arm, install a new retaining ring.
2. Position the Installation Adapter (D) over the face of
the ball joint.
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
3. Position the Spacer (A) over the shaft of the ball joint bearing carrier. Install new pinch bolts and nuts.
so it is against the A-arm. Torque to specification.
4. Install the Press Asm. (C) onto the A-arm to engage TORQUE
the Installation Adapter and Spacer. Front Ball Joint Pinch Bolts (upper and lower):
TORQUE
Front Shock Mounting Bolts:
37 ft. lbs (50 Nm)
8.21
9. If needed, install new brake caliper mounting bolts

CAUTION
TORQUE
Front Caliper Mounting Bolts:
37 ft. lbs (50 Nm)
10. Install wheel and (4) wheel nuts. Torque wheel nuts
to specification.
TORQUE
Wheel Nuts:
Steel Wheel: 45 ft. lbs (61 Nm)
Aluminum Wheel: 75 ft. lbs (102 Nm)
8.22
REAR CONTROLS ARMS

EXPLODED VIEW
NOTE
Image for reference only.
8
1 Bolt
2 Nut 37 ft-lbs (50 Nm)
3 Bushing, LCA
4 Upper A-arm
5 Grease Fitting
6 Pivot Shaft
7 Bolt
8 Lower A-arm
9 Bolt
10 Pivot Shaft, Upper
11 Pivot Shaft, Lower
12 Bushing, Lower
13 Pivot Tube
14 Bushing, UCA
15 Bolt
16 Bushing, Upper
17 90 ° Grease Zerk
18 Bearing Carrier
8.23
REMOVAL 10. Remove the fastener retaining the stabilizer linkage

The following procedure details upper and lower A-arm to the lower A-arm.
removal and replacement on one side of the vehicle.
1. Elevate and safely support the rear of the vehicle
and remove the rear wheel.
Upper A-arm Removal
2. Remove the through-bolt fastener attaching the
upper A-arm to the bearing carrier.
3. Remove the through-bolt fastener attaching the
upper A-arm to the frame. Remove A-arm from the
vehicle.
4. Examine A-arm and bearing carrier bushings and
pivot shafts. Replace if worn and discard the
hardware.
CAUTION
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.
11. Remove through-bolt fasteners attaching lower A-
5. If not replacing the A-arm, thoroughly clean the a- arm to the frame and remove the A-arm from the
arm and pivot shafts. vehicle.
6. Insert new bushings and pivot shafts into new A-arm. 12. Examine A-arm, bearing carrier bushings and pivot
shafts. Replace if worn and discard the hardware.
Lower A-arm Removal
13. If not replacing the A-arm, thoroughly clean A-arm
7. Remove the through-bolt fastener attaching the and pivot shafts. Insert new bushings and pivot
lower A-arm to the bearing carrier. shafts into the A-arm.
8. Remove the lower shock fastener from lower A-arm.
INSTALLATION
1. Install upper and lower A-arm assemblies onto the
vehicle. Torque new fasteners to specification.
TORQUE
New Fasteners:
37 ft-lbs (50 Nm)
2. Grease all (3) A-arm grease fittings after reassembly.

3. Attach lower A-arm to bearing carrier. Torque new
fastener to specification.
TORQUE
New Fastener:
37 ft-lbs (50 Nm)
4. Attach upper A-arm to bearing carrier. Torque new

fasteners to specification. Grease both rear bearing
carrier fittings after reassembly.
9. Remove the brake line retainer from the lower A-arm TORQUE
(if applicable).
New Fasteners:
37 ft-lbs (50 Nm)
8.24
5. Route brake line on top of lower A-arm and install

retainer (if applicable).
6. Reinstall lower portion of shock and lower portion of
stabilizer linkage to the lower A-arm. Torque shock
mounting fastener (see Figure 10-19) to
specification. Torque linkage fastener to
specification.
TORQUE
Shock Mounting Fastener:
37 ft-lbs (50 Nm)
Linkage Fastener:
37 ft-lbs (50 Nm))
7. Install the wheel and torque wheel hub retaining nuts

to specification.
TORQUE
Wheel Hub Retaining Nuts:
80 ft. lbs. (108 Nm)
CAUTION
Upon A-arm installation completion, test vehicle at low
speeds before putting into service.
8.25
REAR STABILIZER BAR

ASSEMBLY VIEW
REF. DESCRIPTION NOTE

1 Bolt
2 Stabilizer Bar Bracket
3 Upper Bushings
4 Nut Torque: 20 ft-lbs (27 Nm)
5 Stabilizer Bar
6 Bushing
7 Linkage
8 Lower Bushings
9 Bolts Torque: 37 ft-lbs (50 Nm)
8.26
LINKAGE REMOVAL / INSTALLATION STABILIZER BAR REMOVAL /

1. Remove the upper linkage bushing from each side. INSTALLATION
Using an 5/16” open-end wrench, hold the linkage 1. Elevate the rear of vehicle and safely support
rod and remove the lower linkage bushing. machine under the frame area.
CAUTION
2. Remove the upper linkage bushing from each side

and rotate the stabilizer bar up.
2. Rotate the stabilizer bar up and remove the stabilizer

linkage from the lower A-arm. Repeat this procedure
if removing or replacing the other linkage.
3. Reverse this procedure to reinstall the stabilizer
linkage. Torque fasteners to specification.
TORQUE
Rear Stabilizer Linkage Nuts
37 ft. lbs (50 Nm) 3. Remove the (2) fasteners from each stabilizer bar
bracket retaining the stabilizer bar to the frame.
TORQUE
Rear Stabilizer Bracket Fasteners
8
37 ft. lbs (50 Nm)
8.27
4. Remove upper shock mounting fastener from the

right rear shock and swing the shock out from the
frame.
5. Carefully remove the stabilizer bar from the frame.
6. Inspect the stabilizer bar for straightness. Inspect the

bushings and replace if needed. Inspect the rubber
stabilizer linkage bushings and replace if needed.
7. Reverse this procedure to reinstall the stabilizer bar.
Refer to the “Exploded View” for torque values.
8.28
SHOCKS / SPRINGS
SHOCK EXPLODED VIEW - BASE MODEL 2. Remove the spring and adjusting cam from the
existing shock and install components onto the new
shock.
3. Compress the shock spring and install the spring
retainer.
4. Reinstall the shock onto the vehicle and torque new
fasteners to specification.
TORQUE
Shock Mounting Bolts:
37 ft-lbs (50 Nm)
SHOCK REMOVAL / INSTALLATION

1. Elevate the vehicle off the ground to relieve the
suspension load.
2. Remove the upper and lower fasteners retaining the
shock and remove the shock from the vehicle.
3. Reverse the procedure to reinstall the shock. Torque
new fasteners to specification.
TORQUE 8
37 ft-lbs (50 Nm)
SHOCK / SPRING REPLACEMENT

1. Using a spring compressor, compress the shock
spring far enough to remove the spring retainer.
8.29
SHOCK REMOVAL / INSTALLATION

1. Elevate the vehicle off the ground to relieve the
suspension load.
2. Support under A-arm or trailing arm.
3. Remove the upper and lower fasteners retaining the
shock and remove the shock from the vehicle.
Discard nuts and replace with new upon installation.
4. Reverse the procedure to reinstall the shock. Torque
new fasteners to specification.
TORQUE
Front: 37 ft-lbs (50 Nm)
SHOCK REPLACEMENT
1. Remove the shock and note the spring preload
distance.
2. Loosen the jam nut (if applicable) and adjustment
ring until the spring is loose. If needed, use a spring
compressor to compress the spring far enough to
remove the spring retainer.
3. Remove the spring and spring retainer from the
existing shock and install components onto the new
shock.
4. Install the spring(s) and spring retainer.
NOTE
The spring retainer gap should be 180° from the end of
the spring upon installation.
5. Tighten the spring adjustment ring to set the preload

distance noted in Step 1.
6. Reinstall the shock onto the vehicle and torque new
fasteners to specification.
8.30
FOX™ SHOCK SERVICE

7044135 SHOCK ASSEMBLY VIEW
REF. QTY DESCRIPTION REF. QTY DESCRIPTION

1. 1 Body Cap Asm.-Piggyback 15. 1 Washer
2. 1 Shock Body 16. 1 Preload Ring
3. 1 Shock Rod 17. 2 Preload Ring Lock
4. 1 Eyelet 18. 2 Bushing
5. 1 Body/Bearing Cap Asm. 19. 1 Sleeve
6. 1 Bearing Cap Asm. 20. 2 Bushing
7. 1 Piston Valve Asm. 21. 1 Sleeve
8. 1 Lock Nut 22. 1 Retaining Ring
9. 1 Reservoir 23 1 Retaining Ring
10. 1 Reservoir End Cap Asm. 24. N/A Decal
11. 1 Piston Asm, Floating (IFP) 25. 1 Spring Guide
12. 1 Damping Adjuster Asm. N/A - Shock Oil (2870995)
13. 1 Damping Adjuster Cartridge Asm.
14. 1 Bumper
8.31
7044080 / 7044081 SHOCK ASSEMBLY

VIEW
NOTE
Rear FOX™ shocks on 2014 models are labeled
“LEFT” and “RIGHT” to indicate placement on vehicle.
R-
RE-
E- DESCRIPTION NOTE DESCRIPTION NOTE
F.
F.
Apply Loctite® 638™ / Primer
1 Body Cap Asm. N™ to threads. Torque: 100 ft- 13 Bumper
lbs (136 Nm)
2 Shock Body 14 Washer
3 Shock Rod 15 Preload Ring
Apply Loctite® 638™ / Primer
4 Eyelet 16 Preload Ring Lock Torque: 10 ft-lbs (14 Nm)
N™ Torque: 50 ft-lbs (68 Nm)
5 Body/Bearing Cap Asm. 17 Bushings
6 Bearing Cap Asm. 18 Sleeve
7 Piston Valve Asm. 19 Bushings
Use new part. Torque: 18 ft-
8 Lock Nut lbs (24 Nm) 20 Sleeve
9 Reservoir 21 Retaining Ring

10 Reservoir End Cap Asm. 22 Retaining Ring
11 Piston Asm., Floating IFP 23 Decal (Not Shown)
12 LSC Asm. 24 Spring Guide
8.32
7044135 SHOCK SERVICE INFORMATION 7044080 / 7044081 SHOCK SERVICE

INFORMATION
SHOCK DESIGN DETAILS

Travel 4.86” SHOCK DESIGN DETAILS
Extended Length 15.96” Travel 6.16”
IFP Location 2.90” (73.6 mm) Extended Length 19.44”
Factory Clicker Setting 10 IFP Location 2.90” (73.6 mm)
Nitrogen Pressure 200 psi +/- 5% Factory Clicker Setting 10
Gas Shock Oil 2870995 (qt.) Nitrogen Pressure 100 psi +/- 5%
Gas Shock Oil 2870995 (qt.)
SHOCK VALVING
COMPRESSION REBOUND SHOCK VALVING
1.3 x 0.008 (DB) 1.1 x 0.008 COMPRESSION REBOUND
1.3 x 0.008 1.1 x 0.008 1.3 x 0.008 (DB) 1.1 x 0.008
1.3 x 0.008 0.8 x 0.004 1.3 x 0.08 1.1 x 0.008
8
0.7 x 0.006 1.1 x 0.012 1.3 x 0.08 0.8 x 0.004
1.3 x 0.008 1.0 x 0.012 1.3 x 0.08 1.1 x 0.012
1.25 x 0.008 0.9 x 0.012 0.8 x 0.004 1.0 x 0.012
1.1 x 0.008 1.125 x 0.093 Back-Up 1.3 x 0.010 0.9 x 0.012
1.0 x 0.008 0.950 x 0.050 1.25 x 0.010 1.125 x 0.093 Back-Up
0.9 x 0.008 1.1 x 0.010
0.8 x 0.008 1.0 x 0.010
1.23 x 0.082 Top-Out 0.9 x 0.010
0.8 x 0.010
0.7 x 0.010
1.23 x 0.082 Top-Out
8.33
GENERAL SERVICE INFORMATION 2. Thoroughly clean all shock components and shock
Recommended Service Intervals body prior to disassembly.
FOX™ Racing Shocks will perform the best if serviced at 3. Back preload adjuster all the way down and carefully
regular intervals: remove spring retainer and spring.
• Every ride - Wash and dry the vehicle and suspension 4. Use the appropriate shock body holding tool
• Every 100 hours - Visually inspect shock seals (2871071) to properly secure the shock body
• Every 500 hours or Annually - Change shock oil and assembly into a vise for service.
replace seals 5. Remove the nylon ball from the reservoir cap using a
heavy duty pick. Discard nylon ball and replace with
FOX™ SHOCK REBUILD INFORMATION new upon assembly.
When performing maintenance on FOX™ shocks, use
the Gas Shock Recharging Kit (PN 2200421), as it
contains the necessary valves, pressure gauge, and
fittings to deflate and pressurize shocks.
WARNING
FOX™ shocks contain high pressure nitrogen gas.
Extreme caution must be used while handling and
working with FOX™ shocks and related high pressure
service equipment. The pressure must be released
from the shock before disassembly. It is strongly
recommended you wear safety glasses and ear
protection during these procedures.
TIP: Extreme cleanliness is very important during all 6. Slowly loosen hex screw from reservoir cap and
disassembly and reassembly operations. This prevents allow nitrogen gas to completely escape. Push the
dirt or foreign particles from entering the shock, which shock rod down to relieve all residual gas pressure.
causes premature failure. 7. Remove the hex screw and charge port.
8. Depress reservoir cap and remove retaining ring
SPECIAL TOOLS from the reservoir.
PART NUMBER DESCRIPTION
2200421 Gas Shock Recharging Kit
PS-45259 Gas Fill Tool
PS-45259-1 Replacement Needles (20)
2871351 IFP Tool
1 5/8" Shock Body Holding Tool
2871071 (Front and Rear)
2871352 1/2" Shock Rod Holding Tool
2201639 Shock Seal Protector Sleeve
Bosch Automotive Service Solutions 1-800-328-6657
FOX™ SHOCK DISASSEMBLY 9. Remove the reservoir cap.
NOTE
To prevent damage or marks to the shock, the use of
special tools and a soft jaw vise is recommended.
1. Remove the shock from the vehicle and note the

spring preload distance.
8.34
10. Use a small, flat-blade screwdriver to pry the bearing 18. Remove and discard the lock nut from the end of
assembly cap out of the shock body. shock rod.
NOTE
Keep the rebound and compression valve stacks in the
NOTE order they were removed. If unsure of order, refer to
Above image shows spring guide pushed down for “Shock Valving” under the “Shock Service Information”
clarity. provided earlier in this section.
11. Press downward on the bearing assembly to expose 19. Remove the shims and piston from the shock rod.
the retaining ring. Remove the retaining ring from the Note that the valve shim closest to the piston is
shock body. ported. This is the air bleed valve shim.
20. A tie strap can be used to keep the shims in the
proper order.
12. Install the Shock IFP Tool (2871351) onto the IFP
located in the reservoir.
21. Inspect the valve shims for kinks, waves, pits or
13. Push downward on the IFP tool while pulling upward foreign material.
on the shock shaft to remove the shock shaft
assembly. 22. Inspect the piston wear band and replace if damaged
or worn.
14. Remove the center screw and O-ring from the IFP.
23. Replace the piston o-ring.
15. Remove the IFP using the Shock IFP Tool
(2871351). 24. Make note of the positioning of the piston for proper
assembly. The compression side of the piston has
16. Remove shock body assembly from the vise. Drain larger ports with raised edges.
and properly dispose of shock oil.
25. Inspect the shock rod bumper. Replace the bumper if
17. Secure the shock rod in a vise. Position the shock required.
rod so the threaded end is facing upward.
8.35
FOX™ SHOCK BODY AND RESERVOIR 7. Use a 5/8" socket to remove the compression control
SERVICE assembly.
NOTE
WARNING
The compression control assembly is not serviceable.
The following procedure involves the use of an open Replace assembly if required.
flame.
Perform this procedure in a well-ventilated area, away
from gasoline or other flammable materials. Assembly
Be sure the area to be flame treated is clean and free of 8. Install new o-rings in the shock body and reservoir.
gasoline or flammable residue.
9. Apply Loctite® 638 to the first two threads on shock
body and reservoir threads. Do not allow thread lock
Disassembly
to contact the o-rings.
1. Mount the shock body cap into a vise for service.
10. Use a spanner or strap wrench to torque the
2. Heat the body cap and reservoir base with a torch to reservoir body to specification.
break the adhesive bond between cap and shock
body. TORQUE
Reservoir Body: 30 ft-lbs (40 Nm)
Shock Body: 50 ft-lbs (40 Nm)
11. Remove excess Loctite® 638 from surfaces.

12. Install and torque the compression adjuster
assembly to specification.
TORQUE
Compression Adjuster Assembly:
14 ft-lbs (19 Nm)
3. Use a strap wrench to remove the shock body tube FOX™ SHOCK COMPONENT REBUILD
and reservoir from the body cap.
NOTE
4. Clean the adhesive out of the threads with a wire
brush and/or a small pick. To prevent damage or marks to the shock, the use of
WARNING
IFP and Reservoir Cap

5. Apply Loctite Primer N to the shock body and 1. Use a small pick to remove the IFP piston wear band
reservoir threads and let dry for reassembly. (A), IFP o-ring (B) and the reservoir cap o-ring (not
shown).
6. Remove the compression adjuster cap using a #10
Torx bit driver. 2. Lubricate new o-rings and bearing with shock oil
before and after installation onto the piston and cap.
3. Install a new nylon fill valve into the reservoir cap.
8.36
4. Refer to the assembly instructions for component 8. Refer to the assembly instructions for component
installation onto the shock asm. installation onto the shock asm.
Bearing Assembly
9. Use a small pick to remove the U-cup seal (C),
internal (D) and external (E) O-rings from the bearing
assembly.
Body/Bearing Cap
5. Use a small pick to remove seal from the body/
bearing cap.
NOTE
If the bearing bushing requires replacement, replace
the bearing assembly.
10. Lubricate and install the O-rings and U-cup seal.

11. Push the Shock Seal Protector Sleeve (2201639)
through the bearing assembly O-ring and U-cup seal
to insure proper installation.
8
6. Lubricate a new seal and fully install into body/
bearing cap.
7. Install the Shock Seal Protector Sleeve (2201639)
through the bearing cap seal to insure proper
installation.
8.37
FOX™ SHOCK ASSEMBLY 5. Lubricate and install the body/bearing cap onto the
shock rod.
NOTE
To prevent damage or marks to the shock, the use of
WARNING
6. Lubricate and install the bearing assembly onto the
shock rod.
WARNING
The following procedure involves the use of an open
flame.
Perform this procedure in a well-ventilated area, away

from gasoline or other flammable materials.
Be sure the area to be flame treated is clean and free of

gasoline or flammable residue.
1. Secure the shock rod in a vise so the threaded end is

facing upward.
2. Install the washer and bumper onto the shock rod.
3. Install the Shock Seal Protector Sleeve (2201639)
onto the shaft threads. 7. Remove the Shock Seal Protector Sleeve.
8. Lubricate and install the compression valve stack.
NOTE
The last compression valve shim is the air bleed shim.
The shim must be orientated correctly with the piston
valve to allow air to bleed through the assembly during
installation.
4. Lubricate the shock rod and the Shock Seal

Protector Sleeve with new shock oil.
8.38
9. Replace the o-ring on the piston valve and lubricate • Note the orientation of the bleed shim tabs as the
with low temperature grease. Install the piston valve assembly would be installed on the shock shaft.
as follows:
• This is the COMPRESSION side of the piston valve.
When installed, the compression side FACES the
compression valve stack.
10. Install the piston valve as shown in the photo. Install

the lock nut and torque to specification. Keep the
bleed shim tab aligned with the piston valve when
tightening the lock nut.
• The bleed shim tabs are centered in the middle of the

compression ports.
8
11. Install the rebound valve stack onto the shock shaft.
Tighten the lock nut to specification.
NOTE
Verify the bleed valve shim tab is orientated correctly
with the piston valve when tightening lock nut.
8.39
12. Install new lock nut and torque to specification. 21. Insert the shock rod/piston assembly into shock
body. Be sure the piston wear band stays in the
TORQUE proper position. Do not install bearing assembly at
Shock Rod Nut: this time.
18 ft-lbs (24 Nm)
22. Press shaft downward. Rotate and wiggle the shaft

as it submerges in the shock oil until no more air
bubbles rise out of the shock oil.
13. Secure the shock body assembly into a vise for
service. 23. Hold pressure downward on IFP tool. Stroke shock
rod assembly up and down 1/4" (6.35 mm) to work
14. Fill the remote reservoir 3/4 full with shock oil.
the air bubbles out of the piston and piston ports.
Polaris Gas Shock Oil - 5 wt. 24. Slide the bearing assembly partially into the shock
PN 2870995 - qt. body.
PN 2872279 - 2.5 gal.
25. Tap shock rod eyelet with a rubber mallet 3-5 times
to remove any trapped air from the valve shims.
15. Install IFP without bleed screw. Install the IFP into
the reservoir.
16. Press IFP downward until 1/4" (6.35 mm) of shock oil
is on top of the IFP.
17. Install a new O-ring on the IFP bleed screw and
install the screw. Tighten the screw.
18. Install the IFP tool and push IFP bore until bottomed.
19. Fill the main shock body with shock oil until it is 2"
(50.8 mm) from the top of the shock body.
20. Pass a torch over the shock body to remove any air
bubbles from the oil.
26. Slide bearing assembly up and pass a torch over the

shock body to remove any air bubbles from the oil.
27. Add shock oil to 1/8" (3.18 mm) below the top of the
shock body.
28. Wrap a clean shop towel around top of shock body
and depress the bearing assembly downward below
the retaining ring groove.
29. Install the bearing assembly retaining ring and clean
excess shock oil. Properly dispose of shop towel.
30. Add shock oil to reservoir until it is 1" (25.4 mm)
above the top of the IFP.
8.40
31. Remove the IFP center screw and O-ring. 43. Use the Gas Fill Tool (PS-45259) and charge the
shock to the recommended pressure for 10 seconds.
32. Pull upward on shock shaft until fully extended and
seated against the bearing assembly retaining ring. Nitrogen Pressure:
33. Set the IFP depth to the recommended height. Reference shock specifications.
NOTE 44. Stroke the shock through its travel and adjust the
Keep sufficient amount of shock oil above the IFP and compression adjuster to ensure proper function.
pull it past the recommended IFP depth. 45. Use a rubber mallet to fully seat the body/bearing
ALWAYS reset IFP depth in a downward motion. cap.
46. Use a dead blow hammer to fully seat a new nylon

ball into the reservoir cap.
34. Remove the IFP tool.

35. Hold IFP with a 9/16" wrench to prevent IFP rotation.
36. Install the IFP center screw and O-ring; tighten the
IFP center screw sufficiently. 8
37. Drain and properly dispose of the shock oil from on
top of the IFP.
38. Remove oil residue from above the IFP with a clean
shop towel.
39. Lubricate and install a new pellet into the reservoir
cap.
47. Install suspension spring (s) and reset preload to
40. Lubricate the reservoir cap O-ring. factory settings.
41. Install and depress the reservoir cap past the 48. Adjust external adjusters to the factory settings
retaining ring groove.
49. Install shock onto the vehicle and torque fasteners to
42. Install the reservoir cap retaining ring. specification.
WARNING NOTE
CHARGE THE SHOCK USING NITROGEN GAS After installation, be sure to RIDE SLOWLY initially to
ONLY. DO NOT FILL WITH ANY OTHER GASES. ensure the shock and the vehicle’s suspension is
Doing so compromises the performance of the shock performing correctly.
and may be EXTREMELY DANGEROUS!
8.41
NOTES
8.42
BRAKE SYSTEM
CHAPTER 9
BRAKE SYSTEM
GENERAL BRAKE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
SPECIAL TOOLS / BRAKE FLUID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
BRAKE SYSTEM SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
BRAKE SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
BRAKE SYSTEM ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
SPORTSMAN / SCRAMBLER 850 BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
SPORTSMAN / SCRAMBLER 1000 BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
SPORTSMAN / SCRAMBLER INTERNATIONAL BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
BRAKE CALIPER EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
HAND MASTER CYLINDER EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
BRAKE HOSE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
INTERNATIONAL BRAKE SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.10
HAND MASTER CYLINDER HYDRAULIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.10
FOOT MASTER CYLINDER HYDRAULIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.10
BRAKE FLUID BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
FLUID REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
FRONT BRAKE SYSTEM BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
REAR BRAKE SYSTEM BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.12
HAND BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.14
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.14
BRAKE SWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.15
FOOT BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.16 9
FOOT MASTER CYLINDER REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.16
BRAKE PEDAL REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.16
BRAKE PADS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.17
PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.17
PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.17
PAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.17
BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.18
BRAKE CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.19
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.19
CALIPER DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.19
CALIPER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.20
CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.20
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.21
BRAKE DISC SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.22
DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.22
DISC REMOVAL / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.23
9.1
BRAKE SYSTEM
BRAKE SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.25

BRAKE SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.25
BRAKE NOISE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.26
9.2
BRAKE SYSTEM
GENERAL INFORMATION
GENERAL BRAKE SPECIFICATIONS
FRONT BRAKES
ITEM STANDARD SERVICE LIMIT
Brake Pad Thickness – .030” / .762 mm
Brake Disc Thickness .187” / 4.75 mm .167” / 4.24 mm
Brake Disc Thickness Variance Between Measurement – .002” / .051 mm
Brake Disc Runout – .010” / .254 mm
Caliper Piston Diameter 1.186” / 30.12 mm 1.184” / 30.07 mm
Caliper Bore Diameter 1.192” / 30.28 mm 1.194” / 30.33 mm
Caliper Piston Diameter (INT’L Models) 1.250” / 31.75 mm 1.246” / 31.65 mm
Caliper Bore Diameter (INT’L Models) 1.254” / 31.85 mm 1.256” / 31.90 mm
REAR BRAKES
ITEM STANDARD SERVICE LIMIT
Brake Pad Thickness – .030” / .762 mm
Brake Disc Thickness .187” / 4.75 mm .167” / 4.24 mm
Brake Disc Thickness Variance Between Measurements – .002” / .051 mm
Brake Disc Runout – .010” / .254 mm
Caliper Piston Diameter 1.500” / 38.1 mm 1.498” / 38.05 mm
Caliper Bore Diameter 1.505” / 38.23 mm 1.507” / 38.28 mm
SPECIAL TOOLS / BRAKE FLUID

2870975 Mity Vac
2872189 DOT 4 Brake Fluid
9.3
BRAKE SYSTEM
BRAKE SYSTEM SERVICE NOTES BRAKE SYSTEM OPERATION

Disc brake systems are light weight, low maintenance, The brake system consists of the following components
and perform well in the conditions this vehicle will or assemblies: hand brake master cylinder w/lever, foot
routinely encounter. There are a few things to remember brake master cylinder w/pedal, brake fluid reservoirs,
when replacing disc brake pads or performing brake brake lines, brake calipers, brake pads, and brake discs,
system service to ensure proper system function and which are secured to the drive line.
maximum pad service life. When the brake lever or pedal is applied, it moves the
• DO NOT over-fill the master cylinder fluid reservoir(s). hydraulic piston within the master cylinder. As the piston
• Make sure the brake lever / pedal returns freely and moves inward it closes a small opening (compensating
completely. port) within the cylinder and starts to build pressure
• Adjust stop pin on calipers after pad service. within the brake system. As the pressure within the
• Check and adjust master cylinder reservoir fluid level system is increased, the pistons located in the brake
after pad service. calipers move outward and apply pressure to the
• Make sure atmospheric vent on reservoir is moveable brake pads. These pads contact the brake
unobstructed. discs and move the calipers in their floating bracket,
• Test for brake drag after any brake system service and pulling the stationary side pads into the brake discs. The
investigate cause if brake drag is evident. resulting friction reduces brake disc and vehicle speed.
• Make sure caliper moves freely on guide pins (where The friction applied to the brake pads will cause the pads
applicable). to wear. As these pads wear, the piston within the caliper
• Inspect caliper piston seals for foreign material that moves further outward and becomes self adjusting. Fluid
could prevent caliper pistons from returning freely. from the reservoir fills the additional area created when
• Perform a brake burnishing procedure after installing the caliper piston moves outward.
new pads to maximize service life.
Brake fluid level is critical to proper system operation.
• DO NOT lubricate or clean the brake components with
Too little fluid will allow air to enter the system and cause
aerosol or petroleum products. Use only approved
the brakes to feel spongy. Too much fluid could cause
brake cleaning products.
brakes to drag due to fluid expansion.
• DO NOT allow brake cleaning products to contact
painted surfaces. Paint damage will occur as a result. Located within the master cylinder is the compensating
port which is opened and closed by the master cylinder
piston assembly. As the temperature within the hydraulic
system changes, this port compensates for fluid
expansion or contraction. Due to the high temperatures
created within the system during heavy braking, it is very
important that the master cylinder reservoir have
adequate space to allow for fluid expansion. Never
overfill the reservoir! Do not fill the reservoir beyond
the MAX LEVEL line!
When servicing Polaris brake systems use only Polaris
DOT 4 Brake Fluid (PN 2872189). WARNING: Once a
bottle is opened, use what is necessary and discard the
rest in accordance with local laws. Do not store or use a
partial bottle of brake fluid. Brake fluid is hygroscopic,
meaning it rapidly absorbs moisture. This causes the
boiling temperature of the brake fluid to drop, which can
lead to early brake fade and the possibility of serious
injury.
9.4
BRAKE SYSTEM
BRAKE SYSTEM ASSEMBLY VIEWS

SPORTSMAN / SCRAMBLER 850 BRAKE SYSTEM
9.5
BRAKE SYSTEM
SPORTSMAN / SCRAMBLER 1000 BRAKE SYSTEM
9.6
BRAKE SYSTEM
SPORTSMAN / SCRAMBLER INTERNATIONAL BRAKE SYSTEM
BRAKE CALIPER EXPLODED VIEW
9.7
BRAKE SYSTEM
HAND MASTER CYLINDER EXPLODED VIEW
BRAKE HOSE ROUTING

Retainers are indicated with a q. The first image is the front routing, the second image is the rear.
9.8
BRAKE SYSTEM
9.9
BRAKE SYSTEM
INTERNATIONAL BRAKE SYSTEM OPERATION

HAND MASTER CYLINDER HYDRAULIC OPERATION
FOOT MASTER CYLINDER HYDRAULIC OPERATION
9.10
BRAKE SYSTEM
BRAKE FLUID BLEEDING

FLUID REPLACEMENT 5. Add brake fluid to .25” - .30” (6 - 8 mm) from the top
of the reservoir.
NOTE
When bleeding the brakes or replacing the fluid, always
start with the caliper farthest from the master cylinder.
CAUTION
Always wear safety glasses during these procedures.
Brake fluid will damage finished surfaces.
Do not allow brake fluid to come in contact with finished
surfaces.
This procedure should be used to change fluid or bleed

brakes during regular maintenance.
Polaris DOT 4 Brake Fluid
1. Clean reservoir cover thoroughly. PN: 2872189
2. Remove screws, cover and diaphragm from master
cylinder reservoir.
FRONT BRAKE SYSTEM BLEEDING
1. Remove the reservoir cover from the hand brake
master cylinder and verify fluid is at specified level.
2. If fluid level is low, add brake fluid to .25” - .30” (6 - 8
mm) from the top of the reservoir.
3. Install a box end wrench on foot master cylinder
bleeder screw. Attach a clean, clear hose to fitting
and place the other end in a container. Be sure the
hose fits tightly on fitting.
3. Inspect vent slots in cover and remove any debris or

blockage.
4. If changing fluid, remove old fluid from reservoir and 9
lines at the bleeders with a Mity Vac or similar tool.
NOTE
Do not move brake lever when reservoir fluid level is
low.
NOTE
Install diaphragm and cover onto the hand master
cylinder reservoir to prevent spills. Do not tighten the
cover.
4. Slowly pump the hand brake lever until pressure

builds and holds.
5. While maintaining lever pressure, open bleeder
screw.
9.11
BRAKE SYSTEM
6. Close bleeder screw and release brake lever. REAR BRAKE SYSTEM BLEEDING
NOTE 1. Remove the front rack or front storage box and
locate the foot brake fluid reservoir for the foot
Do not release lever before bleeder screw is tight or air master cylinder.
may be drawn into caliper.
7. Repeat procedure until clean fluid appears in bleeder

hose and all air has been purged. Add fluid as
necessary to maintain level in reservoir.
CAUTION
Maintain at least 1/2” (1.27 cm) of brake fluid in the
reservoir to prevent air from entering the master
cylinder.
8. Tighten bleeder screw securely and remove bleeder

hose. Torque bleeder screw to specification.
TORQUE
Bleeder Screw:
47 in. lbs (5 Nm)
9. Repeat the procedure on the two remaining front

calipers.
10. Add DOT 4 brake fluid to .25” - .30” (6 - 8 mm) from
the top of the reservoir.
11. Install diaphragm, cover and screws. Torque the
screws to 7 in-lbs (0.8 Nm). 2. Thoroughly clean the fluid reservoir cover before
removal.
3. Remove the cap and diaphragm from the reservoir
and verify fluid level is at the MAX level mark.
4. If changing fluid, remove old fluid from reservoir with
a Mity Vac (PN 2870975) or similar tool.
5. Using a funnel, add brake fluid to the MAX level mark
on the reservoir.
12. Proceed to “Rear Brake System Bleeding” to

complete bleeding procedure.
9.12
BRAKE SYSTEM
6. Install a box end wrench on the rear caliper bleeder

screw. Attach a clean, clear hose to fitting and place
the other end in a container. Be sure the hose fits
tightly on fitting.
7. Slowly pump the foot brake pedal until pressure

builds and holds.
8. While maintaining pedal pressure, open bleeder
screw.
9. Close bleeder screw and release brake pedal.
NOTE
Do not release pedal before bleeder screw is tight or air
may be drawn into caliper.
10. Repeat procedure until clean fluid appears in bleeder

hose and all air has been purged. Add fluid as
necessary to maintain level in reservoir.
11. Tighten bleeder screw securely and remove bleeder
hose. Torque bleeder screw to specification.
9
TORQUE
Bleeder Screw:
47 in. lbs (5 Nm)
12. Repeat the procedure on the remaining rear caliper.

13. Using a funnel, add brake fluid to the MAX level mark
on the reservoir.
14. Field test machine at low speed before putting into
service. Check for proper braking action and lever
reserve. With lever firmly applied, lever reserve
should be no less than 1/2”, (1.3 cm) from handlebar.
15. Check brake system for fluid leaks and inspect all
hoses and lines for wear or abrasion. Replace hose if
wear or abrasion is found.
9.13
BRAKE SYSTEM
HAND BRAKE MASTER CYLINDER

REMOVAL DISASSEMBLY
1. Clean master cylinder and reservoir assembly. Make The hand master cylinder is a serviceable component.
sure you have a clean work area to disassemble Polaris offers a number of service kits to rebuild this style
brake components. of master cylinder. Refer to the Polaris Electronic Parts
Catalog.
2. Place a shop towel or suitable catch container under
the master cylinder brake line connection. Remove
the banjo bolt fitting that connects the brake line to INSTALLATION
the master cylinder. Discard the sealing washers.
NOTE
Use only OEM parts that were designed for the model
ATV being serviced. There are different hand master
cylinders for the different Polaris ATV models. Refer to
the Electronic Parts Catalog.
Some master cylinders are not serviceable and are
replaced only as an assembly.
1. Install master cylinder on handlebars. Torque bolt

furthest from the reservoir first, followed by the bolt
closest to the reservoir. Torque clamp bolts to
specification.
TORQUE
Clamp Bolts:
70 in. lbs (8 Nm)
CAUTION
Brake fluid will damage finished surfaces.
Do not allow brake fluid to come in contact with finished
surfaces.
3. Remove the Torx screws from the master cylinder

clamp.
4. Hold master cylinder upright and lift the master
cylinder from the handlebars. Cover brake line orifice
to avoid spilling fluid.
2. Place new sealing washers on each side of banjo

line and torque banjo bolt to specification.
NOTE
Speed up brake bleeding by purging air before brake
line is attached. Fill with DOT 4 Brake Fluid and pump
lever slowly 2 to 3 times with finger over the outlet end
to purge master cylinder of air.
TORQUE
Brake Line Banjo Bolt:
15 ft. lbs (20 Nm)
3. Fill reservoir with DOT 4 brake fluid (PN 2872189).
9.14
BRAKE SYSTEM
4. Follow brake bleeding procedures. Check all

connections for leaks and repair if necessary.
BRAKE SWITCH REPLACEMENT

1. Set the parking brake lock and locate the brake
switch behind the hand brake lever.
2. Using a small screwdriver or similar tool, push up on
the mounting tabs through the holes on the bottom
side while rotating the switch to disengage the tabs
from the holes.
3. Install the new switch. The tabs should snap in place.
9.15
BRAKE SYSTEM
FOOT BRAKE MASTER CYLINDER

FOOT MASTER CYLINDER REMOVAL / BRAKE PEDAL REMOVAL / INSTALLATION
INSTALLATION 1. Remove the RH mud guard and footwell.
1. Remove the RH mud guard and footwell. 2. Remove the through-bolt retaining the brake pedal to
2. Remove the front and rear brake line from the master the mount bracket.
cylinder. Use a suitable container to catch the brake 3. Remove the bolt, bushings, spacer, spring and brake
fluid. Dispose of brake fluid properly. lever.
3. Remove the (2) through-bolts retaining the master 4. Inspect and replace components as needed.
cylinder to the mount bracket. Replace components
as needed. 5. Reverse this procedure when reinstalling and torque
mounting fastener to specification.
4. Reverse this procedure when reinstalling and torque
mounting fasteners to specification. TORQUE
TORQUE Brake Pedal Mounting Fastener:
38 ft. lbs (52 Nm)
Master Cylinder Mounting Fasteners:
8 ft. lbs (11 Nm)
5. Reinstall the brake line and torque the banjo bolt

(with new sealing washers installed) to specification.
TORQUE
Brake Line Banjo Bolts:
15 ft. lbs (20 Nm)
6. Bleed the master cylinder following the procedure

outlined in the “Brake Bleeding” section of this
chapter. Front Brake System Bleeding, page
9.11Rear Brake System Bleeding, page 9.12
9.16
BRAKE SYSTEM
BRAKE PADS
PAD REMOVAL PAD INSPECTION
1. Loosen the (4) wheel nuts. 1. Measure the thickness of the pad material by taking
two measurements. Measure the thickness of the
2. Elevate and support the side of the ATV in which the
friction material and backing plate, then measure the
caliper brake pads are being serviced.
thickness of just the backing plate. Subtract the
backing plate thickness from the plate and friction
CAUTION thickness to get the thickness of just the pad friction
Use care when supporting vehicle so that it does not tip material. Compare to the specification. Replace pads
or fall. Severe injury may occur if machine tips or falls. if worn thinner than the service limit.
3. Remove the wheel nuts and wheel.

caliper.
MEASUREMENT
Brake Pad Material Thickness:
5. Push mounting bracket inward and slip the outer PAD INSTALLATION
brake pad past the edge of the pin. Remove the
inner brake pad. 1. Lubricate mounting bracket pins and external slide
pin O-ring with a light film of silicone grease.
2. Compress mounting bracket. Install pads with friction

material facing each other.
WARNING
If the brake pads are contaminated with grease, oil, or
liquid soaked do not use the pads.
Use only new clean brake pads.
9.17
BRAKE SYSTEM
3. Install the caliper and torque new mounting bolts to 7. Install the wheel (s) and wheel nuts. Torque wheel
specification. nuts to specification.
TORQUE TORQUE
Brake Caliper Bolts Lug Nuts
37 ft. lbs (50 Nm) Aluminum Wheels: 75 ft. lbs (102 Nm)
CAUTION
New bolts have a pre-applied locking agent which is BRAKE BURNISHING PROCEDURE
destroyed upon removal. Always use new brake caliper It is required that a burnishing procedure be performed
mounting bolts upon assembly. 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.
4. Slowly pump the brake lever/pedal until pressure has

been built up. Maintain at least 1/2, (12.7 mm) of
brake fluid in the reservoir to prevent air from
entering the brake system.
5. Install the adjustment set screw and turn clockwise
until stationary pad contacts disc. After making
contact, back off set screw 1/2 turn
(counterclockwise).
6. Verify fluid level in reservoir is at specified level

inside reservoir and install reservoir cap.
9.18
BRAKE SYSTEM
BRAKE CALIPER SERVICE

CALIPER REMOVAL CALIPER DISASSEMBLY
1. Loosen the (4) wheel nuts. 1. Push mount bracket inward and slip outer brake pad
past the edge of the pin. Remove the inner brake
2. Elevate and support the side of the ATV in which the
pad.
caliper is being serviced.
CAUTION
Use care when supporting vehicle so that it does not tip
or fall. Severe injury may occur if machine tips or falls.

4. Place a suitable container under the caliper to catch
brake fluid draining from brake line. Using a wrench,
loosen and remove brake line from the caliper.
2. Remove mount bracket, pin assembly and dust boot.
5. Remove (2) caliper mounting bolts and remove the

caliper assembly from the bearing carrier.
3. Apply force to the back of the piston through the

open brake fluid supply port. This will remove the
9
piston from the caliper body. Also remove the square
cut O-rings at this time.
9.19
BRAKE SYSTEM
4. Clean the caliper body, piston, and mounting bracket 2. Inspect piston for nicks, scratches, wear or damage.
with brake cleaner or denatured alcohol. Measure diameter and replace if damaged or worn
beyond service limit.
NOTE
Be sure to thoroughly clean the seal grooves in the
caliper body.
CALIPER INSPECTION
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.
3. Inspect the brake pad and disc.
MEASUREMENT
Front Calipers:
Caliper Piston O.D.
Rear Caliper(s):
Caliper Piston O.D.
General Brake Specifications, page 9.3
CALIPER ASSEMBLY
1. Install new O-rings in the caliper body. Be sure
MEASUREMENT grooves are clean or brakes may drag upon
assembly.
Front Calipers:
Caliper Bore I.D. 2. Coat piston with DOT 4 Brake Fluid. Install piston
with a twisting motion while pushing inward. Piston
should slide in and out of the bore smoothly, with
Rear Caliper(s): light resistance.
Caliper Bore I.D.
General Brake Specifications, page 9.3 3. Lubricate the mounting bracket pins with silicone
grease, and install the rubber dust seal boots.
4. Compress the mounting bracket and make sure the

dust seals are fully seated.
9.20
BRAKE SYSTEM
5. Install the brake pads. 2. Install brake line with new seals, and torque the
banjo bolt fitting to specification.
6. Clean the disc and pads with brake parts cleaner or

denatured alcohol to remove any dirt, oil or grease.
TORQUE
CALIPER INSTALLATION Brake Line Banjo Fastener
1. Install caliper assembly over the brake disc and onto 37 ft. lbs (50 Nm)
the bearing carrier. Torque mounting bolts to
specification. 3. Perform brake bleeding procedure as outlined earlier
in this chapter., page 9.11
TORQUE
4. Install the wheel and (4) wheel nuts. Torque wheel
Brake Caliper Bolts nuts to specification.
37 ft. lbs (50 Nm)
TORQUE
Lug Nuts
CAUTION Aluminum Wheels: 75 ft. lbs (102 Nm)
New bolts have a pre-applied locking agent which is Steel Wheels: 45 ft. lbs (61 Nm)
9.21
BRAKE SYSTEM
BRAKE DISC SERVICE

DISC INSPECTION 3. Mount a dial indicator and measure disc runout.
1. Visually inspect brake disc for scoring, scratches, or Slowly rotate the disc and read total runout on the
gouges. Replace disc if deep gouges are evident. dial indicator. Replace the disc if runout exceeds
specification.
2. Measure the disc thickness at 8 different points
around the pad contact surface using a 0– 1” MEASUREMENT
micrometer. Replace disc if worn beyond service Brake Disc Runout
limit. Service Limit: 010” (.254 mm)
MEASUREMENT
Brake Disc Thickness:
New: .187” (4.75 mm)
Service Limit: .167” (4.24 mm)
MEASUREMENT
Brake Disc Thickness Variance:
(difference between measurements)
9.22
BRAKE SYSTEM
DISC REMOVAL / REPLACEMENT 9. Install the new disc and press new wheel studs into
1. Loosen the (4) wheel nuts. the hub until they are flush with the mating surface.
2. Elevate and support the side of the ATV in which the CAUTION
brake disc is being serviced. Always use new wheel studs if removed from the wheel
hub assembly.
CAUTION
Use care when supporting vehicle so that it does not tip 10. Install wheel hub assembly, cone washers, and hand
or fall. Severe injury may occur if machine tips or falls. tighten the castle nut. Install washers with domed
side out.
4. Remove the axle nut cotter pin, the axle castle nut,
and cone washers.
11. Install the brake caliper and torque the new mounting
CAUTION
Do not hang the caliper by the brake line. Use wire to
hang caliper to prevent damage to the brake line.
6. Remove the wheel hub assembly from the bearing

carrier.
7. Press out the wheel studs and remove the brake 9
disc.
CAUTION
TORQUE
Caliper Mounting Bolts:
37 ft. lbs (50 Nm)
8. Clean the wheel hub mating surface.
9.23
BRAKE SYSTEM
12. Torque wheel hub nut to specification and install a

new cotter pin. Tighten nut slightly if necessary to
align cotter pin holes.
TORQUE
80 ft. lbs (108 Nm)
13. Install the wheel and (4) wheel nuts. Torque wheel
nuts to specification.
TORQUE
Lug Nuts
14. Field test the ATV for proper braking action before
putting into service. Inspect for fluid leaks and firm
brakes. Make sure the brake is not dragging when
lever is released. If the brake drags, re-check
assembly and installation.
9.24
BRAKE SYSTEM
BRAKE SYSTEM TROUBLESHOOTING

BRAKE SYSTEM TROUBLESHOOTING
• Dirty/contaminated friction pads
• Improper alignment
• Worn disc
• Worn caliper
• Glazed brake pads
Poor Brake Performance
• Air in system
• Water in system (brake fluid contaminated)
• Caliper/disc misaligned
• Caliper dirty or damaged
• Brake line damaged or lining ruptured
• Worn disc and/or friction pads
• Incorrectly adjusted stationary pad
• Worn or damaged master cylinder or components
Lever / Pedal Vibration

• Disc damaged
• Disc worn / warped (runout or thickness variance
exceeds service limit)
Caliper Overheats (Brakes Drag)
• Compensating port plugged
• Brake lever or pedal binding or unable to return fully
• Parking brake left on
• Residue build up under caliper seals
• Operator riding brakes
Brakes Lock
• Alignment of caliper to disc
• Reservoir is overfilled with fluid
• Master cylinder compensating port plugged
• Caliper piston is stuck
• Parking brake left on
9.25
BRAKE SYSTEM
BRAKE NOISE TROUBLESHOOTING

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

POSSIBLE CAUSE REMEDY
Spray disc and pads with CRC Brakeleen™ 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 (noise or premature pad wear) Adjust pad stop
because of improper adjustment
Master cylinder reservoir overfilled Set to proper level
Master cylinder compensating port restricted Clean compensating port
Master cylinder piston not returning completely Clean, inspect, and repair as necessary
Caliper piston not returning Clean piston seals and inspect the seal grooves
Operator error (riding the brake) Educate operator
Check wheel and hub for abnormal movement (see
Loose wheel hub or bearings
Chapter 8).
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
9.26
BODY / FRAME
CHAPTER 10
BODY / FRAME
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.2
DECAL REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.2
PLASTIC PUSH RIVET REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.2
MULTI-FUNCTION PLIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.2
2018 850 / 1000 SPORTSMAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3
HEADLIGHT POD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3
HEADLIGHT POD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3
HEADLIGHT POD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.4
SEAT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.4
SEAT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.4
SIDE PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.5
SIDE PANEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.5
SIDE PANEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.5
FRONT RACK / STORAGE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.6
FRONT RACK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.6
FRONT RACK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.7
FRONT BUMPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.8
FRONT BUMPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.8
FRONT BUMPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.8
MUD GAURDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.9
MUD GUARD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.9
MUD GUARD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.9
FRONT CAB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
FRONT CAB REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
FRONT CAB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
REAR RACK / STORAGE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
REAR RACK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
REAR RACK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
REAR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
10
REAR CAB REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
REAR CAB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
REAR BUMPER COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
REAR BUMPER COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
REAR BUMPER COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
MAIN FRAME / FRAME SUPPORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
MAIN FRAME ASSEMBLY VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
10.1
BODY / FRAME
GENERAL INFORMATION
DECAL REPLACEMENT PLASTIC PUSH RIVET REMOVAL
Polaris ATVs use a two piece plastic push rivet to fasten
WARNING most body components. Using the “Multi-Function Pliers”
The following procedure involves the use of an open eases removal and prevents from damaging the push
flame. Perform this procedure in a well ventilated area, rivets and body components.
away from gasoline or other flammable materials. Be
sure the area to be flame treated is clean and free of MULTI-FUNCTION PLIERS
gasoline or flammable residue. Included in the tool kit, the multi-function pliers is
designed to remove the plastic push rivets used to fasten
body components.
CAUTION
Do not flame treat components that are installed on the
vehicle. Remove the component from the vehicle
before flame treating.
The side panels, front and rear fender cabs are plastic
polyethylene material. Therefore, they must be “flame
treated” prior to installing a decal to ensure good
adhesion. A bonus of the flame treating procedure is it
can be used to reduce or eliminate the whitish stress
marks that are sometimes left after a fender or cab is
bent, flexed, or damaged.
CAUTION
Do not flame treat painted plastic components. Painted
plastic surfaces should only be wiped clean prior to
decal adhesion.
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.
10.2
BODY / FRAME
2018 850 / 1000 SPORTSMAN HEADLIGHT POD ASSEMBLY
HEADLIGHT POD 1. Install and electrical components removed form the

pod.
HEADLIGHT POD DISASSEMBLY 2. Reconnect all electrical components.
3. Route and refasten the wiring harnesses, vent lines,
1. Remove the screws retaining the front of the pod. and throttle cables as they were prior to disassembly.
4. Align the rear half of the pod with the mounting holes
and install the screws.
TORQUE
Pod Screws:
Until Fully Seated
2. Remove the front half of the pod.

3. Remove the Screws retaining the rear of the pod.
5. Align the front half of the pod and install screws.
TORQUE
Pod Screws:
Until Fully Seated
4. Disconnect the wiring harness form the electrical

components fastened to the pod.
10
NOTE
Take note of all vent lines, wire harness and throttle
cable routings for reassembly purposes.
10.3
BODY / FRAME
SEAT SEAT INSTALLATION

1. Align the seat with the tabs and pin.
SEAT REMOVAL
1. Grasp the latchq at the rear of the seat and squeeze.
2. Slide the seat forward and lower the rear.
2. Lift the rear of the seatw and slide the seat rearward.
3. Press the rear of the seat down firmly to seat the pin
in the latchq.
10.4
BODY / FRAME
SIDE PANELS SIDE PANEL INSTALLATION

1. With the side panel tipped as shown, insert the front
SIDE PANEL REMOVAL
tab begin to lower the rear
1. Remove the seat.
2. Remove the push rivets that retain the side panels.
2. Continue to lower the rear of the panel. Align the tabs

that align the side panel assembly as the rear of the
panel is lowered in to place.
3. Grasp the rear of the side panel assemblyq then
rotate lift the rear of the panel and rotate then pull to 3. Install the push rivets that retain the side panels.
the rear of the vehicle.
10
10.5
BODY / FRAME
FRONT RACK / STORAGE BOX 4. Remove the screws retaining the travel limiter
cablese.
FRONT RACK REMOVAL
1. Unlatch the front rackq.
5. Turn the quarter turns r at the back of the storage

tray to the unlock position.
2. Open the front rack.
6. Remove the storage trayt.
3. Remove the pins retaining the front rack.
10.6
BODY / FRAME
FRONT RACK INSTALLATION 4. Install the pins r that retain the front rack.
1. Install the front storage tray q by inserting the tabs at

the front of the tray into the slots on the front cab,
then lower the back of the tray.
5. Close the front rack.
2. Align the quarter turn fasteners w, then turn them to

the lock position.
6. Latch the straps that retain the front rack.
3. Install the screws that retain the travel limiter

cablese.
10
10.7
BODY / FRAME
FRONT BUMPER FRONT BUMPER INSTALLATION

1. Install the upper bumper cover q then install the
FRONT BUMPER REMOVAL
fasteners that retain the upper bumper cover w.
1. Remove the fasteners q retaining the lower bumper
cover.
2. Install the lower bumper cover e then install the

fasteners that retain the lower bumper cover r.
2. remove the lower bumper cover w
3. Disconnect the bumper mounted headlights from the

main wiring harness.
4. Remove the fasteners e retaining the upper bumper
cover r
10.8
BODY / FRAME
MUD GAURDS MUD GUARD INSTALLATION

1. Align the mud guard with the mounting holes.
MUD GUARD REMOVAL
2. Install the front top Tuflock fastener q that retains the
1. Locate and remove the Tuflock fastener q at the top mud guard w.
front corner of the mud guard w.
3. Install the remaining Tuflock fasteners e that retain

2. Remove the remaining Tuflock fasteners e. the mud guard.
3. Remove the mud guard.
10
10.9
BODY / FRAME
FRONT CAB 7. Remove the center cover t located under the pod.
FRONT CAB REMOVAL

1. Remove the seat.
2. Remove the side panels.
3. Remove the front rack and storage compartment.
4. Remove the Tuflock fasteners q and screws w
fastening the front cab to the fender flares and
footwells.
8. Remove the diagnostic port cover y from the front

cab.
NOTE
Right side shown
5. Remove the gas cap and cover opening with tape to

prevent debris from entering the fuel tank.
6. Remove the fasteners e r retaining the front cab.
9. Remove the front cab.
10.10
BODY / FRAME
FRONT CAB INSTALLATION 5. Install the diagnostic connector tree clip y in the hole
in the cab.
1. Place the front cab and align the mounting holes.
2. Place the center cover q under the pod.
6. Remove the tape from the gas tank inlet.

7. Install the gas cap.
3. Install the mounting fasteners we that retain the 8. Install the storage tray.
front cab and center cover.
9. Install the front rack.
10. Install the side panels.
4. Install the Tuflock fasteners r and screws t that

fasten the front cab to the footwells and fender flares .
10
10.11
BODY / FRAME
REAR RACK / STORAGE BOX REAR RACK INSTALLATION

1. Place the rear rack in place and align the mounting
REAR RACK REMOVAL
holes.
1. Open the rear storage compartment. 2. Loosely install the fasteners that retain the rear rack.
2. Remove the screws retaining the rear rack..
3. Torque fasteners to specification.

3. Remove rack. TORQUE
Until Fully Seated
10.12
BODY / FRAME
REAR CAB
REAR CAB REMOVAL
1. Remove the seat. 5. Remove the fasteners w retaining the fender flares.
2. Remove the side panels. 6. Remove the fastener e retaining the footwell sheild.
3. Remove the rear rack.
4. Remove the Tuflock fasteners q retaining the rear
cab.
10
10.13
BODY / FRAME
REAR CAB INSTALLATION
1. Place the rear cab and align the mounting holes.

2. Install the Tuflock fasteners q that retain the rear
cab.
3. Install the fasteners w that retain the fender flares.
TORQUE
Fender Flare Fasteners:
Until Fully Seated
4. Install the fastener e retaining the footwell shield.
TORQUE
Footwell Shield Fastener:
Until Fully Seated
5. Install the rear rack.

6. Install the side panels.
10.14
BODY / FRAME
REAR BUMPER COVER REAR BUMPER COVER INSTALLATION

1. align the rear bumper cover with the mounting holes
REAR BUMPER COVER REMOVAL
and loosely install the fastenersq.
1. Open the rear storage lid and remove the rear rack.
2. Toque to specification.
2. Disconnect the tail lights from the main wiring TORQUE
harness.
3. Remove the tail lights. Until Fully Seated
4. Remove the screws retaining the rear bumper cover.
3. Install the tail lights.
4. Connect the tail lights to the main wiring harness.
5. align the rack with the mounting holes and loosely
install fasteners.
10
6. Torque to specification.
TORQUE
Until Fully Seated
10.15
BODY / FRAME
MAIN FRAME / FRAME SUPPORTS
MAIN FRAME ASSEMBLY VIEW

q Screw 30 ft-lbs (41 Nm)
w Screw 30 ft-lbs (41 Nm)
e Screw
10.16
ELECTRICAL
CHAPTER 11
ELECTRICAL
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
CHASSIS HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.6
HARNESS RETENTION LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.6
HARNESS ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7
ELECTRICAL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8
ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8
DIGITAL MULTI-METER (DMM) NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8
STATIC AND DYNAMIC TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8
STATIC TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8
DYNAMIC TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8
CONNECTOR PROBING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9
FRONT PROBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9
BACK PROBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9
BREAK OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9
TESTING CONTINUITY/RESISTANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.10
TESTING FOR A SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.11
TESTING FOR A SHORT TO VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.12
TESTING FOR INTERMITTENT CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.12
TESTING CURRENT FLOW (AMPERAGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.13
TESTING PARASITIC DRAW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.13
TESTING VOLTAGE DROP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.14
DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.15
INSTURMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.15
INSTRUMENT CLUSTER OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.15
RIDER INFORMATION DISPLAY - SPORTSMAN / SCRAMBLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.16
INFORMATION DISPLAY AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.17
DIAGNOSTIC MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.20
INSTRUMENT CLUSTER PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.21
INSTERMENT CLUSTER TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.22
INSTRUMENT CLUSTER - KEY OFF / NO POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.22
INSTRUMENT CLUSTER - KEY ON / NO POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.23
INSTRUMENT CLUSTER - NO HIGH BEAM INDICATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.24 11
INSTRUMENT CLUSTER - NO / INCORRECT FUEL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.25
MESSAGE CENTER GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.26
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.26
INDICATOR LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.27
DISPLAY AREA 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.28
DISPLAY AREA 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.29
OPTIONS MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.30
UNIT SELECTION DISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.31
11.1
ELECTRICAL
UNIT SELECTION TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.32

CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.33
BACK LIGHT COLOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.34
BACK LIGHT LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.35
SERVICE HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.36
DIAGNOSTIC CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.37
INSTRUMENT CLUSTER PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.38
POLARIS INTERACTIVE DIGITAL DISPLAY (PIDD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.39
INTERACTIVE DIGITAL DISPLAY (PIDD) CONNECTOR PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.39
IDD USER’S GUIDE / OWNER’S MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.39
IDD – USB FLASH DRIVE RECOMMENDATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.40
INTERACTIVE DIGITAL DISPLAY (PIDD) FROZEN DISPLAY SCREEN RECOVERY METHODS . . . . 11.41
INTERACTIVE DIGITAL DISPLAY (PIDD) RESET AND UPDATE PROCEDURE . . . . . . . . . . . . . . . . . . . . . 11.43
GPS RECEIVER TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.44
SWITCHES / CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.46
BRAKE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.46
IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.46
IGNITION SWITCH - INTERNATIONAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.46
DRIVE MODE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.46
OFF / RUN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.47
LEFT-HAND SWITCH CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.48
LEFT-HAND SWITCH CONTROLS - INTERNATIONAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.49
REVERSE / MODE BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.50
HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.50
THROTTLE RELEASE SWITCH (TRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.51
GEAR SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.52
GEAR SELECTOR RESISTOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.52
SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.53
VEHICLE SPEED SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.53
ALL WHEEL DRIVE (AWD) AND ADC COILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.54
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.54
DIAGNOSING SYSTEM FAILURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.54
FUSE / RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.56
RELAY OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.56
CHASSIS RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.56
FAN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.56
EFI RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.56
BUMPER LIGHTS RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.56
START SOLENOID RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.57
POWER STEERING RELAY (EPS MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.57
LOW BEAM RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.57
HIGH BEAM RELAY - INTERNATIONAL MODELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.57
FUSE PROTECTED CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.57
FUSE / RELAY BOX LAYOUT - SPORTSMAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.58
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.59
HEADLAMPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.59
HEADLIGHT ADJUSTMENT, POD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.59
11.2
ELECTRICAL
HEADLIGHT REPLACEMENT, POD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.59

HEADLIGHT ADJUSTMENT, BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.60
HEADLIGHT REPLACEMENT, BUMPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.60
TAILLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.61
TAIL / BRAKE LIGHT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.61
CENTER BRAKE LIGHT / WORK LIGHT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.61
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.63
CHARGING SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.63
VOLTAGE RECTIFIER / REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.63
VOLTAGE RECTIFIER / REGULATOR OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.63
NON-HIGH LIFTER MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.63
VOLTAGE REGULATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.63
VOLTAGE REGULATOR INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.63
HIGH LIFTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.64
VOLTAGE REGULATOR REMOVAL, HIGH LIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.64
VOLTAGE REGULATOR INSTALLATION, HIGH LIFTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.66
CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.67
BATTERY CHARGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.67
STATOR / ALTERNATOR TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.68
STATOR / ALTERNATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.69
STATOR / ALTERNATOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.70
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.71
STARTER / STARTER LOCKOUT SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.71
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.71
STARTER MOTOR REMOVAL / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.71
BATTERY SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.73
BATTERY SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.73
GENERAL BATTERY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.73
BATTERY REMOVAL (NON-HIGH LIFTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.73
BATTERY INSTALLATION (NON-HIGH LIFTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.74
BATTERY REMOVAL (HIGH LIFTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.74
BATTERY INSTALLATION (HIGH LIFTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.75
BATTERY TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.75
OCV - OPEN CIRCUIT VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.75
LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.75
BATTERY CONDUCTANCE ANALYZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.75
CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.76
ELECTRONIC POWER STEERING (EPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.77
EPS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.77 11
EPS TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.78
HAND / THUMB WARMERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.79
HAND / THUMB WARMER RESISTANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.79
WINCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.80
WINCH ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.80
WINCH CONTACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.81
CONTROLLER AREA NETWORK (CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.82
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.82
11.3
ELECTRICAL
CAN TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.82

BREAKOUT WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.83
AWD (NON-ETC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.83
AWD INPUT (ETC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.83
COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.83
CRANKSHAFT POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.83
DIAGNOSTIC CIRCUIT/CAN BUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.84
EFI AND CHASSIS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.84
ELECTRONIC THROTTLE SIGNAL/INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.84
ELECTRONIC THROTTLE OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.84
ENGINE TEMP. SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.84
IGNITION COIL (ETC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.84
IGNITION COIL (NON-ETC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.84
INTAKE AIR TEMP SENSOR (ETC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.84
INTAKE AIR TEMP SENSOR (NON-ETC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.85
THROTTLE POSITION SENSOR (NON-ETC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.85
TMAP (ETC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.85
TMAP (NON-ETC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.85
11.4
ELECTRICAL
GENERAL INFORMATION
SPECIAL TOOLS
PV-43568 Fluke™77 Digital Multimeter
PA-49466 Test Relay
PV-43526 Connector Test Kit
11
11.5
ELECTRICAL
CHASSIS HARNESS
HARNESS RETENTION LOCATIONS
Tie-strap retainers indicated by q.
FRONT RETENTION POINTS
REAR RETENTION POINTS
11.6
ELECTRICAL
HARNESS ROUTING
NOTE
If replacing the harness, noting routing during removal will aid in proper installation.
11
11.7
ELECTRICAL
ELECTRICAL DIAGNOSTICS
ELECTRICAL SERVICE NOTES STATIC AND DYNAMIC TESTING
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
• When measuring resistance of a component that has a The two most common forms of static testing are:
low resistance value (under 10 Ohms), remember to
subtract meter lead resistance from the reading. • Resistance testing (the Ohms setting on your DMM)
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
• Become familiar with the operation of your meter. Be Voltage”.
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
use when diagnosing electrical problems. Readings Before attempting dynamic testing (as it is intrusive on
obtained with other meters may differ. sealed connectors and damage could be done if not
• Pay attention to the prefix on the meter reading (K, M, careful), verify the following:
etc.) and the position of the decimal point. • Static voltage testing advised for that circuit has been
• For resistance readings, isolate component to be completed, and is in spec.
tested. Disconnect wire harness or power supply. • All associated circuits have under 1 ohm of resistance
from end to end. , page 11.10
• All associated circuits have no shorts to ground. , page
DIGITAL MULTI-METER (DMM) NOTES 11.11
Polaris advises to only use a high quality DMM that • All associated circuits have no shorts to voltage. , page
meets the same standards as the Fluke™ 77 (PV-43568) 11.12
for electrical testing.
DYNAMIC TESTING
Unless you are very familiar with Ohm’s Law, and have
There are two types of dynamic testing we will advise to
complete information about the circuit you are trying to
use when diagnosing electrical concerns:
diagnose, test lights are likely to provide results that
would be misleading. This is especially true if any solid • Current flow testing (Amperage) , page 11.13.
state component is involved, where you will almost Measuring Amperage is not a common practice, as
certainly not have complete circuit information. you will not typically have a spec to compare your
Polaris also specifically advises against the use of other reading to. Also, many components on this machine
circuit testing devices, including but not limited to: flow over 10 Amps, which will blow the majority of
DMM fuses. The exception to this is a parasitic draw
• Short finders test. , page 11.13
• Simplified circuit testers • Measuring voltage drop. Performing this test correctly
• Fuse piggy-back devices will give you understanding of how electrical pressure
Testers beside a DMM will only work in one scenario, (voltage) varies in a circuit as current is flowing. , page
and slight variables can provide you with misleading 11.14
results. The testing practices described in this chapter
are more certain and rely only on the DMM and your
knowledge.
11.8
ELECTRICAL
CONNECTOR PROBING GUIDELINES

FRONT PROBING
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 BACK PROBING
tension. If there is no tension, you will have either no Back probing is typically not advisable on sealed
connection or a poor connection. connectors, as it can easily cause damage to the wire,
To avoid causing damage, use of the appropriate terminal, connector body, or body to wire seal.
adapters is required. Most terminals used on Polaris
machines can be tested using terminal test kit PV– NOTE
43526. It includes male and female adapters that can be There are commercially available back probe kits. Fine,
plugged into banana connectors to adapt to your meter. 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. BREAK OUT
If very little or no resistance is felt, or if the tester falls out This is a method of front probing to achieve the goal of
when the connector is held upside down, this is an back probing, which is to measure the circuit while it is
indication that the female connector in the harness has functioning.
insufficient tension and will cause connection issues. You
You can use test probe kit PV– 43526, test leads, and
can either replace that harness, or service it by replacing
electrical tape to create a bridge with exposed testing
the terminal or attempting to adjust/tighten the tang in the
female terminal.
areas to have everything exposed but still working. 11
For a video demonstration, scan the QR code below, or CAUTION
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.
11.9
ELECTRICAL
TESTING CONTINUITY/RESISTANCE
Testing using the Ohmmeter function of your DMM is one
of the first things you will do when troubleshooting an
electrical issue. It is especially convenient when the
wiring diagram provides a resistance spec for the
component in the circuit you are diagnosing. It can
quickly give you a good idea if you simply need to
replace a part, or if there might be another circuit issue.
Using the following points in conjunction with your DMM
owner’s manual will ensure your resistance testing is
always accurate:
• Only measure resistance on an isolated part of the
circuit. This means if you are testing internal resistance
of a component, it cannot be connected to the
harness. If you are measuring a wire (typically from the
ECU to a sensor) both the sensor and ECU would
need to be unplugged. Most Ohmmeters provides a
precise amount of current to determine resistance. Any
other sources will make your reading inaccurate.
• Ensure you are making good contact by using the
proper terminal adapters. , page 11.9
• If you are not using a self ranging meter, double check
your range setting.
• If your continuity is under 1 ohm, leave the harness
disconnected, and move on to testing for shorts to
ground , page 11.11 and shorts to voltage , page 11.12
11.10
ELECTRICAL
TESTING FOR A SHORT TO GROUND

Shorts to ground happen when the current flowing in a
given circuit bypasses the load. The current flowing from
B+ finds an easier way to return to ground (B-), so much
more of it can flow than the circuit is designed for. This
causes the circuit’s protection device (either a fuse or
circuit breaker) to open, protecting the circuit from
damage.
There are many possible causes of a short to ground,
here are some:
• The harness rubbing against a component that is
grounded, such as the frame, chassis component, or
engine.
• A component’s internal circuitry contacting it’s case.
• Wire to wire chaffing causing contact with the
conductor of a ground side circuit.
• Corrosion/moisture in a component providing a ground
path.
• Moisture in a connector body providing a ground path.
NOTE
This test is typically done right after checking continuity
from sensor to ECU when diagnosing an EFI DTC. It
can also be used to help diagnose concerns about
blowing fuses. Ensure you are able to duplicate the
concern before testing so that your results point you in
the right direction., page 11.12
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. ,
page 11.10
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., page 11.9
8. If there is continuity, the harness is damaged and
should be repaired or replaced.
11
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. , page 11.12
11.11
ELECTRICAL
TESTING FOR A SHORT TO VOLTAGE TESTING FOR INTERMITTENT CONDITIONS

There are three possible short to voltage causes: Intermittent conditions are very difficult to diagnose, as
when you are testing the circuit, you may not have the
1. Internal electronic component short.
circuit failing to indicate where the issue is. Intermittent
2. Harness chaffing leading to contact of the circuit electrical failures are almost always related to a poor
being diagnosed to one with B + or a different connection that only goes open in specific situations,
reference voltage. such as going over a certain kind of bump, at a certain
3. Moisture in a connector or component. temperature, or when the machine is torque loaded in
one way.
TESTING PROCEDURE
Here is a list of possible failures that can be associated
1. Consult the wiring diagram. Determine which circuit with an intermittent electrical failure:
you will be testing.
• Loose female terminal in an electrical connector.
2. Ensure that any static voltage checks advised in
relation to the DTC or concern you are diagnosing NOTE
have been performed and are in spec. If the terminals in question are the correct size/series,
3. Ensure you have checked continuity of the circuit. , always use PV–43526 to test the drag when inserting
page 11.10 and removing the test terminal adapters. Compare the
4. Ensure you have checked for a short to ground. , effort to the drag against the known good tester
page 11.11 terminal for reference.
5. Ensure that neither end of the circuit is connected. • Poor terminal to wire crimp.
6. Set your DMM to DC volts. • Terminal crimp that occurred at least partially on
insulation instead of the conductor wire strands.
7. Connect one meter lead securely to the battery
• Terminal fretting corrosion
negative post.
• Contamination/moisture corrosion
8. Connect the other lead to either end of the • A full or partial break of the conductor wires in the
disconnected circuit. Ensure you are using the correct insulation, with or without visible insulation damage.
adapter., page 11.9 • Improper routing, especially when it leads to chaffing
9. If there is voltage present, the harness is damaged or heat damage, especially near exhaust.
and should be repaired or replaced. You may need to
remove the protective tape and tubing to inspect. You may need to use different techniques to duplicate
these concerns. These include but are not limited to:
10. If the DMM reads 0 volts, the concern may be in a
component related to the circuit. If so, checking • Moving the harness by wiggling it or flexing certain
internal continuity of non-electronic components may areas.
reveal the concern, but diagnosis at this point may • Pulling at or near the suspected connector.
require using known good parts. • Pushing in different directions to flex the connector
body and try to isolate poor connections.
For a video demonstration, scan the QR code below, or • Changing the temperature. This can be accomplished
right click it and select “open in new tab”. 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
temp of an area. Failure to do so can lead to Serious
injury and/or damage to the machine.
11.12
ELECTRICAL
TESTING CURRENT FLOW (AMPERAGE) TESTING PARASITIC DRAW

Performing a current flow test requires the meter leads Parasitic draw is when there is excessive current flow
be inserted into the correct cavities in the meter, and be with the key off.
placed in series in the circuit to be tested. Refer to your
While the most common causes of draws are improperly
Digital Multi Meter’s owner’s manual for potential model
installed accessories (tapping into un-switched B +
specific instructions. Ensure you are using acceptable
instead of switched) there can be electronic component
adapters to avoid damaging the connector terminals. , failures that can cause this as well.
page 11.9
TESTING PROCEDURE
NOTE 1. Remove the negative cable from the battery.
As there are very infrequently amperage specs 2. Connect a jumper from the negative battery cable
provided for circuits/components, please only perform terminal to the negative battery post.
this test when advised in the manual.
3. Ensure your meter leads and selector dial are set to
measure amperage.
CAUTION 4. Connect your red lead to the battery negative cable
Many circuits on this machine will exceed the 10 Amp terminal.
fuse in most Digital Multi Meters in normal operation. 5. Connect your black lead to the battery negative post.
6.
CAUTION
Ensure all electrical components are switched off, or
damage to your jumper and/or meter will occur.
Momentarily key the ignition switch on, then off.

7. Wait 30 minutes before checking the value. Vehicles
will vary, but electronic components will take time to
fully go to sleep after switched power is removed.
8. Maximum allowable is 10 milliamps. If your meter is
ranged to the 10 Amp scale, this will appear as 0.010
Amps.
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
attention.
11
11.13
ELECTRICAL
TESTING VOLTAGE DROP

NOTE
If you disconnect the connector at the load, and
measure voltage with one lead on the power supply
wire, and one to ground, you will be measuring
available voltage. This is a static test and not dynamic
voltage drop testing. Refer to page , page 11.8
The measurement of voltage is the DIFFERENCE in

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.
NOTE
You will need to backprobe to perform this test. For
information about doing this safely, refer to , page 11.9
Voltage should be near fully depleted by the load. This

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).
If you do have a difference in pressure, this means there
is something adding resistance to the circuit such as
corrosion.
11.14
ELECTRICAL
DISPLAYS
INSTURMENT CLUSTER
INSTRUMENT CLUSTER OVERVIEW

The instrument cluster displays critical vehicle information to the user. Reference the following page for display
functions and descriptions.
NOTE
Some features are not applicable to all models.
The use of a high pressure washer may damage the instrument cluster. Wash the ATV by hand or with a garden hose
using mild soap. Certain products, including insect repellents and chemicals, will damage the instrument cluster lens.
Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean
off any gasoline that splashes on the instrument cluster. 11
11.15
ELECTRICAL
RIDER INFORMATION DISPLAY - SPORTSMAN / SCRAMBLER

The rider information display is located in the instrument cluster. All segments will light up for 1 second at start-up.
NOTE
If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may
have shut off to protect the electronic speedometer.
q Vehicle Speed Display - Analog display of vehicle speed in MPH or km/h

Information Display Area - Odometer / Trip Meter / Tachometer / Engine Temp. / Engine Hours / Service
w / Clock - LCD display
MPH / KM/H Display - MPH is displayed when the instrument cluster is in the Standard mode. KM/H is
e displayed when the cluster is in the Metric mode.
r High Beam Indicator - LED icon illuminates when the headlamp switch is in the high beam position.
Fuel Level Indicator - LCD bar graph indicating current fuel level. All segments will flash when the last
t segment is cleared indicating a low fuel warning.
y Clock - Display current time in either 12–hour or 24–hour formats
Engine Temperature Indicator - LED icon illuminates when the ECM determines the engine is
u overheating. The indicator will flash to indicate the engine is overheating. The indicator will stay lit and not
flash if a severe overheating condition exists.
Service Interval Indicator - Preset at the factory and adjustable by the user; a flashing wrench symbol
i alerts the operator that the preset service interval has been reached and maintenance should be
performed. The wrench icon will flash for 10 seconds upon start-up once it reaches 0.
Check Engine MIL - Illuminated when the ECM has detected a diagnostic trouble code in the engine
o management system.
a AWD Indicator - Illuminated when the AWD / TURF switch is in the AWD position.
s TURF Indicator (INTL. Only) - Illuminated when the AWD / TURF switch is in the TURF position.
d Neutral Gear Indicator - LED icon illuminates when the gear shifter is in the neutral (N) position.
Gear Position Indicator - Displays gear shifter position.
H = High
L = Low
f N = Neutral
R = Reverse
P = Park
– = Gear Signal Error (shifter stuck between gears)
Power Steering System MIL (EPS Models) - LED icon illuminates when a fault has occurred in the EPS
g system. This indicator also turns on momentarily when the key is turned on.
Turn Signal / Hazard Lamp Indicator - If equipped with turn signals, the LED icon illuminates whenever
h the left, right or hazard blinker is activated.
Active Descent Control Indicator - Illuminated when the RH control switch is in the ADC 4x4 position
j and ADC is active.
11.16
ELECTRICAL
INFORMATION DISPLAY AREA Tachometer (RPM)

The LCD portion of the instrument cluster is the
information display area. Information displayed in this
area includes: odometer, trip meters, engine RPM,
engine hours, service interval, clock, engine Diagnostic
Trouble Codes (DTCs) and power steering DTCs.
The reverse override button on the LH control acts as the
MODE button when pressed and released quickly. The
transmission cannot be in reverse when using the
override button as a MODE button.
Odometer
Engine RPM can be displayed digitally.

Engine Hours
The odometer records and displays the total distance

traveled by the ATV. The odometer can not be reset.
Trip Meters (Trip 1 / Trip 2)
Engine hours are logged anytime the engine is running.

Total hours can not be reset.
The trip meters records the miles traveled by the ATV on

each trip. To reset the trip meters:
1. Toggle the MODE button to Trip 1.
2. To reset to 0, push and hold the MODE button until
the distance display changes to 0.
11
3. Perform this same procedure to reset Trip 2.
11.17
ELECTRICAL
Programmed Service Interval Clock
The initial factory service interval setting is 50 hours. The clock displays the time in a 12-hour or 24-hour
Each time the engine is started, the engine hours are format. Refer to “Units of Measurement” to change the
subtracted from the service interval hours. When the format (Standard 12-hour / Metric-24 hour). To set the
service interval reaches 0, the LCD wrench icon will flash clock, follow these steps:
for approximately 10 seconds each time the key is turned 1. Toggle the MODE button until the odometer is
ON. displayed.
To change the hour setting or reset the function, follow 2. Press and hold the MODE button until the hour
these steps: segment flashes. Release the button
1. Toggle the MODE button until the wrench icon is 3. With the segment flashing, tap the MODE button to
displayed in the information area. advance to the desired setting.
2. Press and hold the MODE button until the information 4. Press and hold the MODE button until the next
display area begins to flash. segment flashes. Release the button.
3. Toggle the MODE button to increase the service 5. Repeat steps 3-4 twice to set the 10 minute and 1
interval hours in 5 hour increments to a maximum of minute segments. After completing the 1-minute
100 hours. segment, step 4 will save the new settings and exit
4. To turn off the service interval function, toggle the the clock mode.
MODE button until “OFF” is displayed.
UNITS OF MEASUREMENT
STANDARD
METRIC DISPLAY
DISPLAY
Distance Miles (MPH) Kilometers (KM/H)
Time 12-Hour Clock 24-Hour Clock
To change between Standard and Metric units of

measurement, follow these steps:
1. Turn the key to the OFF position.
2. Press and hold the MODE button while turning the
key to the ON position.
11.18
ELECTRICAL
3. When the display flashes the distance setting, tap the Under / Over Voltage
MODE button to advance to the desired setting. This warning usually indicates that the vehicle is
operating at an RPM too low to keep the battery charged.
It may also occur when the engine is at idle and a high
electrical load is applied (lights, cooling fan or other
accessories).
If battery voltage drops below 11 volts, a warning screen
will display “Lo” and provide the present battery voltage.
If voltage drops below 8.5 volts, LCD backlighting and
icons will turn off.
If battery voltage rises above 15 volts, a warning screen

will display “OV” and provide the present battery voltage.
If voltage rises above 16.5 volts, LCD backlighting and
icons will turn off.
4. Press and hold the MODE button to save the setting

and advance to the next display option.
5. Repeat the procedure to change remaining display
settings.
11
11.19
ELECTRICAL
DIAGNOSTIC MODE 3. A set of three numbers will appear in the information

display area.
The diagnostic mode is accessible only when the check
engine MIL has been activated. • The first number (located far left) can range from 0 to
9. This number represents the total number of trouble
NOTE codes present (example: 2 means there are 3 codes
If there is a diagnostic problem with the power steering present).
system, the power steering MIL will illuminate and blink • The second number (located top right) can be 2 to 6
in place of the check engine MIL. digits in length. This number equates to the suspected
area of fault (SPN).
• The third number (located bottom right) can be 1 to 2
Use the following procedure to display diagnostic trouble digits in length. This number equates to the fault mode
codes that were activated during current ignition cycle (FMI).
causing the MIL to illuminate. Diagnostic trouble codes
will remain stored in the gauge (even if MIL turns off) until
the key is turned off.
1. If the trouble code (s) are not displayed, use the
MODE button to toggle until “CK ENG” displays on
the information display area.
4. Use the trouble code reference table in the EFI

Chapter for a description of each code.
2. Press and hold the MODE button to enter the 5. If more than one code exists, press the MODE button
diagnostics code menu. to advance to the next trouble code.
6. To exit diagnostic mode, press and hold MODE
button or turn ignition key OFF once the codes are
recorded.
11.20
ELECTRICAL
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
Fuel Level Sensor 11
International Models Only
Turn Signal Input, LH 6
Turn Signal Input, RH 7
11
11.21
ELECTRICAL
INSTERMENT CLUSTER TROUBLESHOOTING
INSTRUMENT CLUSTER - KEY OFF / NO POWER
11.22
ELECTRICAL
INSTRUMENT CLUSTER - KEY ON / NO POWER
11
11.23
ELECTRICAL
INSTRUMENT CLUSTER - NO HIGH BEAM INDICATOR
11.24
ELECTRICAL
INSTRUMENT CLUSTER - NO / INCORRECT FUEL LEVEL
11
11.25
ELECTRICAL
MESSAGE CENTER GAUGE
OVERVIEW
NOTE
The use of a high pressure washer may damage the instrument cluster. Wash the vehicle by hand or with a garden
hose using mild soap. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the
lens. Immediately clean off any gasoline that splashes on the instrument cluster.
H = High Gear
L = Low Gear
N = Neutral
q Gear Indicator R = Reverse Gear
P = Park
– = Gear Signal Error (or shifter between gears)
This area displays odometer, trip meter, trip meter 2, voltage, engine temperature, engine hour meter, programmable
w Display Area 2 service hour interval, ground speed, or engine RPM.
e Display Area 1 This area displays engine RPM, ground speed, or coolant temperature.
The segments of the fuel gauge show the level of fuel in the fuel tank. When the last segment clears, a low fuel warning is
r Fuel Gauge activated. All segments including the fuel icon will flash. Refuel immediately.
A flashing wrench symbol alerts the operator that the preset service interval has been reached. Your POLARIS dealer can
t Service Indicator provide scheduled maintenance. See , page 11.36 for more information.
y Clock The clock displays time in a 12-hour or 24-hour format. See , page 11.33 for more information.
u AWD Indicator Segments of the indicator illuminate based on drive mode engaged.
11.26
ELECTRICAL
INDICATOR LAMPS
This indicator appears if an EFI-related fault occurs. Do not operate the vehicle if this warning appears.
q Check Engine Serious engine damage could result. Your authorized POLARIS dealer can assist.
This indicator illuminates when a fault has occurred in the EPS system. Your authorized POLARIS
w EPS Warning (if equipped) dealer can assist. EPS operation is possible with key on/engine off for up to 5 minutes.
This lamp illuminates to indicate an overheated engine. If the indicator flashes, a severe overheating
e Engine Hot condition exists.
r Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position.
This lamp flashes for several seconds when the key is turned to the ON position. The lamp is a
t Helmet/Seat Belt reminder to wear helmet and seat belt (if equipped) before operating.
y High Beam This lamp illuminates when the headlamp switch is set to high beam.
u Chassis Fault If applicable.
i Performance Limited If applicable.
11
11.27
ELECTRICAL
DISPLAY AREA 1
Pressing the MODE button will change the information displayed in Area 1 q.
Speed Engine Temperature
Ambient Temperature
RPM (Optional)
11.28
ELECTRICAL
DISPLAY AREA 2
Toggle the Up/Down buttons to change the information displayed in Area 2 w.
Odometer Engine Temperature
Ambient Temperature
Trip 1
(Optional)
Trip 2 RPM
Voltage Speed
11
Engine Hours Service Hours
11.29
ELECTRICAL
OPTIONS MENU
Press and hold the MODE button to enter the Options Menu.
OPTIONS MENU NOTES

Diagnostic Codes Only displays if fault codes are present or stored
Units - Distance Select MPH or KPH

Units - Temp Select between °F and °C
Clock Select between 12H or 24H, and set time
Backlight Color Select between Blue or Red
Backlight Level Set backlight brightness level
Service Hours View/Set Service hours

Exit Menu Exit
11.30
ELECTRICAL
UNIT SELECTION DISTANCE
1. Press and hold the MODE button to enter the Options Menu.
NOTE
“OPTIONS” will display on the screen for 3 seconds before showing first menu item
2. Select “Units-Distance” from the Options Menu by pressing the MODE button.
Reference the image shown above:
q Press the MODE button.

w Toggle the Up/Down Buttons to change the units (MPH or KPH)
e With the correct unit displayed, Press the mode button which will set the unit and return to the Options
Menu.
3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit
out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu.
11
11.31
ELECTRICAL
UNIT SELECTION TEMPERATURE
NOTE
2. Select “Units - Temp” from the Options Menu by pressing the MODE button.

w Toggle the Up/Down Buttons to change the units (°F or °C)
Menu.
11.32
ELECTRICAL
CLOCK
NOTE
2. Select “Clock” from the Options Menu by pressing the MODE button.

w Toggle the Up/Down Buttons to change the units (12H or 24H)
e With the correct unit displayed, Press the mode button which will set the unit.
r Toggle the Up/Down Buttons to change the units (Cycles Hours)
t With the correct unit displayed, Press the mode button which will set the unit.
y Toggle the Up/Down Buttons to change the units (Cycles 10s of Minutes)
u With the correct unit displayed, Press the mode button which will set the unit.
i Toggle the Up/Down Buttons to change the units (Cycles 1s of Minutes)
o With the correct unit displayed, Press the mode button which will set the unit and return to the Options
Menu.
out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu. 11
11.33
ELECTRICAL
BACK LIGHT COLOR
NOTE
2. Select “Backlight Color” from the Options Menu by pressing the MODE button.

w Toggle the Up/Down Buttons to change the units (Blue or Red)
Menu.
11.34
ELECTRICAL
BACK LIGHT LEVEL
NOTE
2. Select “Backlight Level” from the Options Menu by pressing the MODE button.

w Toggle the Up/Down Buttons to change the units (Increase or Decrease Level)
Menu.
11
11.35
ELECTRICAL
SERVICE HOURS
NOTE
2. Select “Service Hours” from the Options Menu by pressing the MODE button.

w Toggle the Up/Down Buttons to change the units (0, 5, 10, - 95,100)
Menu.
NOTE
To reset service hours after they have counted down to "0.0" reselect the existing setpoint or select a new service
hour value.
11.36
ELECTRICAL
DIAGNOSTIC CODE
NOTE
Diagnostic Code Screen will show available MIL that has come on during that ignition cycle.
NOTE
2. Select “Diagnostic Codes” from the Options Menu by pressing the MODE button.
Toggle the Up/Down Buttons to cycle through Code(s).
NOTE
This option will only be available if a fault code was set or is active during the current ignition key 'on' cycle. Turning
off the ignition will clear any save fault codes from the gauge.
q Area A will Display FMI (XX)

w Area B will Display SPN (XXXXXX)
e Clock Area will Display Count (XXX)
11
11.37
ELECTRICAL
INSTRUMENT CLUSTER PINOUTS
FUNCTION PIN
CAN High 1
CAN Low 2
Constant Power (Vdc) 3
Switched Power (Vdc) 4
Ground 5
Fuel Level Sensor 11
11.38
ELECTRICAL
POLARIS INTERACTIVE DIGITAL DISPLAY E PIDD 16 PIN CONNECTOR – (POWER / SIGNALS)

(PIDD) PIN FUNCTION WIRE COLOR
12 Set Switch WHT / BLK
INTERACTIVE DIGITAL DISPLAY (PIDD) CON- 13 Mode Switch WHT / RED
NECTOR PINOUTS
IDD USER’S GUIDE / OWNER’S MANUAL

For information on how to use the IDD, troubleshoot
potential issues reference the IDD User’s Guide and
Owner’s Manual, part number 9925416.
A printed copy of the manual was included with all ATV’s
equipped with the IDD. If the manual is lost, a new one
can be obtained through normal parts ordering channels.
The manual can also be viewed by accessing the Polaris
Owner’s Manual website.
DOWNLOAD POLARIS OWNER’S MANUALS
WEBSITE:
http://www. polaris. com/en-us/company/owners-manual.
com
When on the Owner’s Manual website, select “ATV” from
the Vehicle Type drop-down menu.
Select “Owners” from the Manual Type drop-down menu.
Select model year from the Model Year drop-down menu.
After making these selections, a full menu list of all
available owner’s manuals will appear on the screen.
The back of the PIDD features a decal with the serial From this selection, click on “ Interactive Digital Display”.
number q , 24 pin connector w and 16 pin connector e. The manual can be viewed online, or downloaded and
saved as a local copy on the electronic device.
W PIDD 24 PIN CONNECTOR – (USB)
PIN FUNCTION WIRE COLOR
6 USB Ground BLK
7 USB Shield GRAY
17 USB VBUS RED
18 USB DATA – WHT
19 USB DATA + DK GRN
E PIDD 16 PIN CONNECTOR – (POWER / SIGNALS)

PIN FUNCTION WIRE COLOR
1 CAN HIGH YEL
2 CAN LOW DK GRN
3 Power (+) RED / DK GRN
4 (From either switched 11
constant PWR (GY/
RD) or Gauge / EV
Actuator Relay PWR
(RD/BK).
5 Chassis Ground BN / WHT
8 High Beam YEL / RED
11 Fuel Level VT / WHT
11.39
ELECTRICAL
IDD – USB FLASH DRIVE RECOMMENDATIONS

Polaris recommends using a Scandisk® or similar USB
flash drive with a minimum of 4 GB available memory.
USB Flash Drive Notes / Troubleshooting
• The flash drive must be formatted as FAT 32. Use
Quick Format on the PC to format the drive as FAT 32.
IMPORTANT
Formatting the flash drive will erase all of its contents.
• Use a dedicated USB flash drive with only RIDER X

Maps-Trails / IDD update files on the drive.
• Don’t create file folders on the flash drive. Download
the RIDER X Maps-Trails or IDD update files to the
root level of the drive.
• When removing the flash drive from the PC or laptop,
use the “Safely Remove Hardware and Eject Media”
tool provided by the operating system.
• Updating the IDD does not require the engine to be
running if the ATV is equipped with a battery. Verify the
battery is fully-charged.
• If errors are encountered during the update process or
the IDD does not recognize the USB flash drive, follow
these steps:
1. Re-format the drive as FAT 32.
2. Download the update file again from RIDER X.
3. Re-attempt to update the IDD.
4. If the IDD does not recognize the USB flash drive,
try the procedure with a different flash drive.
11.40
ELECTRICAL
INTERACTIVE DIGITAL DISPLAY (PIDD) FRO-

ZEN DISPLAY SCREEN RECOVERY METHODS
PIDD POWER-ON DISPLAY (NORMAL OPERATION)
When the PIDD is turned on, the screen will display
“Booting...”. After the PIDD completes the booting
process, the screen will display the Polaris logo and then
display the vehicle home screen.
This concern is caused by the IDD being inadvertently

left in diagnostics mode during manufacturing testing.
ERROR 1 RECOVERY METHOD:
Perform PIDD Reset Procedure and Update Procedure.
ERROR 2: PIDD DISPLAYS “BOOTING...” AFTER
TURNING ON / DISPLAYS ALL BLACK SCREEN
WITH NO TEXT
11
ERROR 1: PIDD DISPLAYS “BOOTING...” AFTER
TURNING ON / DISPLAYS ALL WHITE SCREEN WITH
TEXT
11.41
ELECTRICAL
PIDD screen does not display “Booting…” in the upper

left corner of the screen immediately after the PIDD is
turned on.
1. Verify there is power at the PIDD wire harness
connector. Does the screen or buttons illuminate?
2. If the PIDD is not receiving power, troubleshoot the
wire harness, connectors, and ignition switch to
determine why.
3. If the screen and buttons do illuminate, turn the PIDD
off.
4. Perform the PIDD RESET and UPDATE
PROCEDURE.
5. During the procedure, if “Booting…” is never
displayed, replace the PIDD.
ERROR 4: PIDD DISPLAY IS WHITE WITH NO TEXT
After the PIDD is turned on, “Booting…” is displayed in

the upper left corner of the screen but then displays an
all-black screen with NO TEXT.
This concern is caused by mis-formatted or corrupted
memory which can be caused by a failed or corrupted
software update file download.
Perform PIDD Reset Procedure and Update Procedure.
ERROR 3: “BOOTING...” MESSAGE NOT DISPLAYED
ON SCREEN
11.42
ELECTRICAL
After the PIDD is turned on, the screen immediately INTERACTIVE DIGITAL DISPLAY (PIDD) RESET
displays a white background with NO TEXT on the AND UPDATE PROCEDURE
screen.
ERROR 4 RECOVERY METHOD: 1. Log on to: https://www.riderx.com/en-us/home
1. Turn the PIDD off. 2. Download the most current TRAILS UPDATE .zip file.
2. Perform the PIDD RESET and UPDATE 3. Extract the contents of the TRAILS UPDATE .zip file
PROCEDURE. to the root of your USB flash memory stick.
3. During the procedure, if “Booting...” is never IMPORTANT
displayed, replace the PIDD.
Do not unzip the files to a folder. Always extract the files
ERROR 5: MAP IS NOT DISPLAYED ON GPS to the root of the USB flash memory stick.
4. Insert the USB flash memory stick into the PIDD USB
cable port.
5. Push and hold KEY 5 on the PIDD and then turn the
PIDD on.
6. Continue pressing KEY 5 until “Booting...” is no
longer displayed on the screen.
7. Release KEY 5. Follow the prompts on the screen to
update the PIDD with the files on the USB flash
memory stick.
8. When the update process is complete, the PIDD will
reboot.
When the user selects GPS display on the PIDD, the

screen turns gray. This concern is caused by an
incomplete or corrupted MAP file.
1. Log on to: https://www.riderx.com/en-us/home
2. Download the most current vehicle TRAILS + MAP
UPDATE .zip file.
3. Extract the contents of the TRAILS + MAP UPDATE .
zip file to the root of your USB flash memory stick.
IMPORTANT
Do not unzip the files to a folder. Always extract the files
to the root of the USB flash memory stick.
4. Insert the USB flash memory stick into the PIDD USB
cable port.
11
5. Turn on the PIDD and access the UPDATE function
under the SYSTEM SETTINGS menu. Update the
PIDD with the new files.
6. When the update process is complete, the PIDD will
reboot.
11.43
ELECTRICAL
GPS RECEIVER TROUBLESHOOTING Test the GPS Receiver Power Connector to identify why
the receiver is not turning on. If the power connector
Satellite / GPS Receiver Terminology:
passes inspection, install a new receiver and re-test.
DOP: Dilution of Precision (Position / Time Accuracy) No Satellite Reception (DOP Values All Zeros)
HDOP: Horizontal Dilution of Precision
VDOP: Vertical Dilution of Precision
TDOP: Time Dilution of Precision
PIDD Satellite Status Display
1. Move the ATV to an outside area with a clear view of
the sky.
2. Start the engine and allow the PIDD to boot.
3. From the main screen access the GPS Manger Menu
and then Satellite Status.
Over a period of a few seconds, the satellite status
screen should be begin to acquire satellite signals and
resemble the screen shot below.
CAN communication link between receiver and PIDD is
functional but receiver has not yet acquired satellites.
This is normal during the first 30 to 90 seconds after
power up if the GPS has been off for several days. If the
receiver has been off for just a few hours the signal
should be acquired in a few seconds. If satellites are not
acquired after several minutes, check for clear view of
the sky or interfering electrical devices near the receiver.
If the DOP values all remain at zero, replace the receiver
with a new part and re-test.
Poor Satellite Reception
NOTE
Typically, the rider will see more than 4 satellites and
DOP numbers less than 2.
GPS Receiver Not Communicating with the PIDD
If the number of satellites is greater than zero then the

receiver has acquired a signal from each satellite listed
but either has not calculated a position or the position is
not very accurate.
A HDOP number of 100 and no LAT / LON indicates no
position has been calculated. If a valid LAT / LON
number is indicated but the HDOP number is still high
(>5) that indicates the position is not very accurate. The
position at rest in the map screen will jump around. This
The HDOP, VDOP, and TDOP fields will be grayed out
could be due to poor visibility of the sky, electrical
and there will be no position data. When this occurs, the
interference or a faulty receiver.
GPS receiver is either not receiving power, missing CAN
communications, or the receiver is faulty.
11.44
ELECTRICAL
GPS Receiver Power Connector Testing

1. Move the ATV to an outside area with a clear view of
the sky.
2. Open the left side engine compartment panel.
Disconnect the power connector from the GPS
receiver.
3. Start the engine.
4. Using a digital multimeter, perform the following tests:
• Measure VDC between pins 3 and 4. Verify there is B+
between these two pins.
• Measure VDC between pins 1 and 3. Verify there is 1.5
to 2.5 volts between these two pins.
• Measure VDC between pins 2 and 3. Verify there is 2.5
to 3.45 volts between these two pins.
5. If there is no power at the connector, inspect the wire

harness for broken wires.
6. If either of the CAN data signals are 0 VDC, check for
a loose connection in the wire harness.
7. If either of the CAN data signals are out of range, but
not 0, check from possible ECU or PIDD CAN
communication failures.
GPS RECEIVER POWER CONNECTOR

(TERMINAL VIEW)
11
PIN # FUNCTION
1 CAN Low
2 CAN High
3 Sensor Ground (-)
4 Voltage Supply (B+)
11.45
ELECTRICAL
SWITCHES / CONTROLS
BRAKE SWITCH Turn the ignition key to START. There should be
Applying the brakes closes a switch to activate the brake continuity between pins A and B; C and D; E and F.
lamps. Use a multimeter to test for continuity when the
brakes are applied.
Replace the brake switch if function does not pass test.
IGNITION SWITCH
Use a multimeter to test for continuity between the 3
ignition switch outputs (OFF / ON / START). If any of the DRIVE MODE SWITCH
tests fail, replace ignition switch assembly. Use a multimeter to test for continuity between the two
switch outputs (ADC/AWD).
NOTE
Selecting 2x4 drive mode does not complete any
circuits. All circuits should be OL when 2x4 is selected.
Turn the ignition key to ON. There should be continuity

between pins C and D; A and F.
Turn the ignition key to START. There should be
continuity between pins A and B; C and D.
Move the drive selector switch to each drive mode, and
IGNITION SWITCH - INTERNATIONAL then test for continuity.
Use a multimeter to test for continuity between the 4
ignition switch outputs (OFF / ON, LIGHTS / ON /
START). If any of the tests fail, replace ignition switch
assembly.
Turn the ignition key to ON, LIGHTS. There should be

continuity between pins A, E and F; C and D.
Turn the ignition key to ON. There should be continuity
between pins C and D; E and F.
11.46
ELECTRICAL
If any of the tests fail, replace the RH throttle / switch

assembly.
OFF / RUN SWITCH

Use a multimeter to test for continuity when the LH
switch is moved to the RUN position. If the test fails,
replace the LH control assembly.
Move the switch to the RUN position and test.
11
11.47
ELECTRICAL
LEFT-HAND SWITCH CONTROLS

Use a multimeter to test for continuity for each of the LH switch functions. If any test fails, replace the LH control
assembly.
11.48
ELECTRICAL
LEFT-HAND SWITCH CONTROLS - INTERNATIONAL

Use a multimeter set to test for continuity for each of the left-hand control switch functions. If any test fails, replace the
left-hand control assembly.
11
11.49
ELECTRICAL
REVERSE / MODE BUTTON HEADLAMP SWITCH

Use a multimeter to test for continuity when pressing the Use a multimeter to test for continuity between the head
Reverse Override / Mode button. If the test fails, replace lamp outputs in the LH control assembly. If any of the
the LH control assembly. tests fail, replace the LH control assembly.
Push the Reverse Override / Mode button. There should
be continuity between pins B and C.
There should be no continuity when the switch OFF.

Move the switch to LOW. There should be continuity
between pins D and F.
Move the switch to HIGH. There should be continuity
between pins D and E.
Push the Reverse Override / Mode button. There should

be continuity between pins M (BN) and E (GY/OG).
Move the switch to LOW. There should be continuity

between pins YE/DG and DG.
Move the switch to HIGH. There should be continuity
between pins YE and YE/DG.
11.50
ELECTRICAL
THROTTLE RELEASE SWITCH (TRS)
NOTE
Machines with Electronic Throttle Control (ETC) will not
have this switch.
The Throttle Release Switch (TRS) is designed to close

during throttle movement in the event the throttle cable
sticks or breaks.
When the throttle lever is at idle position, the TRS
contacts should be closed (touching). When the throttle
lever is moved the contacts will open and allow normal
operation. If the contacts remain closed or become
closed during throttle movement, the ECM will limit NOTE
engine RPM.
The throttle cable must have the proper amount of free-
play adjustment. Refer to Chapter 2 “Throttle Cable
Adjustment” procedure.
TRS SWITCH — CONTACT POSITIONS

Throttle Lever at Rest (idle) TRS is CLOSED.
Pins 1 and 2: 2.15kΩ
Normal Operation (throttle TRS is OPEN.
open or above idle) Pins 1 and 2: 6.76kΩ
TRS is CLOSED
Throttle Cable Stuck
Pins 1 and 2: 2.15kΩ
11
11.51
ELECTRICAL
GEAR SELECTOR SWITCH

1. Locate the gear selector switch on the transmission.
Remove the wiring harness connector and insert the
multimeter probes into the switch.
2. Move the gear selector handle to each of the 5 drive
positions (HIGH, LOW, NEUTRAL, REV, or PARK).
3. Test for continuity between the switch contacts and
connector leads. Replace the switch if no continuity
or high resistance is found in any of the gear
positions.
GEAR SELECTOR RESISTOR MODULE

The resistor module relays a different resistance reading
to the ECM depending on which gear is selected by the
operator. If the module fails, the ECM will not be able to
determine what gear the transmission is in.
1. Disconnect the ECM harness connector from the
ECM. Locate pins 23 (WHITE) and 30 (VIOLET).
2. Set the multimeter to register OHMS (resistance).
Insert the RED probe into pin 23 and the BLACK
probe into pin 30.
3. Reference the Resistance Table for specifications. If
any of the tests fail, replace the resistor module.
MODULE RESISTANCE ±5%
GEAR POSITION RESISTANCE (Ω)
HIGH 620
LOW 300
NEUTRAL 160
REVERSE 75
PARK 24
11.52
ELECTRICAL
SPEED SENSOR
VEHICLE SPEED SENSOR
The vehicle speed sensor is mated to the transmission housing and reads the speed of the transmission output gear.
Battery voltage is supplied to the sensor on the ORANGE circuit and is energized when the OFF/RUN and ignition
switches are in the RUN and ON positions.
To test the circuit:
1. Turn the ignition key to the “ON” position and move the OFF/RUN switch to “RUN”.
2. Verify there is battery voltage present on the ORANGE circuit. If voltage is not found, inspect the ORANGE splices
/ circuits, LH control assembly, and ignition switch.
3. If voltage is found, test the BROWN ground circuit. Verify there is continuity between the circuit and chassis
ground.
4. If all circuits function, remove the speed sensor from the transmission. Verify the sensor is not damaged.
5. Test the speed sensor using the following tools:
• Hall Sensor Probe: PN 2460761
• Static Timing Light Tool: PN 2871745
6. Connect the tools together as shown below.
7. Insert the sensor probe’s 3 terminals into the speed sensor as follows:
• WHITE wire into pin C.
• BLACK wire into pin B.
• RED wire into pin A.
8. Verify a good 9V battery is connected to the timing light tool.
9. Pass the blade of a screwdriver back and forth across the sensor tip. The timing light tool LED should illuminate
each time the blade passes the sensor face.
10. If the test fails, replace the speed sensor.
11
11.53
ELECTRICAL
ALL WHEEL DRIVE (AWD) AND ADC COILS

OPERATION OVERVIEW
• Key on power is supplied to the AWD hub coil from terminal 23 in the fuse block, on the RED/GREEN wire. The
AWD hub coil is engaged when ground is supplied on the BROWN/WHITE circuit for the AWD hub coil.
• Ground is provided through the ECU, the BROWN/WHITE circuit terminates at ECU pin 217.
• The ECU must see all required operating conditions (rpm in range, correct gear range) and an AWD switch signal to
activate. It then communicates with the Instrument Cluster via CAN bus to display the AWD icon.
DIAGNOSING SYSTEM FAILURES

• Verify the AWD/ADC switch is functional. This can be accomplished by seeing if the AWD indicator comes on when
the switch is turned on and all AWD criteria are met..
• Verify the AWD/ADC Coil circuit(s).
1. Check the DRIVE fuse.
2. Disconnect the AWD/ADC hub coil connector at the front gear case.
3. Connect the clamp lead of your test light to battery negative (B-).
NOTE
The BROWN/WHITE (BN/WH) and BROWN/YELLOW (BN/YE) wires in the AWD/ADC hub coil connector are
grounds, but they are ECU controlled. They will not be consistent and reliable for either this test or trying to read
voltage with a DVOM. Only use B- at the battery or a known good chassis ground for testing this and the ADC circuit.
4. Turn the key on, engine off.

5. Probe the RED/GREEN (RD/GN)wire in terminal C or D (C is AWD, D is for ADC) on the main harness side.
If it illuminates, the circuit is verified up to the front gearcase.
If not, you have an open. Check continuity from the AWD/ADC connector RD/GN in terminal C or D (C for AWD,
D for ADC) back to the DRIVE fuse.
If all checked good, test continuity from the BN/WH in terminal B of the front gearcase connector to terminal 17 in
the ECU connector (circuit E217) if the issue is with AWD. If the issue is with ADC, check the BN/YE back to ECU
terminal 49 (circuit E249).
• Test the AWD hub coil using an ohm meter.
AWD Hub Coil Resistance:

24 Ω ± 5%
11.54
ELECTRICAL
• Verify that connector pins and grounds are undamaged, clean and connect properly.
NOTE
Verify all wires and wiring connections have been tested properly with a known good volt/ohm meter before
suspecting a component failure. A high percentage of electrical issues are caused by bad/failed connections and
grounds.
11
11.55
ELECTRICAL
FUSE / RELAYS
RELAY OVERVIEW FAN RELAY
Relays use low current circuits to control high current The fan relay provides power to the following system:
circuits. The low current circuit flows through a coil
• Fan Motor
winding, which magnetically attracts the contact to close
the high current side, allowing that side of the circuit to
flow current. COLOR FUNCTION
20A Circuit breaker-protected 12 Vdc
RD / WHT battery voltage.
ORG / YEL ECM control circuit for relay coil.
Constant 12 Vdc battery voltage to
RD / WHT relay coil.
ORG / BLK Fan motor power 12 Vdc.
EFI RELAY
The EFI relay provides power to the following systems:
• Ignition Coil Power
• Fuel Pump Power
• Fuel Injector Power
COLOR FUNCTION
20A fuse-protected 12 Vdc battery
RD / GRN voltage.
GRN / YEL Relay coil ground from ECM.
LH RUN switch supplied 12 Vdc battery
ORG
CHASSIS RELAY voltage to relay coil.
The chassis relay provides power to the following 12 Vdc power splice for:
systems: -Ignition coil pack
RD / BLU -Fuel Pump
• Head Lights / Tail Lights / Brake Light -Fuel Injectors
• AWD Coil / ADC Coil / RH Drive Switch
• Accessory Power Points
BUMPER LIGHTS RELAY
COLOR FUNCTION
The bumper lights relay provides power to the following
Fuse link-protected 12 Vdc battery system:
RD voltage.
ECM control circuit for relay coil. • Front Bumper Head Lights
DB / RD
LH RUN switch supplied 12 Vdc COLOR FUNCTION
ORG battery voltage to relay coil.
12 Vdc Bus bar for: RD / BRN voltage.
-Lights 20A Fuse
WHT -Drive 20A Fuse BRN Ground for relay coil.
-Accessory 20A Fuse High / Low LH control 12 Vdc battery
DG voltage to relay coil.
DG LH / RH front bumper lights power.
11.56
ELECTRICAL
START SOLENOID RELAY HIGH BEAM RELAY - INTERNATIONAL

The start solenoid relay provides power to the following MODELS
system: The high beam relay provides power to the high beam
• Starter Motor Solenoid light on international models only.
COLOR FUNCTION
COLOR FUNCTION
20A circuit breaker-protected 12 Vdc RD / BRN (1)
RD / WHT voltage.
battery voltage.
High LH control 12 Vdc battery voltage
BRN / WHT ECM control for relay coil. YEL (2)
to relay coil.
WHT / RD Starter solenoid power.
RED (4) High beam lights power.
Key-switched (START) relay coil power
BLU / YEL BRN (5) Ground for relay coil.
12 Vdc battery voltage.
POWER STEERING RELAY (EPS MODELS) FUSE PROTECTED CIRCUITS

FUSE PROTECTED CIRCUITS
NOTE 20A Fan Circuit Fan Motor
The power steering relay is not located inside the fuse Breaker Starter Solenoid
box. 10A Fuel Pump Fuel Pump
EFI Relay-controlled circuits:
The power steering relay provides power to the following -Ignition coil pack
20A EFI
system: -Fuel Injectors
• Power Steering Drive Motor ECM
Fan Relay Driver
COLOR FUNCTION 10A Unswitched Ignition Switch
Power Instrument Cluster
ORG (85) or LH RUN switch supplied 12 Vdc
(1) battery voltage to relay coil. Diagnostic Connector
BRN Relay coil ground. 30A EPS Power Steering Relay / Motor
ORG (87) or Head lights
Power steering 12 Vdc battery power. 20A Lights Tail lights
(5)
Brake lights
RD voltage. AWD Coil
ADC Coil
20A Drive
RH AWD / ADC switch
LOW BEAM RELAY Winch Switch Power
The low beam relay provides power to the low beam 20A Accessory All accessory power point pigtails
lights. 10A Hazard
Not in Relay / Hazard and Flasher circuits
COLOR FUNCTION Fuse Box
RD / BRN (1)
voltage.
Low LH control 12 Vdc battery voltage
DG (2)
to relay coil.
11
DG (4) Low beam lights power.
BRN (5) Ground for relay coil.
11.57
ELECTRICAL
FUSE / RELAY BOX LAYOUT - SPORTSMAN

The fuse box is located under the front rack or storage box.
To gain access, remove the front rack or storage box assembly by unlatching the two locking anchors.
The cover label identifies the location of each relay and fuse.
7180678 - SPORTSMAN 850 / 850 SP / 1000 XP
SPORTSMAN 850 / 1000 TOURING
(Including MD Models)
7180704 - SPORTSMAN 850 / 1000 EU MODELS

SPORTSMAN 850 TOURING EU MODEL
11.58
ELECTRICAL
LIGHTS
HEADLAMPS WARNING
HEADLIGHT ADJUSTMENT, POD Due to the nature of ATVs and where they are
operated, headlight lenses become dirty. Frequent
1. Place the vehicle on a level surface with the headlight washing is necessary to maintain lighting quality. Riding
approximately 25 ft. (7.6 m) from a wall. with poor lighting can result in severe injury or death.
HEADLIGHT REPLACEMENT, POD

1. Remove the screws retaining the front half of the pod
assembly.
NOTE
Rider weight must be included on the seat while
performing this procedure.
2. Place the transmission in PARK.

3. Measure the distance from the floor to the center of
the headlight and make a mark on the wall at the
same height.
4. Start the engine and turn the headlight switch to high
beam.
2. Remove the front half of the pod.
5. Observe the headlight aim on the wall. The most
intense part of the headlight beam should be aimed 2 3. Disconnect the lampq from the main harness.
in. (5 cm) below the mark placed on the wall in Step
3.
6. Loosen the adjustment screw at the rear of the
headlamp.
11
4. Remove the lamp form the housing.
NOTE
If lens housing replacement is required, do so at this
7. Adjust the beam to desired position and tighten the time.
screw.
5. Install new lamp.
6. Connect lamp to main wiring harness.
11.59
ELECTRICAL
7. Install front half of the pod. Torque fasteners until fully HEADLIGHT REPLACEMENT, BUMPER
seated.
Before replacing the lamp, use a digital multimeter to test
the harness to ensure the lamp is receiving 12 volts and
that a ground path is present.
HEADLIGHT ADJUSTMENT, BUMPER 1. Disconnect headlight lamp from the wiring harness.
Be sure to pull on the connector, not on the wiring.
1. Place the vehicle on a level surface with the headlight
approximately 25 ft. (7.6 m) from a wall.
NOTE
Rider weight must be included on the seat while
performing this procedure.
2. Place the transmission in PARK.

3. Measure the distance from the floor to the center of
the headlight and make a mark on the wall at the
same height.
4. Start the engine and turn the headlight switch to high
beam.
5. Observe the headlight aim on the wall. The most
intense part of the headlight beam should be aimed 2
in. (5 cm) below the mark placed on the wall in Step 2. Turn the lamp q counterclockwise to remove it.
3.
6. Open the front rack.
7. Adjust the beam to desired position and tightening or
loosening the screws at the top of the lights. Adjust
each light independently.
3. Insert new the new lamp and turn it clockwise to

secure it. Reinstall the wire harness to the lamp.
NOTE
Make sure the tab on the lamp locates properly in the
housing.
WARNING
Due to the nature of ATVs and where they are
operated, headlight lenses become dirty. Frequent
washing is necessary to maintain lighting quality. Riding
with poor lighting can result in severe injury or death.
11.60
ELECTRICAL
TAILLAMPS 3. Remove the mounting fasteners w.

Right Rear:
TAIL / BRAKE LIGHT REPLACEMENT
NOTE
The LED tail lights are not serviceable and must be
replaced as an assembly.
1. Turn the key to the off position.

2. Disconnect the tail light from the main wiring harness
q.
Right Rear:
Left Rear:
Left Rear:
4. Remove the tail light.

5. Install the NEW tail light
TORQUE
Tail light Fasteners:
Until Fully Seated
6. Connect the tail light to the Main Harness.

7. Verify proper operation.
CENTER BRAKE LIGHT / WORK LIGHT 11

REPLACEMENT
NOTE
The LED tail lights are not serviceable and must be
replaced as an assembly.
11.61
ELECTRICAL
1. Open the rear storage lid ad remove the rear rack. 5. Connect the tail light to the Main Harness.
6. Install the rear rack.
TORQUE
Rear Rack Fasteners:
Until Fully Seated
2. Disconnect the tail light from the main wiring

harnessq.
3. Remove the tail light fastenersw and the tail light.
4. Install the NEW Tail light
TORQUE
Tail light Fasteners:
Until Fully Seated
11.62
ELECTRICAL
CHARGING SYSTEM
CHARGING SYSTEM DIAGRAM 10. Locate the stator wires q near the front of the engine
The charging system consists of:. and disconnect the regulator from the stator.
• Battery
• Stator / Alternator
• Voltage Rectifier / Regulator
VOLTAGE RECTIFIER / REGULATOR
VOLTAGE RECTIFIER / REGULATOR

OVERVIEW
The voltage rectifier / regulator is responsible for
converting AC voltage to DC voltage and controls the DC
output.
NOTE
If the temperature of the regulator / rectifier exceeds 11. Tape a string or cable to the regulator harness.
194°F (90°C), the unit will turn itself off to cool down.
The unit will turn on at approximately 167°F (75°C). If NOTE
voltage output is equal to or less than static battery The rope or cable used should be long enough to allow
voltage, verify the housing cooling fins are clean, free the regulator to be fully removed from the front of the
from debris and that adequate airflow is present. vehicle while leaving some rope or cable exposed at
the footwell. During installation the rope or cable will be
used to properly route the new regulator wiring.
NON-HIGH LIFTER MODELS 12. Grasp the regulator wiring near the regulator and
slowly remove the wiring harness.
VOLTAGE REGULATOR REMOVAL
NOTE
1. Place the vehicle in park.
Do not apply excessive force while removing the
2. Remove the front rack / storage compartment to allow regulator wiring.
access to the battery.
3. Disconnect the battery negative.
13. Remove the Regulator from the vehicle.
4. Disconnect the battery positive.
5. Remove the fasteners retaining the voltage regulator. NOTE
6. Remove the center cover under the pod. Ensure the rope or cable may be grasped and pulled
during assembly as this will be used to install the new
7. Remove the seat.
regulator wiring.
8. Remove the left side panels.
9. Remove the left footwell.
NOTE
VOLTAGE REGULATOR INSTALLATION
This step is only required on 2017 sportsman 850/1000
1-UP machines (excluding High Lifter)
(Applies to NON - High Lifter models only) 11
1. Fasten the rope or cable used during regulator
removal to the NEW regulator wiring harness.
2. Route the regulator harness as it was originally
installed.
NOTE
Do not apply excessive force while installing the
regulator wiring.
11.63
ELECTRICAL
3. Connect the regulator harness to the stator. 4. Remove the fasteners q retaining the voltage
4. Install the left footwell. Torque to specification. regulator.
TORQUE
Footwell Fasteners: Torque Until Fully Seated
5. Install the side panel and seat.

6. Install the fasteners that retain the regulator. Torque
to specification
TORQUE
Regulator Fasteners: 75 in-lbs (7Nm)
7. Connect the battery positive terminal.
TORQUE
5. Release the Lock & Ride fastenersw retaining the
Battery Terminal radiator cover and remove the cover.
6 ft /lbs
8. Connect the battery negative terminal.
TORQUE
Battery Terminal
6 ft/lbs
9. Install the center panel below the pod.

10. Install the front rack / storage compartment.
HIGH LIFTER
6. Remove the fuse box cover.
VOLTAGE REGULATOR REMOVAL, HIGH LIFTER
(Applies to High Lifter models)
1. Place the vehicle in park.
2. Disconnect the battery negative.
3. Disconnect the battery positive.
11.64
ELECTRICAL
7. Remove the fasteners retaining the radiator shroud 18. Loosen the worm clamps u that clamp the clutch
r and fuse box t. duct connector inside of the left front wheel well.
Disconnect the clutch duct.
8. Disconnect the fans from the main wiring harness.

19. Remove the left mud guard.
9. Remove the fan shroud assembly.
20. Loosen the worm clamps i that clamp the clutch
10. Remove the snorkel shroud. duct connector at the front of the clutch housing.
11. Remove the fasteners .y retaining the radiator. Disconnect the clutch duct.
12. Remove the fasteners retaining the center cover 21. Pull the clutch housing end of the duct down and to
under the pod. the left, then pull the duct that routes to the rear of the
vehicle away from the front of the engine.
13. Lift the rear of the radiator, pull center and left duct
towards the front of the vehicle.
14. Pull the center panel forward to disengage the tabs
the push it back towards the steering post and rotate
the front of the panel towards the left side of the
vehicle and remove the center panel.
15. Remove the seat. 11
16. Remove the left side panels.
17. Remove the left footwell.
11.65
ELECTRICAL
22. Locate the stator wires and disconnect the Regulator 2. Draw the voltage regulator wiring harness through the
from the stator. chassis as it was removed.
NOTE
Do not apply excessive force while installing the
regulator wiring. Ensure the regulator harness routes
correctly through the front cab support bracket.
3. Remove the string or cable used to route the

regulator wiring harness.
4. Connect the regulator to the stator.
5. Install the left mud guard.
6. Reconnect the clutch ducts and tighten the worm
clamps to specification.
NOTE
NOTE PVT Worm Clamps: 14 in-lbs (1.6 Nm)
o stator wire outlet shown for reference.

7. Install the left footwell.
23. Tape a string or cable to the regulator harness. 8. Install the left side panels.
NOTE
10. Install the center panel under the pod.
The rope or cable used should be long enough to allow 11. Align the radiator and install the screws that retain it.
the regulator to be fully removed from the front of the
vehicle while leaving some rope or cable exposed at TORQUE
the footwell. During installation the rope or cable will be
used to properly route the new regulator wiring. Radiator Fasteners:
10 ft. lbs (13 Nm)
24. Grasp the regulator wiring near the air intake and
PVT duct snorkels and slowly remove the wiring 12. Install the snorkel shroud. Torque worm clamps to
harness. specification.
NOTE TORQUE
Do not apply excessive force while removing the Snorkel Worm Clamps:
regulator wiring. 14 ft. lbs (2 Nm)
25. Remove the Regulator from the vehicle. 13. Connect the fan wiring connectors to the main wiring
harness.
NOTE
14. Install the fan shroud assembly.
Ensure the rope or cable may be grasped and pulled
during assembly as this will be used to install the new 15. Install the fasteners that retain the fan shroud
regulator wiring. assembly and fuse box. Torque to specification.
TORQUE
Fan Shroud Fasteners:
Until Fully Seated
VOLTAGE REGULATOR INSTALLATION, HIGH LIFTER
(Applies to High Lifter models)
1. Tape the new regulator stator connector to the rope or TORQUE
cable used during disassembly. Fuse Box:
Until Fully Seated
16. Install the fuse box cover.
11.66
ELECTRICAL
17. Install the radiator shroud cover. Engage the Lock & CURRENT DRAW - KEY OFF
Ride fasteners.
18. Install the fasteners that retain the voltage regulator. CAUTION
Do not connect or disconnect the battery cable or
TORQUE ammeter with the engine running. Damage will occur to
Regulator Fasteners: electrical components.
75 in. lbs (7 Nm)
Connect an ammeter in series with the negative battery
cable. Check for current draw with the key off. If the draw
19. Reconnect the battery positive torque to specification. is excessive, loads should be disconnected from the
system one by one until the draw is eliminated. Check
TORQUE component wiring as well as the component for partial
Battery Terminals: shorts to ground to eliminate the draw.
6 ft. lbs (8 Nm)
20. Reconnect the battery negative torque to

specification.
TORQUE
Battery Terminals:
6 ft. lbs (8 Nm)
Current Draw - Key Off:

Maximum of .01 DCA (10 mA)
BATTERY CHARGE TEST

CAUTION
Do not allow the battery cables to become
disconnected with the engine running. Follow the steps
below as outlined to reduce the chance of damage to
electrical components.
1. Verify the battery is fully charged and in good

condition.
2. With the engine running, connect the multimeter to
the positive and negative battery terminals.
11
3. Test for Vdc with the multimeter.
4. The meter display should read approximately 14.0 -
14.4 Vdc at idle.
5. If the voltage is lower than 14.0 - 14.4 Vdc, the
alternator should be tested.
11.67
ELECTRICAL
STATOR / ALTERNATOR TESTS 2. Measure the resistance value of each of the stator
Three tests can be performed using a multimeter to legs to ground.
determine the condition of the stator (alternator). CONNECT
OHMS
TEST METER LEADS
READING
TO:
Battery Charge Y1, Y2, or Y3 Open Line
Coil to Ground (Infinity)
NOTE
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
3. Set your multimeter meter to measure AC Voltage.
4. Disconnect the 3-wire stator connector near the
stator housing.
5. Start the engine and let it idle.
6. While holding the engine at a specified RPM,
separately measure the voltage across each ‘leg’ of
the stator by connecting the meter leads to the wires
leading from the stator (Y1 to Y2, Y1 to Y3, Y2 to
Y3).
7. Refer to the following table for approximate AC
Voltage readings according to RPM. Test each leg at
the specified RPM in the table.
NOTE
If one or more of the stator leg output AC voltage varies
TEST 1: Resistance Value of Each Stator Leg significantly from the specified value, the stator may
need to be replaced.
1. Measure the resistance value of each of the three
stator legs.
RPM
STATOR RESISTANCE VALUES AC VOLTAGE READING
READING
CONNECT METER OHMS 115 Vac ± 10 % (Nominal)
TEST 6000
LEADS TO: READING 171 Vac ± 10 % (Peak)
Charge Coil Y1 to Y2 (Pin B to C) 0.13 Ω ± 15%
Charge Coil Y1 to Y3 (Pin A to C) 0.13 Ω ± 15%
Charge Coil Y2 to Y3 (Pin A to B) 0.13 Ω ± 15%
NOTE
If there are any significant variations in ohm readings
between the three legs, one of the three stator legs may
be weak or failed.
TEST 2: Resistance Value of Each Stator Leg to

Ground
11.68
ELECTRICAL
STATOR / ALTERNATOR REMOVAL 8. Remove the (8) screws retaining the stator cover.
1. Remove the fuel tank.Fuel Tank Removal, page 4.9
2. Remove the (4) screws retaining the engine skid
plate and remove the plate from the vehicle.
3. Place a drain pan under the front portion of the
engine.
4. Remove the coolant hose from the water pump
housing.
9. Carefully remove the stator cover taking care not to

damage the plastic coolant pipe.
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
5. Slowly drain the coolant into the drain pan. Dispose result.
10. Remove the stator wire guide and stator from the
cover.
6. Disconnect the stator wire harness and remove the

CPS from the stator cover.
7. Remove the coolant by-pass hose from the water
11
pump cover fitting.
11.69
ELECTRICAL
STATOR / ALTERNATOR INSTALLATION 5. Torque the (8) stator cover bolts to specification
1. Reverse the “Stator / Alternator Removal” procedure using the torque sequence provided.
to reinstall the stator.
2. Use the following steps to ensure proper assembly.
3. Torque the stator and wire guide bolts to
specification.
4. Install new O-rings on the coolant pipe and lightly

lubricate for ease of installation.
11.70
ELECTRICAL
STARTER MOTOR
STARTER / STARTER LOCKOUT SYSTEM 2. Disconnect the battery negative (-) cable.
DIAGRAM 3. Clean the area around the starter motor.
The starter and starter lockout system consists of:
4. Using an 8 mm allen socket, with an extension,
• Battery / Fuse or Circuit Breaker remove the (2) bolts retaining the starter motor.
• Key Switch / Off/Run Switch
• Starter Solenoid
• Brake Switch / Transmission (Neutral) Switch
• Start Diode
• Starter Motor
TROUBLESHOOTING
Starter Motor Does Not Run
• Battery discharged
• Loose or faulty battery cables or corroded connections
(see Voltage Drop Tests)
• Related wiring loose, disconnected, or corroded
• Poor ground connections at battery cable, starter
motor or starter solenoid (see Voltage Drop Tests)
• Faulty key switch or Off/Run Switch
• Faulty transmission switch
• Faulty Start Diode(s). Use a digital multi-meter to test 5. Remove the engine oil dipstick to allow for starter
diode operation. Locate the diode(s) in the main motor removal.
harness under the hi-temp conduit and measure 6. Remove the starter motor from the crankcase
between the diode connections. Continuity should flow housing. Reinstall the engine oil dipstick.
one direction only.
• Faulty starter solenoid or starter motor 7. Remove the key switch energize wire and battery
• Engine problem - seized or binding (can engine be cable from the starter solenoid. Remove the starter
rotated easily) motor assembly from the chassis.
Starter Motor Turns Over Slowly

• Battery discharged
• Excessive circuit resistance - poor connections (see
Voltage Drop Test)
• Engine problem - seized or binding (can engine be
rotated easily)
• Faulty or worn brushes in starter motor
Starter Motor Turns - Engine Does Not Rotate
• Faulty starter drive
• Faulty starter drive gears or starter motor gear
• Faulty flywheel gear or loose flywheel
STARTER MOTOR REMOVAL /

REPLACEMENT 8. Install the new starter motor assembly by reversing
11
this procedure.
NOTE
The starter motor and solenoid can not be serviced.
Removing the black protective coating from the
components will allow for premature component failure.
Replace the starter motor and solenoid as an assembly.
1. Remove the seat and the upper and lower LH side

panels.
11.71
ELECTRICAL
9. Be sure to install new O-rings on the starter motor

bell housing.
10. Torque the mounting bolts to specification.
TORQUE
Starter Motor Mounting Bolts:
20 ft. lbs (27 Nm)
11.72
ELECTRICAL
BATTERY SERVICE
BATTERY SPECIFICATIONS 2. If the voltage is below 12.6 V, the battery will need to
be recharged (see “Charging Procedure”). Charging
BATTERY PN 4011496 Procedure , page 11.76
Type Polaris / Yuasa YTX20HL-BS
Sealed - Maintenance Free NOTE
Voltage 12 Vdc Never attempt to add electrolyte or distilled water to a
Nominal Capacity Maintenance Free battery. Doing so will damage the
@ 10 HR Rate 18 AH case and shorten the life of the battery.
CCA 310
To service a Maintenance Free battery:
Nominal Open
Circuit Voltage 12.8 Vdc or more. 3. Remove battery from the vehicle (see Chapter 2).
Recommended 4. Test battery with a voltage meter or load tester to
1.8A @ 5-10 HR
Charging Rate determine battery condition. This will determine the
length of time required to charge the battery to full
capacity. Refer to OCV table (see “OCV - Open
GENERAL BATTERY INFORMATION Circuit Voltage Test”). OCV - Open Circuit Voltage
Test, page 11.75
WARNING 5. Charge the battery as recommended (see “Charging
CALIFORNIA PROPOSITION 65 WARNING: Procedure”).Charging Procedure , page 11.76
Batteries, battery posts, terminals and related
accessories contain lead and lead compounds, and BATTERY REMOVAL (NON-HIGH LIFTER)
other chemicals known to the State of California to 1. Remove the front rack or storage box to access the
cause cancer and birth defects or other reproductive battery.
harm. WASH HANDS AFTER HANDLING.
2. Remove the (2) Torx screws q retaining the front
cover w and remove the cover from the vehicle.
WARNING
Battery electrolyte is poisonous. It contains acid!
Serious burns can result from contact with the skin,
eyes, or clothing.
ANTIDOTE:
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow
with milk of magnesia, beaten egg, or vegetable oil. Call
a physician immediately.
Eyes: Flush with water for 15 minutes and get prompt
medical attention.
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 11

charged battery should be 12.8 V or higher.
11.73
ELECTRICAL
3. Remove the nute retaining the hold-down strap r 2. Place the battery into the ATV on its side with the
near the rear portion of the battery and remove the positive (+) e and negative (-) r cable terminals
strap. connected in the orientation shown.
4. Disconnect the battery negative (-) (black) cables 3. Coat the battery terminals and bolt threads with
first, followed by the positive (+) (red) cables. Dielectric Grease (PN 2871329) or petroleum jelly.
4. Connect and tighten the positive (+) (red) battery
CAUTION cables first, followed by the negative (-) (black)
To reduce the chance of sparks: Whenever removing battery cables.
the battery, disconnect the negative (black) cables first.
CAUTION
5. Carefully lift the battery out of the ATV. To reduce the chance of sparks:
Whenever installing the battery, install the negative
BATTERY INSTALLATION (NON-HIGH (black) cables last.
LIFTER)
TORQUE
NOTE
Battery Terminal Fastener
Using a new battery that is not fully charged can
6 ft. lbs (8 Nm)
damage the battery, resulting in a short battery life and
can hinder performance. Charge battery before
installation. 5. Install the hold-down strap, cover and retaining nut.
6. Verify cables are properly routed and fasteners are
1. Position the battery spacer w on the frame. Place tight.
the battery q on the spacer.
7. Reinstall the front rack or storage box.
BATTERY REMOVAL (HIGH LIFTER)

1. Steer the wheels all the way to the left to provide
better access.
2. Remove the negative, then positive, battery cables
from the battery posts.
11.74
ELECTRICAL
3. Remove the fastener q that retains the battery hold OCV - OPEN CIRCUIT VOLTAGE TEST
down bracket. Battery voltage should be checked with a digital
multitester. Readings of 12.6 volts or less require further
battery testing and charging. See the following chart and
“Load Test”.
NOTE
Maintenance Free batteries should be kept at a high
state of charge during storage. If the battery is stored or
used at a low state of charge, hard crystal sulfation will
form on the plates, reducing the efficiency and service
life of the battery.
Use a volt/ohm meter to test battery voltage.
OPEN CIRCUIT VOLTAGE

4. Remove the battery w and hold down. State of Charge Maintenance Free
100% 13.0 V
BATTERY INSTALLATION (HIGH LIFTER)
75% Charged 12.8 V
1. Install the battery w , hold down strap, and hold down 50% Charged 12.5 V
fastener q.
25% Charged 12.0 V
0% Charged 11.5 V or less
LOAD TEST
CAUTION
To prevent shock or component damage, remove spark
plug high tension leads and connect securely to engine
ground before proceeding.
A battery may indicate a full charge condition in the OCV

test, but still may not have the storage capacity
necessary to properly function in the electrical system.
2. Install the positive, then negative battery cables.
For this reason, a battery capacity or load test should be
Torque fasteners to specification.
conducted whenever poor battery performance is
TORQUE encountered.
Battery Terminal Fastener To perform this test, use a load testing device that has an
adjustable load. Apply a load of three times the ampere-
6 ft. lbs (8 Nm)
hour rating. At 14 seconds into the test, check battery
voltage. A good 12V battery will have at least 10.5 volts.
If the reading is low, charge the battery and retest.
BATTERY TESTING
Whenever a service complaint is related to either the BATTERY CONDUCTANCE ANALYZER
starting or charging systems, the battery should be Conductance describes the ability of a battery to conduct 11
checked first. current. A conductance tester functions by sending a low
Following are two tests which can easily be made on a frequency AC signal through the battery and a portion of
sealed Maintenance Free battery to determine its the current response is captured, from this output a
condition: OCV Test and a Load Test. conductance measurement is calculated. Conductance
testing is more accurate than voltage, specific gravity, or
load testing.
Authorized Polaris dealers/distributors are required to
use the conductance analyzer when testing 12V Polaris
batteries.
11.75
ELECTRICAL
BATTERY PN 4011496
STATE OF VOLTAGE CHARGE
(DC) ACTION
CHARGE TIME
Needs
50% - 75% 12.0 - 12.5 Charge 5 - 11 hrs
Needs At least
25% - 50% 11.5 - 12.0 Charge 13 hrs
Needs At least
0% - 25% 11.5 or less Charge 20 hrs
NOTE
Follow the charger instructions supplied by the
manufacture regarding the order or connections, switch
positions and when to connect the charger to an outlet.
Polaris MDX-610P
SPX PN: PU-50296
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.
Do not exceed 9 amps when charging the 4011496
battery.
NOTE
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.
WARNING
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 4011496
STATE OF VOLTAGE CHARGE
(DC) ACTION
CHARGE TIME
None, check None
100% 12.8 - 13.0 again in 3 Required
months
May need
75% - 100% 12.5 - 12.8 slight charge 3 - 6 hrs
11.76
ELECTRICAL
ELECTRONIC POWER STEERING (EPS)

EPS OPERATION WARNING
The EPS module is an intelligent electronic power
steering system that operates off of the vehicle’s 12V Electronic Power Steering (EPS) units are not
electrical system. It calculates steering assist by sensing interchangeable between ATV and RANGER product
the difference between the input torque of the steering lines.
post and the output torque required to turn the wheels,
and then provides assist by energizing an electric motor. NOTE
The process provides a smooth, seamless assist.
Refer to Chapter 10 “Steering / Suspension” for power
The system is continuously running diagnostic checks steering unit removal and installation procedures.
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,
WIRE COLOR FUNCTION
the system will illuminate a fault indicator and transition
to a normal mechanically coupled steering system. The Key-On / Run Switch On
ORANGE Battery Voltage / EPS Power
system is Polaris Digital Wrench compatible for simplified
diagnostics and system troubleshooting through the RED Battery Voltage
vehicle’s diagnostic port.
BROWN Ground
With the engine off and the key on, the power steering
YELLOW CAN High Signal
unit will operate for up to five minutes. After the five
minutes, you will need to cycle the key switch and restart GREEN CAN Low Signal
the engine to regain power steering operation.
The Power Steering 30A Fuse.
• If the fuse fails, the Power Steering Malfunction
Indicator Light (MIL) on the instrument cluster will
illuminate. During this time, the vehicle will have no
power steering operation. You will be able to connect
and communicate with the vehicle’s Engine Controller,
but not the Power Steering Controller, while using
Digital Wrench™.
NOTE
DO NOT SPLICE OR CUT INTO THE CAN CIRCUITS.
11
11.77
ELECTRICAL
EPS TROUBLESHOOTING
11.78
ELECTRICAL
HAND / THUMB WARMERS

HAND / THUMB WARMER RESISTANCE CHECKS
The low heat element circuit in the element pad will always be the circuit with high resistance. The circuit with low re-
sistance will be the high setting element. If an element pad’s circuit is out of range (either too high or too low), the oper-
ator may notice a heat imbalance between the left and right warmers.
Handlebar Hand Warmer Elements - PN: 2410567
HANDLEBAR HAND WARMERS
COLORS CONNECTOR PIN CONNECTOR PIN Ω VALUE @ 72° F
BRN - BLU/RED A B 7.6 - 9.6 ± 12%
BRN - BLU A C 12.9 - 16.5 ± 12%
Thumb Warmer Element - PN: 2410420

THUMB WARMER
BRN - WHT/GRY A B 40.5 - 49.5
BRN - OR/GRY A C 81 - 99
Passenger Hand Warmer Elements - PNs: 2411651 / 2411652

PASSENGER HAND WARMER ELEMENTS
3 4
BRN - BLU 22.3 - 27.2
LO = Pin 1 LO = Pin 4
2 4
BRN - BLU/RED 14.9 - 18.2
HI = Pin 1 HI = Pin 4
NOTE
The passenger hand warmer kits feature an element pad and switch / connector assembly for the right-hand grip.
The left-hand grip element pad plugs into the right-hand grip switch harness.
11
11.79
ELECTRICAL
WINCH
WINCH ASSEMBLY VIEW
CAUTION
Disconnect battery prior to servicing winch. Always disconnect the negative (BLACK) cable from battery first during
disassembly, and last during assembly.
11.80
ELECTRICAL
WINCH ASSEMBLY VIEW

q Winch Kit Assembly
w Winch Switch
e Screws Hand Tight - Do not Over-Torque
r Winch Bracket
t Winch Assembly
y Service Kit
u Latch Hook
i Fairlead Roller
o Winch Cable
a Wire, Yellow, 6 GA Connect at Yellow contactor / winch posts (NEG)
s Wire, Blue, 6 GA Connect at Blue contactor / winch posts (POS)
d Wire, Black, Ground, 6 GA Connect at battery / Black contactor post
f Wire, Red, Power, 6 GA Connect at battery / Red contactor post
g Contactor
h Clips
j Screws 20 ft-lbs (27 Nm)
k Screws
l Carriage Bolts
1( Flange Nuts 20 ft-lbs (27 Nm)
2) Washers
2! Lock Washers
2@ Bolts 20 ft-lbs (27 Nm)
WINCH CONTACTOR
11
11.81
ELECTRICAL
CONTROLLER AREA NETWORK (CAN)

OVERVIEW
This vehicle uses a Controller Area Network (CAN) to
perform some functions. Similar to a computer network,
CAN establishes a communication network between the
ECM and several on-board components.
The CAN network includes:
• ECM
• Instrument Cluster
• Digital Wrench Diagnostic Plug
• Electronic Power Steering (EPS models only)
NOTE
DO NOT SPLICE OR CUT INTO THE CAN YELLOW
OR GREEN WIRE CIRCUITS.
CAN TROUBLESHOOTING
No CAN functionality can be indicated by the following
items not working on the instrument cluster:
• No engine speed displayed
• No vehicle speed displayed
• No gear position displayed
• Odometer / Tripmeters not working
• Reverse override button does not toggle between
display modes
• ECM-monitored inputs are not displayed when DTCs
or problems exist, i.e. check engine LED, engine
overheat LED, etc.
• There is power at the Smart Link connector, but it
cannot connect to Digital Wrench
To test the CAN circuit, turn the ignition key to OFF, and
then use a multimeter to verify there is 60 +/- 10 ohms
between the CAN High (YELLOW) and CAN Low
(GREEN) wires on the diagnostic connector.
If 120 ohms is measured at the connector, there is a
break somewhere within the CAN circuit.
11.82
ELECTRICAL
BREAKOUT WIRING DIAGRAMS

AWD (NON-ETC)
AWD INPUT (ETC)
COOLING FAN
CRANKSHAFT POSITION SENSOR
11
11.83
ELECTRICAL
DIAGNOSTIC CIRCUIT/CAN BUS ENGINE TEMP. SENSOR
EFI AND CHASSIS POWER IGNITION COIL (ETC)
ELECTRONIC THROTTLE SIGNAL/INPUT IGNITION COIL (NON-ETC)
ELECTRONIC THROTTLE OUTPUT INTAKE AIR TEMP SENSOR (ETC)
11.84
ELECTRICAL
INTAKE AIR TEMP SENSOR (NON-ETC) TMAP (ETC)
THROTTLE POSITION SENSOR (NON-ETC) TMAP (NON-ETC)
11
11.85
ELECTRICAL
NOTES
11.86
INDEX
7044080 / 7044081 Shock Service Information ................8.33 Sportsman / Scrambler International............................ 9.7
Brake System Inspection ............................................2.38
Brake System, Operation ............................................. 9.4 IX
A Break-In Period.......................................................... 2.3
Breather Hose ..........................................................2.17
ADC, Coil Resistance.................................................7.31 Breather, Engine
Adjustment Removal...............................................................3.47
Valve Clearance.....................................................2.18 Bumper Lights Relay................................................ 11.56
Air Filter Service........................................................2.14
Air Intake Assembly View ............................................3.24
Assembly View, 7044080 / 7044081 Shocks ...................8.32 C
Assembly View, 7044135 Shock ...................................8.31
Assembly View, Camshaft ...........................................3.29 Cam Chain
Assembly View, Connecting Rod ..................................3.33 Inspection.............................................................3.59
Assembly View, Crankcase Complete ............................3.35 Camshaft
Assembly View, Crankcase Lower.................................3.38 Assembly .............................................................3.76
Assembly View, Crankcase Upper.................................3.36 Inspection.............................................................3.48
Assembly View, Crankshaft .........................................3.34 Installation ............................................................3.76
Assembly View, Cylinder Head .....................................3.30 Removal...............................................................3.47
Assembly View, Oil Pump............................................3.38 Timing..................................................................3.77
Assembly View, Piston and Rings .................................3.33 Camshaft Bore
Assembly View, Rocker Arm ........................................3.29 Inspection.............................................................3.48
Assembly View, Valve ................................................3.30 Camshaft Carrier.......................................................3.29
Authorization Camshaft Chain
Reflash ................................................................4.45 Removal...............................................................3.59
AWD, Coil Resistance ................................................7.31 Carrier, Camshaft
AWD, Diagnosis........................................................7.31 Installation ............................................................3.76
Charging System..................................................... 11.63
Chassis Relay ........................................................ 11.56
B Compression Test .....................................................2.20
Connecting Rod
Balance Shaft ...........................................................3.37 Assembly .............................................................3.67
Installation ............................................................3.70 Bearing Selection Charts .........................................3.62
Removal, Inspection ...............................................3.58 Inspection.............................................................3.59
Balance Shaft Timing .................................................3.71 Installation ............................................................3.67
Ball Joint Service.......................................................8.20 Connecting Rod, Assembly View ..................................3.33
Battery Connector................................................................ 11.9
Installation – High Lifter ......................................... 11.75 Continuity .............................................................. 11.10
Removal............................................................. 11.73 Conversion Table ......................................................1.24
Removal – High Lifter ............................................ 11.74 Coolant Drain ...........................................................3.16
Battery Maintenance ..................................................2.30 Coolant Level Inspection
Battery Storage.........................................................2.32 High Lifter .............................................................2.23
Battery, Installation .................................................. 11.74 Coolant Strength and Type ..........................................2.24
Bearing Inspection, Crankshaft Main .............................3.59 Cooling System Assembly View (High Lifter) ...................3.15
Bearing Selection Chart Cooling System Hoses ...............................................2.24
Con Rod...............................................................3.62 Cooling System, Bleeding Procedure.............................3.12
Brake Bleeding, Front Brake System ............................. 9.11 Cooling System, Specifications .................................... 3.11
Brake Bleeding, Rear Brake System..............................9.12 Cooling System, Troubleshooting .................................3.80
Brake Burnishing.......................................................9.18 Counterbalance Shaft ................................................3.37
Brake Caliper Assembly........................................ 9.7, 9.20 Installation ............................................................3.70
Brake Caliper Exploded View ........................................ 9.7 Removal...............................................................3.58
Brake Caliper Inspection .............................................9.20 Timing..................................................................3.71
Brake Caliper Installation ............................................9.21 Coupler, Drive ..........................................................3.41
Brake Caliper Piston Bore I.D.......................................9.20 Coupler, Water Pump ......................................... 3.22, 3.39
Brake Caliper Removal...............................................9.19 Cover, Stator .................................................... 3.21, 3.40
Brake Disc Service ....................................................9.23 CPS
Brake Fitting Inspection ..............................................2.39 Replacement.........................................................4.30
Brake Hose Inspection ...............................................2.39 Service ................................................................4.30
Brake Pad Crank Position Sensor
Inspection.............................................................2.38 Replacement.........................................................4.30
Brake Pad Installation ................................................9.17 Crankcase
Brake Pedal Inspection...............................................2.39 Assembly .............................................................3.74
Brake System Assembly, Lower ....................................................3.72
Troubleshooting .....................................................9.25 Assembly, Upper ............................................ 3.66, 3.69
Brake System Assembly View Disassembly .........................................................3.55
Sportsman / Scrambler 1000 ..................................... 9.6 Disassembly (Lower)...............................................3.56
Sportsman / Scrambler 850 ....................................... 9.5 Disassembly (Upper)...............................................3.57
IX.1
INDEX
Sealing ................................................................3.73 E
Crankcase (lower)
Inspection.............................................................3.59 ECU
Crankcase Assembly View, Complete ............................3.35 ETC Learn Procedure ..................................... 4.25, 4.45
Crankcase Assembly View, Lower.................................3.38 Replacement.........................................................4.45
Crankcase Assembly View, Upper.................................3.36 ECU Connector Pinout ...............................................4.23
Crankshaft EFI Operation Overview..............................................4.20
Inspection.............................................................3.59 EFI Priming / Starting Procedure...................................4.20
Installation ............................................................3.68 EFI Relay .............................................................. 11.56
Removal...............................................................3.59 EFI System
Crankshaft Assembly View ..........................................3.34 Assembly View ......................................................4.16
Crankshaft Position Sensor (CPS) ................................4.30 EFI, Component Locations ..........................................4.17
Current ................................................................. 11.13 EFI, Service Notes.....................................................4.19
CV Joint / Boot Electrical ............................................... 11.8, 11.11–11.14
CV Joint Replacement (Inner) ...................................7.58 Electronic Control Unit (ECU).......................................4.21
Replacement (Outer) ..............................................7.56 Electronic Throttle Body
Cylinder Learn Procedure ............................................ 4.25, 4.45
Inspection.............................................................3.64 Engine
Cylinder Head...........................................................3.30 Combustion Chamber .............................................3.52
Assembly .............................................................3.74 Crankcase Disassembly ..........................................3.55
Combustion Chamber .............................................3.52 Cylinder Head Assembly..........................................3.74
Disassembly .........................................................3.50 Cylinder Head Inspection .........................................3.49
Inspection.............................................................3.49 Cylinder Head Removal ...........................................3.49
Installation ............................................................3.75 Cylinder Head Torque Procedure ...............................3.75
Removal...............................................................3.49 Cylinder Head Warp................................................3.50
Warp Inspection .....................................................3.50 Cylinder Inspection .................................................3.64
Flywheel Removal ..................................................3.55
Oil Level ...............................................................2.16
Piston to Cylinder Clearance.....................................3.65
D Removal...............................................................3.42
Decal Replacement ...................................................10.2 Valve Sealing Test ..................................................3.75
Decimal Equivalent Chart............................................1.26 Valve Seat Reconditioning........................................3.52
Diagnostic Codes, Instrument Cluster .......................... 11.20 Engine Antifreeze
Diagnostic Connector .................................................. 4.5 50/50 Extended-Life................................................2.12
Diagnostic Trouble Code List .......................................4.39 Engine Breather
Digital Wrench Removal...............................................................3.47
Communication Errors.............................................4.43 Engine Installation Notes ............................................3.46
ECU Reprogramming ..............................................4.45 Engine Oil Pressure Test.............................................. 3.5
Guided Diagnostics ................................................4.43 Engine Serial Number ................................................. 1.3
Overview ..............................................................4.41 Engine Temperature Sensor ........................................4.35
Serial Number .......................................................4.43 Engine Temperature Sensor Replacement......................4.35
Updates ...............................................................4.42 Engine Temperature Sensor Test ..................................4.35
DMM ...................................................................... 11.8 Engine,
Draw .................................................................... 11.13 Valve Inspection.....................................................3.51
Drive Belt Engine, Accessible Components ..................................3.42
Installation ............................................................ 5.11 Engine, Cooling System.............................................. 3.11
Removal...............................................................5.10 Engine, Oil and Filter Change ......................................2.16
Drive Belt, Break-In....................................................5.10 Engine, Troubleshooting .............................................3.80
Drive Belt, Inspection ................................................. 5.11 EPS, Cleaning ..........................................................2.33
Drive Clutch ETC
Assembly .............................................................5.22 Test .....................................................................4.24
Cover Bushing Service ............................................5.20 ETC Learn Procedure ........................................ 4.25, 4.45
Exploded View.......................................................5.13 ETC Overview ..........................................................4.24
Drive Clutch, Operation ............................................... 5.3 ETC Replacement .....................................................4.24
Drive Coupler ...........................................................3.41
Drive Mode Switch................................................... 11.46
Drive Shaft / CV Joint F
Handling Tips ........................................................7.56
Drive Shaft Boot Inspection .........................................2.25 Fan Relay .............................................................. 11.56
Driven Clutch Final Drive
Assembly .............................................................5.26 Propshaft U-Joint Assembly......................................7.17
Disassembly .........................................................5.24 Propshaft U-Joint Disassembly..................................7.16
Slider Inspection ....................................................5.24 Flywheel
Driven Clutch, Operation.............................................. 5.3 Removal...............................................................3.55
Driveshaft / CV Joint Foot Master Cylinder, Operation (INT’L Models) ...............9.10
CV Joint Replacement (Outer) ..................................7.56 Front A-arm, Removal / Replacement ............................8.18
Dynamic.................................................................. 11.8 Front A-arms, Exploded View.......................................8.17
IX.2
INDEX
Front Bumper Guide,Valve

Installation ............................................................10.8 Removal...............................................................3.52
Front Bumper Removal...............................................10.8 IX
Front Cab
Installation .......................................................... 10.11 H
Removal............................................................. 10.10
Front Drive Shaft, Installation .......................................7.14 Hand / Thumb Warmers
Front Drive Shaft, Removal .........................................7.13 Resistance Checks ............................................... 11.79
Front Gearcase Hand Master Cylinder, Exploded View ............................ 9.8
Assembly View Hand Master Cylinder, Operation (INT’L Models)..............9.10
NON-ADC .........................................................7.29 Handlebar, Removal / Replacement ............................... 8.3
Disassembly / Inspection (ADC) ................................7.40 Harness .................................................................. 11.6
Lubrication............................................................2.28 Routing ................................................................ 11.7
Operation .............................................................7.30 Head, Cylinder..........................................................3.30
Operation (4WDC)..................................................7.39 Headlamp Switch .................................................... 11.50
Reassembly (ADC) .................................................7.43 Headlight Pod
Front Gearcase Assembly View Assembly .............................................................10.3
4WDC..................................................................7.38 Disassembly .........................................................10.3
Front Gearcase Installation..........................................7.26 Headlight Replacement
EPS Models ..........................................................7.23 Pod ................................................................... 11.59
Front Gearcase Removal Heat .......................................................................3.26
Non-EPS ..............................................................7.19 High Beam Lights Relay, 2014 ................................... 11.57
Front Gearcase, Assembly ..........................................7.35 High Lifter ................................................................3.16
Front Gearcase, Disassembly / Inspection ......................7.32 Hose ......................................................................4.15
Front Gearcase, Installation.........................................7.20
Front Gearcase, Removal (EPS Models) ........................7.22
Front Hubs
Assembly View ....................................................... 7.7
I
Front Propshaft, Service .............................................7.15 IDD
Front Rack USB Flash Drive Recommendations......................... 11.40
Installation ............................................................10.7 Idle Air Control (IAC) ..................................................4.32
Removal...............................................................10.6 Ignition Coil Replacement ...........................................4.36
Fuel Ignition Switch ........................................................ 11.46
Line.....................................................................4.15 International ........................................................ 11.46
Fuel Check Valve Impeller, Water Pump .................................................3.17
Testing .................................................................4.13 Injector
Fuel Filters...............................................................2.13 O-rings.................................................................4.28
Fuel Injector Inspection, Cam Chain ...............................................3.59
O-rings.................................................................4.28 Instrument Cluster
Fuel Injectors............................................................4.28 Back Light Color................................................... 11.34
Fuel Line .................................................................4.13 Back Light Level................................................... 11.35
Fuel Lines................................................................2.13 Clock ................................................................. 11.33
Fuel Pump Replacement.............................................. 4.9 Connector Pinouts ................................................ 11.21
Fuel Pump Test.......................................................... 4.7 Diagnostic Code .................................................. 11.37
Fuel Sender Test ........................................................ 4.7 Display Area 1 ..................................................... 11.28
Fuel System .............................................................2.13 Display Area 2 ..................................................... 11.29
Fuel System Troubleshooting.......................................4.49 Indicator Lamps ................................................... 11.27
Fuel Tank Options Menu ...................................................... 11.30
Assembly View ....................................................... 4.6 Overview ................................................... 11.15, 11.26
Fuel Tank Installation .................................................4.12 Pinouts .............................................................. 11.38
Fuel Tank Removal ..................................................... 4.9 Rider Information Display ....................................... 11.16
Fuel Vent .................................................................4.14 Service Hours...................................................... 11.36
Fuel Vent Line Unit Selection Distance.......................................... 11.31
Testing .................................................................4.13 Unit Selection Temperature .................................... 11.32
Fuse / Relay Box Layout ........................................... 11.58 Integrated Throttle Body, Torque Sequence.....................3.30
Fused Circuits ........................................................ 11.57 Interactive Digital Display (IDD)
User’s Guide ....................................................... 11.39
Interactive Digital Display (PIDD)
G Connector Pinouts ................................................ 11.39
Frozen Display Screen Recovery ............................. 11.41
Gear Position Switch................................................ 11.52 Reset and Update Procedure .................................. 11.43
Gear Selector Intermittent ............................................................ 11.12
Resistor Module ................................................... 11.52
Gear Selector Removal ............................................... 6.3
GPS Receiver
Troubleshooting ................................................... 11.44
J
Grease Points............................................................ 2.7 Journal, Crankshaft
IX.3
INDEX
Inspection.............................................................3.59 Bore Inspection......................................................3.64

Piston Ring
Inspection.............................................................3.63
L Installation ............................................................3.66
Piston to Cylinder Clearance........................................3.65
Lash Adjustment Piston, Assembly View ...............................................3.33
Valve ...................................................................2.18 Plunging Joint / Boot
Leakdown Test .........................................................2.20 Replacement (Inner) ...............................................7.58
Left-Hand Controls Polaris Mobile Digital Wrench (PMDW) .................... 1.6, 4.48
International ........................................................ 11.49 Power Steering Relay............................................... 11.57
Left-hand Switch Controls ......................................... 11.48 Power Steering Unit Installation ....................................8.12
Low Beam Lights Relay, 2014 .................................... 11.57 Power Steering Unit Removal ...................................... 8.11
Lower Crankcase Power Steering Unit, Cleaning .....................................2.33
Assembly .............................................................3.72 Pre-Filter Service ......................................................2.14
Lubrication Diagram.................................................... 3.6 Pre-Ride Checklist...................................................... 2.4
Lubrication Grease Points ............................................ 2.7 Probe ..................................................................... 11.9
Probing ................................................................... 11.9
Propshaft U-Joint
M Assembly .............................................................7.17
Disassembly .........................................................7.16
Main Frame Pump, Water .................................................... 3.21, 3.40
Assembly View .................................................... 10.16 Pump, Water, Mechanical Seal Replacement ..................3.18
Maintenance PVT
Quick Reference Button to Tower Clearance .......................................5.18
High Lifter ..........................................................2.10 Drive Clutch Bushing Service ....................................5.20
Maintenance and Service Products ............................... 2.11 Drive Clutch Spider Removal ....................................5.17
Maintenance Quick Reference Chart .............................. 2.8 PVT Assembly View .................................................... 5.5
Master ..................................................................... 1.7 PVT System
Mechanical Seal, Water Pump .....................................3.18 Drive Clutch Disassembly ........................................5.15
Meter...................................................................... 11.8 Drive Clutch Spring.................................................5.15
Model Number Designation .......................................... 1.2 PVT System, Assembly ............................................... 5.8
Model Specifications PVT System, Disassembly ........................................... 5.5
2018 PVT System, Maintenance ........................................... 5.3
Sportsman 1000 XP Touring ..................................1.18 PVT Troubleshooting .................................................5.29
Sportsman 850 ...................................................1.10 PVT, Drain Plug ........................................................2.25
Sportsman 850 SP ..............................................1.12 PVT, Drying..............................................................2.25
Sportsman 850 Touring.........................................1.14
Sportsman XP 1000 High lifter ...............................1.22
Sportsman XP 850 Highlifter ..................................1.20 Q
Sportsman 1000 XP
2017.................................................................1.16 Quick Disconnect ......................................................4.13
Mud Guard
Installation ............................................................10.9
Removal...............................................................10.9 R
Radiator ..................................................................3.12
O Radiator Installation (High Lifter)...................................3.17
Radiator Removal .....................................................3.16
O-rings Radiator, Removal .....................................................3.13
Fuel Injector ..........................................................4.28 Rear A-arm, Removal.................................................8.24
OFF / RUN Switch ................................................... 11.47 Rear A-arms, Exploded View .......................................8.23
Oil Flow Diagram........................................................ 3.6 Rear Bumper Cover
Oil Passage Tube ......................................................3.68 Installation .......................................................... 10.15
Oil Pump .................................................................3.56 Removal............................................................. 10.15
Oil Pump Assembly View ............................................3.38 Rear Cab / Storage
Oil Pump Rotor Clearance...........................................3.56 Installation .......................................................... 10.14
Removal............................................................. 10.13
Rear Drive Shaft, Installation .......................................7.55
P Rear Drive Shaft, Removal ..........................................7.54
Rear Gearcase
Parasitic ................................................................ 11.13 Assembly View ......................................................7.70
Periodic Maintenance Chart.......................................... 2.3 Lubrication............................................................2.28
Piston Rear Gearcase Installation ..........................................7.71
Assembly .............................................................3.67 Touring.................................................................7.73
Installation ............................................................3.67 Rear Gearcase Removal
Removal, Inspection ...............................................3.57 Touring.................................................................7.64
Piston Pin Rear Gearcase,
IX.4
INDEX
Removal...............................................................7.62 Start Solenoid Relay ................................................ 11.57

Rear Gearcase, Assembly...........................................7.69 Starter Motor, Removal / Replacement......................... 11.71
Rear Gearcase, Disassembly and Inspection ..................7.66 Starter Ring Gear ......................................................3.41 IX
Rear Hubs Starter System........................................................ 11.71
Assembly View ....................................................... 7.8 Starter System, Troubleshooting................................. 11.71
Rear Propshaft, Service..............................................7.61 Static ...................................................................... 11.8
Rear Rack Stator ............................................................. 3.21, 3.40
Installation .......................................................... 10.12 Stator Cover
Removal............................................................. 10.12 Installation ............................................................3.20
Rear Stabilizer Bar, Assembly View...............................8.26 Stator, Installation.................................................... 11.70
Reflash Authorization .................................................4.45 Stator, Removal ...................................................... 11.69
Removal, Engine, Accessible Components .....................3.42 Steering (Non-EPS Models).......................................... 8.6
Replacement Steering Assembly View
Throttle Control Sensor............................................4.27 EPS Models ........................................................... 8.8
Reverse / Mode Button ............................................. 11.50 Non-EPS ............................................................... 8.5
Ring Gear, Starter .....................................................3.41 Steering Inspection ....................................................2.33
Ring, Piston Steering Post Installation (Non-EPS Models).................... 8.7
Inspection.............................................................3.63 Steering Post Removal (Non-EPS Models) ...................... 8.6
Installation ............................................................3.66 Steering, Electronic Power Steering (EPS)......................8.10
Rings, Piston, Assembly View ......................................3.33 Steering, Inspection ...................................................2.33
Rocker Arm..............................................................3.29 Steering, Tie Rod Replacement ....................................8.16
Assembly .............................................................3.76 Suspension Inspection ...............................................2.36
Removal and Inspection ..........................................3.48 Suspension Spring Preload Adjustment .........................2.36
Rocker Carrier Suspension, Compression Adjustment (FOX) ..................2.37
Removal...............................................................3.47 Suspension, Spring Preload Adjustment (FOX)................2.36
Rocker Cover ...........................................................3.28
Removal...............................................................3.47
Routing ........................................................... 4.14–4.15 T
RPM Limit................................................................4.21
Tap / Drill Sizes {SAE} ................................................1.25
Temp / Manifold Absolute Pressure Sensor (T-MAP) .........4.31
S Test
ETC ....................................................................4.24
Seat Throttle Control Sensor............................................4.27
Installation ............................................................10.4 Testing .................................................. 11.8, 11.10–11.14
Removal...............................................................10.4 Throttle Body, Torque Sequence ...................................3.30
Sequence, Engine Cover Torque ..................................3.27 Throttle Cable Adjustment ...........................................2.14
Service ................................................................... 11.8 Throttle Control .........................................................4.25
Shaft, Rocker Arm Throttle Control Sensor
Removal...............................................................3.48 Replacement.........................................................4.27
Shield .....................................................................3.26 Test .....................................................................4.27
Shift Weights ............................................................. 5.3 Throttle Lever Position Sensor
Shock Rebuilding Tools, FOX.......................................8.34 Overview ..............................................................4.27
Shock, FOX, Rebuild Information ..................................8.34 Throttle Operation .....................................................2.13
Short ........................................................... 11.11–11.12 Throttle Position Sensor (TPS) .....................................4.33
Side Panel Throttle Release Switch (TRS) ............................2.14, 11.51
Installation ............................................................10.5 Tie Rod Ends............................................................2.33
Removal...............................................................10.5 Timing
Special Tools ............................................................. 1.5 Camshaft..............................................................3.77
Special Tools, Clutching............................................... 5.2 Counterbalance Shaft .............................................3.71
Special Tools, Cooling System ..................................... 3.11 Timing, Balance Shaft ................................................3.37
Special Tools, EFI....................................................... 4.4 Tire Inspection ..........................................................2.26
Special Tools, Electrical .............................................. 11.5 Tire Pressure............................................................2.26
Special Tools, Engine .................................................. 3.4 TMAP
Special Tools, Final Drive ............................................. 7.3 Replacement.........................................................4.31
Specification, Fuel Pressure ......................................... 4.7 Toe Alignment .................................................. 2.34–2.35
Specifications, Brake Disc Runout ................................. 9.3 Toe Alignment Adjustment...........................................2.35
Specifications, Brake Pad Thickness .............................. 9.3 Torque ..................................................................... 1.7
Specifications, Brakes ................................................. 9.3 Torque Patterns, Engine Components............................3.27
Specifications, Clutching .............................................. 5.2 Torque Specifications, Clutching .................................... 5.2
Specifications, Cooling System .................................... 3.11 Torque Specifications, Wheel and Hub ...........................2.25
Specifications, Engine ............................................3.7, 3.9 TPS
Specifications, Engine Lubrication.................................. 3.4 Adjustment ...........................................................4.34
Specifications, Engine Oil Pressure ................................ 3.5 Replacement.........................................................4.34
Specifications, FOX 7044135 Shock..............................8.33 Transmission
Speed Sensor, Operation Overview............................. 11.53 Lubrication............................................................2.27
Sprocket, Cam Chain, Inspection ..................................3.59 Transmission, Assembly .............................................6.13
IX.5
INDEX
Transmission, Disassembly .......................................... 6.8

Transmission, Exploded View ......................................6.20
Transmission, Installation............................................6.18
Transmission, Lubrication ............................................ 6.2
Transmission, Removal ............................................... 6.5
Transmission, Shaft Service ........................................6.10
Troubleshooting
Front Gearcase (ADC).............................................7.46
Troubleshooting, Brake Noise ......................................9.26
Troubleshooting, Clutching ..........................................5.29
Troubleshooting, Engine .............................................3.80
Tube, Oil Passage .....................................................3.68
U
Upper Crankcase
Assembly ..................................................... 3.66, 3.69
Upper Steering Post Installation ...................................8.10
Upper Steering Post Removal (EPS Models) ...................8.10
V
Valve
Inspection.............................................................3.51
Valve Clearance Adjustment ........................................2.18
Valve Cover
Removal...............................................................3.47
Valve Cover Assembly View ........................................3.28
Valve Guide
Inspection.............................................................3.51
Removal...............................................................3.52
Valve Sealing Test .....................................................3.75
Valve Seat Reconditioning...........................................3.52
Valve Spring
Removal...............................................................3.50
Valve Spring Installation Detail
SPM1000 .............................................................3.32
SPM850 ...............................................................3.31
Valve, Assembly View ................................................3.30
Vehicle Identification
Model Number Designation ....................................... 1.2
Vehicle Information
VIN Number ........................................................... 1.2
Vent Line .................................................................2.13
VIN ......................................................................... 1.2
VIN Location ............................................................. 1.3
VIN Number .............................................................. 1.2
Voltage Drop .......................................................... 11.14
W
Water Pump ..................................................... 3.21, 3.40
Water Pump Coupler.......................................... 3.22, 3.39
Water Pump Impeller..................................................3.17
Water Pump Mechanical Seal Replacement ....................3.18
Water Pump Removal ................................................3.17
Wheel Removal / Installation.................................. 2.26, 7.4
Wheel Stud
Service ................................................................. 7.5
Winch
Contactor Connections .......................................... 11.81
Winch Assembly View .............................................. 11.80
IX.6
2017-18 SPORTSMAN 850 XP
WINCH EPS POWER (A)
HARNESS: 2413823-01 PIN FUNCTION
SWITCH (HEADLIGHT BULB SERVICE P/N 4010253) B
SPEEDOMETER
(HEADLIGHT BULB SERVICE P/N 4010253) (HEADLIGHT BULB SERVICE P/N 4010253) A BATTERY (+) A
P/N RIGHT HANDLEBAR SWITCH ASSEMBLY
DIAGNOSTIC B BATTERY (-)
POD HEADLIGHT (P/N 2413427)
SHEET NO. 1 OF 2 2205636
BULKHEAD ACCESSORY 1 B+
WINCH 1 2 3 4 5 6 7 8
EPS SENSOR (B) E246 BK (0.5)
1 2 3 4 5
LH BUMPER HEADLIGHT (P/N 2413432) RH BUMPER HEADLIGHT (P/N 2413433)
ADC 4X4 2X4 ADC 4X4 2X4
WIRE COLOR LEGEND WINCH SWITCH CONTACTOR PIN FUNCTION E228 GY (0.5)
BG BEIGE (TAN) A BCD 1 9 GABL BN
1 2 3 4 5
10 11 12 13 14 15 16 1 ENGINE RPM (NEG. REF)
E = ENGINE GROUND P/N
BK BLACK E FGH 1
2 ENGINE RPM E230C VT (0.5) 4640%%185
BU LIGHT BLUE 4013465
DB DARK BLUE 2 4 6 8 10 12 14 16 3 IGNITION SIGNAL E232 PK/WH (0.5)
C = CHASSIS GROUND 1 3 5 7 9 11 13 15
BN BROWN
FAB OG/WH
4 CAN BUS LOW SWITCH
2150%%185
GY GRAY A BCDE FGH
FAC OG/WH
TRS
GN LIGHT GREEN 5 VEHICLE SPEED
NC = SWITCH NORMALLY CLOSED P1 P2 6 VEHICLE SPEED (NEG. REF)
FUE RD/BK
DG DARK GREEN
E248C DG
XHC YE
S11 VT/WH
OG ORANGE NO = SWITCH NORMALLY OPEN 1 2 3 4 7 EPAS SYSTEM FAULT SIGNAL
E236C YE
GABN BN
KDD OG
PK PINK
FUD RD/BK
E248B DG
E236B YE
GABG BN
8 CAN BUS HIGH
KDC OG
RD RED
VT VIOLET (PURPLE)
XA1 GN
XA3 BK
WH WHITE POWER STEERING ASSEMBLY (P/N 2411530)
FDC RD/GN
YE YELLOW
XA1 GN
XA3 BK
CL CLEAR
P4 P3 P2 P1
TWO WIRE COLORS ARE SHOWN FUF RD/WH
WITH MAIN/TRACE COLORS.
KDA RD/BK KEY SWITCH
EXAMPLE:RD/YE = RED WITH A B
YELLOW TRACE. A B A B A B GABO BN P/N 4015033
KB BU/YE
3 4 8
GABM BN
XHB YE
GABH BN
GABC BN
RLC DG
RLB DG
GBF BN
RT OG
E248D DG
E236D YE
KDE OG
LEFT HANDLEBAR SWITCH ASSEMBLY POD ACC GROUND
(P/N 4011835) OFF LOW 12V RECEPTACLE
F GABK BN
HEADLAMP
1
LHC CONR A
HIGH
OFF E
LEFT XLA DG FAD OG/WH
A BCDE F
1
D XHA YE (P/N 4010638)
FLF RD/BN POD ACC B+
KDB OG
C
B
RUN
A SPLICE, GROUND POD FAB OG/WH FAC OG/WH
GABK BN FAA OG/WH 1 2 FAD OG/WH
GABL BN
F GABM BN SPLICE, ACCESSORY
GABJ BN 1 2 GABO BN
FDC RD/GN
E SPLICE, CAN LOW
OFF KDA RD/BK GABB BN E248C DG
A BCDE F
RIGHT E248B DG 1 2 E248D DG

D
E248A DG
SPLICE, GROUND FRONT E236C YE
GABJ BN
C GABB BN E236B YE 1 2 E236D YE
E211 GY/OG (0.5)
SPLICE, DRIVE
GABH BN GABC BN E236A YE
PUSH SPLICE, HIGH BEAM
B GABG BN 1 2 GABN BN
XHB YE
GABD BN SPLICE, CAN HIGH
OVERRIDE LHC CONR B XHA YE 1 2 XHC YE
1 2
FREE GABA BN
A XHD YE SPLICE, B+ UNSWITCHED
GABE BN
GABF BN BBD RD WORKLIGHT SWITCH
BBB RD 1 2 BBE RD FLE RD/BN
1
BBF RD
FDD RD/GN
FDA RD/GN
FDE RD/GN
RLB DG BBG RD
RLA DG 1 2 RLC DG
SPLICE, B+ SWITCHED XW YE
1
SPLICE, LOW BEAM RCC WH (P/N 4011074)
RCD WH 1 2 RCA WH
RCB WH
FLE RD/BN FLC RD/BN

FLF RD/BN 1 2 FLB RD/BN FUEL PUMP
FLD RD/BN
FLA RD/BN TANK LEVELRESISTANCE (%%185)
FULL 6.0%%p1.0%%185
SPLICE, LIGHTS B+ FUE RD/BK EMPTY 90.0%%p4.5%%185
REVERSE POLARITY DIODE
FUD RD/BK 1 2 FUA RD/BK
FUF RD/WH PIN FUNCTION
2
FUB RD/BK FUB RD/BK
1
SPLICE, UNSWITCHED FUSE B+ 1 FUEL LEVEL SENSOR "+"
(P/N 2411035, 6A DIODE)
2 FUEL LEVEL SENSOR "-"
3 FUEL PUMP "+"
HIGH BEAM SIGNAL DIODE 4 FUEL PUMP "-"
XLA DG
XLB DG
2
XHD YE
1
(P/N 2411035, 6A DIODE)
FUEL PUMP/LEVEL
SPLICE, R/S B+ KDE OG GAA BN
4
KDL OG
KDD OG KDF OG RP RD/BU
3
KDC OG 1 2 KDG OG
GABD BN
2
KDB OG
KDH OG S11 VT/WH
1
KDJ OG
THERMISTOR
(P/N 4010644)
E230B VT
1
FAN
E244 YE MOTOR
2
RF OG/BK
A B
NOMINAL RESISTANCE: GAD BN
SPLICE, FP
AT 20%%127C=2,5 k%%185%%p6%
AT 100%%127C=0,186 k%%185%%p2%
1 2
1 AWD/ADC HUB COIL
AWD COIL
T 24%%185
AIR TEMP 2 FDE RD/GN
A B C D
SENSOR
(P/N 2410687) FDD RD/GN
E217 BN/WH
E224 BU E249 BN/YE
1
ADC COIL
E242C VT 12%%185
2
NOMINAL RESISTANCE
FPC RD/GN
FDA RD/GN
RJA RD/BU
RJF RD/BU
RF OG/BK
RP RD/BU
FLA RD/BN
RCC WH
RCA WH
RCB WH
KDG OG
KDL OG
E204 OG/YE
E202 DG/YE
AT -20%%127C (16.2k%%185)
CBA RD/WH
E219 DG/YE
FPA RD/GN
FPB RD/GN
E211 GY/OG (0.5)
E232 PK/WH (0.5)
FJ RD/GN
FJ RD/GN
BBG RD
GAE BN
BBE RD
BBF RD
AT 20%%127C
2.45%%p0.24k%%185
E246 BK (0.5)
0.4%%185 PLUG
E228 GY (0.5)
AT 80%%127C
0.322%%p0.032k%%185 SPARK
E248A DG
E239 WH
E207 OG
E210 DG
E224 BU
E244 YE
E245 GN/RD
KDJ OG
E223A WH
E236A YE
E230A VT
E242A VT
E206 OG
E227 BK
E222 YE
E231 VT
3
2
1 PLUG
1 3 5 7 9 11 13 15 17 19 21 23 0.4%%185 SPARK
2 4 6 8 10 12 14 16 18 20 22 24 E255 BK
3
T-MAP
(P/N 2411528) 1 5 9 13 17 21 25 29 33 37 41 45 RJD RD/BU
2
212 241 247 248 211 246 209 239 233 210 244 232 207 224 243 COIL
HIGH
RELAY COIL
OUT HIGH
RELAY COIL
OUT HIGH
RELAY COIL
OUT HIGH
RELAY COIL
OUT HIGH
RELAY COIL
OUT HIGH
RELAY
OUT
E256 WH
1
229 234 235 236 228 240 245 227 206 231 223 230 242 222 EFI FAN FUEL PUMP LOW BEAM EPS START
RELAY COIL RELAY COIL RELAY COIL RELAY COIL RELAY COIL RELAY COIL
SPLICE, GROUND TMAP IN LOW IN LOW IN LOW IN LOW IN LOW IN LOW
COIL RELAY LIGHTS/STARTDRIVE ACC EPS SPARE
HIGH OUT
20A OUT IN 20A OUT IN 30A OUT IN 10A OUT
IN 20A OUT IN
E242C VT CHASSIS
FUEL PUMP EFI UNSWITCH FAN CKT BKR SPARE
(P/N 4010425)
E242B VT E242B VT 1 2 E242A VT
RELAY COIL
LOW IN 10A OUT IN 10A OUT IN 10A OUT IN 20A OUT IN 20A OUT IGNITION COIL
4 3 2 1
IN
1 GROUND LAST 2 DIGITS OF 200 SERIES
NUMBER CORESPOND TO CONNECTOR 4 8 12 16 20 24 28 32 36 40 44 48
2 NTC E207 OG CAVITY NUMBER (IE. 210=CAVITY 10) 26 28 30 32 34 36 38 40 42 44 46 48
3 +5V E222 YE 25 27 29 31 33 35 37 39 41 43 45 47
PRESSURE
SENSOR 4 OUTPUT
SIGNAL
CBA RD/WH
BEB WH/RD
CON. IGNITION COIL GROUND
BCA RD/BN
FUA RD/BK
FLC RD/BN
KB BU/YE
GABE BN
GABF BN
BBD RD
FAA OG/WH
RSA WH/RD
FT RD
251 253 208 203 219 204 217 220 225 238 256 216 214
RCD WH
KDF OG
XBB OG
P1
RLA DG
BAB RD
GBGD BN
XLB DG
GBGC SHLD P1
RT OG
1
FT RD
250 252 254 221 202 201 218 249 226 237 255 205 213 215
ASSEMBLE TO CENTER MOUNTING
BOLT OF IGNITION COIL
E217 BN/WH
E225 RD/DG
E204 OG/YE
E219 DG/YE
E238 BU/RD
RJE RD/BU
P1 P2 P3
E256 WH
E216 WH
E231 VT
E205 WH/BK
E237 DG/RD
GBB BN
E202 DG/YE
E249 BN/YE
E226 BU/BK
P3 P2
E255 BK
GBC BN
GBA BN
P1
E210 DG
E206 OG
TPS
4-6 k%%185
PTO FUEL INJECTOR
RJB RD/BU 2
IDLE AIR CONTROL E216 WH 1
RESISTANCE BETWEEN PINS
PINS RESISTANCE
1-2 30%%185%%p1.2%%185
2-3 30%%185%%p1.2%%185 MAG FUEL INJECTOR
1-3 60%%185%%p2.4%%185
4-5 30%%185%%p1.2%%185 RESISTANCE:
RJC RD/BU 2 12%%185%%p5%
5-6 30%%185%%p1.2%%185
4-6 60%%185%%p2.4%%185 E205 WH/BK 1 FUEL INJECTOR
ALL OTHER COMBINATIONS:OPEN
SPLICE, SHIELD
GBGB BN
E238 BU/RD
1 2 3 4 5 6
GBGA BN 1 2 GBGC SHLD
RJF RD/BU
1 2 3
6 5 4
E226 BU/BK
RJA RD/BU RJD RD/BU
E225 RD/DG RJE RD/BU 1 2 RJB RD/BU
RJC RD/BU
E237 DG/RD SPLICE, EFI RELAY
SPLICE, REAR LIGHTS B+

FLO RD/BN
FLB RD/BN 1 2 FLN RD/BN HALL SENSOR
TEMP RESISTANCE SPEED SENSOR
FLM RD/BN 100%%185
POWER IN
860%%185
68%%127F 20%%127C
E239 WH PIN "A"
3 2 1
E227 BK KDH OG
CB A
68%%185
CRANK GBD BN X V OUT
POSITION GBGB BN PIN "C"
E245 GN/RD
SENSOR SPLICE, GROUND REAR 1000pf
COMMON
GBHA BN 1 2 GBHE BN .01uf PIN "B"
GBHD BN (LOCATED ON TRANSMISSION)
BDB RD 1 2 BDA GY BAA BK 1 2 BAB RD GBHC BN
SPLICE, FUSIBLE #4 SPLICE, FUSIBLE #1
START DIODE SPLICE, BRAKE
RESISTOR MODULE (P/N 4014055)
RSB WH/RD
2
GAC BN XBB OG XBE OG

1
XBA OG 1 2 XBD OG A B C D E F
(P/N 2411035, 6A DIODE) XBC OG 24%%185
70 YE
71 YE
72 YE
BBA BU 2 1 BBB RD SPLICE,RESISTOR MODULE 75%%185

SPLICE, FUSIBLE #2 E223A WH 1 2 E223B WH 160%%185
300%%185
E230C VT (0.5) 620%%185
E230B VT 1 2 E230D VT
BEA BU 1 2 BEB WH/RD E230A VT
A B C
SPLICE, FUSIBLE #3 SPLICE, ECM SIGNAL GROUND E223B WH
F EDCB A
50 OG
51 RD
52 DG
FLD RD/BN
53 YE
XBA OG
54 DB
GAB BN
BDB RD
72 YE
71 YE
70 YE
CRANK STATOR P/N 4014406

POSITION FLYWHEEL P/N 4015703
SENSOR SENSOR (P/N 3233835)
4014525-360 BK
A B C D E F
4014525-360 BK
FLM RD/BN
FLO RD/BN
FLN RD/BN
4012709 BK
P1
PARK
P2
4012709 BK
GBHC BN
GBHD BN
GBHE BN
XBC OG
XBD OG
4012710
4012710
XBE OG
XW YE
REVERSE
P1 P2 P3 P1 P2 P3
NEUTRAL
LOW
BCA RD/BN
YE1
YE2
YE3
BDA GY
BBA BU
BEA BU
BAA BK
HIGH
A B C D A B C D A B C D
STATOR 1 50 OG
F EDCB A
1 1 51 RD
GBGA BN
E230D VT
GBHA BN
GABA BN
GBC BN
GBD BN
GAC BN
GAD BN
GBB BN
GBA BN
GAB BN
GAA BN
GAE BN
GBF BN
BK 52 DG
1
1 53 YE
WH 54 DB
TAIL STOP GND TURN
CENTER TAILLIGHT (P/N 2413431) TAIL STOP GND TURN
TAIL STOP GND WORK
RESISTANCES (%%p20% @ 68%%127F/20%%127C)

RSB WH/RD
POSITION RESISTANCE RSA WH/RD 1 1 1 1
1
CHARGE COIL YE1 - YE2 0.13 %%p15% LH TAILLIGHT (P/N 2413429) RH TAILLIGHT (P/N 2413430)
CHARGE COIL YE1 - YE3 0.13 %%p15% BATTERY (OPTIONAL LED WORK LIGHT P/N 2413558)
STARTER MOTOR BRAKE SWITCH
CHARGE COIL YE2 - YE3 0.13 %%p15% VOLTAGE: 12V
REGULATOR (P/N 4012855)
GROUND D GROUND C GROUND B GROUND A
(P/N 4014856) P/N 4010372
(LOCATED ON LEFT SIDE CHASSIS)
2017-18 SPORTSMAN 1000 XP ETC
(HEADLIGHT BULB SERVICE P/N 4010253)
HARNESS: 2413824 (HEADLIGHT BULB SERVICE P/N 4010253)
POWER STEERING ASSEMBLY (P/N 2411530)
(HEADLIGHT BULB SERVICE P/N 4010253) POD HEADLIGHT (P/N 2413427)
SPEEDOMETER EPS POWER (A)
RH BUMPER HEADLIGHT (P/N 2413433) PIN FUNCTION
WINCH LH BUMPER HEADLIGHT (P/N 2413432)
DIAGNOSTIC A BATTERY (+)
1 2 3 4 5 6 7 8 B BATTERY (-)
SWITCH
WIRE COLOR LEGEND
BG BEIGE (TAN) P/N EPS SENSOR (B)
E = ENGINE GROUND 9 10 11 12 13 14 15 16
BK BLACK 1 1 2205636 WINCH PIN FUNCTION
BU LIGHT BLUE A BCD
DB DARK BLUE E FGH CONTACTOR 2 4 6 8 10 12 14 16 1 ENGINE RPM (NEG. REF)
C = CHASSIS GROUND
BN BROWN 1 3 5 7 9 11 13 15 2 ENGINE RPM
WINCH SWITCH P/N
GY GRAY
3 IGNITION SIGNAL
FAB OG/WH
FAC OG/WH
GN LIGHT GREEN 4013465
NC = SWITCH NORMALLY CLOSED A BCDE FGH 4 CAN BUS LOW
DG DARK GREEN
FUE RD/BK
E144B DG
OG ORANGE NO = SWITCH NORMALLY OPEN 5 VEHICLE SPEED
XHC YE
S11 VT/WH
E132B YE
GAAF BN
KDD OG
PK PINK
A 6 VEHICLE SPEED (NEG. REF)
RD RED
B
FUD RD/BK
7 EPAS SYSTEM FAULT SIGNAL
E144C DG
E132C YE
VT VIOLET (PURPLE)
GAAJ BN
P1 P2 SPLICE, HIGH BEAM
KDC OG
WH WHITE 8 CAN BUS HIGH
YE YELLOW 1 2 3 4 SPLICE, LOW BEAM
2 1
CL CLEAR
TWO WIRE COLORS ARE SHOWN A B
1 2
A B
A B
SH.2,SH.1
SH.2,SH.1
XA1 GN
XA3 BK
EXAMPLE:RD/YE = RED WITH
FDC RD/GN
XA1 GN
YELLOW TRACE.
XA3 BK
SH.2,SH.1
SH.2,SH.1
A B
GABP BN
XHD YE
XHC YE
XHA YE
XHB YE
XHB YE
GAAD BN
RLC DG
GAAG BN
RLB DG
RLC DG
RLB DG
RLA DG
3 4 8
GBF BN
RT OG
RJ156 RD/DB SH.2,SH.1
RJ155 RD/DB SH.2,SH.1
KDE OG
E144D DG
E132D YE
RJG RD/BU RJD RD/DB SH.2,SH.1
RJA RD/BU 1 2 RJB RD/DB SH.2,SH.1
RJC RD/DB SH.2,SH.1
SPLICE, EFI RELAY
SH.2,SH.1
SH.2,SH.1
FUF RD/WH
2
FUB RD/BK
1
P4 P3 P2 P1
6A DIODE (P/N 2411035) FUF RD/WH
FUB RD/BK KDA RD/BK KEY SWITCH

FUD RD/BK GAAC BN P/N 4015033
SPLICE, UNSWITCHED FUSE B+ 1 2 FUE RD/BK
FUA RD/BK KB BU/YE
KDC OG
SH.2,SH.1
SH.2,SH.1
SH.2,SH.1
KDD OG
SPLICE, R/S B+ KDE OG
KDH OG SH.2,SH.1
KDF OG POD ACC GROUND
1 2 KDG OG 12V RECEPTACLE
GABR BN
RCC WH
RCB WH
RCA WH
KDK OG
BBG RD
BBE RD
BBF RD
1
KDJ OG SH.2,SH.1
FPC RD/GN
FDA RD/GN
RJG RD/BU
RJA RD/BU
RF OG/BK
RP RD/BU
FLA RD/BN
RCC WH
RCA WH
RCB WH
KDG OG
KDK OG
KDB OG
E141 OG/BK
E115 DG/YE
CBA RD/WH
E142 DG/YE
FPA RD/GN
FPB RD/GN
FJ RD/GN
FJ RD/GN
FAD OG/WH
BBG RD
GAE BN
BBE RD
BBF RD
SPLICE, B+ UNSWITCHED
1
SPLICE, B+ SWITCHED
SPLICE, GROUND POD POD ACC B+ (P/N 4010638)
GABP BN
GABR BN
SPLICE, FP
1 2 GAAH BN FUEL PUMP
1 2
1 2
GABM BN
1 2
LEFT HANDLEBAR SWITCH ASSEMBLY TANK LEVELRESISTANCE (%%185)
(P/N 4011835) OFF LOW 1 3 5 7 9 11 13 15 17 19 21 23
F FULL 6.0%%p1.0%%185
HEADLAMP 2 4 6 8 10 12 14 16 18 20 22 24 FAD OG/WH
FAB OG/WH EMPTY 90.0%%p4.5%%185
HIGH LHC CONR A 1 5 9 13 17 21 25 29 33 37 41 45
OFF E FAC OG/WH 1 2
COIL RELAY COIL RELAY COIL RELAY COIL RELAY COIL RELAY COIL RELAY
FAA OG/WH PIN FUNCTION
LEFT
RCD WH
BBD RD
BBB RD
HIGH OUT HIGH OUT HIGH OUT HIGH OUT HIGH OUT HIGH OUT
XLA DG
A BCDE F
D EFI FAN FUEL PUMP LOW BEAM EPS START 1 FUEL LEVEL SENSOR "+"
XHA YE RELAY COIL RELAY COIL RELAY COIL RELAY COIL RELAY COIL RELAY COIL
FLD RD/BN IN LOW IN LOW IN LOW IN LOW IN LOW IN LOW
SPLICE, ACCESSORY 2 FUEL LEVEL SENSOR "-"
C KDB OG COIL LIGHTS DRIVE
RELAY ACC EPS SPARE
HIGH OUT 3 FUEL PUMP "+"
IN 20A OUT IN 20A OUT IN 20A OUT IN 30A OUT IN 10A OUT
CHASSIS
RELAY COIL
FUEL PUMP EFI UNSWITCH FAN CKT BKR SPARE 4 FUEL PUMP "-"
B IN LOW IN 10A OUT IN 10A OUT IN 10A OUT IN 20A OUT IN 20A OUT
RUN 4 8 12 16 20 24 28 32 36 40 44 48
A
26 28 30 32 34 36 38 40 42 44 46 48
25 27 29 31 33 35 37 39 41 43 45 47 FUEL PUMP/LEVEL
F
GAF BN
4
CBA RD/WH
BEB WH/RD
BCA RD/BN
FUA RD/BK
FLE RD/BN
KB BU/YE
GAAE BN
E
BBD RD
XLB DG
FAA OG/WH
RSA WH/RD
RP RD/BU
FT RD
3
OFF
GAAK BN
RCD WH
KDF OG
XBB OG
RLA DG
BAB RD
KDA RD/BK
RT OG
FT RD
RIGHT
A BCDE F
D GAAB BN
2
S11 VT/WH
1
C GABM BN
E124 GY/OG (0.5) SH.1,SH.2
PUSH
B
OVERRIDE
FREE LHC CONR B
A FAN
RF OG/BK MOTOR
A B
GAD BN
HIGH BEAM SIGNAL DIODE FDC RD/GN SPLICE, DRIVE

XLA DG FDA RD/GN
XHD YE FDD RD/GN 1 2
1
XLB DG
2
FDE RD/GN
(P/N 2411035, 6A DIODE) AWD/ADC HUB COIL
AWD COIL
24%%185
FDE RD/GN
A B C D
FDD RD/GN
WORKLIGHT SWITCH SH.1,SH.2 E246 BN/WH
FLF RD/BN
1
SH.1,SH.2 E240 BN/YE

ADC COIL
12%%185
XW YE
1
(P/N 4011074) RSB WH/RD

2
GAC BN SPLICE, GROUND REAR

1
6A DIODE (P/N 2411035)

GAHA BN 1 2 GAHE BN
GAHD BN
GAHC BN
FLC RD/BN
FLD RD/BN
FLE RD/BN 1 2 FLA RD/BN
FLB RD/BN FLF RD/BN
SPLICE, LIGHTS B+
BEB WH/RD
BDB RD
BAB RD
BBB RD
SPLICE, REAR LIGHTS B+

FLM RD/BN
SPLICE, FUSIBLE #1
SPLICE, FUSIBLE #2
SPLICE, FUSIBLE #3
SPLICE, FUSIBLE #4
FLN RD/BN 1 2 FLB RD/BN

FLO RD/BN
4014423-350 BK
4014423-650 BK
4014423-650 BK
4014423-350 BK
1 2
2 1
1 2
1 2
4012710
4012710
GBE BN
BDB RD
72 YE
71 YE
70 YE
FLC RD/BN
BDA GY
BBA BU
BEA BU
BAA BK
XBA OG
FLO RD/BN
FLM RD/BN
GAHE BN
FLN RD/BN
GAHC BN
XBE OG
XBD OG
XBC OG
XBC OG
GAHD BN
XBE OG
XBD OG
XW YE
GAAG BN
GAAH BN
GAAD BN
GAAC BN
GAAK BN
GAAE BN
GAAB BN
GAAA BN
GAAF BN
GAAJ BN
P1 P2 P3 P1 P2 P3
BCA RD/BN
SH.2,SH.1
SH.2,SH.1
SH.2,SH.1
SH.2,SH.1
SH.2,SH.1
SH.2,SH.1
1 2
BDA GY
BBA BU
BEA BU
BAA BK
SPLICE, BRAKE
Deutsch_DTM06-2S
70 YE
71 YE
72 YE
*MUST USE WM-2S WEDGELOCK* A B C D A B C D
1 2
A B C D
1 2
1 1
1
GBGA BN
GAHA BN
GAAA BN
GBC BN
GBD BN
GAC BN
GAD BN
GBB BN
GBA BN
GBE BN
GAE BN
GBF BN
GAF BN
GBJ BN
1 SPLICE, GROUND FRONT
XBB_135 OG
A B C 1
BATTERY PLUS #1
XBB OG
XBA OG
TAIL STOP GND TURN
CENTER TAILLIGHT (P/N 2413431) TAIL STOP GND TURN
TAIL STOP GND WORK
RSB WH/RD
STATOR AC RSA WH/RD 1 1 1 1
1
LH TAILLIGHT (P/N 2413429) RH TAILLIGHT (P/N 2413430)

(OPTIONAL LED WORK LIGHT P/N 2413558)
SH.2,SH.1
STATOR P/N 4014406 BATTERY
VOLTAGE: 12V
FLYWHEEL P/N 4015585 STARTER MOTOR
REGULATOR (P/N 4012855) BRAKE SWITCH
(P/N 4014856) GROUND D GROUND C GROUND B GROUND A
P/N 2206566
(LOCATED ON LEFT SIDE CHASSIS)
2017-18 SPORTSMAN 1000 XP ETC
HARNESS: 2413824
HALL SENSOR
SPEED SENSOR
100%%185
POWER IN
PIN "A"
68%%185
WIRE COLOR LEGEND X V OUT
BG BEIGE (TAN) PIN "C"
E = ENGINE GROUND
BK BLACK
1000pf
BU LIGHT BLUE COMMON
DB DARK BLUE .01uf PIN "B"
C = CHASSIS GROUND
BN BROWN (LOCATED ON TRANSMISSION)
GY GRAY RESISTANCE: RESISTANCE:
GN LIGHT GREEN 12%%185%%p5% 12%%185%%p5%
NC = SWITCH NORMALLY CLOSED
DG DARK GREEN FUEL INJECTOR FUEL INJECTOR
OG ORANGE NO = SWITCH NORMALLY OPEN
PK PINK MAG FUEL INJECTOR
PTO FUEL INJECTOR
RD RED
VT VIOLET (PURPLE)
WH WHITE A BC
YE YELLOW
2
1
2
1
CL CLEAR
TWO WIRE COLORS ARE SHOWN
E232 GN/RD
KDH OG
EXAMPLE:RD/YE = RED WITH A B C D E F
YELLOW TRACE.
E244 BK
E243 WH
24%%185
RJB RD/DB
75%%185
160%%185
RJC RD/DB
300%%185
620%%185
SPLICE,RESISTOR MODULE
GBD BN
E123A WH 1 2 E123B WH E123B WH
F EDCB A
50 OG
51 RD
52 DG
53 YE
54 DB
SH.2,SH.1
SH.2,SH.1
SH.2,SH.1
SH.2,SH.1
SENSOR (P/N 3233835)
SPLICE,CAN HIGH A B C D E F
SH.2,SH.1 E132B YE
SH.2,SH.1 E132C YE 1 2 E132A YE PARK
SH.2,SH.1 E132D YE REVERSE
NEUTRAL
LOW
SPLICE,CAN LOW HIGH
SH.2,SH.1 E144B DG
SH.2,SH.1 E144C DG 1 2 E144A DG
SH.2,SH.1 E144D DG
50 OG
F EDCB A
51 RD
E204B VT
52 DG
53 YE
54 DB
SH.2,SH.1
SH.2,SH.1
SH.2,SH.1
SH.1,SH.2
SH.2,SH.1
SH.1,SH.2
SH.1,SH.2
E124 GY/OG (0.5)
E141 OG/BK
C_C111 WH
E144A DG
E132A YE
XBB_135 OG
E142 DG/YE
C_D106 BK
E123A WH
E246 BN/WH
E232 GN/RD
C_D210 RD
E243 WH
E244 BK
GBJ BN
E240 BN/YE
E223 OG
E227 DB
E204B VT
SPLICE, ECM SIGNAL GROUND
112 141 147 148 111 146 109 139 133 110 144 132 107 124 143
129 134 135 136 128 140 145 127 106 131 123 130 142 122
212 241 247 248 211 246 209 239 233 210 244 232 207 224 243
229 234 235 236 228 240 245 227 206 231 223 230 242 222
1 2
LAST 2 DIGITS OF 100 SERIES
NUMBER CORESPOND TO CONNECTOR
ECM 1 CAVITY NUMBER (IE. 110=CAVITY 10) LAST 2 DIGITS OF 200 SERIES
ECM 2 NUMBER CORESPOND TO CONNECTOR
E204C VT/WH
E204D VT/WH
E204A VT/WH
CAVITY NUMBER (IE. 210=CAVITY 10)
151 153 108 103 119 104 117 120 125 138 156 116 114
150 152 154 121 102 101 118 149 126 137 155 105 113 115
251 253 208 203 219 204 217 220 225 238 256 216 214
250 252 254 221 202 201 218 249 226 237 255 205 213 215
RJ156 RD/DB
E108 BK/RD
C_C125 RD
C_C103 BK
E104A VT
RJ155 RD/DB
E120 GY
GBA BN
E126 OG/BN
E137 OG/BK
E115 DG/YE
C_D121 WH
E105 VT/PK
C_E251 GN/BK
E204A VT/WH
GBB BN
E220 DG/BN
KDJ OG
C_B256 BK
C_E252 BK/GN
E203 DG
E219 YE
E208 VT
C_B254 WH
E213 WH
E218 OG
E201 BK
E215 YE
GBC BN
SH.2,SH.1
SH.2,SH.1
SH.2,SH.1
SH.2,SH.1
SH.2,SH.1
SH.2,SH.1
SH.2,SH.1
DRIVE MODE SWITCH: P/N 4016507
SPLICE, GROUND TMAP E218 OG Deutsch_DTM04-2P-E004
2 1
E204D VT/WH
E104C VT 1 2 E104A VT
*MUST USE WM-2PB WEDGELOCK*
E104B VT
SH.2,SH.1
GBGC BN
E213 WH
C_BD SHLD
E201 BK
GBGB BN
E104C VT
E227 DB
C_DD SHLD
C_CD SHLD
C_B254 WH
C_EC SHLD
C_BD SHLD
RJD RD/DB
C_B256 BK
E104B VT
GBGC BN
GBGB BN
E223 OG
E219 YE
E204C VT/WH
E215 YE
1 2 3
P1
-
C_CD SHLD
C_DD SHLD
C_EC SHLD
E108 BK/RD
C_D210 RD
C_C125 RD
C_D106 BK
C_C103 BK
1 2
C_E252 BK/GN
C_E251 GN/BK
E120 GY
E126 OG/BN
C_C111 WH
C_D121 WH
E220 DG/BN
E137 OG/BK
E105 VT/PK
1 2 3 4 1 2 3
1 2
SPLICE, SHIELD
E208 VT
E203 DG
TRIM FLUSH
P1
1 2
1
4 OUTPUT
1 GROUND
SIGNAL
T 1
GBGA BN
AIR TEMP
GBGD BN
2 N
2 NTC
11 9 7 5 3 1
3 +5V
SENSOR 3
12 10 8 6 4 2 1 2 3 4 5 6 S THERMISTOR
(P/N 2410687)
2 (P/N 4010644)
TRIM FLUSH
TRIM FLUSH
TRIM FLUSH
PRESSURE
12 11 10 9 8 7 IGNITION COIL CRANK POSITION

SENSOR
(P/N 4010425) SENSOR

6 5 4 3 2 1 (P/N 2411589)
1 NOMINAL RESISTANCE:
SH.2,SH.1
AT 20%%127C=2,5 k%%185%%p6%
NOMINAL RESISTANCE
ETC THROTTLE BODY AT 100%%127C=0,186 k%%185%%p2%
AT -20%%127C (16.2k%%185) T-MAP RIGHT HAND CONTROL
AT 20%%127C
2.45%%p0.24k%%185 (P/N 2411528) CAVITY 1-4 = GOLD TERMINALS
CAVITY 5-6 = TIN TERMINALS IGNITION COIL GROUND
AT 80%%127C
0.322%%p0.032k%%185
BOLT OF COIL
2017-18 SPORTSMAN 850/1000 HIGH LIFTER
WINCH WINCH
HARNESS: 2413688-01 EPS POWER (A)
SWITCH CONTACTOR PIN FUNCTION
SPEEDOMETER B
A B A BATTERY (+) A
P/N P/N RIGHT HANDLEBAR SWITCH ASSEMBLY
DIAGNOSTIC B BATTERY (-)
SHEET NO. 1 OF 2 2205636 4013465 POD LIGHT
CAP
1 2 3 4 5 6 7 8 E246 BK (0.5)
EPS SENSOR (B)
1 2 3 4 5
ADC 4X4 2X4 ADC 4X4 2X4
WIRE COLOR LEGEND WINCH SWITCH PIN FUNCTION E228 GY (0.5)
1 1
BG BEIGE (TAN) A BCD 9 GABL BN
1 2 3 4 5
10 11 12 13 14 15 16 1 ENGINE RPM (NEG. REF)
E = ENGINE GROUND
BK BLACK E FGH 2 ENGINE RPM E230C VT (0.5) 4640%%185
BU LIGHT BLUE
DB DARK BLUE 2 4 6 8 10 12 14 16 3 IGNITION SIGNAL E232 PK/WH (0.5)
C = CHASSIS GROUND LH HEADLIGHT (P/N 2411492) 1 3 5 7 9 11 13 15 RH HEADLIGHT (P/N 2411493)
FAC OG/WH
BN BROWN
FAB OG/WH
4 CAN BUS LOW SWITCH
2150%%185
GY GRAY A BCDE FGH TRS
GN LIGHT GREEN POD LIGHT 5 VEHICLE SPEED
NC = SWITCH NORMALLY CLOSED P1 P2 6 VEHICLE SPEED (NEG. REF)
FUE RD/BK
DG DARK GREEN
E248C DG
S11 VT/WH
OG ORANGE NO = SWITCH NORMALLY OPEN 1 2 3 4 7 EPAS SYSTEM FAULT SIGNAL
E236C YE
GABN BN
KP1D OG
PK PINK
FUD RD/BK
A B
E248B DG
E236B YE
GABG BN
KP1C OG
RD RED 8 CAN BUS HIGH
VT VIOLET (PURPLE)
XA1 GN
XA3 BK
WH WHITE POWER STEERING ASSEMBLY (P/N 2411530)
FDC RD/GN
P4 P3 P2 P1
YE YELLOW A B A B FUF RD/WH
XA1 GN
XA3 BK
GABM BN
CL CLEAR
RLD DG
TWO WIRE COLORS ARE SHOWN KP1A RD/BK KEY SWITCH
PN 4015033
FDB RD/GN
EXAMPLE:RD/YE = RED WITH
***EPS MODELS ONLY***
GABH BN
GABC BN
KP4 BU/YE
RLC DG
RLB DG
YELLOW TRACE. A B
3 4 8
GBF BN
RT OG
E248D DG
E236D YE
KP1E OG
TE 42511-2 w/ 1-480307-1
POD ACC GROUND
12V RECEPTACLE
GABK BN
1
A
B
KP1A RD/BK FAD OG/WH
A BCDE F
1
(P/N 4010638)
C POD ACC B+
GABJ BN
D E211 GY/OG (0.5)
E
LHC CONR B
F SPLICE, GROUND POD FAB OG/WH FAC OG/WH
1 2 FAD OG/WH
GABK BN FAA OG/WH
A GABL BN SPLICE, ACCESSORY
LHC CONR A GABJ BN 1 2 GABM BN
FDC RD/GN
FDB RD/GN
B GABP BN SPLICE, CAN LOW
XL DG GABB BN E248C DG
A BCDE F
E248B DG 1 2 E248D DG
C E248A DG
FLF RD/BN SPLICE, GROUND FRONT
KP1B OG E236C YE
D GABB BN E236B YE 1 2 E236D YE
SPLICE, DRIVE
GABH BN GABC BN E236A YE
E GABG BN 1 2 GABN BN
SPLICE, CAN HIGH
1 2
GABD BN
LEFT HANDLEBAR SWITCH ASSEMBLY F
(P/N 4011655) GABA BN SPLICE, B+ UNSWITCHED FUEL PUMP
GABE BN BBD RD
GABF BN BBB RD 1 2 BBE RD TANK LEVELRESISTANCE (%%185)
A B C D E F A B C D E F RLD DG BBF RD FULL 6.0%%p1.0%%185
FDD RD/GN
FDE RD/GN
FDA RD/GN
OFF RLB DG BBG RD
IGNITION EMPTY 90.0%%p4.5%%185
RLA DG 1 2 RLC DG
ENGINE SPLICE, B+ SWITCHED
RUN PIN FUNCTION
SPLICE, LOW BEAM RCC WH
OFF RCD WH 1 2 RCA WH 1 FUEL LEVEL SENSOR "+"
ON RCB WH 2 FUEL LEVEL SENSOR "-"
HEADLAMP
OFF 3 FUEL PUMP "+"
SPEEDO/ FREE FLC RD/BN 4 FUEL PUMP "-"
REVERSE FLF RD/BN 1 2 FLD RD/BN
OVERRIDE PUSH FLE RD/BN
FLA RD/BN
FUEL PUMP/LEVEL
SPLICE, LIGHTS B+ FUE RD/BK
FUD RD/BK 1 2 FUA RD/BK GAA BN
4
FUF RD/WH
2
FUB RD/BK FUB RD/BK
1
RP RD/BU
3
SPLICE, UNSWITCHED FUSE B+
(P/N 2411035, 6A DIODE)
GABD BN
2
S11 VT/WH
1
FAN,LEFT
SPLICE, R/S B+ KP1E OG FAN
KP1L OG RFB OG/BK MOTOR
A B
KP1D OG KP1F OG
KP1C OG 1 2 KP1G OG GAF BN
KP1B OG
KP1H OG
KP1J OG SPLICE, FAN
THERMISTOR RFB OG/BK
(P/N 4010644) RFA OG/BK 1 2
RFC OG/BK
E230B VT
1
FAN
E244 YE MOTOR
2
RFC OG/BK
A B
NOMINAL RESISTANCE: GAD BN
SPLICE, FP
AT 20%%127C=2,5 k%%185%%p6%
AT 100%%127C=0,186 k%%185%%p2%
1 2
FAN, RIGHT
1 AWD/ADC HUB COIL

AWD COIL
T 24%%185
AIR TEMP 2 FDE RD/GN
A B C D
SENSOR
(P/N 2410687) FDD RD/GN
E217 BN/WH
E224 BU E249 BN/YE
1
ADC COIL
E242C VT 12%%185
2
NOMINAL RESISTANCE
FPC RD/GN
FDA RD/GN
RFA OG/BK
RJA RD/BU
RJF RD/BU
RP RD/BU
FLA RD/BN
KP1G OG
KP1L OG
RCC WH
RCA WH
RCB WH
E204 OG/YE
E202 DG/YE
E219 DG/YE
AT -20%%127C (16.2k%%185)
CBA RD/WH
E211 GY/OG (0.5)
FPA RD/GN
FPB RD/GN
E232 PK/WH (0.5)
FJ RD/GN
FJ RD/GN
BBG RD
GAE BN
BBE RD
BBF RD
AT 20%%127C
2.45%%p0.24k%%185 0.4%%185
E246 BK (0.5)
PLUG
AT 80%%127C
0.322%%p0.032k%%185
E228 GY (0.5)
SPARK
E248A DG
E239 WH
KP1J OG
E207 OG
E210 DG
E224 BU
E244 YE
E245 GN/RD
E223A WH
E236A YE
E230A VT
E242A VT
E206 OG
E227 BK
E222 YE
E231 VT
3
2
1 PLUG
1 3 5 7 9 11 13 15 17 19 21 23 0.4%%185 SPARK
2 4 6 8 10 12 14 16 18 20 22 24 E255 BK
3
T-MAP
(P/N 2411528) 1 5 9 13 17 21 25 29 33 37 41 45 RJD RD/BU
2
212 241 247 248 211 246 209 239 233 210 244 232 207 224 243 COIL
HIGH
RELAY COIL
OUT HIGH
RELAY COIL
OUT HIGH
RELAY COIL
OUT HIGH
RELAY COIL
OUT HIGH
RELAY COIL
OUT HIGH
RELAY
OUT
E256 WH
1
229 234 235 236 228 240 245 227 206 231 223 230 242 222 EFI FAN FUEL PUMP LOW BEAM EPS START
RELAY COIL RELAY COIL RELAY COIL RELAY COIL RELAY COIL RELAY COIL
SPLICE, GROUND TMAP IN LOW IN LOW IN LOW IN LOW IN LOW IN LOW
COIL RELAY LIGHTS DRIVE ACC EPS SPARE
HIGH OUT
20A OUT IN 20A OUT IN 20A OUT IN 30A OUT IN 10A OUT
IN
E242C VT CHASSIS
FUEL PUMP EFI UNSWITCH FAN CKT BKR SPARE
(P/N 4010425)
E242B VT E242B VT 1 2 E242A VT
RELAY COIL
LOW IN 10A OUT IN 10A OUT IN 10A OUT IN 20A OUT IN 20A OUT IGNITION COIL
4 3 2 1
IN
1 GROUND LAST 2 DIGITS OF 200 SERIES
NUMBER CORESPOND TO CONNECTOR 4 8 12 16 20 24 28 32 36 40 44 48
2 NTC E207 OG CAVITY NUMBER (IE. 210=CAVITY 10) 26 28 30 32 34 36 38 40 42 44 46 48
3 +5V E222 YE 25 27 29 31 33 35 37 39 41 43 45 47
PRESSURE
SENSOR 4 OUTPUT
SIGNAL
CBA RD/WH
BDB WH/RD
XBB BN/WH
BCA RD/BN
FUA RD/BK
FLC RD/BN
GABE BN
GABF BN
BBD RD
FAA OG/WH
RSA WH/RD
KP4 BU/YE
FT RD
KP1F OG
251 253 208 203 219 204 217 220 225 238 256 216 214
RCD WH
P1
RLA DG
BAB RD
GBGC SHLD P1 GBGD BN
RT OG
1
XL DG
FT RD
250 252 254 221 202 201 218 249 226 237 255 205 213 215
BOLT OF IGNITION COIL
E217 BN/WH
E225 RD/DG
E204 OG/YE
E219 DG/YE
E238 BU/RD
RJE RD/BU
P1 P2 P3
E256 WH
E216 WH
E231 VT
E205 WH/BK
E237 DG/RD
GBB BN
E202 DG/YE
E249 BN/YE
E226 BU/BK
P3 P2
E255 BK
GBC BN
GBA BN
P1
E210 DG
E206 OG
TPS
4-6 k%%185
PTO FUEL INJECTOR
RJB RD/BU 2
IDLE AIR CONTROL E216 WH 1
RESISTANCE BETWEEN PINS
PINS RESISTANCE
1-2 30%%185%%p1.2%%185
2-3 30%%185%%p1.2%%185 MAG FUEL INJECTOR
1-3 60%%185%%p2.4%%185
4-5 30%%185%%p1.2%%185 RESISTANCE:
RJC RD/BU 2 12%%185%%p5%
5-6 30%%185%%p1.2%%185
4-6 60%%185%%p2.4%%185 E205 WH/BK 1 FUEL INJECTOR
ALL OTHER COMBINATIONS:OPEN
SPLICE, SHIELD
GBGB BN
E238 BU/RD
1 2 3 4 5 6
GBGA BN 1 2 GBGC SHLD
RJF RD/BU
1 2 3
6 5 4
E226 BU/BK
RJA RD/BU RJD RD/BU
E225 RD/DG RJE RD/BU 1 2 RJB RD/BU
RJC RD/BU
E237 DG/RD SPLICE, EFI RELAY
HALL SENSOR
TEMP RESISTANCE SPEED SENSOR
100%%185
POWER IN
860%%185
68%%127F 20%%127C
E239 WH PIN "A"
3 2 1
E227 BK KP1H OG
CB A
68%%185
CRANK GBD BN X V OUT
POSITION GBGB BN PIN "C"
E245 GN/RD
SENSOR
BRAKE DIODE 1000pf
XBB BN/WH COMMON
XBA GY (0.5) PIN "B"
2
.01uf
XBC BN/WH
1
XBD BN/WH (LOCATED ON TRANSMISSION)
(P/N 2411035, 6A DIODE)

A B C D E F
24%%185
70 YE
71 YE
72 YE
SPLICE,RESISTOR MODULE 75%%185

E223A WH 1 2 E223B WH 160%%185
BAA BK 1 2 BAB RD 300%%185
BEB RD 1 2 BEA GY E230C VT (0.5)
SPLICE, FUSIBLE #1 620%%185
SPLICE, FUSIBLE #4 E230B VT 1 2 E230D VT
E230A VT
A B C BBA BU 2 1 BBB RD SPLICE, ECM SIGNAL GROUND E223B WH
F EDCB A
50 OG
SPLICE, FUSIBLE #2 SPLICE, GROUND REAR 51 RD
52 DG
GBHA BN 1 2 GBHE BN 53 YE
BDA BK 1 2 BDB WH/RD GBHF BN 54 DB
CAB BN
BEB RD
72 YE
71 YE
70 YE
SPLICE, FUSIBLE #3
CRANK STATOR P/N 4014406 START DIODE
POSITION SENSOR (P/N 3233835)
XBA GY (0.5)
FLYWHEEL P/N 4015585
XBD BN/WH
XBC BN/WH
SENSOR RSB WH/RD
2
FLD RD/BN
FLE RD/BN
GAC BN
GBHE BN
GABP BN
GBHF BN
1
A B C D E F
(P/N 2411035, 6A DIODE) PARK
P1 P2 P3 P1 P2 P3
REVERSE
NEUTRAL
LOW
BCA RD/BN
BEA GY
BBA BU
BDA BK
BAA BK
HIGH
YE1
YE2
YE3
P1
P2
1
2
3
1
2
3
50 OG
F EDCB A
STATOR 51 RD
(LOCATED NEAR BATTERY) 1
E230D VT
GBGA BN
52 DG
GBHA BN
GABA BN
GROUND A
GBC BN
GBD BN
GAC BN
GAD BN
GBB BN
GBA BN
GAA BN
GAE BN
GBF BN
CAB BN
GAF BN
1
1
BK 53 YE
GROUND B
1
54 DB
WH 1
STARTER MOTOR
1
(P/N 4012855)
RESISTANCES (%%p20% @ 68%%127F/20%%127C)

POSITION RESISTANCE RSA WH/RD 1 1
CHARGE COIL YE1 - YE2 0.13 %%p15% RSB WH/RD
1
LH TAILLIGHT (P/N 2411153) RH TAILLIGHT (P/N 2411154)

CHARGE COIL YE1 - YE3 0.13 %%p15% REGULATOR BATTERY (TAILLIGHT SOCKET SERVICE P/N 4011101) (TAILLIGHT SOCKET SERVICE P/N 4011101)
(P/N 4014856) VOLTAGE: 12V (TAILLIGHT BULB SERVICE P/N 4010764) (TAILLIGHT BULB SERVICE P/N 4010764)
CHARGE COIL YE2 - YE3 0.13 %%p15% BRAKE SWITCH
GROUND B GROUND A (ON LEFT HANDLEBAR)

Sportsman 850

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Sportsman 850

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2018 Sportsman 850/1000

Publication Printed August 2017 (PN 9928503 R02)

NOTE provides key information by clarifying instructions.

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

REVISION INDEX: 2018 SPORTSMAN

REV RELEASE CHANGES

CHAPTER 1: GENERAL INFORMATION

VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION

VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS

VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS

Wireless Vehicle Link (WVL) – Part Number PU-

To download the PMDW app, navigate your Android

PMDW App Notes:

MASTER TORQUE TABLE ENGINE / COOLING SYSTEM

MAINTENANCE ITEM TORQUE 1

Crankcase Bolts M6 89 in. lbs (10 Nm)

PVT SYSTEM FINAL DRIVE

Drive Clutch Cover Front Gearcase Fill /

Transmission Fill / Drain ITEM TORQUE

A-arm Fasteners 37 ft. lbs (50 Nm)

Ball Joint Pinch 17 ft. lbs (24 Nm) Plus

STEERING / SUSPENSION ELECTRICAL

CATEGORY DIMENSION Fuel Pressure 58 psi (400 kPa)

ENGINE Champion REA6MC / .035

ELECTRICAL WHEELS / BRAKES

2018 SPORTSMAN 850 SP ENGINE

Fuel Pressure 58 psi (400 kPa)

DRIVETRAIN CLUTCH SETTINGS

2018 SPORTSMAN 850 TOURING ENGINE

Fuel Pressure 58 psi (400 kPa)

DRIVETRAIN CLUTCH SETTINGS

2018 SPORTSMAN 1000 XP ENGINE

Fuel Pressure 58 psi (400 kPa)

ELECTRICAL WHEELS / BRAKES

2018 SPORTSMAN 1000 XP TOURING ENGINE

Fuel Pressure 58 psi (400 kPa)

DRIVETRAIN CLUTCH SETTINGS

2018 SPORTSMAN XP 850 HIGH LIFTER ENGINE

Fuel Pressure 58 psi (400 kPa)

DRIVETRAIN CLUTCH SETTINGS

2018 SPORTSMAN XP 1000 HIGH LIFTER ENGINE

Fuel Pressure 58 psi (400 kPa)

ELECTRICAL WHEELS / BRAKES

Transmission Type Automatic PVT BLK/ 64-

MISC. SPECIFICATIONS AND CHARTS

pounds (lb) x 0.454 = kg

cubic centimeters (cc) x 0.061 = cubic inches

SAE TAP / DRILL SIZES METRIC TAP / DRILL SIZES

TIRE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

MAINTENANCE CHART KEY

GREASE LUBRICATION POINTS

ITEM RECOMMENDED LUBE METHOD FREQUENCY

MAINTENANCE QUICK REFERENCE

Add fluid until it is visible at Check level every 25 hours;

# ITEM LUBE REC. METHOD FREQUENCY*