2011 2013 Ranger Diesel SM 02840

GENERAL INFORMATION
1
CHAPTER 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . 1.3
PUBLICATIONS AND REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
MODEL: 2011-2013 RANGER DIESEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
MODEL: 2012-2013 RANGER DIESEL CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
VEHICLE CONTROLS / GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
FUEL INFORMATION, USAGE AND RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
FUEL INFORMATION / RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
BIO-DIESEL FUELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
B5 DIESEL FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
BIO-FUEL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
B6 TO B20 BIO-DIESEL FUEL BLEND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
ENGINE WARRANTY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
COLD WEATHER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
BLOCK HEATER USAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
STANDARD BOLT TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
METRIC BOLT TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
9924084 - 2011-2013 RANGER DIESEL / CREW

1.1
© Copyright 2012 Polaris Sales Inc.
GENERAL INFORMATION
VEHICLE IDENTIFICATION
Model Number Designation
Example: R13TH90DG
MODEL
GROUP CHASSIS DRIVELINE ENGINE CATEGORY OPTION REGION
YEAR
1st digit 2/3rd digit 4th digit* 5th digit* 6th digit* 7th digit* 8th digit* 9th digit** 10th digit
C = Sportsman 6x6
D = Sportsman Tour Displacement in cc divided
E = Trail Boss by 10 and rounded to two
F = Sportsman Youth digits
A = 2x4 Chain
G = Sport (i.e. 50 = 498cc)
B = 2x4 Shaft
H = RANGER 6x6 ------------
C = 4x4 AC Drive A = ORV
J = RZR XP For electric vehicles
E = 4x4 Shaft / IRS D = Diesel
K = Sport Youth 08 = 48 Volt
G = 4x4 Chain rear /  E = EU On-road
M = Sportsman 12 = 72 Volt
11 shaft front F = INT’L
A = ATV N = Trail Blazer
12 H = 4x4 Shaft / IRS G = EV C = Calif.
R = RANGER P = Phoenix
13 J = 2x4 Swing arm Manual - - OR - - L = LSV
R = RANGER Midsize
N = 4x4 Shaft ADC M = Military
S = RZR
P = 2x4 / IRS Manual S = Scandinavian
T = Sportsman X2 / 
R = 6x6 Shaft / IRS 5 = 550 V = EU On-road
RANGER Fullsize
T = 4x4 Shaft / Trailing Arm 6 = 570 E = EPS
U = RANGER Fullsize
X = 4x4 Shaft EBS 7 = 760 D = Diesel
V = RZR
W = Multi-pass RGR 8 = 850 F=D+E
X = Multi-pass RZR 9 = 875
Z = Sportsman XP
* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively
** = 9th digit will be used on color/featured versions of models (not including the base)
First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN.
Vehicle Identification Number (VIN) Designation

Example: 4XATH90D0D3000000
Vehicle Descriptors Vehicle Identifiers

Engine Modifier
Mfg. Location
Model Year *
Engine Size
Check Digit
World Mfg. ID
Individual Serial No.
Category
Driveline
Chassis
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4 X A T H 9 0 D 0 D 3 0 0 0 0 0 0
* Model Year: A = 2010; B = 2011; C = 2012; D = 2013
1.2 9924084 - 2011-2013 RANGER DIESEL / CREW

GENERAL INFORMATION
Engine Number Designation 1
3TNM72 - APL........................................................................................3-Cylinder, Liquid Cooled, Diesel, Electric Start
Vehicle and Engine Serial Number Locations

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

VIN Number

1.3
GENERAL INFORMATION
PUBLICATIONS AND REPLACEMENT KEYS
Publication Numbers
Model Model No. Owner’s Manual PN Parts Manual PN

2011 RANGER DIESEL R11TH90DG 9923138 9923139
2012 RANGER DIESEL CREW R12WH90DG 9923514 9923528
2013 RANGER DIESEL CREW R13WH90DG 9924088 9924105
NOTE: When ordering service parts be sure to use the correct parts manual.
NOTE: Polaris factory publications can be found at www.polarisindustries.com or purchased from

www.purepolaris.com.
Replacement Keys
Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the
original key and refer to the chart to the right for the proper part number.
Series# Part Number

KEY COVER
20 4010278
P/N 5533534
21 4010278
22 4010321
23 4010321
Key Series 27 4010321
Number 28 4010321
31 4110141
32 4110148
67 4010278
68 4010278
SPECIAL TOOLS
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other
tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when
servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation,
by phone at 1-800-328-6657 or on-line at http://polaris.spx.com/.

GENERAL INFORMATION
GENERAL SPECIFICATIONS 1
MODEL: 2011-2013 RANGER DIESEL
MODEL NUMBER: R11TH90DG (2011)
R12TH90DG (2012)
R13TH90DG (2013)
ENGINE MODEL: 3TNM72-APL
Category Dimension / Capacity
Length 114 in. / 289.6 cm
Width (cargo box) 60 in. / 152.4 cm
Width (tires) 58 in. / 147.3 cm
Height 76 in. / 193 cm
Wheel Base 76 in. / 193 cm
Ground Clearance 12 in. / 30.5 cm
Turning Radius 158 in. / 401.3 cm
Dry Weight 1435 lbs. / 690 kg
Cargo Box Capacity 1000 lbs. / 454 kg
Cargo Box
36.5 x 54 x 11.5 in.
Dimensions
(93 x 137 x 29 cm)
(inside dimensions)
1500 lbs. / 680 kg
(Includes weight of
Vehicle Payload
operator, passenger, cargo
and accessories.
Hitch Towing Capacity 2000 lbs. / 907 kg
Hitch Tongue Capacity 150 lbs. / 68 kg
1.5
GENERAL INFORMATION
MODEL: 2011-2013 RANGER DIESEL Drivetrain
Engine Transmission Type Polaris Automatic PVT
Yanmar 3-Cylinder, Shift Type In Line Shift - H / L / N / R
Platform
Liquid Cooled, Diesel Front Gearcase Lubricant Demand Drive Plus
Engine Model Number 3TNM72-APL Requirements 6.75 oz. (200 ml)
Engine Displacement 904 cc Rear Gearcase Lubricant ATV Angle Drive Fluid
Number of Cylinders 3 Requirements 22 oz. (650 ml)
Bore & Stroke (mm) 72 x 74 mm Transmission Lubricant Polaris AGL plus

Requirements 32 oz. (946 ml)
Compression Ratio 23.5 : 1
Drive Belt 3211135
Compression Pressure 470 ± 15 psi
Steering / Suspension
Engine Idle Speed 1075 ± 50 RPM
Toe Out 1/8 - 1/4 in. (3.2 - 6.35 mm)
Engine Max Operating Speed 3600 RPM
Front Suspension Dual A-arm
Lubrication Pressurized Wet Sump
Front Travel 9.6 in. (24.4 cm)
Oil Requirements Polaris DIESEL Oil
Rear Suspension Independent (IRS)
Oil Capacity 1.8 qts. (1.7 L)
Rear Travel 9 in. (22.9 cm)
Coolant Capacity 6.2 qts. (5.9 L)
Shock Preload Adjustment Cam Adjustment
Overheat Warning Instrument Cluster Indicator
Wheels / Brakes
Exhaust System Canister Style
Front Wheel Size / Type 12 x 6 / Steel
Starting Aid Glow Plugs / Opt. Block Heater
Rear Wheel Size / Type 12 x 8 / Steel
Fuel System
Front Tire
Fuel Injection Unit Yanmar MC Fuel Injection AT489 / 25 x 10 R12
Make / Model / Size
(non-serviceable) Pump
Rear Tire
Fuel Transfer System Electric Fuel Pump (in-line) AT489 / 25 x 11 R12
Make / Model / Size
Fuel Pump Pressure 1-5 psi Tire Air Pressure 8-12 psi
Fuel Capacity 9 gal. (34 L) Brake System Type 4 Wheel Hydraulic Disc
Fuel Requirement Low Sulfur / Ultra Low Sulfur Brake Fluid DOT 4
Electrical Parking Brake Hand Actuated (in dash)
Alternator Max Output 55A, 742Watts @ 3000 RPM
Main Headlights 50 Watt / Halogen x 2
Tail Lights 0.3 Watts / L.E.D. x 2
Brake Lights 3.1 Watts / L.E.D. x 2
Starting System Electric Start
Glow Plugs Yanmar Quick Type
Battery Low-Maintenance / Sealed
Instrumentation Multifunction Speedometer
DC Outlets (2) - Front
Chassis / Glow Plug / Fan /
Relays Fuel Pump / Differential /
Brake Light
Circuit Breaker Fan Motor: 15 Amp
Main: 20 Amp
Accessory: 20 Amp
Lights: 15 amp
Fuses Fuel Pump: 30 Amp
Glow Plugs: 30 Amp
Fuel Pump: 30 Amp
Auxiliary Lights: 20 Amp

GENERAL INFORMATION
MODEL: 2012-2013 RANGER DIESEL CREW
MODEL NUMBER: R12WH90DG (2012)
R13WH90DG (2013)
ENGINE MODEL: 3TNM72-APL
Category Dimension / Capacity
Length 145 in. / 386 cm
Width (cargo box) 60 in. / 149.8 cm
Width (tires) 58 in. / 147.3 cm
Height 76 in. / 193 cm
Wheel Base 108 in. / 274 cm
Ground Clearance 11.5 in / 29 cm
Turning Radius 255 in. / 648 cm
Dry Weight 1685 lbs. / 764.3 kg
Cargo Box Capacity
1000 lbs. / 454 kg
CREW
Cargo Box
36.5 x 54 x 11.5 in.
Dimensions
(93 x 137 x 29 cm)
(inside dimensions)
1750 lbs. / 794 kg
(Includes weight of
Vehicle Payload
operator, passenger, cargo
and accessories.
Hitch Towing Capacity 2000 lbs. / 907 kg
Hitch Tongue Capacity 150 lbs. / 68 kg
1.7
GENERAL INFORMATION
MODEL: 2012-2013 RANGER DIESEL CREW
Drivetrain
Engine Transmission Type Polaris Automatic PVT
Yanmar 3-Cylinder, Shift Type In Line Shift - H / L / N / R
Platform
Liquid Cooled, Diesel
Front Gearcase Lubricant Demand Drive Plus
Engine Model Number 3TNM72-APL Requirements 6.75 oz. (200 ml)
Engine Displacement 904 cc Rear Gearcase Lubricant ATV Angle Drive Fluid
Number of Cylinders 3 Requirements 22 oz. (650 ml)
Bore & Stroke (mm) 72 x 74 mm Full Synthetic Transmission
Transmission Lubricant
Fluid
Compression Ratio 23.5:1 Requirements
32 oz. (946 ml)
Compression Pressure 470 ± 15 psi
Drive Belt 3211135
Engine Idle Speed 1075 ± 50 RPM
Steering / Suspension
Engine Max Operating Speed 3600 RPM
Toe Out 1/8 - 1/4 in. (3.2 - 6.35 mm)
Lubrication Pressurized Wet Sump
Front Suspension Dual A-arm
Oil Requirements Polaris DIESEL Oil
Front Travel 9.6 in. (24.4 cm)
Oil Capacity 1.8 qts. (1.7 L)
Rear Suspension Independent (IRS)
Coolant Capacity 6.64 Qts (6.28 L)
Rear Travel 9 in. (22.9 cm)
Overheat Warning Instrument Cluster Indicator
Shock Preload Adjustment Cam Adjustment
Exhaust System Canister Style
Wheels / Brakes
Starting Aid Glow Plugs / Opt. Block Heater
Front Wheel Size / Type 12 x 6 / Steel
Fuel System
Rear Wheel Size / Type 12 x 8 / Steel
Fuel Injection Unit Yanmar MC Fuel Injection
Front Tire
(non-serviceable) Pump Carlisle / PXT / 26 x 9 R12
Make / Model / Size
Fuel Transfer System Electric Fuel Pump (in-line)
Rear Tire
Carlisle / PXT / 26 x 11 R12
Fuel Pump Pressure 1-5 psi Make / Model / Size
Fuel Capacity 9 gal. (34 L) Front: 12 PSI (83 kPa)
Tire Air Pressure
Fuel Requirement Low Sulfur or Ultra Low Sulfur Rear: 16 PSI (110 kPa)
Electrical Brake System Type 4 Wheel Hydraulic Disc
Alternator Max Output 55A, 742 Watts, @ 3000 RPM Brake Fluid DOT 4
Main Headlights 50 Watt / Halogen x 2 Parking Brake Hand Actuated (in dash)
Tail Lights 0.3 Watts / L.E.D. x 2
Brake Lights 3.1 Watts / L.E.D. x 2
Starting System Electric Start
Glow Plugs Yanmar Quick Type
Battery Low-Maintenance / Sealed
Instrumentation Multifunction Speedometer
DC Outlets 2 front / 1 rear
Chassis/ Glow Plug / Fan /
Relays Fuel Pump / Differential/ Brake
Light
Circuit Breaker Fan Motor: 15 Amp
Main: 20 Amp
Accessory: 20 Amp
Lights: 15 amp
Fuses Fuel Pump: 30 Amp
Glow Plugs: 30 Amp
Fuel Pump: 30 Amp
Auxiliary Lights: 20 Amp

GENERAL INFORMATION
Vehicle Controls / Gauges
Switches &
Parking Brake Lever Gear selector (shifter) Indicator lights
Speedometer / MFD
12V Outlets Ignition Switch
Wait-to-start (Glow plug)

Low Oil Pressure Indicator Indicator
Head lamp Speedometer

Switch
Ignition Switch MFD

Off / On / Start
Mode Button

1.9
GENERAL INFORMATION
FUEL INFORMATION, USAGE AND • Ash content must not exceed 0.01% by volume.
RECOMMENDATIONS • Carbon residue content must not exceed 0.35% by
volume. Less than 0.1% is preferred.
Fuel Information / Recommendations • Total aromatics content should not exceed 35% by
volume. Less than 30% is preferred.
CAUTION • PAH (poly cyclic aromatic hydrocarbons) content
should be below 10% by volume.
NEVER use an engine starting aid such as ether. • Metal content of Na, Mg, Si and Al should be equal
Engine damage will result. to or lower than 1 mass ppm (test analysis method
JPI-5S-44-95).
NOTE: For the best engine performance, to prevent
engine damage and to comply with EPA/ARB • Lubricity: Wear mark of WS1.4 should be Max.
0.018 in. (.457 mm) at HFRR test.
warranty requirements, use ONLY the recommended
diesel fuels. Use only CLEAN low sulfur or ultra low
sulfur #2 or #1 Diesel fuel.
Bio-Diesel Fuels
NOTE: Never use bio-diesel blended fuel containing
Diesel fuel should comply with the following specifica-
more than 5% bio-diesel in this vehicle.
tions. The table lists several worldwide specifications for
diesel fuels: In Europe and in the United States, as well as some other
countries, non-mineral oil based fuel resources such as
RME (Rapeseed Methyl Ester) and SOME (Soybean
Methyl Ester), collectively known as FAME (Fatty Acid
DIESEL FUEL Methyl Esters), are being used as extenders for mineral oil
LOCATION
SPECIFICATION derived diesel fuels.
ASTM D975 YANMAR approves the use of bio-diesel fuels that do not
No. 1D S15, S500 USA exceed a blend of 5% (by volume) of FAME with 95% (by
No. 2D S15, S500 volume) of approved mineral oil derived diesel fuel. Such
EN590:96 European Union bio-diesel fuels are known in the marketplace as B5 diesel
fuels.
ISO 8217 DMX International
BS 2869-A1 or A2 United Kingdom B5 Diesel Fuel Requirements
JIS K2204 Grade No. 2 Japan
1. The bio-fuels must meet the minimum specifications
KSM-2610 Korea for the country in which they are used.
GB252 China
• In Europe, bio-diesel fuels must comply with the
European Standard EN14214
Additional Technical Fuel Requirements
• In the United States, bio-diesel fuels must comply
• The fuel cetane number should be equal to 45 or with the American Standard ASTMD-6751.2
higher.
2. Bio-fuels should be purchased only from recognized
• The sulfur content must not exceed 0.5% by and authorized diesel fuel suppliers.
volume. Less than 0.5% is preferred. Especially in
the U.S.A. and Canada, Low Sulfur (300 to 500
ppm (mg/kg) or Ultra Low Sulfur fuel should be
used.
• NEVER mix kerosene, used engine oil or residual
fuels with the diesel fuel.
• Water and sediment in the fuel should not exceed
0.05% by volume.
• Keep the fuel tank and fuel-handling equipment
clean at all times.
• Poor quality fuel can reduce engine performance
and/or cause engine damage.
• Fuel additives are not recommended. Some fuel
additives may cause poor engine performance.

GENERAL INFORMATION
Bio-Fuel Precautions Engine Warranty 1
1. Free methanol in FAME may result in corrosion of Damages, performance or service concerns determined
aluminum and zinc FIE components. to be caused by the use of bio-diesel fuel not meeting the
specifications outlined above are not considered to be
2. Free water in FAME may result in plugging of fuel
defects in material or factory workmanship and are not
filters and increased bacterial growth.
covered under warranty. The same applies to damages or
3. High viscosity at low temperatures may result in fuel other concerns induced by not complying with the
delivery problems, injection pump seizures, and poor recommended operating conditions of YANMAR engines
injection nozzle spray atomization. with bio-diesel fuel.
4. FAME may have adverse effects on some elastomers
(seal materials) and may result in fuel leakage and Cold Weather Operation
dilution of the engine lubricating oil.
Cold weather operation can result in fuel gelling if the
5. Even bio-diesel fuels that comply with a suitable
standard as delivered, will require additional care and incorrect fuel type is used. Use the fuel blending guide-
attention to maintain the quality of the fuel in the line table below to prevent this from occurring.
equipment or other fuel tanks. It is important to
maintain a supply of clean, fresh fuel. Regular flushing Block Heater Usage
of the fuel system, and/or fuel storage containers, may
If this vehicle will be operated when temperatures are in
be necessary.
the +30° to -25° F. (-1° to -32° C) range, a block heater
6. The use of bio-diesel fuels that do not comply with the must be installed. Please see your dealer to purchase a
standards as agreed to by the diesel engine block heater kit.
manufacturers and the diesel fuel injection equipment
NOTE: A block heater kit is recommended for use
manufacturers, or bio-diesel fuels that have degraded
below 30 degrees F.
as per the precautions and concerns above, may
affect the warranty coverage of your engine.
Cold Weather Fuel Usage Table:
B6 to B20 Bio-Diesel Fuel Blend Temperature NO. 2 Diesel NO. 1 Diesel
B6 to B20 bio-diesel is not approved for this POLARIS Above 15° F (9° C) 100% 0%
application. Down to -20° F (-29° C) 50% 50%
Below -20° F (-29° C) 0% 100%
Approved Engines
Only the YANMAR TNM engine series 3TNM72 may

operate with bio-diesel fuel concentrations up to B5 for
POLARIS applications.
Approved Fuel
IMPORTANT: Raw pressed vegetable oils are not
considered bio-diesel, and are unacceptable for use
as fuel in any concentration in YANMAR engines.
Bio-diesel fuel blends up to B5 must comply with the
following standards:
• EN14214 (European standard) and/or ASTM D-

6751 (American standard)
• All applicable engines may operate with bio-diesel
fuel up to a maximum B5 (5% bio-diesel blend)
concentration
1.11
GENERAL INFORMATION
MISC. SPECIFICATIONS AND CHARTS
Conversion Table
°C to °F: 9/5(°C + 32) = °F °F to °C: 5/9(°F - 32) = °C

GENERAL INFORMATION
Standard Bolt Torque Specification 1
Grade 2 Grade 5 Grade 8
Grade 2 Grade 5 Grade 8

Bolt Size
ft-lbs (Nm) ft-lbs (Nm) ft-lbs (Nm)
1/4-20 5 (7) 8 (11) 12 (16)
1/4-28 6 (8) 10 (14) 14 (19)
5/16-18 11 (15) 17 (23) 25 (35)
5/16-24 12 (16) 19 (26) 29 (40)
3/8-16 20 (27) 30 (40) 45 (62)
3/8-24 23 (32) 35 (48) 50 (69)
7/16-14 30 (40) 50 (69) 70 (97)
7/16-20 35 (48) 55 (76) 80 (110)
1/2-13 50 (69) 75 (104) 110 (152)
1/2-20 55 (76) 90 (124) 120 (166)
Metric Bolt Torque Specification
GRADE
Bolt Size 4.6 4.8 8.8/8.9 10.9 12.9

FT-LBS / NM (DRY THREADS)
M3 .3/.5 .5/.7 1/1.3 1.5/2 1.5/2
M4 .8/1.1 1/1.5 2/3 3/4.5 4/5
M5 1.5/2.5 2/3 4.5/6 6.5/9 7.5/10
M6 3/4 4/5.5 7.5/10 11/15 13/18
M8 7/9.5 10/13 18/25 26/35 33/45
M10 14/19 18/25 37/50 55/75 63/85
M12 26/35 33/45 63/85 97/130 110/150
M14 37/50 55/75 103/140 151/205 177/240
M16 59/80 85/115 159/215 232/315 273/370
M18 81/110 118/160 225/305 321/435 376/510
1.13
GENERAL INFORMATION
SAE Tap / Drill Sizes Decimal Equivalents
Metric Tap / Drill Sizes

MAINTENANCE
CHAPTER 2
MAINTENANCE
PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2
PERIODIC MAINTENANCE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PRE-RIDE - 50 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
50 - 100 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
100 - 300 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
GREASE LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
SERVICE PRODUCTS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
FLUID MAINTENANCE REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
COMPONENT QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
COMPONENT QUICK REFERENCE, CONTINUED...... . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 2.10
PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
SHIFT CABLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
SHIFT CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
VENT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
THROTTLE PEDAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
THROTTLE FREEPLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
ENGINE AIR INTAKE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
PVT AIR INTAKE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
AIR INTAKE EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
FUEL FILTER / WATER SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
FUEL FILTER / WATER SEPARATOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
FUEL FILTER / WATER SEPARATOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 2.16
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
COMPRESSION AND LEAKDOWN TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
ENGINE OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
TRANSMISSION AND GEARCASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
FRONT GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
REAR GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
LIQUID COOLING SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
RADIATOR INSPECTION / CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
RADIATOR REMOVAL (2011) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
RADIATOR REMOVAL (2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
2.1
MAINTENANCE
FINAL DRIVE / WHEEL AND TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
WHEEL AND HUB TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
CV SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
WHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
TIRE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
ELECTRICAL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
BATTERY STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
BATTERY CHARGING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
ENGINE GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35
STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35
TIE ROD END / STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35
WHEEL TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35
TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37
SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37
SPRING PRE-LOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37
SHOCK POSITION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37
BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38
BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38
BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38
BRAKE PAD / DISC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38
PARKING BRAKE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39
PARKING BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39
2.2
MAINTENANCE
PERIODIC MAINTENANCE CHART
Periodic Maintenance Overview
Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement 2
parts, use genuine Pure Polaris parts available from your Polaris dealer.
NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment
procedures, have a qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of
approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand

• Frequent or prolonged operation in dusty environments
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the
oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to
rise, discontinue use and determine the cause or see your dealer.
Break-In Period
The break-in period consists of the first 50 hours of operation. Careful treatment of a new engine and drive components
will result in more efficient performance and longer life for these components.
• Drive vehicle slowly at first while varying the throttle position. Do not operate at sustained idle.
• Pull only light loads.
• Perform regular checks on fluid levels and other areas outlined on the daily pre-ride inspection checklist.
• Change both the engine oil and filter after 50 hours.
• See “Owner’s Manual” for additional break-in information.
Maintenance Chart Key

The following symbols denote potential items to be aware of during maintenance:
 = CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an
authorized Polaris dealer.
= SEVERE USE ITEM: See information provided above.
E = Emission Control System Service (California).
NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.
WARNING
Improperly performing the procedures marked < could result in component failure and
lead to serious injury or death. Have an authorized Polaris dealer perform these services.
2.3
MAINTENANCE
Pre-Ride - 25 Hour Maintenance Interval
Make adjustments / changes as needed.
See Pre-Ride Checklist on Page 2.10.
Maintenance Interval
(whichever comes first)
Item Remarks
Miles
Hours Calendar
(KM)
 Steering - Pre-Ride -
 Front Suspension - Pre-Ride -
 Rear Suspension - Pre-Ride -
Tires - Pre-Ride -
Make adjustments / changes as needed. 
 Brake Pedal Travel - Pre-Ride -
See Pre-Ride Checklist on Page 2.10.
 Brake System and Fluid - Pre-Ride -
Wheels / Fasteners - Pre-Ride -
Frame Fasteners - Pre-Ride -

Engine Oil Level - Pre-Ride -
E
Fuel filter / water separator should be
drained every 50 hours (normal conditions
with quality fuel) OR drained daily (severe

Fuel Filter / Water Separator - Pre-Ride - conditions / poor fuel quality). Fuel filter /
E
water separator should be replaced every
150 hours OR 12 months OR 2000 miles
(3200KM). WHICHEVER COMES FIRST.
Air Filter / Pre-Filter

(Located Behind LF - Daily - Inspect;clean often
E
Headlamp)

Air Box Sediment Tube - Daily - Drain deposits when visible
E
Check level daily, change coolant every 2
Coolant Level - Daily -
years
Check operation; apply dielectric grease if
Head Lamp / Tail Lamp - Daily -
replacing
 Air Filter, Inspect; replace as needed or replace
- Weekly -
E Main Element every 150 hours.
 Brake Pad Wear / Inspect
10 H 1M 100 (160) Inspect periodically
 Parking Brake Pads
Battery 20 H 1M 200 (320) Check terminals; clean; test
 Parking Brake Cable
25 H - - Inspect; adjust tension after first 25 hours
 Adjustment
 Front Gearcase Fluid 25 H 1M 250 (400) Initial fluid level inspection
Mid Gearcase Fluid
 25 H 1M 250 (400) Initial fluid level inspection
(if equipped)
 Transmission Fluid 25 H 1M 250 (400) Initial fluid level inspection
Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
 Have an authorized Polaris dealer perform these services.
2.4
MAINTENANCE
50 - 100 Hour Maintenance Interval
Item
Hours Calendar
Miles
(KM)
Remarks
2
 Engine Oil Change  50 H 1M - Perform a break-in oil and filter change
E (Break-In Period)
with quality fuel) OR drained daily (severe
Fuel Filter / Water
 Separator 50H 3M 300 (480) conditions / poor fuel quality). Fuel filter /
Lubricate all grease fittings, pivots, cables,
 General Lubrication 50 H 3M 500 (800)
etc.
Shift Linkage 50 H 6M 500 (800) Inspect, lubricate, adjust
 Steering 50 H 6M 500 (800) Lubricate (if applicable)
 Front Suspension 50 H 6M 500 (800) Lubricate (if applicable)
 Rear Suspension 50 H 6M 500 (800) Lubricate (if applicable)
 Throttle Cable / Throttle Inspect; adjust; lubricate; replace if
50 H 6M 500 (800)
E Pedal necessary
Throttle Body Air Intake
E 50 H 6M 500 (800) Inspect ducts for proper sealing/air leaks
Ducts / Flange
Drive Belt 50 H 6M 500 (800) Inspect; adjust; replace as needed
Inspect coolant strength seasonally;
Cooling System 50 H 6M 500 (800)
pressure test system yearly
 Parking Brake Cable 100 H 6M 1000 (1600) Inspect; adjust tension as needed
 Adjustment
 Engine Oil Change 100 H 6M 1000 (1600)
Perform a break-in oil change at 50 hours
E or after one month of operation.
 Oil Filter Change 100 H 6M 1000 (1600) Replace during engine oil change
E
 Front Gearcase Fluid 100 H 12 M 1000 (1600) Change fluid
Mid Gearcase Fluid
 (if equipped) 100 H 12 M 1000 (1600) Change fluid
 Transmission Fluid 100 H 12 M 1000 (1600) Change fluid

 Fuel System - 24 M - Replace fuel lines every 2 years.
E
Perform these procedures more often for vehicles subjected to severe use.
Have an authorized Polaris dealer perform these services.
2.5
MAINTENANCE
100 - 300 Hour Maintenance Interval
Item Remarks
Miles
Hours Calendar
(Km)
Check for leaks at tank cap, fuel lines, fuel

Fuel System 100 H 12 M 1000 (1600) pump, and fuel rail. 
E
Replace lines every two years.
 Radiator 100 H 12 M 1000 (1600) Inspect; clean external surfaces
 Cooling Hoses 100 H 12 M 1000 (1600) Inspect for leaks
 Engine Mounts 100 H 12 M 1000 (1600) Inspect
Exhaust Silencer / Pipe 100 H 12 M 1000 (1600) Inspect
Inspect; replace as needed. See chapter
 Alternator Belt
11 for maintenance interval.
Inspect for wear, routing, security; apply
 Wiring 100 H 12 M 1000 (1600) dielectric grease to connectors subjected
to water, mud, etc.
 Clutches 
100 H 12 M 1000 (1600) Inspect; clean; replace worn parts
 (Drive and Driven)
 Front Wheel Bearings 100 H 12 M 1000 (1600) Inspect; replace as needed
with quality fuel) OR drained daily severe
 Fuel/Water Separator  150 H 12 M 2000 (3200) conditions / poor fuel quality). Fuel filter /
E
 Air Filter 150 H 12 M -
Replace air filter. Inspect / replace more
E often if vehicle is subject to severe use.
 Brake Fluid 200 H 24 M 2000 (3200) Change every two years (DOT 4)
Spark Arrestor 300 H 36 M 3000 (4800) Clean out
Inspect periodically; adjust when parts are
 Toe Adjustment -
replaced
Headlight Aim - Adjust as needed
 Perform these procedures more often for vehicles subjected to severe use.
 Have an authorized Polaris dealer perform these services.
Grease Lubrication Points

There is a grease fitting on the front propshaft yoke.
Item Recommended Lube Method Frequency

Grease before long periods
Grease fittings of storage, and after pressure
Front Propshaft Yoke Polaris Premium U-Joint Grease
(3 pumps maximum) washing or submerging the
vehicle.
2.6
MAINTENANCE
SERVICE PRODUCTS AND LUBRICANTS
Polaris Lubricants, Maintenance and Service NOTE: Each item can be purchased separately at
Products your local Polaris dealer.
Part No. Description Part No. Description

2
Engine Lubricant Additives / Sealants /
Thread Locking Agents / Misc.
2878473 Diesel 15w40 Engine Oil (Quart)
Loctite™ Threadlock 242 
2878471 15w40 Oil Change Kit - Summer 2871950
(6 ml.) (12 count)
2878474 Diesel 10w30 Engine Oil (Quart) 2872189 DOT 4 Brake Fluid (12 count)
2878472 10w30 Oil Change Kit - Winter 2871557 Crankcase Sealant, 3-Bond 1215 (5 oz.)
Gearcase / Transmission Lubricants
NOTE: The number count indicated by each part
Demand Drive Plus  number indicates the minimum order quantity.
2877922
(Quart)
Demand Drive Plus 
2877923
(2.5 Gallon) SPECIAL TOOLS
AGL plus Synthetic Gearcase Lube
2878068
(Quart) SPX Corp: 1-800-328-6657 or http://polaris.spx.com
AGL plus Synthetic Gearcase Lube 
2878069
(Gallon)
ATV Angle Drive Fluid
2876160
(Quart) (12 count)
ATV Angle Drive Fluid 
2872276
(2.5 Gallon) (2 Count)
2870465 Oil Pump for 1 Gallon Jug
Grease / Specialized Lubricants
Premium All Season Grease 
2871322
(3 oz. cartridge) (24 Count)
Premium All Season Grease 
2871423
(14 oz. cartridge) (10 Count)
2871515 Premium U-Joint Lube (3 oz.) (24 Count)
2871551 Premium U-Joint Lube (14 oz.) (10 Count)
2871312 Grease Gun Kit
2871329 Dielectric Grease (Nyogel™)
Coolant
2871323 60/40 Coolant (Gallon) (6 Count)
2871534 60/40 Coolant (Quart) (12 Count)
2.7
MAINTENANCE
FLUID MAINTENANCE REFERENCES
Component Quick Reference
III. # Item Lube Rec. Method Frequency*

Change after 1st month or first
Add oil to proper level on
1 Engine Oil Polaris Diesel Engine Oil 50 hours of operation, 100 hours
dipstick
thereafter.
Maintain coolant level in Check level daily, change
2 Engine Coolant Polaris 60/40 Coolant
coolant reservoir bottle. coolant every 2 years
Maintain fluid level between Check level during pre-ride
3 Brake Fluid Polaris DOT 4 Brake Fluid “MAX and “MIN” lines on the inspection; change fluid every
master cylinder reservoir two years
* More often under severe use, such as operation in water or under severe loads.
1. Engine Oil 2. Brake Fluid Reservoir

(Under seat base) (Front LH wheel well)
Dip stick
location
Master cylinder
3. Engine Coolant* Radiator cap

Recovery *Open front hood
bottle to add coolant
MAX
MIN
View level through

front RH wheel well
2.8
MAINTENANCE
Component Quick Reference (continued)
III. # Item Lube Rec. Method Frequency*
4 Front Gearcase Polaris Demand Drive Plus

Add lubricant until it is visible
at the fill hole threads
Initial fluid level inspection at 25
hours; change fluid yearly 2
Polaris ATV Angle Drive Add lubricant until it is visible Initial fluid level inspection at 25
5 Rear Gearcase
Fluid (ADF) at the fill hole threads hours; change fluid yearly
Polaris Full Synthetic Add lubricant until it is visible Initial fluid level inspection at 25
6 Transmission
Gearcase Lubricant (AGL) at the fill hole threads hours; change fluid yearly
* More often under severe use, such as operation in water or under severe loads.
4. Front Gearcase 6. Transmission

(Front of vehicle) (Rear of vehicle)
Check / Fill plug
5. Rear Gearcase
(Rear of vehicle)
Check / Fill plug
Drain plug
Check / Fill plug
2.9
MAINTENANCE
GENERAL VEHICLE INSPECTION Inspect shift cable, clevis pins, and pivot bushings and
replace if worn or damaged.
AND MAINTENANCE
Shift Cable Adjustment
Pre-Ride / Daily Inspection
NOTE: The shift cable should be adjusted at the rear
Perform the following pre-ride inspection daily, and when adjustment point located near the transmission. If
servicing the vehicle at each scheduled maintenance. adjustment is needed beyond that, remove the dash
panel to access the shift cable adjustment point
• Tires - check condition and pressures located underneath the shift lever.
• Fuel tank - fill tank to proper level
1. Place gear selector in neutral. Make sure the
• All brakes - check operation, fluid level and transmission bell crank is engaged in the neutral
adjustment (includes parking brake) position detents.
• Throttle - check for free operation and closing
• Headlight/Taillight/Brakelight - check operation of
all indicator lights, instrument cluster and switches Adjustment
• Ignition switch - check for proper function Point
• Wheels - check for tightness of wheel nuts and

axle nuts; check to be sure axle nuts are secured
by cotter pins
• Air cleaner element - check for dirt; clean or
replace
• Steering - check for free operation noting any
unusual looseness in any area
• Loose parts - visually inspect vehicle for any
damaged or loose nuts, bolts or fasteners 2. Locate the shift cable adjustment point at the engine-
to-transmission mount bracket.
• Engine coolant - check for proper level at the
recovery bottle 3. With two open-end wrenches, loosen the outside jam
• Check all suspension components for wear or nut counterclockwise. Turn the outside jam nut 1 1/2
damage turns.
4. After turning the outside jam nut 1 1/2 turns. Hold the
Frame, Nuts, Bolts, and Fasteners outside jam nut with a wrench and tighten the inside
Periodically inspect the torque of all fasteners in jam nut clockwise, until it is tight against the bracket.
accordance with the maintenance schedule. Check that all
5. Repeat Step 3 and Step 4 until the proper adjustment
cotter pins are in place. Refer to specific fastener torques
is made to the shift cable.
listed in each chapter.
6. Use this procedure to loosen or tighten the shift
linkage cable as needed.
Shift Cable Inspection
Shift cable adjustment is necessary when symptoms
include:
• Noise on deceleration
• Inability to engage a gear
• Excessive gear clash (noise)
• Gear selector is moving out of desired range
2.10
MAINTENANCE
FUEL SYSTEM AND AIR INTAKE Vent Lines
1. Check fuel tank vent lines for signs of wear,
Fuel System
deterioration, damage or leakage. Replace every two
WARNING
years.
2. Be sure vent line is routed properly and secured with

2
cable ties.
• Gasoline is highly flammable and explosive
under certain conditions.
CAUTION
• Always exercise extreme caution whenever
handling gasoline.
Make sure vent line is not kinked or pinched.
• Always refuel outdoors or in a well-ventilated
area. Throttle Pedal Inspection
• Always turn off the engine before refueling. If the throttle pedal has excessive play due to cable stretch
or cable misadjustment, it will cause a delay in throttle
• Do not overfill the tank. Do not fill the tank neck. speed and the throttle may not open fully. If the throttle
pedal has no play, it may be hard to control, and the idle
• Do not smoke or allow open flames or sparks in speed may be erratic.
or near the area where refueling is performed or
where gasoline is stored. Check the throttle pedal play periodically in accordance
with the Periodic Maintenance Chart and adjust the play if
• If gasoline spills on your skin or clothing, necessary.
immediately wash it off with soap and water and
change clothing. Throttle Freeplay Adjustment
• Never start the engine or let it run in an enclosed Inspection
area. Engine exhaust fumes are poisonous and
can cause loss of consciousness or death in a 1. Apply the parking brake.
short time.
2. Put the gear shift lever in the N (Neutral) position.
• EFI components are under high pressure.
Verify system pressure has been relieved before 3. Start the engine, and warm it up thoroughly.
disassembly.
4. Measure the distance the throttle pedal moves before
• Never drain the fuel system when the engine is the engine begins to pick up speed. Free play should
hot. Severe burns may result. be 1/16” - 1/8” (1.5 - 3 mm).
Fuel Lines
1. Check fuel lines for signs of wear, deterioration,
damage or leakage. Replace if necessary. Be sure
fuel lines are routed properly.
CAUTION
Make sure lines are not kinked or pinched.
2. Replace all fuel lines every two years.
2.11
MAINTENANCE
Adjustment Air Filter Service
1. Remove the seat. It is recommended the air filter be replaced every 150 hrs.
When riding in extremely dusty or wet conditions, or at
2. Locate the throttle cable adjuster on RH side of wide open throttle for extended periods, replacement is
engine. required more often.
3. Squeeze the end of the rubber boot and slide it far The filter should be inspected before each ride, using the
enough to expose the end of the inline cable adjuster. following procedure.
Removal
1. Lift the rear cargo box to access the airbox cover.
Boot
Lock Nut
Adjuster
4. Loosen the adjuster lock nut.

Airbox Cover
5. Rotate the boot to turn the adjuster until 1/16” to 1/8”
(1.5 - 3 mm) of freeplay is achieved at the throttle
pedal.
2. Unhook the 4 clips from airbox cover and remove
NOTE: While adjusting, lightly flip the throttle pedal cover. Inspect the cover seal. It should adhere tightly
in and out. to the cover.
6. Tighten the lock nut. 3. Remove the air filter assembly by using a pulling/
twisting motion. Be sure not to damage the filter
7. Squeeze the end of the rubber boot and slide it over element.
the cable adjuster to its original position.
4. Inspect the air filter and replace if necessary.
8. Start the engine.
IMPORTANT: If the filter has been soaked with fuel or
9. Disengage the parking brake and field test unit to oil it must be replaced. Do not attempt to wash the air
ensure proper throttle operation. filter. If cleaning is required, replace the filter.
Cover
Seal Clips
Airbox
Filter
2.12
MAINTENANCE
Installation Engine Air Intake Inspection
5. Clean airbox of any oil or water deposits and apply a 1. Open the hood to access the engine intake air baffle
small amount of grease to the sealing surfaces of the box (A).
filter.
Plastic Ring
2. 2011-2012 models only: Remove headlight bulb from
RH front headlamp assembly (B).
2
3. Loosen hose clamp (C) and remove hose from intake
baffle box.
4. Remove intake baffle box from the vehicle.
2013
. Polaris All Purpose Grease to

Apply
inner sealing area. A
2011-2012
Be sure tab and notch A

are in alignment
6. Reinstall the air filter into the airbox container. Be sure

the filter fits tightly in the air box and engage the 4 clips
onto the airbox. C
5. Remove the filter element from the baffle box. Be

careful not to damage / cut the foam.
6. If the filter element is dirty, clean it with a high flash

point solvent, followed by hot soapy water. Rinse and
dry the filter element thoroughly. Inspect element for
tears or damage. Replace if necessary.
7. Reinstall the filter element into the air baffle box.
8. Reinstall the baffle box, hose clamp and headlamp

bulb.
2.13
MAINTENANCE
PVT Air Intake Inspection
1. Lift the cargo box to access the PVT air intake baffle
box.
2. Remove the filter element (A) from the baffle box.
3. If the filter element is dirty, clean it with a high flash

point solvent, followed by hot soapy water. Rinse and
dry the filter element thoroughly. Inspect element for
tears or damage. Replace if necessary.
4. Reinstall the filter element into the air baffle box.
2.14
MAINTENANCE
Air Intake Exploded View
Airbox
2
Clamp
Filter
Engine Air Intake

Baffling Box (front) Hose (lower)
2011-2012 2013
To Engine
Intake
Filter
Clamp Hose (front)
PVT
Engine Intake Seal
Intake Duct
PVT Air Intake

CREW Baffling Box Clamp
Clamp
Models (located behind front seat)
To PVT
PVT
Intake Hose
2.15
MAINTENANCE
FUEL FILTER / WATER SEPARATOR 5. Reach under the fuel filter and unscrew the black drain
valve until fuel starts to drain out of the bottom of the
General Information valve. (1/2 to 1 turn) Do not unscrew the drain valve
completely. The drain valve has standard rotation
The fuel filter / water separator assembly is located under threads.
the seat on the RH side of the vehicle, in-between the
Fuel filter drain valve as viewed from under filter.
engine and the fuel tank. The filter should be:
Tighten Valve
• Inspected daily.
• Drained every 50 hours (normal conditions with
quality fuel) OR drained daily (severe conditions /
poor fuel quality).
• Replaced every 150 hours OR 12 months OR
2000 miles (3200KM). WHICHEVER COMES
FIRST.
Fuel Filter / Water Separator Draining Loosen Valve

1. See chapter 4 of this manual for safety information.
Fuel Drain
2. Be sure engine is cool and the battery is
disconnected. 6. Wait for fuel and water to stop draining from the valve
and firmly retighten valve hand tight only.
3. Remove seat.
7. Clean up any excess fuel properly.
4. Place container / drain pan / shop towels under fuel
filter area to catch any excess fuel. 8. Reconnect battery.
9. Turn key switch ON for 10-15 seconds.
10. Start engine and verify that no fuel leaks are present.
11. Dispose of shop towels and drained fuel properly.
Fuel Filter Fuel Filter / Water Separator Replacement

1. Follow Steps 1-7 from the “Fuel Filter / Water
Separator Draining” Procedure.
2. Unscrew fuel filter / water separator from the filter

Drain Valve mount using a commercially available filter wrench if
it is not removable by hand. The filter has standard
rotation threads.
3. Properly drain and dispose of fuel filter / water

separator.
4. Lightly lubricate the rubber gasket of the new fuel filter

/ water separator with fresh engine oil. Thread new
filter onto the filter mount until the gasket lightly
touches the filter housing. Tighten filter 1/2-3/4 of a
turn after initial contact of the rubber gasket to the filter
mount. Be sure that the drain valve on the bottom of
the filter is snug and did not loosen up during filter
installation.
2.16
MAINTENANCE
6. Reconnect battery. ENGINE
7. Turn key switch ON for 10-15 seconds to prime the Compression and Leakdown Test
fuel system.

NOTE: This engine does NOT have decompression
components. Compression readings will vary in 2
proportion to cranking speed during the test. Refer
9. Dispose of shop towels and drained fuel properly. to Yanmar Engine Service Chapter 11 for the proper
tools and procedures.
A smooth idle generally indicates good compression. Low

engine compression is rarely a factor in running problems
above idle speed. Abnormally high compression can be
caused by carbon deposits in the combustion chamber or
worn, damaged exhaust cam lobes. Inspect camshaft and
combustion chamber if compression is abnormally high.
A cylinder leakdown test is the best indication of engine

condition. Follow the manufacturer's instructions to
perform a cylinder leak-down test.
Cylinder Compression
Standard: 470 ± 15 PSI
Cylinder Leakdown
Service Limit 15%
(Inspect for cause if test exceeds 15%)
Special Tools
PART NUMBER TOOL DESCRIPTION

Diesel Engine Compression
PU-50529
Tester and Adapter
PU-50531 Diesel Oil Pressure Adapter
PU-50530 Diesel Injection Timing Tool
PU-50532 Diesel Fuel Injector Tester
SPX Corp: 1-800-328-6657 or http://polaris.spx.com/
2.17
MAINTENANCE
Engine Oil Level NOTE: A rising oil level between checks in cool
weather driving can indicate contaminants such as
This engine is a wet-sump engine, meaning the oil is fuel or moisture collecting in the crankcase. If the oil
contained in the bottom of the crankcase. To check the oil level is over the full mark, change the oil
level, follow the procedure listed below. immediately.
1. Park machine on a level surface and set the parking
brake.
Engine Oil and Filter Change
It is important to use oil viscosities that will work efficiently
2. Stop the engine. Allow the oil level to settle for 3 in the ambient temperature the vehicle will be operated in
minutes before removing the dipstick. for extended periods. Please refer to the viscosity chart for
proper oil usage.
IMPORTANT: Do not check oil immediately after
engine operation.
Oil Viscosity Requirement vs. Temperature
3. Remove the seat base. Remove the dipstick (A) and
wipe dry with a clean cloth.
Recommended Engine Oil:

4. Reinstall dipstick and ensure it seats completely.
Use only Polaris Diesel oil 15W40 Summer
NOTE: Make certain the dipstick is inserted all the
or 10W30 Winter. (CI-4 rated)
way into the filler tube to produce consistent oil level

readings.
2878471 Diesel Oil Change Kit, Summer 15W40
2878472 Diesel Oil Change Kit, Winter 10W30 
5. Remove dipstick and check that the oil level is in the
2878473 Diesel Oil 2 qt. Summer 15W40
SAFE range. Add oil as indicated by the level on the
2878474 Diesel Oil 2 qt. Winter 10W30
dipstick. Do not overfill.
1. Place vehicle on a level surface and allow the engine

to run for two to three minutes until warm. Stop
engine.
Maintain Oil Level In SAFE Range
DO NOT Overfill the Engine
NOTE: Use only Polaris Diesel oil 15W40 Summer or

10W30 Winter.
2.18
MAINTENANCE
2. Clean the area around the drain plug (B) at the bottom 8. Place shop towels beneath oil filter (C). Using Oil Filter
of the crankcase. Drain plug is accessible through the Wrench (PU-50105), turn the filter counter-clockwise
skid plate. to remove it.
B 2
C
Oil Filter Wrench:

PU-50105: 2.5” (64 mm)
WARNING
Personal injury can occur when handling used 9. Using a clean, dry cloth, clean filter sealing surface on
oil. Hot oil can cause burns or skin damage. crankcase.
3. Place a drain pan beneath the crankcase and remove 10. Lubricate gasket area on new oil filter with a film of
drain plug. fresh engine oil. Check to make sure the sealing areas
are in good condition.
4. Allow oil to drain completely.
11. Install new filter and turn to specification.
5. Clean sealing area of drain plug and oil pan.
NOTE: The sealing surface on the drain plug should =T

be clean and free of burrs, nicks or scratches.
Oil Filter:
6. Reinstall drain plug and torque to specification. Turn by hand until filter gasket contacts
sealing surface, then turn an additional 1/2-
3/4 turn.
=T
12. Fill the sump with Polaris Diesel Engine Oil to the
Engine Crankcase Drain Plug: recommended level through the oil filler access on top
25 ft-lbs (33.9 Nm) of the valve cover.
7. Remove the seat base. 13. Place gear selector in neutral and set parking brake.
14. Start the engine and let it idle for one to two minutes.
Stop the engine and inspect for leaks.
15. Re-check the oil level on the dipstick and add oil as
necessary to bring the level to the upper mark on the
dipstick.
16. Dispose of used oil and oil filter properly.
2.19
MAINTENANCE
Exhaust Pipe 3. If some carbon is expelled, cover the exhaust outlet
and lightly tap on the pipe around the clean out plugs
with a rubber mallet while revving the engine several
WARNING more times.
Do not perform clean out immediately after the

engine has been run, as the exhaust system
becomes very hot. Serious burns could result from
contact with exhaust components.
To reduce fire hazard, make sure that there are no

combustible materials in the area when purging
the spark arrestor.
Wear eye protection.

4. If particles are still suspected to be in the muffler, back
Do not stand behind or in front of the vehicle while the machine onto an incline so the rear of the machine
purging the carbon from the spark arrestor. is one foot higher than the front. Set the parking brake,
block the wheels and repeat Steps 2 and 3.
Never run the engine in an enclosed area. Exhaust
contains poisonous carbon monoxide gas.
Do not go under the machine while it is inclined. Set

the hand brake and block the wheels to prevent roll
back.
Failure to heed these warnings could result in

serious personal injury or death.
The exhaust pipe must be periodically purged of

accumulated carbon as follows:
1. Remove the clean out plug located on the bottom of

the muffler as shown below.
5. If particles are still suspected to be in the muffler, drive
the machine onto the incline so the front of the
machine is one foot higher than the rear. Set the
parking brake, block the wheels and repeat Steps 2
and 3.
Clean Out Plug 6. Repeat steps 2 through 5 until no more particles are
expelled when the engine is revved.
2. Set the parking brake and start the engine. Purge 7. Stop the engine and allow the arrestor to cool.
accumulated carbon from the system by momentarily
revving the engine several times. 8. Reinstall the clean out plug.
2.20
MAINTENANCE
TRANSMISSION AND GEARCASES 4. Reinstall the fill plug and torque to specification.
Transmission Lubrication
=T
NOTE: It is important to follow the transmission
maintenance intervals described in the Periodic Drain / Fill Plug: 2
Maintenance Chart. Regular fluid level inspections 12 ft-lbs (16 Nm)
should be performed as well.
Transmission Lubricant Change
The transmission lubricant level should be checked and
changed in accordance with the maintenance schedule. The drain plug is located on the right side of the
transmission. Access the drain plug from the rear right-
• Be sure vehicle is positioned on a level surface hand side of the vehicle.
when checking or changing the lubricant.
• Check vent hose to be sure it is routed properly 1. Remove the fill plug (refer to “Transmission Lubricant
and unobstructed. Level Check”).
Transmission Lubricant Level Check 2. Place a funnel into the skid plate hole and under the
transmission drain plug.
The fill plug is located on the right side of the transmission.
Access the fill plug from the rear right-hand side of the 3. Place a drain pan under the vehicle at the location of
vehicle. Maintain the fluid level even with the bottom the funnel.
threads of the fill plug hole.
4. Remove the drain plug and allow lubricant to drain
1. Position vehicle on a level surface. Raise the cargo completely.
box for easier access if required.
2. Remove the fill plug and check the lubricant level.
12 ft-lbs
(16 Nm)
Transmission Drain
5. Clean the drain plug magnetic surface. Reinstall drain

plug with a new O-ring and torque to specification.
Add lubricant until
even with bottom 6. Add the recommended amount of lubricant through
of threads the fill plug hole. Maintain the lubricant level at the
bottom of the fill plug hole when filling the
transmission. Do not overfill.
3. If lubricant level is not even with the bottom threads,
add the recommended lubricant as needed. Do not
overfill.
=
Recommended Transmission Lubricant:

Synthetic AGL Plus (PN 2878608) (Quart)
Capacity: 32 oz. (946 ml)
2.21
MAINTENANCE
7. Reinstall fill plug with a new O-ring and torque to 4. Remove the (3) bolts from the lower portion of the
specification. bumper.
5. Remove the fasteners from each side of the upper

=T portion of the bumper.
Drain / Fill Plug Torque: 6. Carefully remove the bumper from the vehicle.
12 ft-lbs (16 Nm)
7. Remove the fill plug and check the fluid level.
8. Check for leaks. Dispose of used lubricant properly.
Fill Plug
Front Gearcase Lubrication ft-lbs
12 Nm)
NOTE: It is important to follow the front gearcase
maintenance intervals described in the Periodic
Maintenance Chart. Regular fluid level inspections
should be performed as well.
The front gearcase fluid level should be checked and

changed in accordance with the maintenance schedule.
• Be sure vehicle is positioned on a level surface Add lubricant until Drain Plug
when checking or changing the fluid. even with bottom ft-lbs
of threads (12 Nm)
• Check vent hose to be sure it is routed properly
and unobstructed.
Front Gearcase Fluid Level Check 8. If fluid level is not even with the bottom threads, add
the recommended fluid as needed. Do not overfill.
The fill plug is located on the front left side of the front
gearcase. Access the fill plug from the front of the vehicle. 9. Reinstall the fill plug and torque to specification.
Maintain the fluid level even with the bottom threads of the
fill plug hole. =T
1. Position vehicle on a level surface.
Drain / Fill Plug:
2. Begin by removing the front bumper to gain access to 9 ft-lbs (12 Nm)
the gearcase fill plug.
Front Gearcase Fluid Change:
3. Remove the (2) T27 Torx-head screws retaining the
fascia screen and remove the screen. The drain plug is located on the bottom side of the front
gearcase. Access the drain plug through the skid plate.
Remove 1. Remove the fill plug (refer to “Front Gearcase Fluid
Level Check”).
Remove
2. Place a drain pan under the front gearcase drain plug.
3. Remove the drain plug and allow fluid to drain

T27 Screws completely.
4. Clean the drain plug magnetic surface.
5. Reinstall drain plug with a new O-ring and torque to

specification.
Remove
2.22
MAINTENANCE
6. Add the recommended amount of fluid through the fill 12. Install the (2) T27 Torx-head screws retaining the
hole. Maintain the fluid level even with the bottom fascia screen. Torque screws to specification.
threads of the fill plug hole.
=T
=
2
Upper Bumper Fasteners: 30 ft-lbs (41 Nm)
Lower Bumper Bolts: 14 ft-lbs (19 Nm)
Recommended Front Gearcase Fluid: Fascia Screen Screws: 5 ft-lbs (7 Nm)
Polaris Demand Drive Plus

(PN 2877922) (Quart) Rear Gearcase Lubrication
Capacity: 6.75 oz. (200 ml) NOTE: It is important to follow the rear gearcase
maintenance intervals described in the Periodic
7. Reinstall fill plug with a new O-ring and torque to Maintenance Chart. Regular fluid level inspections
specification. should be performed as well.
The rear gearcase lubricant level should be checked and

=T changed in accordance with the maintenance schedule.
Drain / Fill Plug: • Be sure vehicle is positioned on a level surface

9 ft-lbs (12 Nm) when checking or changing the lubricant.
• Check vent hose to be sure it is routed properly
8. Check for leaks. Dispose of used fluid properly. and unobstructed.
9. Reinstall the front bumper. Rear Gearcase Lubricant Level Check:
30 ft-lbs
The fill plug is located on the left side of the rear gearcase.
41 Nm)
Maintain the lubricant level even with the bottom threads
30 ft-lbs
of the fill plug hole.
(41 Nm)
1. Position the vehicle on a level surface.
2. Remove the fill plug and check the lubricant level.

5 ft-lbs
7 Nm)
Gearcase lubricant
flush with bottom
of threaded area
14 ft-lbs
19 Nm)
10. Install the fasteners on each side of the upper portion

of the bumper. Torque fasteners to specification.
11. Install the (3) bolts in the lower portion of the bumper.
Torque bolts to specification.
3. If lubricant level is not even with the bottom threads,

add the recommended lubricant as needed. Do not
overfill.
2.23
MAINTENANCE
4. Reinstall fill plug and torque to specification. 6. Add the recommended amount of lubricant through
the fill hole. Maintain the lubricant level even with the
bottom threads of the fill plug hole.
=T
Fill Plug: 25 ft-lbs (34 Nm)
Drain Plug: 38 in-lbs (4.3 Nm)
=
Recommended Rear Gearcase Lubricant:

NOTE: The rear gearcase lubricant must be checked
and filled when the gearcase is properly mounted in
ATV Angle Drive Fluid (PN 2876160)
the vehicle and the vehicle resting on level ground.
Rear Gearcase Lubricant Change:
7. Reinstall fill plug with a new O-ring and torque to
The drain plug is located on the bottom right side of the specification.
rear gearcase. Access the drain plug from the rear of the
vehicle through the skid plate. 8. Check for leaks. Dispose of used lubricant properly.
1. Remove the fill plug (refer to “Rear Gearcase

Lubricant Level Check”).
2. Place a drain pan under the rear gearcase drain plug.
3. Remove the drain plug and allow the lubricant to drain

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

specification.
=T
Fill Plug: 25 ft-lbs (34 Nm)
Drain Plug: 38 in-lbs (4.3 Nm)
2.24
MAINTENANCE
COOLING SYSTEM Coolant Level Inspection
Liquid Cooling System Overview The recovery bottle and radiator pressure cap are located
under the hood.
NOTE: Use ethylene glycol coolant / anti-freeze
only. Do not mix coolant types. 1. Position the vehicle on a level surface with the engine
at operating temperature
2
The engine coolant level is controlled or maintained by the
recovery system. The recovery system components are 2. Check the coolant level in the recovery bottle, located
the recovery bottle (A), radiator filler neck, radiator on the ride side of the machine. The coolant level must
pressure cap (B) and connecting hose. be maintained between the “MAX” and “MIN” levels
indicated on the recovery bottle
As coolant operating temperature increases, the
expanding (heated) excess coolant is forced out of the Recovery
radiator past the pressure cap and into the recovery bottle. Bottle
As engine coolant temperature decreases the contracting MAX
(cooled) coolant is drawn back up from the tank past the MIN
pressure cap and into the radiator.
NOTE: Some coolant level drop on new machines is

normal as the system is purging itself of trapped air.
Observe coolant levels often during the break-in
period.
Overheating of engine could occur if air is not fully purged

from system.
Polaris Premium 60/40 is already premixed and ready to

use. Do not dilute with water. 3. If the coolant level is below the “MIN” mark, open the
hood to access the radiator pressure cap and
recovery bottle cap.
NOTE: If overheating is evident, allow system to

A cool completely and check coolant level in the
radiator and inspect for signs of trapped air in
system.
B
WARNING
Escaping steam can cause burns. Never

remove the pressure cap while the engine is
warm or hot. Always allow the engine to cool
before removing the pressure cap.
4. Remove the pressure cap. Using a funnel, add

coolant to the top of the radiator filler neck.
5. Reinstall the pressure cap.
NOTE: Use of a non-standard pressure cap will not

allow the recovery system to function properly.
6. Remove the recovery bottle cap.
2.25
MAINTENANCE
7. Fill the recovery bottle to the “MAX” mark with Polaris Cooling System Hoses
Premium 60/40 Anti-Freeze/Coolant or a 50/50
mixture of antifreeze/coolant and distilled water as 1. Inspect all hoses for cracks, deterioration, abrasion
required for freeze protection in your area. or leaks. Replace if necessary.
8. Reinstall the recovery bottle cap. Recovery

Bottle
9. start engine and check for leaks.
NOTE: Make sure radiator fins are clean to prevent Hose

overheating. To thermostat)
Coolant Strength / Type

Test the strength of the coolant using an antifreeze
hydrometer.
Hose
(To water pump)
2011 SHOWN
Antifreeze Hydrometer
2. Check tightness of all hose clamps.

• A 50/50 or 60/40 mixture of antifreeze and distilled
water will provide the optimum cooling, corrosion
protection, and antifreeze protection. CAUTION
• Do not use tap water, straight antifreeze, or
straight water in the system. Tap water contains Do not over-tighten hose clamps at radiator, or
minerals and impurities which build up in the radiator fitting may distort.
system. Straight water or antifreeze may cause the
system to freeze, corrode, or overheat.
=T
= Radiator Hose Clamp:

36 in-lbs (4 Nm)
Recommended Anti-Freeze/Coolant:
Polaris 60/40 Anti-Freeze/Coolant
(PN 2871534) (Quart)
2.26
MAINTENANCE
Radiator Inspection / Cleaning Radiator Removal (2011)
1. Check radiator air passages for restrictions or 1. Remove the push rivets and front RH wheel well
damage. panel to access the radiator drain valve.
Flush radiator Fan Motor 2. Place a suitable drain pan underneath the radiator. 2
in this direction
3. Allow the vehicle to cool down if recently operated.
WARNING
Escaping steam can cause burns. Never

remove the pressure cap while the engine is
warm or hot. Always allow the engine to cool
Shroud before removing the pressure cap.
Radiator 2011 SHOWN
4. Open the hood and slowly open the radiator pressure
2. Carefully straighten any bent radiator fins. cap to relieve system pressure.
3. Remove any obstructions with compressed air or low 5. Open the drain valve on the front side of the radiator
pressure water. and allow the coolant to completely drain. Properly
dispose of the used coolant.
CAUTION
Washing the vehicle with a high-pressure

washer could damage the radiator fins and
impair the radiators effectiveness. Use of a high-
pressure washer is not recommended.
Drain
valve
6. Remove the (2) T25 screws that retain the recovery

bottle to the frame bracket. Set the recovery bottle out
of the way.
2.27
MAINTENANCE
7. Remove the push rivets and front LH wheel well panel. 12. Remove the recovery bottle return line (see Figure 2-
26).
8. Remove the upper and lower coolant lines from the
radiator. 13. Carefully lift the radiator straight up and out of the
vehicle. Take care not to damage the cooling fins.
9. Remove the (4) bolts that retain the fan motor and
shroud to the radiator.
Installation
14. Reverse removal procedure for installation.
15. Upon installation, be sure the lower radiator mounts

are placed properly in the frame support.
10. Remove the (2) mounting screws that secure the

upper portion of the radiator to the frame (see Figure
2-26).
Figure 2-26
Spring
16. After the radiator is installed, be sure the mounts have
Support
remained in place.
17. After installation and reassembly, remove the

pressure cap and fill the radiator and recovery bottle
with coolant.
18. Refer to the “Cooling System Bleeding Procedure” in

Chapter 3.
Recovery bottle
Radiator
return line
11. Remove the (2) lower hood latch screws and remove
the lower hood latch spring support (see Figure 2-26).
2.28
MAINTENANCE
Radiator Removal (2012) 4. Remove the (2) screws that retain the front cab
assembly to the hood liner.
1. Open the hood and disconnect the headlights.
2
2. Remove the (4) upper screws that retain the hood to
the frame.
5. Remove the (11) remaining screws and (6) push rivets

retaining the front cab.
3. Remove the (8) fasteners retaining the front bumper

assembly and remove the bumper from the vehicle.
6. Lift up on the front cab and slide it up the cab frame

far enough to access the hood liner. Support the front
cab to keep it from sliding down.
7. Disconnect and remove the battery from the vehicle.
8. Loosen the hose clamp and remove the engine air

intake baffle box located behind the RF headlamp
area.
2.29
MAINTENANCE
9. Remove the (4) screws that retain the hood liner to the 14. Allow the vehicle to cool down if recently operated.
frame.
WARNING
Never remove the pressure cap when the

engine is warm or hot. Escaping steam can
cause severe burns. The engine must be cool
before removing the pressure cap.
15. Slowly open the radiator pressure cap to relieve

system pressure.
16. Remove the lower coolant hose and drain the coolant
from the radiator and hose. Allow the coolant to
completely drain. Properly dispose of the used
coolant.
10. Carefully lift up on the hood liner far enough to allow
radiator removal.
NOTE: Turn coolant pressure cap to allow the hood

liner to clear the cap.
11. Remove the (2) screws retaining the upper portion of

the radiator to the frame.
17. Remove the upper coolant hose.
18. Remove the recovery bottle return line from the

radiator.
19. Disconnect the fan motor electrical connector.
20. Carefully lift the radiator/fan motor from the vehicle as

an assembly. Take care not to damage the cooling
fins.
12. Remove the push rivets and front LH wheel well panel
to access the lower coolant hose at the radiator.
13. Place a suitable drain pan under the LH side of the

radiator.
2.30
MAINTENANCE
21. Remove the (4) bolts that retain the fan motor FINAL DRIVE / WHEEL AND TIRE
assembly and service radiator or fan as needed.
Wheel and Hub Torque Table
ITEM NUT TYPE SPECIFICATION 2

Aluminum 30 ft-lbs (41 Nm)
Lug Nut
Wheels plus 90° (1/4 turn)
Steel Wheels Flange Nut 35 ft-lbs (47 Nm)
Front Hub Nut - 80 ft-lbs (108 Nm)
Mid / Rear
Hub Retaining - 110 ft-lbs (150 Nm)
Nut
CV Shaft Boot Inspection

Inspect the CV shaft boots in the front and rear for
damage, tears, wear, or leaking grease. If the rubber boot
Installation exhibits any of these symptoms, replace the boot. Refer to
Chapter 7 for CV boot replacement.
22. Reverse this procedure for installation.
23. Upon installation, be sure the lower radiator mounts

are placed properly in the frame support.
Inspect Boots
24. After the radiator is installed, be sure the mounts have Inspect Boots
remained in place.
25. After installation and reassembly, remove the

pressure cap and fill the radiator and recovery bottle
with coolant.
26. Refer to the “Cooling System Bleeding Procedure” in

Chapter 3.
2.31
MAINTENANCE
Wheel Removal Tire Inspection
• Improper tire inflation may affect vehicle
maneuverability.
Wheel Nuts (4)
• When replacing a tire always use original
equipment size and type.
• The use of non-standard size or type tires may
Front Hub Nut affect vehicle handling.
80 ft-lbs (108 Nm)
Tire Tread Depth
Always replace tires when tread depth is worn to 1/8” (3

mm) or less.
Mid/Rear Hub Nut
110 ft-lbs (150 Nm) Tread
Depth 1/8” (3 mm)
1. Stop the engine, place the transmission in gear and
lock the parking brake.
2. Loosen the wheel nuts slightly.
3. Elevate the side of the vehicle by placing a suitable

stand under the footrest frame.
4. Remove the wheel nuts and washers and remove the

wheel.
Wheel Installation
1. With the transmission in gear and the parking brake WARNING
locked, place the wheel in the correct position on the
wheel hub. Be sure the valve stem is toward the Improper tire inflation or the use of non-standard size
outside and rotation arrows on the tire point toward or type of tires may adversely affect vehicle handling,
forward rotation. which could result in vehicle damage or personal
injury. Always maintain proper tire pressure. When
2. Install the washers (if applicable) and wheel nuts and
replacing tires, always use original equipment size
finger tighten them.
and type.
3. Lower the vehicle to the ground.
Tire Pressure
4. Securely tighten the wheel nuts to the proper torque
listed in the torque table at the beginning of this
Tire Pressure Inspection (PSI - Cold)
section.
Model Front / Rear
CAUTION RANGER DIESEL 8-12 psi / 8-12 psi

RANGER DIESEL
12 psi / 16 psi
If wheels are improperly installed it could affect CREW
vehicle handling and tire wear. On vehicles with
tapered rear wheel nuts, make sure tapered end
of nut goes into taper on wheel.
2.32
MAINTENANCE
ELECTRICAL SYSTEM Battery Removal
Battery Maintenance 1. Remove the seat base.
2
Keep battery terminals and connections free of corrosion. 2. Remove the under-seat storage container on the
If cleaning is necessary, remove the corrosion with a stiff drivers side.
wire brush. Wash with a solution of one tablespoon baking
soda and one cup water. Rinse well with tap water and dry
off with clean shop towels. Coat the terminals with
dielectric grease or petroleum jelly.
Be careful not to allow cleaning solution or tap water into

the battery.
WARNING
CALIFORNIA PROPOSITION 65 WARNING:

Batteries, battery posts, terminals and related
accessories contain lead and lead compounds,
and other chemicals known to the State of 3. Disconnect the black (-, negative) battery cable.
California to cause cancer and birth defects or
other reproductive harm. 4. Disconnect the red (+, positive) battery cable.
WASH HANDS AFTER HANDLING.
5. Remove the hold-down strap from the battery.
Battery electrolyte is poisonous. It contains acid!
Serious burns can result from contact with the 6. Lift the battery out of the vehicle, being careful not to
skin, eyes, or clothing. tip it sideways and spill any electrolyte (if applicable).
ANTIDOTE
CAUTION
External: Flush with water.
Improperly connecting or disconnecting battery
Internal: Drink large quantities of water or milk. cables can result in an explosion and cause
Follow with milk of magnesia, beaten egg, or serious injury or death. When removing the
vegetable oil. Call a physician immediately. battery, always disconnect the negative (black)
cable first. When reinstalling the battery, always
Eyes: Flush with water for 15 minutes and get connect the negative (black) cable last.
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.
NOTE: Batteries must be fully charged before use or

battery life will be reduced by 10-30% of full
potential. Charge battery for 3-5 hours at a current
equivalent of 1/10 of the battery’s rated amp/hour
capacity. Do not use the alternator to charge a new
battery.
2.33
MAINTENANCE
Battery Installation Battery Charging
NOTE: Using a new battery that has not been fully 1. Remove the battery from the vehicle to prevent
charged can damage the battery and result in a damage from leaking or spilled electrolyte during
shorter life. It can also hinder vehicle performance. charging.
Follow the battery charging procedures before
installing the battery. 2. Charge the battery with a charging output no larger
than 1/10 of the battery’s amp/hr rating. Charge as
1. Verify that the battery is fully charged. needed to raise the specific gravity to 1.270 or greater.
2. Place the battery in the battery holder. 3. Reinstall the battery.
3. Install battery hold down strap.

Engine Ground
4. Coat the terminals with dielectric grease or petroleum
jelly. Inspect engine ground cable connection (A). Be sure it is
clean and tight. The ground cable runs from the LH engine
5. Connect and tighten the red (+, positive) cable first. block to the terminal block. Located under the seat next to
the battery.
6. Connect and tighten the black (-, negative) cable last.
7. Verify that cables are properly routed and install the A

hold-down strap.
8. Reinstall the under-seat storage container.
9. Reinstall the seat base.
Use Polaris corrosion resistant Nyogel™ grease (PN

2871329) on battery terminals.
=T
Battery Terminal Pinch Bolt:
12.5 ft-lbs (17 Nm)
Battery Storage
Whenever the vehicle is not used for a period of three
months or more, remove the battery from the vehicle,
ensure that it's fully charged, and store it out of the sun in
a cool, dry place. Check battery voltage each month
during storage and recharge as needed to maintain a full
charge.
NOTE: Battery charge can be maintained by using a

Polaris battery tender charger or by charging about
once a month to make up for normal self-discharge.
Battery tenders can be left connected during the
storage period, and will automatically charge the
battery if the voltage drops below a pre-determined
point.
2.34
MAINTENANCE
STEERING • Elevate front end of machine so front wheels are
off the ground. Check for any looseness in front
Steering Inspection hub/wheel assembly by grasping the tire firmly at
top and bottom first, and then at front and rear. Try
The steering components should be checked periodically
for loose fasteners, worn tie rod ends, and damage. Also
to move the wheel and hub by pushing inward and
pulling outward. 2
check to make sure all cotter pins are in place. If cotter pins
are removed, they must not be re-used. Always use new • If abnormal movement is detected, inspect the hub
cotter pins. and wheel assembly to determine the cause
(loose wheel nuts or loose front hub nut).
Replace any worn or damaged steering components. • Refer to the Body/Steering or Final Drive chapter
Steering should move freely through entire range of travel for more information.
without binding. Check routing of all cables, hoses, and
wiring to be sure the steering mechanism is not restricted
or limited.
Wheel Toe Alignment Inspection
1. Place machine on a smooth level surface and set
NOTE: Whenever steering components are steering wheel in a straight ahead position. Secure
replaced, check front end alignment. Use only the steering wheel in this position.
genuine Polaris parts.
2. Place a chalk mark on the center line of the front tires
approximately 10” (25.4 cm) from the floor or as close
to the hub/axle center line as possible.
WARNING
Due to the critical nature of the procedures

outlined in this chapter, Polaris recommends
steering component repair and adjustment be
performed by an authorized Polaris MSD-
certified technician when replacing worn or Measure
damaged steering parts. here
Use only genuine Polaris replacement parts.
Mark (A), measure,
Tie Rod End / Steering Inspection then roll forward
and measure (B).
• To check for play in the tie rod end, grasp the
steering tie rod, pull in all directions feeling for
movement.
• Replace any worn steering components. Steering
should move freely through entire range of travel
without binding. A 10” B
NOTE: It is important the height of both marks be

equally positioned to get an accurate measurement.
3. Measure the distance between the marks and record

the measurement. Call this measurement “A”.
4. Rotate the tires 180° by moving the vehicle forward.

Position chalk marks facing rearward, even with the
hub/axle center line.
2.35
MAINTENANCE
5. Again measure the distance between the marks and
record. Call this measurement “B”. Subtract
measurement “B” from measurement “A”. The CAUTION
difference between measurements “A” and “B” is the
vehicle toe alignment. The recommended vehicle toe
During tie rod adjustment, it is very important that
tolerance is 1/8”, to 1/4”, (.3 to .6 cm) toe out. This
the following precautions be taken when
means the measurement at the front of the tire (A) is
tightening tie rod end jam nuts.
1/8”, to 1/4”, (.3 to .6 cm) wider than the measurement
If the rod end is positioned incorrectly it will not
at the rear (B).
pivot, and may break.
To adjust toe alignment:

= In. / mm.
• Hold tie rod end to keep it from rotating.
Wheel Toe-Out: (A) - (B) = 1/8 - 1/4" (.3 to .6 cm) • Loosen jam nuts at both end of the tie rod.
• Shorten or lengthen the tie rod until alignment is as
Toe Adjustment required to achieve the proper toe setting as
specified in “Wheel Toe Alignment”.
If toe alignment is incorrect, measure the distance
between vehicle center and each wheel. This will tell you • IMPORTANT: When tightening the tie rod end jam
which tie rod needs adjusting. nuts, the rod ends must be held parallel to prevent
rod end damage and premature wear. Damage
NOTE: Be sure steering wheel is straight ahead may not be immediately apparent if done
before determining which tie rod needs adjustment. incorrectly.
• After alignment is complete, torque jam nuts to
specification.
=T
Tie Rod Jam Nut:
13 ft-lbs (18 Nm)
Measure Distances
(Measurements should be equal)
2.36
MAINTENANCE
SUSPENSION Shock Position Adjustment
Suspension Inspection The front and rear shock position may be adjusted to
provide a stiffer suspension if necessary.
Compress and release the suspension. Damping should
be smooth throughout the range of travel. 1. Elevate the vehicle and safely support the main
frame.
2
• Check all suspension components and mounting
fasteners for wear or damage.
CAUTION
• Inspect each shock body for leakage.
Use care when supporting vehicle so that it does
Spring Pre-Load Adjustment not tip or fall. Serious injury may occur if vehicle
tips or falls.
The front and rear shock absorber springs are adjustable.
Rotate the adjuster cam either direction to increase or
2. Remove the top shock mounting bolts on each side.
decrease spring tension. Always adjust both left and right
sides equally. 3. Reposition the shocks to the outside mounting holes.
Front Shock
Position Adjustment
Inside
(Soft)
Highest amount Lowest amount
of spring pre-load of spring pre-load
Shock Pre-Load Adjustment
Vehicle loads effect suspension spring pre-load

requirements. Use Spanner Wrench (PN 2871095) to Outside
adjust pre-load as necessary to avoid bottoming of the Stiff)
shocks.
Rear Shock
Shock Spanner Wrench: Position Adjustment
PN 2871095
Outside
(Stiff)
Inside
(soft)
2.37
MAINTENANCE
4. Reinstall the shock mounting bolts and torque to Brake Hose and Fitting Inspection
specification.
Check brake system hoses and fittings for cracks,
deterioration, abrasion, and leaks. Tighten any loose
=T fittings and replace any worn or damaged parts.
Shock Mounting Bolt: Brake Pad / Disc Inspection

30 ft-lbs (41 Nm)
1. Check the brake pads for wear, damage, or
looseness.
BRAKE SYSTEM 2. Inspect the brake pad wear surface for excessive
wear.
Brake Fluid Inspection
3. Pads should be changed when the friction material is
Always check the brake pedal travel and inspect the brake worn to .040” (1 mm).
fluid reservoir level before each operation. If the fluid level
is low, add DOT 4 brake fluid only.
Brake fluid should be changed every two years. The fluid

should also be changed anytime the fluid becomes
contaminated, the fluid level is below the minimum level,
or if the type and brand of the fluid in the reservoir is
unknown.
The brake master cylinder reservoir can be accessed Measure Pad Material
through the front left wheel well. Thickness Service Limit:
.040" (1 mm)
2. Place the transmission in Neutral (N) and set the

parking brake. 4. Check surface condition of the brake discs.
3. View the brake fluid level in the reservoir. The level 5. Measure the thickness of the front and rear brake
should be between the MAX and MIN level lines. discs.
4. If the fluid level is lower than the MIN level line, add 6. The disc(s) should be replaced if thickness is less than
brake fluid until it reaches the MAX level line. the specified service limit (see Chapter 9 for
specifications).
5. Install the reservoir cap and apply the brake pedal
forcefully for a few seconds and check for fluid Measure Brake Disc Thickness
leakage around the master cylinder fittings and the
brake caliper fittings.
Front Rear
Disc Disc
Master Cylinder
2.38
MAINTENANCE
Parking Brake Cable Adjustment Parking Brake Pad Inspection
NOTE: Inspect the parking brake cable tension after Measure the thickness of the rear caliper parking brake
the first 25 hours of operation and every 100 hours pads. Replace assembly as needed. See illustration
of operation afterwards to ensure proper cable
tension.
below for proper readings.
Inboard Pad
2
New .304” (7.72 mm)
Loss of tension in the parking brake cable will cause Limit: 0.24” (6.1 mm)
illumination of the parking brake light and activation of the Inboard
Outboard
limiting feature. If this occurs, inspect and adjust parking Pad
Pad
brake cable tension. If performing this service is difficult
due to conditions or location, open the hood and
temporarily disconnect the parking brake connector.
Reconnect the connector as soon as practicable and
adjust the parking brake cable to proper tension. Outboard Pad
New 0.360” (9.14 mm)
1. Pull back on the parking brake lever (located in the Limit: 0.31” (7.87 mm)
dash).
Installed Disc to Park Brake
2. After 3 to 4 clicks the “P” light should illuminate on the 0.375” (0.953 cm)
instrument cluster and the wheels of the vehicle
should not rotate when turning by hand. After 8 full New Rotor Disc Thickness
clicks of lever travel, the vehicle should not roll while 0.169 +/- .008”
parked. (4.29 +/- .20mm)
Replace at .150” (3.81mm) or less
3. If the vehicle moves, adjustment is necessary.
4. Adjust the parking brake cable where the cable

attaches to the caliper mount bracket. The mount
bracket is located on the left-hand side of the
transmission behind the outer PVT cover.
Adjustment Procedure: Refer to Chapter 9 “Brakes”

for complete adjustment procedure.
2.39
MAINTENANCE
NOTES
2.40
ENGINE
CHAPTER 3
ENGINE
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
GENERAL ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
ACCESSIBLE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
OIL PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
ENGINE/TRANSMISSION ASSEMBLY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
3
ENGINE / TRANSMISSION MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
ENGINE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
COOLING SYSTEM SPECIFICATIONS AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
COOLING FAN ON/OFF & HOT LIGHT ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
COOLING SYSTEM BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
REFER TO YANMAR ENGINE SERVICE CHAPTER 11

FOR ENGINE REPAIR INFORMATION

3.1
ENGINE
SPECIAL TOOLS Engine Lubrication Specifications
Special Tools Oil Viscosity Requirement vs. Temperature

Diesel Engine Compression
PU-50529
Tester and Adapter
PU-50531 Diesel Oil Pressure Adapter
PU-50530 Diesel Injection Timing Tool
PU-50532 Diesel Fuel Injector Tester
GENERAL ENGINE SERVICE

Accessible Components =
The following components can be serviced or removed
with the engine installed: Recommended Engine Oil:
• Alternator
Polaris 15W40 Diesel Summer /
• Starter Motor/Drive Polaris 10W30 Diesel Winter (CI-4 rated)
• Camshaft
• Cylinder Head Capacity: Approximately 1.8 U.S. Quarts (1.7 l)
• Valvetrain Components 2878471 - Diesel Oil Change Kit, Summer 15W40

• Fuel Injection Pump 2878472 - Diesel Oil Change Kit, Winter 10W30
• Glow Plugs 2878473 - Diesel Oil 2Qt Summer 15W40
2878474 - Diesel Oil 2Qt Winter 10W30
• Injectors
• Water Pump Oil Pressure Test
• Oil Pump 1. Remove oil pressure switch (A) from right side of the
• Timing Geartrain cylinder block.
The following components require engine removal for
service:
• Connecting Rods
• Crankshaft
• Crankshaft Main Bearings
• Cylinder Block
• Flywheel (transmission removal)
• Piston / Rings A
2. Insert special adapter tool PU-50531 into cylinder

block. Use oil pressure test kit PV-43531-B.
3. Start engine and allow it to reach operating
temperature, while monitoring the gauge. Check for oil
leaks.

© Copyright 2012 Polaris Saes Inc.
ENGINE
NOTE: Use only Polaris Diesel oil 15W40 Summer or 7. Disconnect battery (-) negative cable from the engine
10W30 Winter. block.
Oil Pressure at 3600 RPM (Engine Hot):

MIN: 34 PSI
MAX: 64 PSI
Oil Pressure at IDLE RPM (Engine Hot):
MIN: 8 PSI
4. Using thread sealant, reinsert oil pressure switch and

tighten sufficiently upon completion of test.
3
Engine/Transmission Assembly Removal
IMPORTANT: For efficiency, it is recommended that
the engine and transmission be removed as an
assembly anytime the engine requires complete 8. Remove the cab frame support and lower seat frame
disassembly or rebuilding. This makes the as an assembly (refer to Chapter 5).
transmission / engine coupling and placement
process more efficient.

Some engine repair procedures can be performed
without removing the engine. Refer to “Accessible
Components” for further information.
NOTE: Use a mechanical hoist to remove the engine
and transmission as an assembly from the vehicle to
prevent personal injury or damage to other vehicle Remove as
components. an assembly
WARNING
FRAME
Always wear safety glasses and use the proper
tools when performing the procedures in this
manual. Failing to do so may lead to 
possible injury or death. 9. Disconnect the harness / wires attached to the
alternator.
1. Thoroughly clean the engine / transmission and
chassis before removal.
2. Drain the engine oil (refer to Chapter 5).
3. Drain the engine coolant into a catch container by
removing the lower radiator hose. TIP: Remove
additional engine coolant from the system by sealing
the lower radiator fitting and introducing low-pressure
compressed air into the system. Additional coolant will
flow from the lower radiator hose into the catch
container.
4. Disconnect cargo box harness. Remove Cargo box
and cargo box shock.
5. Remove the seat base.
6. Disconnect the battery positive (+) and negative (-)
cables.
3.3
ENGINE
10. Disconnect the harness / wires attached to the starter. 18. Disconnect the glow plug harness connector (A) and
the stop solenoid connector (B).
B
11. Remove the springs from exhaust pipe.
19. Disconnect the oil pressure sensor connector.
12. Remove the exhaust pipe nuts from the manifold and
remove the pipe.
13. Remove belt guard.
14. Place a small catch-container under the fuel filter /
water separator and fuel supply and return lines.
Disconnect fuel lines on fuel tank and engine.
Carefully remove and plug the fuel supply and return
lines. Remove fuel filter mount and lines as an
assembly from the frame. Store in safe, clean area.
NOTE: Dispose of all fluids properly.
15. Remove the radiator hoses from the water pump.
16. Disconnect and remove the throttle cable.
20. Disconnect the crankshaft position sensor (CPS)
harness located on the bell housing.
17. Remove the air intake filter housing and engine intake
hose assembly. Place a shop towel into the engine 21. Disconnect the gear position switch harness from the
intake to prevent dirt from entering the intake port. transmission (Refer to chapter 8), located on top of the
transmission.

ENGINE
22. Disconnect the speed sensor harness from the rear of 29. Using a hoist, carefully remove the engine/
the transmission. transmission assembly verticality from the chassis
frame using the supplied lifting eyes on the engine.
23. Verify that ALL electrical harness connections are Lifting Points
disconnected from the engine and transmission.
24. Disconnect the shift cable and remove the shift cable
bracket assembly from the frame (refer to chapter 8). 30. Place engine / transmission assembly on suitable flat
working area. Separate engine and transmission if
25. Remove the parking brake to allow rear propshaft
needed. See page 3.11 and chapter 8 for more details
removal (refer to Chapter 9).
when removing transmission from engine.
26. Remove the rear propshaft from the transmission
NOTE: Use extreme caution when lifting the engine
(refer to Chapter 7).
out of the frame. Always use an engine lift or other
27. Remove the front propshaft from the transmission heavy-duty lifting apparatus.
(refer to Chapter 7).
28. Remove the engine and transmission mount Engine Installation
fasteners from underside of the frame. Reverse the removal steps. After the engine is installed in
the frame, review the following and perform all steps that
Remove all 8 lower mount bracket bolts. apply:
NOTE: Access holes in skid plate.
General Items
1. Properly torque all fasteners. Use general torque
guide in Chapter 1 if no specifications are supplied.
Torques values can be found at the end of chapter 3
and in chapter 8
2. Install previously removed components using new
gaskets, seals, and fasteners where applicable.
3. Verify proper throttle operation.
4. Verify the engine ground is installed on the cylinder
block.
5. Verify the alternator belt is properly tensioned.
NOTE: Properly route all electrical harnesses and re-
attach any fasteners or protective tubing. Check for
any possible rubbing points of electrical wires.
6. Perform regular checks on fluid levels, controls, and
all other areas of the vehicle as outlined in the daily
pre-ride inspection checklist (refer to Chapter 2).
PVT System
1. Check the clutch offset, clutch alignment, and belt
deflection if required (see Chapter 6 “Clutching”).
3.5
ENGINE
2. Clean the clutch sheaves thoroughly and inspect inlet
and outlet ducts for proper routing and sealing (see
Chapter 6).
Transmission
1. Inspect transmission operation and adjust the shift
cable if necessary. Refer to Chapter 2 and Chapter 8.
Exhaust
1. Replace exhaust gaskets as part of preventative
maintenance. Seal connections with high temp
silicone sealant if required.
2. Verify all exhaust springs are in good condition.
Bleed Cooling System
NOTE: Follow coolant bleeding procedure outlined in
this chapter
Engine Break-In Period
The break-in period for a Polaris RANGER diesel engine
is defined as the first 50 hours of engine operation. No
single action on your part is as important as a proper
break-in period. Careful treatment of a new engine will
result in more efficient performance and longer engine life.
Perform the following procedures carefully:
CAUTION
Use only Polaris Diesel engine oil or an approved
equivalent. Do not operate at full throttle or high
speeds for extended periods during the first 50
hours of use. Excessive heat can build up and
cause damage to close fitted engine parts.
1. Fill fuel tank with clean fuel.

2. Check oil level indicated on dipstick. Add oil if
necessary (Refer to Chapter 2).
3. Drive slowly at first to gradually bring engine up to
operating temperature.
4. Vary throttle positions during vehicle operation. Do not
operate at sustained idle or sustained high speed.
5. Perform regular checks on fluid levels, controls and all
important bolt torques during the break in period.
6. Pull only light loads during initial break-in.
7. Change oil and oil filter after break-in period of 50
hours.

ENGINE
ENGINE / TRANSMISSION MOUNTING
Exploded View / Torque Values
25 ft-lbs
(34 Nm)
62 ft-lbs
(84 Nm)
30 ft-lbs
(40 Nm)
25 ft-lbs
3
(34 Nm)
18 ft-lbs
(25 Nm)
18 ft-lbs 30 ft-lbs
(25 Nm) 25 ft-lbs (40 Nm)
(34 Nm)
18 ft-lbs
(25 Nm)
17 ft-lbs
(23 Nm)
18 ft-lbs
(25 Nm) Gasket
55 ft-lbs Rubber Coupler

(75 Nm)

3.7
ENGINE
ENGINE EXHAUST SYSTEM
Exploded View - Engine Exhaust System
18 ft-lbs
(24 Nm)
5 ft-lbs
(7 Nm)
18 ft-lbs
(24 Nm)

ENGINE
ENGINE COOLING SYSTEM Radiator Cap Pressure Test
1. Open the front hood (see Warning under “Cooling
Cooling System Specifications and Testing System Pressure Test”).
2. Remove radiator pressure cap and test using a cap
CONDITION SPECIFICATION
tester (commercially available).
Thermostat begins to open approx.160° F (71° C)
3. The radiator cap relief pressure is 13 lbs. Replace cap
Thermostat fully open approx. 185° F (85° C) if it does not meet this specification.
Radiator Cap Pressure 13 PSI
Cooling Fan on/off & HOT Light on/off
SYSTEM CAPACITY
RANGER DIESEL 6.2 Qts. (5.9 L)
The cooling fan and HOT light are both controlled by the
VCM via the coolant temp sensor.
3
RANGER DIESEL CREW 6.64 Qts (6.28 L) FAN HOT LIGHT
ON 194 ° F (90 ° C) ON 221° F (105° C)
Polaris Premium Antifreeze
2871534 - Quart OFF 179 ° F (82 ° C) OFF 212° F (100° C)
2871323 - Gallon
NOTE: If the coolant temperature sensor or circuit
malfunctions the radiator fan will default “ON”.
Recommended Coolant
NOTE: See chapter 10 for more information.
Use only high quality antifreeze/coolant mixed with
distilled water in a 50/50 or 60/40 ratio, depending on
freeze protection required in your area. Use only ethylene
glycol coolant; do not mix coolant types.
IMPORTANT: Using tap water in the cooling system
will lead to a buildup of deposits which may restrict
coolant flow and reduce heat dissipation, resulting in
possible engine damage. Polaris Premium Antifreeze/
Coolant is recommended for use.
Cooling System Pressure Test
1. Open the front hood.
WARNING
Escaping steam can cause burns. Never remove
the pressure cap while the engine is warm or hot.
Always allow the engine to cool before removing
the pressure cap.
2. Remove the pressure cap from the radiator and

pressure test the cooling system using a commercially
available tester.
3. The system must retain 10 psi for five minutes or
longer. If pressure loss is evident within five minutes,
check radiator, all cooling system hoses and clamps
and water pump seal for leakage.
3.9
ENGINE

ENGINE
Cooling System Bleeding Procedure NOTE: If system is partially filled, steps 4 to 8 may be
unnecessary and can be skipped to step 9.
4. Cooling system empty - Completely unscrew the rear
WARNING bleed screw on the thermostat housing.
Always wear safety glasses and proper shop
clothing when performing the procedures in this
manual. Failing to do so may lead to possible
injury or death. Coolant Bleed Screw
CAUTION
Use caution when performing these procedures.
3
Coolant may be hot and may cause severe
injury or burns.
NOTE: If the coolant level is LOW in the radiator, or if

there are leaks in the system, the coolant system will
not draw coolant from the recovery bottle.
NOTE: Use this procedure when overheating occurs 5. Cooling system empty - Place rags around the bleed
and no apparent leaks in the cooling system are hole area to absorb any coolant that may escape
found. during the radiator fill process.
1. Place the vehicle in Neutral and set the parking brake. 6. Cooling system empty - Slowly add coolant to the
radiator while monitoring the thermostat housing
bleed hole. This process purges the air from the
CAUTION system.
Escaping steam can cause burns. Never remove 7. Cooling system empty - Squeeze coolant hoses
the pressure cap while the engine is warm or hot. gently by hand during initial fill to help purge the
Always allow the engine to cool before removing system of air.
the pressure cap. 8. Cooling system empty - When coolant appears at the
bleed hole, replace the bleed screw and tighten, but
2. Remove the radiator cap.
do not fully torque at this time.
3. Verify the recovery bottle is filled between the “MIN”
9. Continue to fill radiator with coolant to the filler neck.
and the “MAX” line with coolant. Add coolant if
required. 10. Loosen the bleed screw on the thermostat housing
(approximately 2 turns or more) and allow any
remaining trapped air to escape. If no air is present,
a steady stream of coolant will be present. If air is
present, the screw area will bubble and sputter as air
escapes.
MAX 11. Once a steady stream of coolant appears at the bleed
screw, tighten the bleed screw to specification on the
MIN thermostat housing.
Recovery
Bottle
=T
Coolant Bleed Screw:
70 in-lbs (8 Nm)
12. Add coolant to the radiator fill neck.

13. Remove rags from the thermostat housing and
dispose of properly.
3.11
ENGINE
14. Place appropriate drain pan under radiator. Start the
engine and allow it to reach operating temperature
with the radiator cap removed from the radiator. Be
sure thermostat has opened before installing the cap
back onto the radiator. (Cooling fan should cycle at
least once) Install radiator cap.
15. Stop the engine and allow it cool. Any air remaining
in the system should continue to bleed out through the
recovery bottle during operation.
CAUTION
Use caution when performing these procedures.
Coolant may be hot and may cause severe
injury or burns.
16. Top off the radiator (A) and recovery bottle (B) with
coolant if required. Fill the radiator first before filling
the recovery bottle.
A
B
17. Repeat this procedure if you are still having difficulty

bleeding the system.
18. It may be necessary to lift the front of the vehicle
higher that the rear of the vehicle to aid in the bleeding
procedure. Use a suitable vehicle hoist or vehicle lift
to raise the front of the vehicle safely.

FUEL SYSTEM
CHAPTER 4
FUEL SYSTEM
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
DIESEL SERVICE NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
FUEL TANK EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
FUEL INJECTION SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
FUEL SYSTEM COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
FUEL LINE REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
PRINCIPAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
INITIAL PRIMING / STARTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
FUEL TRANSFER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4
FUEL PUMP TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
FUEL PUMP REPLACEMENT / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
FUEL TANK ASSEMBLY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
FUEL TANK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
FUEL FILTER / WATER SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
FUEL FILTER / WATER SEPARATOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
FUEL FILTER / WATER SEPARATOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . 4.9
FUEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
FUEL SENDER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
FUEL SENDER REPLACEMENT / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
GENERAL TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
REFER TO YANMAR ENGINE SERVICE CHAPTER 11

FOR ENGINE FUEL INJECTION SYSTEM INFORMATION

4.1
© 2012 Polaris Sales Inc.
FUEL SYSTEM
GENERAL INFORMATION Diesel Service Notes
• Never attempt to service any fuel system
component while engine is running or ignition
switch is "on".
WARNING
• Cleanliness is essential and must be maintained at
• Gasoline is highly flammable and explosive under all times when servicing or working on the fuel
certain conditions. system. Dirt, even in small quantities, can cause
• Always exercise extreme caution whenever significant problems.
handling gasoline. • Do not use compressed air if the system is open.
• Always refuel outdoors or in a well-ventilated area. Cover any parts removed and wrap any open
• Always turn off the engine before refueling. joints with plastic if they will remain open for any
• Do not overfill the tank. Do not fill the tank neck. length of time. New parts should be removed from
• Do not smoke or allow open flames or sparks in or their protective packaging just prior to installation.
near the area where refueling is performed or where • Clean any connection before opening to prevent
gasoline is stored. dirt from entering the system.
• If gasoline spills on your skin or clothing, • Although every precaution has been taken to
immediately wash it off with soap and water and prevent water intrusion failures, avoid high
change clothing. pressure spray contact with system components.
• Never start the engine or let it run in an enclosed • Do not allow the battery cables to touch opposing
area. Engine exhaust fumes are poisonous and can terminals. When connecting battery cables attach
cause loss of consciousness or death in a short time. the positive (+) cable to positive (+) battery
• EFI components are under high pressure. Verify terminal first, followed by negative (-) cable to
system pressure has been relieved before negative (-) battery terminal.
disassembly. • Never start the engine when the cables are loose
• Never drain the fuel system when the engine is hot. or poorly connected to the battery terminals.
Severe burns may result.
• Never disconnect battery while engine is running.
Special Tools • Do not charge battery with key switch "on."

• Always disconnect negative (-) battery cable lead
PART NUMBER TOOL DESCRIPTION before charging battery.
IMPORTANT: The fuel system remains under
PU-50326 PFA Nut Tool
pressure, even when the engine is not running. Before
SPX Corp: 1-800-328-6657 or http://polaris.spx.com/ attempting to service any part of the fuel system,
pressure must be relieved (if applicable).
PFA Nut Tool - PU-50326
NOTE: This vehicle has both low and high fuel
pressure systems. The low pressure system is
covered in this chapter (4) and the high pressure
system is covered in chapter 11.
Refer to Yanmar Engine Service - Chapter 11 for more

information on fuel system special tools.

FUEL SYSTEM
Fuel Tank Exploded View
PFA Nut
Fuel Return
Fuel Sender
ssembly
To Fuel Pump
Float / Arm
ssembly
4
PFA Gasket
Vent
Fuel Tank
Assembly
Fuel Flow
Bypass / Return Flow
Injection
lines
Fuel Tank
Fuel Injection Unit

Fuel Pump
Fuel Injectors
Fuel Filter / Water Separator

4.3
FUEL SYSTEM
Fuel Injection System Exploded View
1. Fuel Transfer Pump 
2. Fuel Filter / Water Separator 
3. Fuel Injection Unit 
4. Fuel Injector High Pressure Lines 
5. Fuel Injector 
6. Low Pressure Return Line Assembly (A)
7. Fuel Inlet / Lines (B) 
8. Fuel Injection Drive Gear 
9. Cylinder Head 
2
6
B
5 9
1
B
A
3 8

FUEL SYSTEM
Fuel System Component Locations Fuel Line Removal / Installation
1. Fuel Transfer Pump (item #1)
Located above fuel tank as an assembly. CAUTION
Verify fuel system has been depressurized
before performing this procedure.
Refer to the steps for fuel line removal / installation:

1. Thoroughly clean the hose connection area and place
a shop towel around the fuel line to catch any excess
fuel.
2. Squeeze the clamp tabs together with a suitable pliers
and slide the clamp down the fuel line approx. 2
inches.
4
2. Fuel Filter / Water Separator (item #2)
Located on the frame by the fuel tank, under the seat.
3. Fuel Injection Unit (Item #3)
Located on the engine under the seat. Refer to
Yanmar Engine Service - Chapter 11.
3. Gently pull and twist the fuel line to remove from the
fuel pump outlet.
4. When installing the fuel hose, verify the hose and fuel
return inlet are clean and free of debris.
5. Slide the hose fully onto the fuel tank outlet. Squeeze
the clamp tabs with suitable pliers and slide clamp
onto hose connection area. See photo above for
proper positioning.
4. Fuel Injectors / Fuel Rail (item #4)
Attached by high pressure fuel lines to the fuel
injection unit. Located on the cylinder head.
5. Fuel Gauge Sender Assembly
Located in fuel tank as an assembly.
4.5
FUEL SYSTEM
FUEL INJECTION FUEL TRANSFER PUMP
Principal Components Operation Overview
The fuel system is a complete engine fuel management The electric fuel transfer pump is used to supply fuel from
design. This system includes the following principal the tank to the fuel injection system. The main in-line
components: components for fuel transfer include the fuel pump and
fuel/water separator. The pump is rated for a 1-5 psi
• Fuel Pump
output.
• Fuel Filter / Water Separator Assembly
• Fuel Injection unit (Refer to the Yanmar Engine
Service Section - Chapter 11)
• The fuel system contains both high and low
pressure systems. (Supply and Injection)
Operation Overview
The fuel injection system is designed to provide peak
engine performance with optimum fuel efficiency and
lowest possible emissions. The injection functions are
mechanically controlled and governed. NOTE: The fuel
injection unit is not serviceable. (Refer to the Yanmar
Engine Service Section - Chapter 11) It must be serviced
by an authorized FIE repair facility.
When the key switch is turned to "ON", 12Vdc power
An in-line electric fuel pump is used to move fuel from the activates the fuel pump, which pressurizes the system for
tank through the fuel line and in-line fuel filter/water start-up.
separator. The fuel pump maintains a system operating
pressure of 1-5 psi. Any excess fuel returns to the tank via The fuel pump is activated any time the key switch is
the return line attached to the injection system. turned to "ON" position.
At the engine, fuel is fed to the fuel injection control unit, Fuel Pump Test
which operates the injectors. A precise amount is injected
into the pre combustion chambers. NOTE: The fuel transfer pump is non-serviceable and
must be replaced if determined to be faulty. If a fuel
Initial Priming / Starting Procedure delivery problem is suspected, make certain the fuel
pump is being activated by key ‘ON’, all electrical
NOTE: The injection system must be purged of all air connections are properly secured, the fuses are good,
prior to the initial start up, and / or any time the system and a minimum of 12.0 Vdc is being supplied.
has been disassembled.
If the fuel system is completely empty of fuel or has been WARNING
disassembled and repaired:
1. Turn the key switch to the ON position for 10-15 Fuel is extremely flammable and may cause
seconds. severe burns, injury, or death.
Do not use any device that produces a flame or
2. Turn the key switch to “START” until the engine starts electrical devices that may spark around
or 5 seconds has passed. fuel or fuel vapors.
3. If the engine failed to start, repeat steps one and two.
1. Cover the fuel line connection with a shop towel and
If the engine fails to start, a problem may still exist, and disconnect the fuel line from the fuel pump where it
should be diagnosed. connects to the engine.
2. Install a commercially available low pressure test
gauge on the fuel line between the fuel pump and the
fuel filter / water separator assembly.

FUEL SYSTEM
3. Turn on the key switch to activate the pump and check Fuel Pump Replacement / Installation
the system pressure on the gauge. If system pressure
of 1-5 psi is observed, the ignition switch and fuel
pump are working properly. Turn the key switch off WARNING
and relieve the system pressure.
Always wear safety goggles when working with
Fuel Pump Pressure: 1-5 psi high pressure or flammable fluids.
Do not use any device that produces a flame or
electrical devices that may spark around
NOTE: If the pressure is too low, check in-tank fuel fuel or fuel vapors.
filter. If in-tank fuel filter is ok, replace the fuel pump
assembly. 1. Disconnect the electrical harness at the fuel pump.
4. If the pump did not activate (Step 3), disconnect the 2. Cover the fuel line connections with a shop towel and
plug from the fuel pump. Connect a DC voltmeter disconnect the fuel lines from the fuel pump.
across terminals in the plug on the vehicle harness
side. Turn on the key switch and observe voltage to 3. Remove the bracket fasteners and remove the pump
ensure a minimum of 12 Vdc is present. from the frame.
NOTE: If the voltage was below 12 Vdc, test battery, 4. Install the new pump onto the frame, and reinstall the
bracket fasteners. Tighten fasteners securely.
4
ignition switch, relay(s), wiring harness and ECM.
5. If the reading is around 12 Vdc, turn key switch off and 5. Install the fuel lines and spring clamps securely.
connect an ohmmeter between the power terminal on 6. Reconnect the electrical harness.
the pump and to frame ground to check for continuity
7. Turn the ignition key ON for 10-15 seconds.
within the fuel pump.
8. Test pump and check for leaks.
NOTE: If there was no continuity, replace the fuel
pump assembly. 9. Start engine and check for fuel leaks.
6. If voltage at the plug is within the specified range, and 10. Properly dispose of shot towels and excess fuel
there is continuity across the pump terminals, properly.
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.
NOTE: If the pump starts but still does not operate,
check the fuel tank assembly for line blockage or no
fuel. Replace the pump if no blockage is found.
4.7
FUEL SYSTEM
Fuel Tank Assembly Removal 6. Remove the (4) bolts retaining the fuel tank to the
frame support.
WARNING Fuel Tank

Always wear safety goggles when working with
high pressure or flammable fluids. Failure to do so
could result in serious injury. Remove
1. Remove the seat base.
2. Disconnect the negative (-) battery cable.
3. Disconnect the fuel lines and electrical harness from
the fuel tank. Remove
Return Line
7. Carefully remove the fuel tank out the RH side of the

frame.
NOTE: A small amount of fuel may come out of the

fuel line or tank. Plug the fuel line and tank inlet or use
a shop towel during removal.
4. Remove the fuel tank vent hose.
5. Remove the right rear fender/rocker panel assembly
and the fuel cap. Reinstall the fuel cap after the fender/
rocker panel has been removed.
RH Rear Fender /
ocker Panel
NOTE: Properly drain fuel into a suitable container.
Fuel Tank Installation

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

FUEL SYSTEM
FUEL FILTER / WATER SEPARATOR 5. Reach under the fuel filter and unscrew the black drain
valve until fuel starts to drain out of the bottom of the
General Information valve. (1/2 to 1 turn) Do not unscrew the drain valve
completely. The drain valve has standard rotation
The fuel filter / water separator assembly is located under threads.
the seat on the RH side of the vehicle, in-between the
Fuel filter drain valve as viewed from under filter.
engine and the fuel tank. The filter should be:
• Inspected daily. Tighten Valve
• Drained every 50 hours (normal conditions with
quality fuel) OR drained daily (severe conditions /
poor fuel quality).
• Replaced every 150 hours OR 12 months OR
2000 miles (3200KM). WHICHEVER COMES
FIRST.
Fuel Filter / Water Separator Draining

1. See chapter 4 of this manual for safety information.
Loosen Valve 4
2. Be sure engine is cool and the battery is Fuel Drain
disconnected.
6. Wait for fuel and water to stop draining from the valve
3. Remove seat. and firmly retighten valve hand tight only.
4. Place container / drain pan / shop towels under fuel 7. Clean up any excess fuel properly.
filter area to catch any excess fuel.
8. Reconnect battery.
9. Turn key switch ON for 10-15 seconds.
Fuel Filter
Fuel Filter / Water Separator Replacement
1. Follow Steps 1-7 from the “Fuel Filter / Water
Separator Draining” Procedure.
2. Unscrew fuel filter / water separator from the filter
mount using a commercially available filter wrench if
Drain Valve it is not removable by hand. The filter has standard
rotation threads.
3. Properly drain and dispose of fuel filter / water
separator.
4. Lightly lubricate the rubber gasket of the new fuel filter
/ water separator with fresh engine oil. Thread new
filter onto the filter mount until the gasket lightly
touches the filter housing. Tighten filter 1/2-3/4 of a
turn after initial contact of the rubber gasket to the filter
mount. Be sure that the drain valve on the bottom of
the filter is snug and did not loosen up during filter
installation.
6. Reconnect battery.
7. Turn key switch ON for 10-15 seconds to prime the
fuel system.
4.9
FUEL SYSTEM
FUEL SENDER 6. Loosen and remove the PFA nut using Special Tool
PU-50326.
Fuel Sender Test
If the fuel gauge reading on the instrument cluster is not
working, or if the display reading differs in large
comparison to the fuel in the tank, perform a resistance
test on the fuel sender.
Disconnect the sending unit connection and measure the
resistance at the connector wires (see chapter 10 for
further details). If out of specification, replace the sender
assembly.
Special Tool:
PU-50326 - PFA Nut Tool
7. Remove the old sender and discard the PFA gasket.

8. Install a new sender and new PFA gasket onto the
tank assembly, using care not to damage or bend the
float arm.
9. Install the PFA nut using Special Tool PU-50326.
Torque the PFA nut to specification.
Fuel Sender Resistance Specifications:
Full: 102 ± 2  =T
Empty: 7 ± 2 
PFA Nut:
75 ft-lbs (101 Nm)
Fuel Sender Replacement / Installation
If the fuel gauge sender is broken, replace the sender as 10. Reconnect the sender harness and return fuel line.
an assembly (Refer to exploded view on Page 4.3). 11. Reconnect the negative battery cable. Test the fuel
1. Remove the seat base. gauge sender by turning the ignition key to ‘On’ and
watch for the gauge to indicate your present fuel level.
2. Thoroughly clean the top of the fuel tank before
disassembly.
3. Disconnect the negative battery cable.
4. Disconnect the return flow fuel line.
5. Disconnect the fuel sender harness connector.

FUEL SYSTEM
GENERAL TROUBLESHOOTING
Fuel System Troubleshooting - Refer to
Yanmar Engine Service Chapter 11 for more
troubleshooting information
Fuel Starvation
Symptoms: Hard start or no start, bog, backfire,
hesitation, low power, surging, high idle, idle speed erratic
and low idle:
• No fuel in tank / Low fuel
• Restricted tank vent, or routed improperly
• Fuel lines or fuel injectors restricted
• Fuel filter plugged / gelled
• Fuel pump inoperative
• Air leak in system 4
• Intake air leak (intake ducts, airbox)
Rich Mixture
Symptoms: Excessive exhaust smoke, rough idle, poor
fuel economy, engine runs rough, poor performance, bog,
engine loads up.
• Air intake restricted (inspect intake duct)
• Air filter dirty/plugged
• Poor fuel quality (old fuel)
• Fouled injectors
• TPS setting incorrect
• Injector dirty / worn
Poor Idle
Symptom: Idle Too High
• Throttle stop screw set incorrect
• Throttle cable sticking, improperly adjusted, routed
incorrectly
Symptom: Idle Too Low
• Plugged air filter
• Low Fuel
• Leaking injector (rich condition)
• PVT Belt dragging
Symptom: Erratic Idle
• Throttle cable incorrectly adjusted or sticking
• Low Fuel
• Air Leaks, dirty injector
• Tight valves
• Timing incorrect
• PVT Belt dragging
• Dirty air cleaner
• Engine worn
4.11
FUEL SYSTEM
NOTES

BODY / STEERING / SUSPENSION
CHAPTER 5
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
DECAL REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
CAB FRAME / SEAT BACK / PVT AIR INTAKE BOX (NON CREW) . . . . . . . . . . . . . . . . . . . . . 5.4
CAB FRAME / SEAT BACK / PVT AIR INTAKE BOX (CREW). . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
CHASSIS / MAIN FRAME (NON CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
CHASSIS / MAIN FRAME (CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
BODY EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
DASH INSTRUMENTS / CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.10
HOOD / DASH / FRONT FENDERS / FRONT FASCIA . . . . . . . . . . . . . . . . . . . . . . . . .5.11
FLOOR / REAR FENDERS (2011 NON CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.12
FLOOR / REAR FENDERS (2012-2013 NON CREW) . . . . . . . . . . . . . . . . . . . . . . . . . .5.13
FLOOR / REAR FENDERS (CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.14
SEAT MOUNTING / SEAT BELTS (NON CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.15
SEAT MOUNTING / SEAT BELTS (CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.16
CARGO BOX - PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.17
CARGO BOX - TAILGATE / BOX SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.18
BODY COMPONENT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19 5
BOX REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.19
BOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.20
LOWER SEAT BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.20
WHEEL WELL PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.21
FRONT BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.21
FRONT FASCIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.21
FRONT FENDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.21
HOOD / DASH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.22
GLOVE BOX / STORAGE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.22
STEERING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23
EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.23
STEERING WHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.24
STEERING SHAFT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.24
STEERING SHAFT BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.25
FRONT A-ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26
BALL JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
SERVICE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.27
BALL JOINT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.28
BALL JOINT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.28
REAR A-ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.29
REMOVAL / REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.29
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.31
EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.32
REAR STABILIZER BAR / LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33
SHOCKS / SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.34

5.1
TORQUE SPECIFICATIONS SPECIAL TOOLS
Torque Specifications Special Tools
ITEM TORQUE VALUE PART NUMBER TOOL DESCRIPTION
Front Frame to Rear Frame 2871095 Shock Spanner Wrench
39 ft-lbs (53 Nm)
Support Fasteners (CREW)
2870623 Shock Spring Compressor Tool
Front Upper / Lower
30 ft-lbs (41 Nm) 2876389 Multi-Function Pliers
A-Arm Bolts
Rear Upper / Lower
30 ft-lbs (41 Nm)
A-Arm Bolts
Multi-Function Pliers
Front Ball Joint Pinch Bolts 23 ft-lbs (31 Nm)
Included in the tool kit, the multi-function pliers is designed
Rear Lower to remove the plastic push rivets used to fasten body
30 ft-lbs (41 Nm)
Bearing Carrier components.
Rear Upper
30 ft-lbs (41 Nm)
Bearing Carrier
Upper / Lower
30 ft-lbs (41 Nm)
Shock Bolts
Stabilizer Bar to Frame 17 ft-lbs (23 Nm)
Stabilizer Bar
17 ft-lbs (23 Nm)
Linkage Bushings
Front Wheel Hub
80 ft-lbs (108 Nm)
Castle Nut
Rear Wheel Hub
110 ft-lbs (150 Nm)
Castle Nut
Wheel Nuts (Cast Rims) 30 ft-lbs (41 Nm)
+ 90° (1/4) turn
Wheel Nuts (Steel Rims) 35 ft-lbs (47 Nm)
Outer Tie Rod to
40 ft-lbs (54 Nm)
Bearing Carrier
Tie Rod End Jam Nut 13 ft-lbs (18 Nm)
Seat Belt to Cab Frame 38 ft-lbs (51 Nm)
Seat Belt to Seat Base 40 ft-lbs (54 Nm)
Steering Wheel to Shaft 28 ft-lbs (38 Nm)
Upper Steering Shaft to
17 ft-lbs (23 Nm)
U-Joint Shaft
Lower Steering Shaft to
30 ft-lbs (41 Nm)
Steering Box
Steering Box 17 ft-lbs (23 Nm)
NOTE: Refer to exploded views throughout this

chapter for more torque specifications, component
identification, and location of components. Pliers
Push Rivet

DECAL REPLACEMENT 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
WARNING until the surface appears slightly glossy. This should
occur after just a few seconds of flame treating. Do not
The following procedure involves the use of an hold the torch too close to the surface (2-3 inches from
open flame. Perform this procedure in a well- the flame tip is recommended). Keep the torch moving
ventilated area, away from gasoline or other to prevent damage.
flammable materials. Be sure the area to be 2. Apply the decal on one edge first. Slowly lay down
flame treated is clean and free of gasoline or remainder of the decal while rubbing lightly over the
flammable residue. decal surface to eliminate any air bubbles during the
application.
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.
5
CAUTION
Do not flame treat painted plastic components.
Painted plastic surfaces should only be wiped clean
prior to decal adhesion.
5.3
CAB FRAME / SEAT BACK / PVT AIR Tighten the hose clamp to specification.
INTAKE BOX (NON CREW)
=T
Exploded View / Assembly
Hose Clamp:
1. Assemble the RH and LH cab frame side hoops by
18 in-lbs (2 Nm)
sliding the tube over the rear coupler. Secure using (2)
5/16” bolts and nuts. Line up the front side hoop 9. Attach the clutch air intake box to the seat back using
couplers with the front frame couplers and secure (4) #14 self-tapping screws. Tighten fasteners to
using (4) 3/8” screws and nuts. Leave all fasteners specification.
finger tight.
2. Attach the front cab frame cross tube to the side hoops =T
using (4) M10 bolts. Attach the rear cab frame cross
tube to the side hoops using (4) M10 bolts. Leave all #14 Self-Tapping Screws:
fasteners finger tight. 19 in-lbs (2.1 Nm)
3. Loosely install the rear cab frame X brace to the side
10. Attach each headrest to the rear cab frame using four
hoops using (8) M8 bolts and nuts. Leave all fasteners
1/4” self-tapping fasteners. Place washers between
finger tight.
the fastener head and headrest as shown below.
4. Tighten the (8) front and rear cab frame cross tube Torque fasteners to 10 in-lbs (1 Nm).
fasteners installed during Step 2 to specification.
=T
=T
Fasteners:
Rear Cab Frame Cross Tube Fasteners: 10 in-lbs (1 Nm)
27 ft-lbs (36 Nm)
5. Tighten the (2) 5/16” fasteners installed during Step 1
to specification and the (4) 3/8” fasteners to
specification.
=T
5/16” Fasteners: 17 ft-lbs (22 Nm)
3/8” Fasteners: 27 ft-lbs (36 Nm)
6. Tighten the (8) M8 X brace fasteners installed during
Step 3 to specification.
=T
M8 X Brace Fasteners:
17 ft-lbs (22 Nm)
7. Fasten the seat back to the X brace using (8) #14 self-
tapping screws. Tighten fasteners to specification.
=T
#14 Self-Tapping Screws:
19 in-lbs (2.1 Nm)
8. Place the 2.5” hose clamp over the clutch air inlet hose
and slide the clutch intake box assembly into the hose.

27 ft-lbs
(36 Nm)
17 ft-lbs
27 ft-lbs (22 Nm)
(36 Nm)
19 in-lbs
(2.1 Nm)
10 in-lbs
(1 Nm)
17 ft-lbs
(22 Nm)
19 in-lbs
(2.1 Nm)
5
27 ft-lbs
(36 Nm)
5.5
CAB FRAME / SEAT BACK / PVT AIR and the (4) M10 fasteners to specification.
INTAKE BOX (CREW)
=T
1. Assemble the RH and LH front cab frame side hoops
by sliding the tube over the rear coupler. Secure using 5/16” Fasteners: 17 ft-lbs (22 Nm)
(2) 5/16” bolts and nuts. Line up the front side hoop M10 Fasteners: 27 ft-lbs (36 Nm)
couplers with the front frame couplers and secure
using (4) 3/8” screws and nuts. Leave all fasteners 11. Tighten the (4) rear cab frame cross tube fasteners
finger tight. installed during Step 8 to specification.
2. Attach the front cab frame cross tube to the side hoops
using (4) M10 screws. Install the rear cab frame cross =T
tube to the side hoops using (4) M10 screws. Leave
all fasteners finger tight. Rear Cab Frame Cross Tube Fasteners:
3. Loosely install the rear cab frame K brace to the side 27 ft-lbs (36 Nm)
hoops using (8) M8 screws and nuts. Leave all 12. Tighten the (8) M8 X brace fasteners installed during
fasteners finger tight. Step 9 to 17 ft-lbs (22 Nm).
4. Tighten the (8) front and rear cab frame cross tube
fasteners installed during Step 2 to specification.
=T
=T M8 X Brace Fasteners:
17 ft-lbs (22 Nm)
Rear Cab Frame Cross Tube Fasteners:
27 ft-lbs (36 Nm) 13. Fasten the seat back to the rear cab frame X brace
using (8) #14 self-tapping screws. Tighten fasteners
5. Tighten the (2) 5/16” fasteners installed during Step 1 to specification. Repeat this step to attach the front
and the (4) 3/8” fasteners to specification. seat back to the mid-cab frame K brace.
14. Place the 2.5” hose clamp over the clutch air inlet hose
=T and slide the clutch intake box assembly into the hose.
Tighten the hose clamp to specification.
5/16” Fasteners: 17 ft-lbs (22 Nm) 15. Attach the clutch air intake box to the seat back using
3/8” Fasteners: 27 ft-lbs (36 Nm) (4) #14 self-tapping screws. Tighten fasteners to
6. Tighten the (8) M8 K brace fasteners installed during specification.
Step 3 to specification. 16. Attach the headrest to the rear cab frame using (4) 1/
4” self-tapping fasteners. Place washers between the
fastener head and headrest as shown below. Torque
=T fasteners to specification.
M8 K Brace Fasteners:
17 ft-lbs (22 Nm) =T
7. Assemble the RH and LH rear cab frame side hoops Hose Clamp: 18 in-lbs (2 Nm)
by sliding the tube over the rear coupler. Secure using #14 Self-Tapping Screws: 19 in-lbs (2.1 Nm)
(2) 5/16” bolts and nuts. Line up the front upper rear 1/4” Self-tapping Fasteners: 10 in-lbs (1 Nm)
hoop couplers with the rear cab frame cross tube
holes and secure using (2) M10 screws and nuts.
Leave all fasteners finger tight.
8. Install the rear cab frame cross tube to the rear side
hoops using (4) M10 screws. Leave all fasteners
finger tight.
9. Loosely install the rear cab frame X brace to the rear
side hoops using (8) M8 screws and nuts. Leave all
fasteners finger tight.
10. Tighten the (2) 5/16” fasteners installed during Step 7

27 ft-lbs 27 ft-lbs
27 ft-lbs (36 Nm) (36 Nm)
27 ft-lbs (36 Nm)
(36 Nm)
10 in-lbs
(1 Nm)
17 ft-lbs
(22 Nm)
19 in-lbs
(2.1 Nm)
27 ft-lbs 17 ft-lbs
(36 Nm) (22 Nm)
17 ft-lbs
(22 Nm) 19 in-lbs
(2.1 Nm)
17 ft-lbs
5
(22 Nm)

5.7
CHASSIS / MAIN FRAME (NON CREW)
Exploded View
Seat Base
Dash Support
RH Floor Support
Main Frame
Cap
30 ft-lbs
Fascia (41 Nm)
Screen
30 ft-lbs
(41 Nm)
T27
Screws
Cap
5 ft-lbs
(7 Nm) 14 ft-lbs
Bumper (19 Nm)
Screen
Bumper Guard
Bracket
Bumper LH Floor Support

CHASSIS / MAIN FRAME (CREW)
Exploded View
Rear Seat Base
Front Seat Base
Dash Support
Rear Frame
5
RH Floor Support
39 ft-lbs
(53 Nm)
30 ft-lbs
(41 Nm)
39 ft-lbs
(53 Nm)
Cap Frame
30 ft-lbs Supports
(41 Nm)
Fascia
Screen
Front Frame LH Floor Support

14 ft-lbs
(19 Nm)
T27
Screws
5 ft-lbs Bumper
(7 Nm) Bumper
Screen

5.9
BODY EXPLODED VIEWS
Dash Instruments / Controls
A. Instrument Cluster (Speedo)
B. Speedometer “Mode” Button
C. Headlight Switch
D. 2WD/AWD Switch
E. 12 Volt Accessory Receptacle (2)
F. Rubber Mount
G. Key Switch
H. Grommet
I. Push Rivet
J. Wait to Start / Low Oil Pressure
Indicator
K. Dash Panel
K A
J
D
C
I
H
B
E

Hood / Dash / Front Fenders / Front Fascia
T27
Screws
T30 5 ft-lbs
Screws (7 Nm)
Hood
Front
RH Fender
Dash
T20
Screws
Push
Rivets Hinge
T27
Screws
5 ft-lbs
(7 Nm)
Cup Holder
T27
Screw
5 ft-lbs
(7 Nm)
5
Front
Fascia T27
Screws
5 ft-lbs
Front
(7 Nm) T27 LH Fender
Screws
U-Type
T27 Speed Nut
Screws
Push
Rivets
T27 U-Type Hood

Screws Speed Nut Liner
5 ft-lbs
(7 Nm) T27
Screws
Fascia
Screen

5.11
Floor / Rear Fenders (2011 NON CREW)
Rear RH Fender T27

Rocker Panel Screws
5 ft-lbs
(7 Nm)
T27 U-Type
Screws
5 ft-lbs Speed Nut
(7 Nm) Storage
Container
Push
Rivets
Rear
Floor
Floor
Cover
U-Type
Speed Nut
T27
Screws
5 ft-lbs
(7 Nm)
T27
Screws
Main
Floor Push
Rivets
T27
Screws
5 ft-lbs
Push (7 Nm)
Rivets
Wheel Well Rear LH Fender

Panels Rocker Panel
Push
Rivets
Skid Plate
Screws
6-8 ft-lbs
(8-10 Nm)

Floor / Rear Fenders (2012-2013 NON CREW)
T27
Rear RH Fender Screws
Rocker Panel 5 ft-lbs Foil
(7 Nm)
T27 Heat Shield
Screws
5 ft-lbs
(7 Nm)
Push
Rivets
Storage
Container
Floor
Cover U-Type
Speed Nut
5
T27
Rear T27 Screws
Floor Screws 5 ft-lbs
5 ft-lbs (7 Nm)
(7 Nm)
Main
Floor Block Off
T27
Panel Screws
Push
Rivets
T27
Screws
Push 5 ft-lbs
Rivets (7 Nm)
Rear LH Fender
Wheel Well Rocker Panel
Panels
Push
Rivets Skid Plate
Screws
7 ft-lbs
(9 Nm)

5.13
Floor / Rear Fenders (CREW)
Storage Foil
Container
Underseat
Storage box Heat Shield
Rear
Floor
T27
Screws
5 ft-lbs U-Type
Floor (7 Nm) Speed Nut
Cover
Rear
Floor
Main Mid
Floor Floor Rear Lower
Floor
U-Type
RH Fenders
Speed Nut
Rocker Panels
U-Type
T27 Speed Nut
Screws T27
5 ft-lbs Screws
(7 Nm)
Push
Rivets U-Type
Speed Nut
Push
Rivets
T27 Rear LH Fender

Screws Rocker Panel
5 ft-lbs
(7 Nm)
Wheel Well
Panels
Front LH Fender
Push Rocker Panel
Block Off Rivets
Panel
Skid Plates
Screws
7 ft-lbs
(9 Nm)

Seat Mounting / Seat Belts (NON CREW)
Bolt
37 ft-lbs
RH 3-Point (50 Nm)
Seat Belt
Bolt
37 ft-lbs
T30 Screws (50 Nm)
Seat Back 19 in-lbs
(2.1 Nm)
LH 3-Point
Seat Belt
Foil
5
2011
2012
2013
Heat Shield
RH 3-Point Seat Base
Seat Belt Lab Belt
Bolt Bolt
40 ft-lbs 40 ft-lbs
(54 Nm) (54 Nm)
Grommet
Bolt
40 ft-lbs
(54 Nm)
LH 3-Point
Seat Belt
Seat Base
Frame Bolt
Grommet 40 ft-lbs
(54 Nm)

5.15
Seat Mounting / Seat Belts (CREW)
T30 Screws
Bolt 19 in-lbs
37 ft-lbs (2.1 Nm)
(50 Nm)
Seat Back
RH 3-Point
Seat Belt (x2)
Foil
T30 Screws
19 in-lbs
(2.1 Nm)
Seat Base
LH 3-Point
Heat Shield Seat Belt (x2)
Bolt
37 ft-lbs
(50 Nm)
Front Seat
Supports
Bolt
40 ft-lbs
(54 Nm) Grommet
RH 3-Point
Seat Belt (x2)
Lab Belt
Pad
Bolt Bolt
40 ft-lbs 40 ft-lbs
(54 Nm) (54 Nm)
Grommet
LH 3-Point
Seat Belt (x2)
Seat Base
Frame Bolt
40 ft-lbs
(54 Nm)

Cargo Box - Panels
RH Box Panel
T30 Latch
Tailgate Support
Screws
Latch
5
T20
Screws
Cargo Box
T20
Screw T30
T20 Screws
Front Screws
Foil Box Panel
LH Box Panel

5.17
Cargo Box - Tailgate / Box Support
Outer Panel Tailgate Cap
Tailgate
Bracket
Tailgate Latch
Cable
Rod
T30
Screws
T20
Screws
Rod
Tailgate
Inner Cable T27
Panel Screws
5 ft-lbs
(7 Nm)
T27
Screw
Tailgate Tube
T30
Screws
Box Support
Nut
(M10)
Box Latch
Hinge Bolt (M10)
Bumper
Springs Bushings
Shock Pins
Clip Screw
Clip

BODY COMPONENT REMOVAL frame on both pivot points.
Box Removal
1. Lift the cargo box into the raised dump position. A
2. Disconnect the rear wire harness attached to the tail B
light harness.
3. Remove the upper clip and pin attaching the shock to
the cargo box.
Box Shock Pin and

Retaining Clip
Tail Light CAUTION

Harness
Safely support the box during the remainder of
the removal process. The box is not as stable
with the hinge pins removed.
6. With both hinge bolts removed, lift the box from the
frame. Two people or an approved hoist may be 5
needed to remove the box from the frame.
CAUTION
Safely support the box during the remainder of CAUTION
the removal process. The box is not as stable
Use caution when removing the box. It is
with the shock removed.
recommended to have two people carefully
4. Remove the lower clip and pin attaching the shock to remove the box from the frame.
the vehicle frame.
Box Shock Pin and

Retaining Clip
5. Remove nut (A) and bolt (B) that secure the box to the
5.19
Box Installation Lower Seat Base
1. If the shock was replaced, install the lower portion of 1. Lift up on the front of the seat base to disengage the
the shock to the frame and secure it with the pin and seat from the rubber grommets.
clip.
Lower
Shock Pin
Rubber
rommets
2. Place the cargo box onto the frame. Align the hinges
2. Pull the seat base forward to disengage the rear tabs
of the box with the bracket on the frame.
and remove the seat base from the vehicle.
3. Install box hinge bolts on both sides.
4. Install hinge bolt nuts on both sides and torque to 
specification.
=T
Rear Box Hinge Bolt Nuts:
30 ft-lbs (41 Nm)
5. With the hinge bolts installed, attach the shock to the
cargo box by inserting the pin and clip.
6. Connect tail light harness connector.
7. Lower the box and secure the latch.

Wheel Well Panels Front Fascia
1. Using the multi-function pliers, remove the (6) push 1. Remove the (2) T27 Torx-head screws retaining the
rivets from the LH panel and the (5) push rivets from fascia screen and remove the screen.
the RH panel. 2. Remove the (6) remaining T27 Torx-head screws
retaining the front fascia.
Remove all T27

screws shown
2. Pull both panels out from the wheel wells.
Front Bumper
3. Turn the headlight bulbs counter-clockwise 90° and
remove the bulbs from the head lamps. 5
1. Remove the (2) T27 Torx-head screws retaining the 4. Carefully remove the fascia from the vehicle.
fascia screen and remove the screen.
Front Fenders
Remove 1. Remove the lower T27 Torx-head screws retaining

the front fascia (see “Front Fascia”).
Remove
T27
crews
Remove
2. Remove the (3) bolts from the lower portion of the

bumper.
3. Remove the fasteners from each side of the upper T27 Screws
portion of the bumper. (See “Front Fascia”)
Push
4. Carefully remove the bumper from the vehicle. Rivets
2. Remove the (4) push rivets retaining the front fender

and remove the fender from the vehicle.
3. Repeat this procedure to remove the other front
fender.
5.21
Hood / Dash 9. Remove the (2) push rivets from the dash panel (see
“Dash Instruments/Controls”). Unhook all electrical
1. Remove the front fascia (see “Front Fascia” removal). components to allow the panel to be completely
2. Unlatch the hood and remove the (4) T27 Torx-head removed.
screws to remove the hood assembly. 10. Carefully remove the dash assembly from the vehicle.
T27 Screws
Glove Box / Storage Panel
1. Remove the hood / dash (see “Hood / Dash”).
Remove
3. Remove the front portion of the cab frame on each
2V outlets
side to allow dash removal (see “Cab Frame -
Exploded View”).
4. Remove the (2) T25 Torx-head screws retaining the glove box storage panel.
front of the dash to the hood liner.
3. Disconnect 12V power outlets and remove the
5. Open the glove box and remove the (4) T20 Torx- assembly.
head screws from the dash.
Remove front
cab frame from T20 Screws
each side
T27 Screws
of dash
T25 Screws
Remove fasteners
and rivets

rear portion of the dash.
7. Remove the (8) fasteners from each side of the dash
where it attaches to the front and rear fenders.
8. Remove the rubber boots from around the parking
brake and shift lever.

STEERING ASSEMBLY
Exploded View
Cap
Steering Wheel
28 ft-lbs
(38 Nm)
Thick Washer
Thin Washer
Bearing 23 ft-lbs
(31 Nm)
Pivot Tube
Spacer
Bearing
7 ft-lbs Spacer
(10 Nm)
Thin Washer
Thick Washers
Thin Washer
Bushing
5
23 ft-lbs
(31 Nm)
Steering Shaft
12 ft-lbs
Oil Locking (16 Nm)
Shock Asm.
40 ft-lbs
(54 Nm)
13 ft-lbs
(18 Nm)
30 ft-lbs
Gear Box (41 Nm)
Asm.
Boot
40 ft-lbs
(54 Nm)
17 ft-lbs
Tie Rod (23 Nm)
13 ft-lbs
Rod End (18 Nm)
Cotter Pin

5.23
Steering Wheel Removal Steering Shaft Removal
1. Remove the pinch bolt retaining the lower portion of
CAUTION the steering shaft to the steering gear box assembly.
This procedure should NOT be used on EPS Steering Shaft

models. Using this procedure on an EPS model can Pinch Bolt
permanently damage the EPS unit and cause a
Power Steering Fault.
1. Remove the steering wheel cap.

Gear Box
Asm.
2. Loosen the nut and back it half way off the steering
shaft.
3. With a glove on your hand, place it under the steering

Figure 5-16
wheel. Lift upward on the inner portion of the steering
wheel while using a hammer to strike the steering
shaft nut. 2. Remove the fastener retaining the upper portion of the
steering wheel tilt shock to the pivot tube.
IMPORTANT: If the steering wheel will not pop loose,
proceed to “Steering Shaft Removal”. Figure 5-17
4. Once the steering wheel pops loose, completely Pivot Tube

remove the nut and lift the steering wheel off the shaft.
Tilt Shock
3. Remove the (2) fasteners that retain the pivot tube.
4. Remove the steering shaft, pivot tube and steering

wheel from the vehicle as an assembly.
5. Refer to steps 11-13 of the “Steering Shaft Bearing

Replacement” procedure for installation.

Steering Shaft Bearing Replacement 9. Reinstall the upper washers and spacers in the order
in which they were removed.
IMPORTANT: Replacement pivot tube assembly
comes with new upper and lower bearings installed. 10. Install the steering wheel and hand tighten the nut.
Use this procedure if replacing just the bearings only.
11. Reinstall the steering shaft assembly in the vehicle.
1. Perform the “Steering Shaft Removal” procedure. Install the lower portion of the steering shaft onto the
steering gear box assembly (see Figure 5-16). Torque
2. Remove the steering wheel cap and retaining nut. the lower pinch bolt to specification.
3. Press steering shaft out of the steering wheel and
pivot tube. =T
4. Note the order and location of the washers and Lower Pinch Bolt:
spacers between the steering wheel and pivot tube. 30 ft-lbs (41 Nm)
5. Drive the bearings out of the pivot tube using a drift
punch. 12. Install the (2) fasteners that retain the pivot tube (see
Figure 5-17). Torque fasteners to specification.
6. Inspect the pivot tube bearing surfaces for signs of
excessive wear or damage.
=T
7. Apply Loctite® 271™ (Red) to the outer circumference
of the new lower bearing race. Slide the new lower Pivot Tube Fasteners:
bearing onto the steering shaft and install the steering
shaft through the pivot tube.
23 ft-lbs (31 Nm)
5
13. Install the fastener retaining the upper portion of the
NOTE: Use care not to allow any of the Loctite® to steering wheel tilt shock to the pivot tube (see Figure
get in the bearing. 5-17). Torque fastener to specification.
Thick
Washer =T
Spacer
Pivot Tube Upper Tilt Shock Fastener:
Cap 7 ft-lbs (10 Nm)
Nut
14. Be sure the front wheels are facing straight forward.
Spacer
Remove the steering wheel and align as needed.
Thin Bearing
Torque the steering wheel nut to specification.
Washer
Thick
Washers
=T
Bearing Thin Steering Wheel Nut:
Washers
28 ft-lbs (38 Nm)
NOTE: Be sure the lower washers and spacers are

15. Wipe the pivot tube clean of any excess Loctite®.
still on the steering shaft.
16. Install steering wheel cap and field test steering
8. Apply Loctite® 271™ (Red) to the outer circumference
operation.
of the new upper bearing race. Slide the new upper
bearing onto the steering shaft and press it into the
pivot tube by hand.
NOTE: Use care not to allow any of the Loctite® to

get in the bearing.
NOTE: Bearings will be seated in the pivot housing

upon tightening the steering wheel nut in step 14.
5.25
FRONT A-ARMS 18. If not replacing the A-arm, thoroughly clean the A-arm
and pivot tubes.
Removal / Replacement 19. Install new ball joint into A-arm. Refer to “Ball Joint
Replacement” section.
The following procedure details upper and lower A-arm
removal and replacement on one side of the vehicle. 20. Insert new A-arm bushings and pivot tubes into new
A-arm.
1. Elevate and safely support the front of the vehicle and
21. Install new lower A-arm assembly onto vehicle frame.
remove the front wheel.
Torque new bolts (E) to specification.
2. Remove the lower shock fastener (A) from the upper
22. Insert lower A-arm ball joint end into the bearing
A-arm.
carrier. Install the lower ball joint pinch bolt (D) into the
3. Remove the brake line clamp from the A-arm. bearing carrier and torque bolt to specification.
4. Remove the upper ball joint pinch bolt (B) from the 23. Upon A-arm installation completion, test vehicle at low
front bearing carrier. speeds before putting into service.
5. Using a soft face hammer, tap on bearing carrier to
loosen the upper A-arm ball joint end while lifting
=T
upward on the upper A-arm. Completely remove the
ball joint end from the bearing carrier.
Upper/Lower A-arm Retainer Bolt: 30 ft-lbs (41 Nm)
6. Loosen and remove the upper A-arm through-bolt Ball Joint Pinch Bolt: 23 ft-lbs (31 Nm)
fasteners (C) and remove the upper A-arm from the Lower Shock Mounting Bolt: 30 ft-lbs (41 Nm)
vehicle.
7. Examine A-arm bushings and pivot tubes (see
“Exploded View”). Replace if worn. Discard hardware. C Remove
C Clamp
WARNING
Fastener has a pre-applied locking agent which
is destroyed upon removal. Always use new
fastener upon assembly.
8. If not replacing the A-arm, thoroughly clean the A-arm B A
and pivot tubes.
9. Install new ball joint into A-arm. Refer to “Ball Joint D
Replacement” section. E
10. Insert new A-arm bushings and pivot tubes into new E
A-arm.
11. Install new upper A-arm assembly onto vehicle frame.
Torque new bolts (C) to specification.
12. Insert upper A-arm ball joint end into the bearing
carrier. Install the upper ball joint pinch bolt (B) into the
bearing carrier and torque bolt to specification.
13. Attach shock to A-arm with fastener (A). Torque lower
shock bolt to specification.
14. Remove the lower ball joint pinch bolt (D) from the
front bearing carrier.
15. Using a soft face hammer, tap on bearing carrier to
loosen the lower A-arm ball joint end while pushing
downward on the lower A-arm. Completely remove
the ball joint end from the bearing carrier.
16. Loosen and remove the lower A-arm through-bolt
fasteners (E) and remove the lower A-arm from the
vehicle.
17. Examine A-arm bushings and pivot tubes (see
“Exploded View”). Replace if worn. Discard hardware.

Exploded View BALL JOINT SERVICE
30 ft-lbs Service Preparation

(41 Nm)
IMPORTANT: Do not reuse a ball joint if it has been
Pivot removed. If removed, it must be replaced. Use this
Nuts Tube removal procedure only when replacing the ball joint.
Bushings Upper
A-arm NOTE: Ball joint tool PU-50506 will allow the upper
and lower ball joints to be replaced with the A-arm
installed on the vehicle.
30 ft-lbs PU-50506
(41 Nm) Press Asm. (C)
Ball
Joint
Removal
Pivot Adapter (B)
Tube
Bearing
Pinch Carrier
Bolts
23 ft-lbs
Pivot (31 Nm)
Tube
Nuts
Bushings
Installation
5
Spacer (A)
30 ft-lbs Adapter (D)
30 ft-lbs (41 Nm)
(41 Nm) Ball The A-arm does not need to be removed to perform this
Joint
procedure if ball joint tool PU-50506 is used.
1. Properly lift and support the vehicle by the frame.

2. Remove the appropriate front wheel.
3. To service the upper ball joint:

- Remove and discard the two front brake caliper
mounting bolts and remove the caliper from the brake
Screws Lower disc (see “Brakes” chapter).
A-arm 
CV Shield - Remove and discard the upper ball joint pinch bolt.

- If necessary, remove the lower front shock fastener
from the A-arm to gain enough clearance to install ball
joint tool (PU-50506) on the upper ball joint.
4. To service the lower ball joint:

- Remove and discard the lower ball joint pinch bolt.

- If necessary, remove the lower front shock fastener
from the A-arm to gain enough clearance to install ball
joint tool (PU-50506) on the lower ball joint.
5.27
Ball Joint Removal Ball Joint Installation
1. Remove the retaining ring from the ball joint. 1. By hand, install the NEW ball joint into the A-arm.
Picture For Reference Only 2. Position the Installation Adapter (D) over the face of
the ball joint.
Ball Joint
D
Upper A-arm
Retaining Ring
2. Install Spacer (A) over the top of the ball joint face.
A-arm
A
Ball Joint Face
3. Position the Spacer (A) over the shaft of the ball joint
A so it is against the A-arm.
4. Install the Press Asm. (C) onto the A-arm to engage
A-arm the Installation Adapter and Spacer.
B 5. Tighten the Press Asm. screw and fully install the ball
C joint into the arm.
A D
3. Place Removal Adaptor (B) over the ball joint shaft.

C
4. Install the Press Asm. (C) onto the A-arm to engage
the ball joint Removal Adapter.
IMPORTANT: Be sure the Press Asm. opening is only
contacting the Spacer (A) and not the ball joint face.
5. Tighten the Press Asm. screw and fully remove the

ball joint from the A-arm. Ball Joint Installation
B C A
Ball Joint Removal

6. After the new ball joint is fully installed into the A-arm, REAR A-ARMS
install a new retaining ring.
Picture For Reference Only Removal / Replacement
Ball Joint The following procedure details upper and lower A-arm
removal and replacement on one side of the vehicle.
Repeat the following steps to remove the A-arm(s) from
the opposite side.
NOTE: Use the exploded view in this section as a

reference during the procedure.
1. Elevate and safely support the rear of vehicle off the
Upper A-arm
ground and remove the rear wheel.
Retaining Ring
7. Repeat the ball joint service procedure for any

additional A-arm ball joint replacements.
8. Insert upper / lower A-arm ball joint end into the
bearing carrier. Install new pinch bolts and nuts.
Torque to specification.
9. If needed, install new brake caliper mounting bolts
and torque to specification. 5
CAUTION
New bolts have a pre-applied locking agent
which is destroyed upon removal. Always
use new brake caliper mounting bolts Upper A-arm Removal
upon assembly. 2. Remove the fastener retaining the lower portion of the
shock and stabilizer linkage to the upper A-arm.
10. Install wheel and (4) wheel nuts. Torque wheel nuts
to specification.
=T
Front Ball Joint Pinch Bolts: 44 ft-lbs (60 Nm)
Front Shock Mounting Bolts: 45 ft-lbs (61 Nm)
Front Caliper Mounting Bolts: 40 ft-lbs (54 Nm)
Wheel Nuts (Alum): 30 ft-lbs (41 Nm) + 90° (1/4 turn)
Wheel Nuts (Steel): 27 ft-lbs (37 Nm)
5.29
3. Remove the fastener attaching the upper A-arm to the Lower A-arm Removal
bearing carrier.
8. Remove the fastener attaching the lower A-arm to the
bearing carrier.
4. Remove the fasteners attaching the upper A-arm to

the frame and remove the upper A-arm from the
9. Remove the fasteners attaching the lower A-arm to
vehicle.
the frame and remove the lower A-arm from the
vehicle.
5. Examine A-arm and bearing carrier bushings and

pivot tubes (see “Exploded View”). Replace if worn.
10. Examine A-arm and bearing carrier bushings and
Discard hardware.
pivot tubes (see “Exploded View”). Replace if worn.
Discard hardware.
WARNING
Fastener has a pre-applied locking agent which WARNING
6. If not replacing the A-arm, thoroughly clean the a-arm fastener upon assembly.
and pivot tubes.
11. If not replacing the A-arm, thoroughly clean the a-arm
7. Insert new A-arm bushings and pivot tubes into the and pivot tubes.
new A-arm.
12. Insert new A-arm bushings into pivot tubes into the
new A-arm.

Installation
1. Install lower A-arm assembly onto vehicle frame.
Torque new fasteners to specification.
2. Attach lower A-arm to bearing carrier. Torque new
fastener to specification.
3. Route the brake line over the top of the lower A-arm
and secure it in the retainer.
Retainer
4. Install upper A-arm assembly onto vehicle frame. 5

Torque new fasteners to specification.
5. Attach upper A-arm to bearing carrier. Torque new
6. Reinstall the lower portion of the shock and stabilizer
linkage to the upper A-arm. Torque shock / linkage
=T
Upper/Lower A-arm Retainer Bolt: 30 ft-lbs (41 Nm)
Upper/Lower Bearing Carrier Bolt: 30 ft-lbs (41 Nm)
Lower Shock/Linkage Mount Bolt: 30 ft-lbs (41 Nm)
7. Install wheel and torque wheel nuts to specification.
ITEM NUT TYPE SPECIFICATION

30 ft-lbs (41 Nm)
Aluminum Wheels Lug Nut
plus 90° (1/4 turn)
8. Upon A-arm installation completion, test vehicle at low
speeds before putting into service.
5.31
Exploded View
30 ft-lbs
(41 Nm) Spring
30 ft-lbs
(41 Nm)
Shaft
Nuts
Bushings
Shock
Bushings Upper A-arm
Shaft
Bushings
30 ft-lbs
30 ft-lbs (41 Nm)
(41 Nm) Shaft
Shaft Bearing
CV Carrier
Shield
30 ft-lbs
(41 Nm)
30 ft-lbs
Bushings (41 Nm)
Screws
Bushings
Bearing
Snap Ring
Shaft 30 ft-lbs
(41 Nm) Bushings
Lower A-arm Shaft

REAR STABILIZER BAR / LINKAGE 6. Inspect the rubber bushings on the stabilizer linkage
rod (E) and replace if needed. If replacing the
Removal / Installation stabilizer linkage, remove the lower shock bolt from
the upper A-arm.
1. Elevate and safely support vehicle with weight
7. Reverse this procedure for installation.
removed from the rear wheels.
8. Torque the stabilizer retaining bolts / nuts (B) and
2. Remove the retaining nut (A) from the upper portion
upper rubber bushing nuts (A) to specification.
of the stabilizer bar linkage bushing on each side of
the vehicle. 9. If the stabilizer linkage was removed, torque the lower
shock retaining bolt to specification.
3. Remove the two fasteners (B) that secure the
stabilizer bar to the main frame on each side.
4. Remove the stabilizer bar (C) from the frame and =T
inspect the stabilizer bar for straightness.
Upper Linkage Retaining Nut: 30 ft-lbs (41 Nm)
5. Inspect the stabilizer bar bushings (D) and replace if Stabilizer Retaining Nuts: 17 ft-lbs (23 Nm)
needed. Lower Shock/Linkage Bolt: 30 ft-lbs (41 Nm)
Exploded View
A
30 ft-lbs D
(41 Nm)
5
C
E
B
17 ft-lbs
(23 Nm)
30 ft-lbs
(41 Nm)
5.33
SHOCKS / SPRINGS Shock Replacement
1. Using a spring compressor, compress the shock
Exploded View
spring far enough to remove the spring retainer.
Spring 30 ft-lbs Shock Spring

(41 Nm) Compressor Tool
2870623
Spring
Retainer
Shock
Adjusting Cam 2. Remove the spring and adjusting cam from the
existing shock and install components onto the new
shock.
30 ft-lbs 3. Compress the shock spring and install the spring
(41 Nm)
retainer.
4. Reinstall the shock onto the vehicle and torque new
Shock Removal / Installation
fasteners to specification.
1. Elevate the vehicle off the ground to relieve the
suspension load. =T
2. Remove the upper and lower fasteners retaining the
shock and remove the shock from the vehicle. Upper/Lower Shock Bolt:
3. Reverse the procedure to reinstall the shock. Torque 30 ft-lbs (41 Nm)
new fasteners to specification.
=T
Upper/Lower Shock Bolt:
30 ft-lbs (41 Nm)

CLUTCH (PVT) SYSTEM
CHAPTER 6
CLUTCH (PVT) SYSTEM
SPECIAL TOOLS AND SUPPLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
2871358-A FIXTURE MODIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
SPECIAL SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
PVT SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
GENERAL OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
DRIVE CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
SHIFT WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
DRIVEN CLUTCH OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
PVT BREAK-IN (DRIVE BELT / CLUTCHES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
MAINTENANCE / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
OVERHEATING / DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
PVT SYSTEM SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
PVT SEALING AND DUCTING COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
PVT DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
PVT ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
PVT BREAK-IN (DRIVE BELT / CLUTCHES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
2011 DRIVE CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
2011 DRIVE CLUTCH EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
CLUTCH DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
6
DRIVE CLUTCH SPRING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12
BUTTON TO TOWER CLEARANCE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
SHIFT WEIGHT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
SPIDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
STATIONARY SHEAVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
MOVEABLE SHEAVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
2012-2013 DRIVE CLUTCH SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
2012-2013 DRIVE CLUTCH EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
CLUTCH DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
DRIVE CLUTCH SPRING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
NEEDLE BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
BUTTON TO TOWER CLEARANCE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
SPIDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
SHIFT WEIGHT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20
CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21
MOVEABLE SHEAVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22
DRIVE CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22
DRIVEN CLUTCH SERVICE (2011 - 2013) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.24
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.24
CLUTCH DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.24
CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.26
CLUTCH OFFSET PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.27
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.28

6.1
CLUTCH (PVT) SYSTEM
SPECIAL TOOLS AND SUPPLIES TORQUE SPECIFICATIONS
Special Tools PVT System Fastener Torques
PART NUMBER TOOL DESCRIPTION ITEM TORQUE VALUE

PA-48595 Drive Clutch Puller Drive Clutch Spider 265 ft-lbs (360 Nm)
2871358-B Clutch Holding Fixture 47 ft-lbs (64 Nm)
Drive Clutch Retaining Bolt
Left-Hand Thread
2870341 Drive Clutch Spider Tool
Driven Clutch Retaining Bolt 13 ft-lbs (18 Nm)
PU-50518 Universal Clutch Compressor Tool
Drive Clutch Cover Bolts 110 in-lbs (12.4 Nm)
SPX Corp: 1-800-328-6657 or http://polaris.spx.com
Inner PVT Cover Screws 7 ft-lbs (9.5 Nm)
2871358-A Fixture Modification Outer PVT Cover Screws 48 in-lbs (5.4 Nm)
Converts existing 2871358-A to 2871358-B for diesel Drive Clutch Weight Pins 45 in-lbs (5 Nm)
clutches
• Thread hole locations of tool 2871358-A to accept

(3) M12 socket head cap screws using a 12mm x
1.75 tap as shown:
(3) M12 Socket Head

Cap Screws
12mm x 1.75 Tap
2871358-A to 2871358-B Modification
(Socket Head Cap Screws Fastenal® P/N 0163647)
Special Supplies
PART NUMBER SPECIAL SUPPLIES

N/A Loctite™ 609
8560054 RTV Silicone Sealer

CLUTCH (PVT) SYSTEM
PVT SYSTEM OVERVIEW Shift Weights
Shift weights have many factors designed into them for
General Operation
controlling engagement RPM and shifting patterns. Shift
weights should not be changed or altered without first
WARNING having a thorough understanding of their positioning and
the effects they may have on belt to sheave clearance,
clutch balance and shifting pattern.
All PVT maintenance or repairs should be performed by
a certified Polaris Master Service Dealer (MSD)
technician who has received the proper training and Driven Clutch Operation
understands the procedures outlined in this manual. Driven clutches primarily sense torque, opening and
Because of the critical nature and precision balance closing according to the forces applied to it from the drive
incorporated into the PVT components, it is absolutely belt and the transmission input shaft. If the torque resis-
essential that no disassembly or repair be made without tance at the transmission input shaft is greater than the
factory authorized special tools and service load from the drive belt, the drive belt is kept at the outer
procedures. diameter of the driven clutch sheaves.
The Polaris Variable Transmission (PVT) consists of three As engine RPM and horsepower increase, the load from
major assemblies: the drive belt increases, resulting in the belt rotating up
toward the outer diameter of the drive clutch sheaves and
• Drive Clutch
downward into the sheaves of the driven clutch. This
• Driven Clutch action, which increases the driven clutch speed, is called
upshifting.
• Drive Belt
Should the throttle setting remain the same and the
The internal components of the drive clutch and driven
vehicle is subjected to a heavier load, the drive belt rotates
clutch control engagement (initial vehicle movement),
back up toward the outer diameter of the driven clutch and
clutch upshift and backshift. During the development of a
downward into the sheaves of the drive clutch. This action,
Polaris ATV, the PVT system is matched first to the engine
power curve; then to average riding conditions and the
which decreases the driven clutch speed, is called
backshifting.
6
vehicle’s intended usage. Therefore, modifications or
variations of components at random are never In situations where loads vary (such as uphill and downhill)
recommended. Proper clutch setup and careful inspection and throttle settings are constant, the drive and driven
of existing components must be the primary objective clutches are continually shifting to maintain optimum
when troubleshooting and tuning. engine RPM. At full throttle a perfectly matched PVT
system should hold engine RPM at the peak of the power
Drive Clutch Operation curve. This RPM should be maintained during clutch
upshift and backshift. In this respect, the PVT system is
Drive clutches primarily sense engine RPM. The two
similar to a power governor. Rather than vary throttle
major components which control its shifting function are
position, as a conventional governor does, the PVT
the shift weights and the coil spring. Whenever engine
system changes engine load requirements by either
RPM is increased, centrifugal force is created, causing
upshifting or backshifting.
the shift weights to push against rollers on the moveable
sheave, which is held open by coil spring preload. When
this force becomes higher than the preload in the spring, PVT Break-In (Drive Belt / Clutches)
the outer sheave moves inward and contacts the drive A proper break-in of the clutches and drive belt will ensure
belt. This motion pinches the drive belt between the spin- a longer life and better performance. Break in the clutches
ning sheaves and causes it to rotate, which in turn and drive belt by operating at slower speeds during the 10
rotates the driven clutch. hour break-in period as recommended (see Chapter 5
“Engine Break-In Period” for break-in example). Pull only
At lower RPM, the drive belt rotates low in the drive clutch
light loads. Avoid aggressive acceleration and high speed
sheaves. As engine RPM increases, centrifugal force
operation during the break-in period.
causes the drive belt to be forced upward on the drive
clutch sheaves.
6.3
CLUTCH (PVT) SYSTEM
Maintenance / Inspection
Under normal use the PVT system will provide years of trouble free operation. Periodic inspection and maintenance is
required to keep the system operating at peak performance. The following list of items should be inspected and
maintained to ensure maximum performance and service life of PVT components. Refer to the troubleshooting checklist
at the end of this chapter for more information.
• Belt Inspection
• Drive and Driven Clutch Buttons and Bushings
• Drive Clutch Shift Weights and Pins
• Drive Clutch Spider Rollers and Roller Pins
• Drive and Driven Clutch Springs
• Sheave Faces (clean and inspect for wear)
• PVT System Sealing. Refer to appropriate illustrations on the following pages. The PVT system is air cooled by
fins on the drive clutch stationary sheave. The fins create a low pressure area in the crankcase casting, drawing
air into the system through an intake duct. The opening for this intake duct is located at a high point on the
vehicle (location varies by model). The intake duct draws fresh air through a vented cover. All connecting air
ducts (as well as the PVT cover) must be properly sealed to ensure clean air is being used for cooling the PVT
system and also to prevent water and other contaminants from entering the PVT area. This is especially critical
on units subjected to frequent water forging.

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

Vehicle Usage What To Do
Loading the vehicle into a truck or tall Shift transmission to Low during loading of the vehicle to prevent belt
trailer when in high range. burning.
Starting out going up a steep incline from When starting out on an incline, use Low, or dismount the vehicle after first
a stopped position. applying the park brake and perform the “K” turn.
Driving at low RPM or low ground speed Drive at higher speed or use Low. The use of Low is highly recommended
(at approximately 3-7 MPH). for cooler PVT operating temperatures and longer component life.
Warm engine at least 5 min., then with transmission in neutral, advance
Insufficient engine warm-up when
throttle to approx. 1/8 throttle in short bursts, 5 to 7 times. The belt will
exposed to low ambient temperatures.
become more flexible and prevent belt burning.
Slow and easy clutch engagement. Fast, effective use of the throttle for efficient engagement.
Towing/Pushing at low RPM/low ground
Use Low only.
speed.
Plowing snow, dirt, etc./utility use. Use Low only.
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. 6
Shift the transmission to Low, carefully use fast, aggressive, brief throttle
Climbing over large objects from a
application to engage clutch. WARNING: Excessive throttle may cause loss
stopped position.
of control and vehicle overturn.
Shift the transmission to neutral. Using the throttle, vary the engine rpm from
Belt slippage from water or snow idle to full throttle. Repeat several times as required. During this procedure,
ingestion into the PVT system. the throttle should not be held at the full position for more than 10 seconds.
Clutch seals should be inspected for damage if repeated leaking occurs.
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
RANGE OPERATION GUIDELINES: through rough terrain (swamps, mountains, ect.), low ground speeds.
High: High ground speeds, speeds above 7 MPH.
IMPORTANT: Using High Gear when pulling heavy loads, operating on hilly terrain, or in wet, muddy conditions
will increase the chance of drive belt damage.

6.5
CLUTCH (PVT) SYSTEM
PVT SYSTEM SERVICE
PVT Sealing and Ducting Components
Air Inlet Housing
Drain Plug Cover Screws
Outer
PVT Cover
O-Ring
Outer Seal
Filter
Clamp
Screws
Inner
PVT Cover
Inlet Duct
Clamp
Outlet Duct

CLUTCH (PVT) SYSTEM
PVT Disassembly 7. Insert Drive Clutch Puller (PA-48595) into the drive
clutch and use it to remove the clutch from the shaft.
Some fasteners and procedures will vary. Refer to the TIP: Lubricate the threads and end of special tool with
appropriate parts manual for proper fastener placement. grease to eliminate binding during the removal
process.
1. Remove ALL items in the dumb / cargo box.
2. Lift the dump / cargo box.
3. Remove dump / cargo box damper clips/pins and

remove damper. Tilt dump / cargo box all the way
back.
4. Remove the outer PVT cover and drive belt. Refer to

“Belt Removal”.
5. Remove the driven clutch retaining bolt and driven PA-48595

clutch.
Drive Clutch Puller: PA-48595
8. If removing the inner PVT cover, continue to step #9.
9. Loosen the clamp and remove the PVT outlet duct

from the inner PVT cover.
10. Remove the screws that retain the inner PVT cover to
the transmission case and remove the cover. 6
6. Remove the drive clutch retaining bolt by turning the
bolt in a clockwise direction.
Reverse Threads
Inner
PVT Cover
11. Remove the old silicone material from the inner PVT
cover and transmission case using a wire brush.
NOTE: The drive clutch retaining bolt has left-hand Clean both surfaces thoroughly in preparation for
threads. Turn the bolt clockwise to remove it. assembly.
6.7
CLUTCH (PVT) SYSTEM
PVT Assembly 9. Clean end of taper on crankshaft and the taper bore
inside drive clutch using a tapered reamer.
1. Inspect the inner PVT cover. Replace if cracked or
damaged. The mating surface must be clean to 10. Install the drive clutch, bushing, washer, lock washer,
ensure adhesion of new silicone sealant. and the left-hand threaded retaining bolt. Torque
retaining bolt to specification.
2. Be sure to “flame treat” the inner PVT cover prior to
applying silicone to ensure good adhesion. Pass the 11. Install drive belt noting direction of rotation if the belt
flame of a propane torch back and forth quickly over is being reused. Refer to “Belt Installation”, steps 1-3.
the area where the silicone is to be applied (2-3 inches
from the flame tip is recommended). Do not hold the 12. Install the PVT outlet duct.
torch too close to the surface. Keep the torch moving
to prevent damage. 13. Replace the outer PVT cover seal.
3. Apply RTV silicone sealant to the outside edge of the 14. Reinstall outer PVT cover and secure with screws.
inner PVT cover to ensure a water tight fit between the Torque screws to specification.
cover and the transmission.
15. Install the seat, start the engine and test operation
Inner PVT PVT.
over
=T
Inner PVT Cover Screws: 7 ft-lbs (9.5 Nm)
Driven Clutch Retaining Bolt: 13 ft-lbs (18 Nm)
Drive Clutch Retaining Bolt: 47 ft-lbs (64 Nm)
Outer PVT Cover Screws: 48 in-lbs (5.4 Nm)
Apply Bead of
TV Silicone
4. Install the cover and torque the inner PVT cover

screws to specification.
5. Wipe away any excess silicone sealant.
6. Clean the splines inside the driven clutch and on the

transmission input shaft.
7. Apply a light film of grease to the splines on the shafts.
8. Install the driven clutch, cup washer, lock washer, and

retaining bolt. Torque retaining bolt to specification.

CLUTCH (PVT) SYSTEM
DRIVE BELT 6. Walk the belt out of the driven clutch while rotating the
driven clutch clockwise as shown below.
Belt Removal
1. Position the vehicle on a level surface and place the
transmission in Neutral. Engage the parking brake.
2. Tilt the dump box up and remove the dump box shock
/ box actuator asm. Secure the dump box in the up
position.
3. Remove the screws retaining the outer PVT cover and

remove the cover,
Remove through PVT
LH wheel well Outlt
7. Release the belt from the driven clutch sheaves by

pressing the belt down where indicated (C).
Outer
VT cover
C
6
Inner
VT Cover
4. Mark the drive belt direction of rotation so that it can

8. Remove belt from the drive clutch and remove the belt
be installed correctly.
from vehicle.
5. Firmly grasp the belt, then pull it out and over the edge
9. Inspect belt for wear and damage. Replace if
of the inner clutch cover as shown below (A). Be sure
necessary.
the driven clutch sheaves have spread as shown
below (B).
Belt Inspection
B 1. Inspect belt for hour glassing (extreme circular wear
in at least one spot and on both sides of the belt).
Hour glassing occurs when the drive train does not
move and the drive clutch engages the belt.
2. Inspect belt for loose cords, missing cogs, cracks,

abrasions, thin spots, or excessive wear. Compare
belt measurements with a new drive belt. Replace if
necessary.
3. Belts with thin spots, burn marks, etc., should be

replaced to eliminate noise, vibration, or erratic PVT
A
operation. See the Troubleshooting Chart at the end
of this chapter for possible causes.
6.9
CLUTCH (PVT) SYSTEM
Belt Installation 4. With the belt fully installed, rotate the driven clutch ten
rotations clockwise and counter-clockwise to properly
1. With the clutches installed, install the belt around the seat the belt on the driven clutch sheaves.
drive clutch and driven clutch as shown below.
5. Reinstall the outer PVT cover with a new cover seal
NOTE: Be sure to install the drive belt in the same and secure with screws. Torque screws to
rotational direction as indicated in the belt removal specification.
procedure.
=T
Outer PVT Cover Screws:
48 in-lbs (5.4 Nm)
6. Tilt the dump box down and install the dump box
shock / box actuator asm.
7. Install the seat, start the engine and test the operation
of the PVT system.
PVT Break-In (Drive Belt / Clutches)

A proper break-in of the clutches and drive belt will ensure
a longer life and better performance. Break in the clutches
2. Rotate the drive and driven clutch clockwise to ‘walk’
and drive belt by operating at slower speeds during the 10
belt onto driven clutch.
hour break-in period as recommended (see Chapter 5
3. Press downward on the drive belt in location (A) while “Engine Break-In Period” for break-in example). Pull only
rotating the drive clutch clockwise to further spread light loads. Avoid aggressive acceleration and high speed
the driven clutch sheaves and install the belt. operation during the break-in period.

CLUTCH (PVT) SYSTEM
2011 DRIVE CLUTCH SERVICE
2011 Drive Clutch Exploded View
Stationary Sheave
Moveable Sheave
Shim
Buttons
Spring Cover
Cover
Bolts
Nut
Weight Pin
Shift
Weight
Spider
Clutch Disassembly and Inspection 2. Mark the stationary sheave and clutch shaft to verify
1. Using a permanent marker, mark the cover, spider,

the shaft has not turned in the sheave after tightening
the spider during clutch assembly.
6
and moveable and stationary sheaves for reference,
as the cast in X's may not have been in alignment
before disassembly.
3. Remove cover bolts evenly in a cross pattern and

remove cover plate.
6.11
CLUTCH (PVT) SYSTEM
4. Inspect cover bushing (A). The outer cover bushing is Drive Clutch Spring Inspection
manufactured with a Teflon coating. Wear is
determined by the amount of Teflon remaining on the
bushing. CAUTION
A
Never shim a drive clutch spring to increase its
compression rate. This may result in complete
stacking of the spring coils and subsequent
clutch cover failure.
The drive clutch spring is one of the most critical

components of the PVT system. It is also one of the
easiest to service. Due to the severe relaxation the spring
is subject to during operation, it should always be
inspected for tolerance limits during any clutch operation
diagnosis or repair.
With the spring resting on a flat surface, measure its free

length from the outer coil surfaces. Also check to see that
Cover Bushing Inspection: spring coils are parallel to one another. Distortion of the
Replace the cover if more spring indicates stress fatigue, requiring replacement.
brass than Teflon is visible on
the bushing.
5. Inspect area on shaft where the cover bushing rides

for wear, galling, nicks, or scratches. Replace clutch
assembly if worn or damaged.
Inspect Shaft
2011 Drive Clutch Spring Specifications

Color Black and Silver
Free Length 3.05” (77.47 mm)

CLUTCH (PVT) SYSTEM
Button To Tower Clearance Inspection Shift Weight Inspection
1. Inspect for any clearance between spider button to 1. Remove shift weight bolts and weights. Inspect the
tower. If excess clearance exists, replace drive contact surface of the weight. The surface should be
clutch. smooth and free of dents or gall marks. Inspect the
weight pivot bore and bolts for wear or galling. If
weights or bolts are worn or broken, replace in sets of
three with new bolts and nuts.
Inspect for
excessive wear
Inspect
.005”
Limit
Nut
Shift Weight
Inspect for
excessive wear
Bolt
Inspect for
excessive wear
6
.001”
Limit WARNING
The clutch assembly is a precisely balanced unit.

Never replace parts with used parts from another
clutch assembly.
NOTE: A damaged shift weight is usually caused by

a damaged or stuck roller in the spider assembly.
See “Roller, Pin and Thrust Washer Inspection”.
= In. / mm.
Button to Tower Clearance:

.000 - .005 in (.000 - .127 mm)
6.13
CLUTCH (PVT) SYSTEM
Spider Removal NOTE: It is important that the same number and
thickness of washers are reinstalled beneath the
1. Install clutch in holding fixture PN 2871358-B. Wedge spider during assembly. Be sure to note the number
the clutch ribs against the hex screws. and thickness of these washers.
NOTE: 2871358-B holding fixture is required to fit To maintain proper clutch balance and
diesel drive clutches due to a thick rib design. belt-to-sheave clearance, be sure to
REFER TO PAGE 6.2 for modification of existing tool reinstall original quantity and thickness
2871358-A. washers.
3. Inspect roller surfaces. Replace the drive clutch

assembly if worn, damaged or cracked.
2871358-B
2870341 Button
Button Roller
Roller
4. Inspect the buttons. Replace the drive clutch

2871358-B
2. Loosen the spider clockwise using Clutch Spider

Tool PN 2870341. Remove the spacers from the shaft
and set aside for reassembly.
IMPORTANT: The clutch shaft has left-hand threads.

Be sure to turn the Spider Removal Tool in a clockwise
direction to remove.

CLUTCH (PVT) SYSTEM
Stationary Sheave Inspection Moveable Sheave Inspection
NOTE: Remove cover, spring, and spider following Inspect the Teflon coating on the moveable sheave
instructions for drive clutch removal, then proceed bushing. Inspect sheave for signs of wear, grooving or
as follows: cracking. De-glaze sheave surfaces with a 3M Scotch-
Brite Pad if needed.
1. Remove the moveable sheave.
2. Measure the stationary sheave shaft thickness and

compare to specification. Replace if worn or
damaged.
3. Inspect surface of shaft for pitting, grooves, or

damage. Measure the outside diameter for out-of-
round or taper. Replace the drive clutch assembly if
shaft is worn or damaged.  Inspect
Inspect sheave for signs of wear, grooving or cracking.
De-glaze sheave surfaces with a 3M Scotch-Brite Pad
if needed.
Moveable Sheave Bushing Inspection:

Replace the clutch if more brass than
Teflon is visible on the bushing.
Clutch Assembly
NOTE: It is important that the same number and
spider during assembly. 6
CAUTION
Do not apply oil or grease to the bushings.

= In. / mm. The Teflon bushings are self-lubricating.
Reassemble the drive clutch in the sequence provided.

Shaft Diameter:
Verify the marks that were made earlier are aligned during
1.370 - 1.375 in (34.798 - 34.925 mm)
each phase of assembly.
1. Install moveable sheave onto the fixed sheave. Install

the shims that were previously removed onto the
clutch shaft.
6.15
CLUTCH (PVT) SYSTEM
2. If removed, install shift weights using new lock nuts on IMPORTANT: If the marks are not in alignment upon
the weight pins. Torque to specification. assembly, the clutch will not be in balance and the
drive clutch assembly must be replaced.
7. Install the drive clutch spring.
Use new lock nuts
3. Apply Loctite® 263™ to the spider threads.
4. Install spider onto the moveable sheave. Verify the

marks that were made earlier are aligned during each
8. Install the drive clutch cover. Be sure all alignment
phase of assembly.
marts are in alignment.
5. Turn the moveable sheave and spider counter-
clockwise on the shaft and torque to specification
using the holding fixture and spider tool. Torque with
a smooth motion to avoid damage to the stationary
sheave.

Be sure to turn the Spider Removal Tool in a counter-
clockwise direction to install. C
CAUTION
Be sure the spider spacer washers are fully

seated on the spider.
Any misalignment will alter clutch balance.
9. Install cover bolts and torque in a cross pattern evenly
to specification.
6. After the spider has been torqued, remove the clutch
assembly from the holding fixture and inspect the
alignment marks made during disassembly. =T
Drive Clutch Weight Pins: 45 in-lbs (5Nm)
Spider Torque: 265 ft-lbs (350 Nm)
Drive Clutch Cover Bolts: 100 in-lbs (12 Nm)

CLUTCH (PVT) SYSTEM
2012-2013 DRIVE CLUTCH SERVICE

2012-2013 Drive Clutch Exploded View
Stationary Sheave
Moveable Sheave
Thrust Washer
Cover
Shim (1)
Bolts
110 in-lbs
Buttons (12.4 Nm)
Spring
Cover
Nut
45 in-lbs
(5 Nm) Shift
Weight
Weight Pin
Non-braking
Needle Bearing Spider
265 ft-lbs
(350 Nm)
6
Clutch Disassembly and Inspection 2. Mark the stationary sheave and clutch shaft to verify
the shaft has not turned in the sheave after tightening
1. Using a permanent marker, mark the cover, spider, the spider during clutch assembly.
and moveable and stationary sheaves for reference,
as the cast in X's may not have been in alignment
before disassembly.
3. Remove cover bolts evenly in a cross pattern and

remove cover plate.
6.17
CLUTCH (PVT) SYSTEM
4. Inspect cover bushing (A). The outer cover bushing is Drive Clutch Spring Inspection
manufactured with a Teflon coating. Wear is
determined by the amount of Teflon remaining on the
bushing. CAUTION
Never shim a drive clutch spring to increase its

compression rate. This may result in complete
stacking of the spring coils and subsequent
A
clutch cover failure.
The drive clutch spring is one of the most critical

components of the PVT system. It is also one of the
easiest to service. Due to the severe relaxation the spring
is subject to during operation, it should always be
inspected for tolerance limits during any clutch operation
diagnosis or repair.
With the spring resting on a flat surface, measure its free

length from the outer coil surfaces. Also check to see that
Cover Bushing Inspection: spring coils are parallel to one another. Distortion of the
Replace the cover if more spring indicates stress fatigue, requiring replacement.
brass than Teflon is visible on
the bushing.
5. Inspect area on shaft where the cover bushing rides

for wear, galling, nicks, or scratches. Replace clutch
assembly if worn or damaged.
Inspect Shaft
2012-2013 Drive Clutch Spring Specifications

Color Black / Red
Free Length 3.05” (77.47 mm)

CLUTCH (PVT) SYSTEM
Needle Bearing Inspection Spider Removal
1. Rotate the clutch bearing in both clockwise and 1. Install clutch in holding fixture PN 2871358-B. Wedge
counter-clockwise directions. The non-braking the clutch ribs against the hex screws.
needle bearing should rotate in both directions on the
shaft with only a slight amount of drag. NOTE: NOTE: 2871358-B holding fixture is required
to fit diesel drive clutches due to a thick rib design.
2. Verify there is no binding or rough spots. If problems REFER TO PAGE 6.2 for modification of existing tool
are noted continue with disassembly. 2871358-A.
2871358-B
Button To Tower Clearance Inspection

1. Inspect for any clearance between spider button to 2. Loosen the spider clockwise using Clutch Spider
tower. If excess clearance exists, replace drive Tool PN 2870341. Remove the spacers from the shaft
clutch. and set aside for reassembly.
6
Be sure to turn the Spider Removal Tool in a clockwise
direction to remove.
Inspect
.005”
Limit
2870341
2871358-B
= In. / mm.
Button to Tower Clearance:

.000 - .005 in (.000 - .127 mm)
6.19
CLUTCH (PVT) SYSTEM
NOTE: It is important that the same number and Shift Weight Inspection
spider during assembly. Be sure to note the number 1. Remove shift weight bolts and weights. Inspect the
and thickness of these washers. contact surface of the weight. The surface should be
smooth and free of dents or gall marks. Inspect the
To maintain proper clutch balance and weight pivot bore and bolts for wear or galling. If
belt-to-sheave clearance, be sure to weights or bolts are worn or broken, replace in sets of
reinstall original quantity and thickness three with new bolts and nuts.
washers.
Inspect for
excessive wear
Nut
3. Inspect roller surfaces. Replace the drive clutch Shift Weight

Inspect for
excessive wear
Bolt
Inspect for
excessive wear
Button WARNING
Roller
The clutch assembly is a precisely balanced
unit. Never replace parts with used parts from
4. Inspect the buttons. Replace the drive clutch
another clutch assembly.
NOTE: A damaged shift weight is usually caused by
a damaged or stuck roller in the spider assembly.
See “Roller, Pin and Thrust Washer Inspection”.

CLUTCH (PVT) SYSTEM
Clutch Inspection 4. Inspect surface of shaft for pitting, grooves or
damage. Measure the outside diameter and compare
NOTE: Remove cover, spring and spider following to specifications. Replace the drive clutch assembly if
the instructions for drive clutch disassembly, then shaft is worn or damaged.
proceed as follows:
1. Remove and inspect the moveable sheave spacer

(A). Visually inspect the spacer for damage and
replace if necessary. Measure thickness of the
moveable sheave spacer and compare to
specification.
= In. / mm.
Shaft Diameter:
1.370 - 1.375 in (34.798 - 34.925 mm)
5. Visually inspect the thrust washers for damage.

= In. / mm. Measure the thickness and compare to specification.
Replace if worn or damaged. 6
Moveable Sheave Spacer Thickness:
.156 +/- .010 in (3.9624 +/- .254mm)
= In. / mm.
2. Remove the moveable clutch sheave. Thrust Washer Thickness:

Standard: .030 in (.76 mm)
3. Lift the bearing and (2) thrust washers off the shaft.
Service Limit: .025 in (.64 mm)
Replace as an assembly if worn, damaged, or if
operational problems were noted prior to
disassembly.
Non-braking
Needle Bearing 3
4
Thrust Washers
6.21
CLUTCH (PVT) SYSTEM
Moveable Sheave Inspection 1. Install the shift weights, bolts and new nuts onto the
moveable sheave. Torque shift weight bolts to
Inspect the Teflon coating on the moveable sheave specification.
bushing. Inspect sheave for signs of wear, grooving or
cracking. De-glaze sheave surfaces with a 3M Scotch- 2. Install the non-braking needle bearing, the (2) thrust
Brite Pad if needed. washers and the spacer onto the stationary sheave.
Washers
Spacer
Inspect
Non-braking
Needle Bearing
Stationary Sheave

Replace the clutch if more brass than 3. Install moveable sheave onto stationary sheave shaft.
Teflon is visible on the bushing. Be sure the moveable sheave slides freely on non
breaking needle bearing surface.
Drive Clutch Assembly 4. Apply Loctite® 263™ to the spider threads.
5. Install the spider assembly onto the shaft threads. Be

CAUTION sure all of the alignment marks are in alignment.
6. Install clutch onto holding fixture (PN 2871358-B) and

secure in a bench vice. Tighten the spider using
The Teflon bushings are self-lubricating.
Clutch Spider Tool (PN 2870341). Torque spider to
Reassemble the drive clutch in the following sequence. Be specification.
sure marks that were made during disassembly are
aligned during each phase of assembly.
2870341
2871358-B

CLUTCH (PVT) SYSTEM
7. After the spider has been torqued, remove the clutch 9. Install the drive clutch cover. Be sure all alignment
assembly from the holding fixture and inspect the marks are in alignment.
alignment marks made during disassembly.
IMPORTANT: If the marks are not in alignment upon

assembly, the clutch will not be in balance and the
drive clutch assembly must be replaced.
10. Install cover bolts and torque in a cross pattern evenly

to specification.
=T
8. Install the drive clutch spring.
Drive Clutch Weight Pins: 45 in-lbs (5 Nm)
Spider Torque: 265 ft-lbs (350 Nm)
Drive Clutch Cover Bolts: 100 in-lbs (12 Nm)
6.23
CLUTCH (PVT) SYSTEM
DRIVEN CLUTCH SERVICE (2011 - 2013)
Exploded View
Compression Spring
Outer Spring Retainer

Secondary Stationary Sheave
Inner Spring Retainer Retaining Ring
Moveable Inner Sheave
Clutch Disassembly / Inspection 3. Place the clutch into the Universal Clutch Compressor
Tool PN PU-50518. Apply and hold downward
pressure on the outer spring retainer. Carefully
CAUTION remove the snap ring.
Wear eye protection when removing snap ring

to prevent serious personal injury. Snap ring
pressure is loaded by the compression spring. PU-50518
1. Remove driven clutch from the transmission input

shaft.
2. Mark the position of the clutch sheaves before

disassembly or use the X’s on the sheaves for
reference. This aids in reassembly and maintains
clutch balance after reassembly.
NOTE: Spring is compression only and has no

torsional wind.

CLUTCH (PVT) SYSTEM
4. With the snap ring (A) removed and spring pressure 7. Remove the inner spring retainer from the inner
relieved, remove the outer spring retainer (B), sheave. Inspect for wear and replace as needed.
compression spring (C), and inner spring retainer (D).
A C
Inspect for abnormal wear
8. Check the rollers in the stationary sheave for wear. If

rollers are worn, a new driven clutch assembly may be
needed.
B
A
D
C
5. Separate the two clutch sheaves.

6
Check rollers for wear
9. Inspect the bushings inside the moveable sheave.
Inspect bushings for wear
6. Inspect the helix on the moveable sheave.
Inspect for abnormal wear

Replace the bushing if more brass than
Teflon™ is visible.
6.25
CLUTCH (PVT) SYSTEM
10. Inspect the Teflon™ coating on the moveable sheave
bushings.
11. Inspect driven clutch sheave faces for wear or

damage.
12. Clean and inspect splines on helix and transmission

input shaft.
13. Lube splines with a light film of grease.
CAUTION
Do not apply oil or grease to the bushings. Assemble Sheaves

3. Install spring into inner retainer.

Clutch Assembly
1. Install the inner spring retainer if removed. 4. Install outer retainer on top of spring.
CAUTION

5. Place the clutch into Universal Clutch Compressor

Tool PN 50518. Apply and hold downward pressure
on the outer spring retainer.
PU-50518
2. Align the “X” marks on each of the sheaves during

reassembly.

CLUTCH (PVT) SYSTEM
6. Compress the outer retainer and install the snap ring. 3. Add or remove offset washers behind the driven clutch
accordingly to avoid belt contact with either drive
Snap Ring clutch sheave.
Offset Washers
CLUTCH OFFSET PROCEDURE

Clutch Offset Adjustment
If the vehicle exhibits drive clutch drag or hard shifting .030” offset washer - PN 7556454
while at idle speed, a clutch offset adjustment may be
required. Washers located behind the driven clutch on the .060” offset washer - PN 755
transmission input shaft may need to be added or
4. Reinstall the driven clutch and drive belt. Torque the
removed in order to obtain the proper offset. Refer to the
driven clutch retaining bolt to specification. Be sure to
“Clutch Offset Procedure” provided below.
rotate the driven clutch counterclockwise several
1. Follow steps 1-4 of the “PVT Disassembly” times to ensure the belt is tight and riding at the proper
procedure. height in the clutch.
2. Inspect / measure the drive clutch belt to sheave 5. Inspect the belt to sheave clearance again. If the belt
rests evenly between the sheaves, the offset is correct
6
clearance with a feeler gauge. There should be a
minimum of .010” of clearance between the belt and and the vehicle can be reassembled. If the belt is still
sheave on both sides of the belt. If the belt is contacting either sheave, remove the drive belt and
contacting either sheave or there is less than .010” of driven clutch. Add or remove offset washers behind
belt to sheave clearance remove the drive belt and the driven clutch accordingly.
driven clutch.
6. To reinstall driven clutch and belt, see step 4.
Sheave Belt 7. Inspect the outer clutch cover gasket and replace if
necessary.
8. Install the outer clutch cover and torque cover screws

to specification.
Sheave
9. Reinstall dump / cargo box damper pins and clips and
lower dump / cargo box into the locked position.
10. Sit in the drivers seat, apply the foot brake and start
Measure both the engine. Place the gear selector in high range and
sides with a test the vehicle for drive clutch drag or hard shifting
feeler gauge while at idle speed.
=T
Driven Clutch Retaining Bolt: 13 ft-lbs (18 Nm)
Outer PVT Cover Screws: 48 in-lbs (5.4 Nm)
6.27
CLUTCH (PVT) SYSTEM
TROUBLESHOOTING
PVT Troubleshooting
Issue Probable Cause Correction
-Replace with recommended spring.
-Wrong or broken drive clutch spring.
Engine RPM 

below specified -Install correct shift weight kit to match engine
-Drive clutch shift weight too heavy.
operating range, application.

although engine is 
-Driven clutch spring broken or installed in
properly tuned. -Replace spring; refer to proper installation
wrong helix location.
location.
A. Disassemble drive clutch; inspect shift weights
for wear and free operation.
B. Clean and polish stationary shaft hub;
-Drive clutch binding. reassemble clutch without spring to determine
Erratic engine  problem area.
operating RPM -Belt worn unevenly - thin / burnt spots. 
during  -Replace belt.
acceleration or -Driven clutch malfunction. 
load variations.  A. Replace ramp buttons.
-Sheave face grooved. B. Inspect movable sheave for excessive bushing
clearance.

-Replace the clutch.
-Install correct recommended spring.

-Incorrect drive clutch spring (too high spring -Install correct recommended shift weights.
rate). 
 -Disassemble and clean clutch, inspecting shift
-Drive clutch shift weights incorrect for weights and rollers. Reassemble without the
Engine RPM application (too light). spring and move sheaves through entire range to
above specified  further determine probable cause.
operating range. -Drive clutch binding. 
 -Disassemble, clean, and inspect driven clutch,
-Driven clutch binding. noting worn sheave bushing and ramp buttons
 and helix spring location.
-Converter sheaves greasy; belt slipage. 
-Clean sheaves with denatured alcohol or brake
cleaner, install new belt.
-Drive belt worn too narrow. -Replace belt.
Harsh drive clutch  
engagement. -Excessive belt / sheave clearance with new -Perform belt / sheave clearance adjustment with
belt. shim washers beneath spider.
-Wrong belt for application. -Replace with correct belt.
 
Drive belt turns
-Clutch alignment out of spec. -Adjust clutch alignment.
over
 
-Engine mount broken or loose. -Inspect / adjust or replace.

CLUTCH (PVT) SYSTEM
PVT Troubleshooting, Continued.....
Issue Probable Cause Correction

-Caution operator to operate machine within
-Abuse (continued throttle application when guidelines.
vehicle is stationary, excess load) 
Belt burnt, thin  -Vehicle operated with park brake on. Inspect
spots -Dragging brake brake system.
 
-Slow, easy clutch engagement -Fast, effective use of throttle for efficient
engagement.
-Clear obstruction

-Plugged air intake or outlet.
-Inspect system. Clean, repair or replace as

necessary. 
-Belt slippage due to water, oil, grease, etc.,
Seal PVT system ducts.
PVT cover rubbing on cover.
overheating
-Remove weight. Inform operator.
(melting) -Clutches or weight being applied to cover

while in operation.
-Instruct operator on guidelines for operation in

proper driving range for different terrain as
-High vs. low range.
outlined in Owner’s Safety and Maintenance
Manual.
-Find leak and repair as necessary.
-Cover seals or ducts leaking 
Water ingestion  -Instruct operator on guidelines for operation in
-Operator error wet terrain as outlined in Owner’s Safety and
Maintenance Manual. 6
-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
-Thin spots on belt, worn belt
Engagement and instruct operator.
erratic or stabby
-Drive clutch bushings stick
-Inspect and repair clutches.
6.29
CLUTCH (PVT) SYSTEM
NOTES

FINAL DRIVE
CHAPTER 7
FINAL DRIVE
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
FRONT BEARING CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
BEARING CARRIER INSPECTION / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
BEARING CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
DRIVE SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
DRIVE SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
FRONT PROPSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
SUPPORT BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
PROPSHAFT U-JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
FRONT GEARCASE - CENTRALIZED HILLIARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
CENTRALIZED HILLIARD EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
AWD DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
GEARCASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
GEARCASE DISASSEMBLY / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17
GEARCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
REAR BEARING CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21
ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22
REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24
DRIVE SHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25
DRIVE SHAFT / CV JOINT HANDLING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25
OUTER CV JOINT / BOOT REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25
INNER PLUNGING JOINT / BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27
DRIVE SHAFT EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30
REAR PROPSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.31
REAR GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.31
GENERAL OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.31
GEARCASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.33
GEARCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.33
REAR GEARCASE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.36
REAR GEARCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.39
REAR GEARCASE EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.40

7.1
FINAL DRIVE
SPECIAL TOOLS FRONT BEARING CARRIER
Special Tools Bearing Carrier Inspection / Removal
1. Elevate front of vehicle and safely support machine
under the frame area.
2872608 Roll Pin Removal Tool
8700226 or PU-48951 Axle Boot Clamp Tool CAUTION
TORQUE SPECIFICATIONS not tip or fall. Serious injury may occur if vehicle
tips or falls.
Wheel and Hub Torque Table
2. Check bearings for side play by grasping the top and
ITEM NUT TYPE SPECIFICATION bottom of the tire firmly and checking for movement.
The tire should rotate smoothly without binding or
Aluminum Lug Nut 30 ft-lbs + 1/4 Turn rough spots.
Wheels (41 Nm + 1/4 Turn)
(Cast)
(Black / Camo)
Front Hub Castle Nut 80 ft-lbs (108 Nm)
Rear Hub Castle Nut 110 ft-lbs (150 Nm)
3. Remove the (4) wheel nuts and remove the front

wheel.
4. Remove the cotter pin and loosen the front wheel hub
castle nut. Remove the nut, and (2) cone washers
from the front wheel hub assembly.
Castle Nut
Cone
Washers
Cotter Pin

FINAL DRIVE
5. Remove the two brake caliper mounting bolts. 9. Remove the upper and lower ball joint pinch bolts.
Pinch
Bolts
CAUTION
10. Using a soft faced hammer, lightly tap on the bearing
carrier while removing the upper and lower ball joint
Do not hang the caliper by the brake line.
ends.
6. Remove the front wheel hub assembly. 11. Remove the bearing carrier from the front drive shaft.
7. Remove the steering tie rod end fastener from the 12. Rotate bearing by hand and check for smooth
front bearing carrier. rotation. Visually inspect bearings for moisture, dirt, or
corrosion.
NOTE: Due to extremely close tolerances and

minimal wear, the bearing must be inspected
visually, and by feel. While rotating bearings by
hand, inspect for rough spots, discoloration, or
corrosion. The bearings should turn smoothly and
quietly, with no detectable up and down movement
and minimal movement sideways between inner and
Steering outer race.
Tie Rod End
13. Replace bearing if moisture or corrosion is evident. 7
Bearing Replacement
8. Remove the lower shock mounting fastener attached Bearing Removal
to the upper A-arm and remove the shock from the A-
arm. 1. Remove outer snap ring.
Snap
Ring
7.3
FINAL DRIVE
2. From the back side of the bearing carrier, tap on the 8. Wipe the housing clean of any excess compound and
outer bearing race with a drift punch in the reliefs as install the snap ring.
shown.
Bearing Carrier Installation
1. Install the end of the drive shaft through the backside
of the bearing carrier.
2. Install the upper and lower ball joint ends into the front
bearing carrier.
3. Install pinch bolts and torque to specification
3. Drive bearing out evenly by tapping on outer race 23 ft-lbs

only. Once bearing is at bottom of casting, support (31 Nm)
casting on outer edges so bearing can be removed.
4. Inspect the bearing carrier housing for scratches,

wear or damage. Replace front bearing carrier if
damaged.
Bearing Installation
5. Thoroughly clean the front bearing carrier housing

=T
and the outer race on the new bearing. Be sure that
Pinch Bolts:
all oil residue has been removed from each surface.
23 ft-lbs (31 Nm)
6. Support the bottom of the bearing carrier housing.
4. Install shock to A-arm and torque fastener to
specification.
CAUTION
Use an arbor and press only on the outer race,
otherwise bearing damage may occur. 30 ft-lbs
(41 Nm)
7. Apply Loctite® 603™ retaining compound to the outer
circumference of the new bearing race and carefully
press the new bearing into the bearing carrier
housing.
NOTE: Use care to not allow any of the Loctite®

compound to get in the bearing.
Apply
Loctite® 603™
=T
Snap Ring
Shock Mounting Bolts:
30 ft-lbs (41 Nm)
5. Apply grease to the drive shaft splines.

Bearing

FINAL DRIVE
6. Install front wheel hub assembly, cone washers, and
hand tighten the castle nut. Install washers with
domed side out.
=T
Front Caliper Mounting Bolts:
Cone Washers 30 ft-lbs (41 Nm)
Wheel CAUTION
Hub
Out fastener upon assembly.
7. Install the steering tie rod end onto the front bearing 9. Torque wheel hub nut to specification and install a
carrier and torque fastener to specification. NEW cotter pin. Tighten nut slightly if necessary to
align cotter pin holes.
80 ft-lbs
(108 Nm)
40 ft-lbs
54 (Nm)
NEW Cotter Pin
=T
Tie Rod End Fastener:
=T
7
40 ft-lbs (54 Nm) Front Hub Castle Nut:
80 ft-lbs (108 Nm)
8. Install the front brake caliper. Install new mounting
bolts and torque to specification. 10. Install wheel and (4) wheel nuts. Torque wheel nuts
to specification.
=T
Wheel Nut:
Steel Wheels: 35 ft-lbs (47 Nm)
30 ft-lbs Aluminum Wheels: 30 ft-lbs + 1/4 Turn
(41 Nm)
(41 Nm + 1/4 Turn)
11. Rotate wheel and check for smooth operation. Bend

both ends of cotter pin around the end of the shaft.
7.5
FINAL DRIVE
FRONT DRIVE SHAFT Drive Shaft Installation
1. Install new spring ring on the end of the drive shaft.
Drive Shaft Removal
Apply an anti-seize compound to splines.
1. Perform the “Bearing Carrier Inspection / Removal”
procedure listed under the “FRONT BEARING
Apply
CARRIER” section within this chapter.
Anti-Seize
NOTE: Perform all removal steps with the exception
of removing the steering tie rod end. It will not be
necessary to remove the tie rod end from the front
bearing carrier when removing the front drive shaft.
CAUTION

not tip or fall. Serious injury may occur if vehicle
tips or falls.
New
Spring Ring
2. Remove the drive shaft from the front bearing carrier.
3. With a short, sharp jerk, remove drive shaft from the

front gearcase.
2. Align splines of drive shaft with front gearcase and
reinstall the drive shaft. Use a rubber mallet to tap on
the outboard end of the drive shaft if necessary.
4. Refer to the “DRIVE SHAFT SERVICE” procedure if

repairing the drive shaft.
3. Install drive shaft into the front bearing carrier.
4. Perform the “Bearing Carrier Installation” procedure

listed under the “FRONT BEARING CARRIER”
section within this chapter.

FINAL DRIVE
FRONT PROPSHAFT 5. Remove the (2) nuts and bolts retaining the bearing
support
Removal / Installation
1. Elevate and safely support vehicle under the frame.
The use of a vehicle hoist is recommended for this
procedure.
CAUTION
Use care when supporting vehicle so that it does Remove

not tip or fall. Serious injury may occur if vehicle Remove
tips or falls.
2. Access the front propshaft roll pin through the skid

plate hole beneath vehicle.
3. Use the Roll Pin Removal Tool (PN 2872608), to drive 6. Slide the rear portion of the shaft rearward to separate
out the roll pin from prop shaft from beneath the front it from the front portion. Remove the front portion of
skid plate. the prop shaft from the vehicle through the floor panel.
7. Slide the front portion of the prop shaft slightly back

Roll Pin Removal Tool: PN 2872608 and from front gearcase to remove the shaft from the
front gearcase splines.
4. Remove the rear floor panel to access the support 8. Using care, pull the rear portion of the propshaft
bearing. The bearing is located just in front of the forward to disengage the transmission output splines
engine, under the floor. and gently slide it forward out of the removed floor
area.
Support Bearing 9. Reverse removal for properly installing prop shafts.
10. Be sure to lubricate the rear and mid splines with all
purpose grease and the front gearcase splines with
anti-seize.
7
11. Torque bearing support fasteners to specification.
=T
Bracket Bearing Support Fasteners:
33 ft-lbs (45 Nm)
12. Use a NEW roll pin upon installation.
7.7
FINAL DRIVE
Support Bearing Replacement 9. Apply Loctite 242 or equivalent to the bearing set
screws. Tighten the (2) bearing set screws to
1. Follow steps 4-6 of the “Front Propshaft Removal / specification. Next, tighten the bearing support
Installation” procedure. fasteners.
2. Remove the bearing support (upper and lower half)
and the (2) set screws retaining the bearing to the =T
shaft.
Bearing Set Screws: 33 in-lbs (3.7 Nm)
3. Remove the bearing retaining ring. Apply Loctite 242
Bearing Support Fasteners: 33 ft-lbs (45 Nm)
Remove
10. Reinstall the large storage container, floor panel and
front seat base.
Remove
Remove
4. Slide the bearing off the end of the shaft.
5. Clean the surface of the shaft and install the new

bearing.
6. Align the front and rear portions of the propshaft and

slide them together.
7. Install the upper and lower halves of the bearing

support along with the (2) fasteners. Finger tighten
only. Be sure rubber isolator ring is installed. Install
bearing retaining ring.
8. Slide the rear portion of the propshaft forward or

backward to obtain the proper spline engagement.

FINAL DRIVE
PROPSHAFT U-JOINT SERVICE 3. Support U-joint in vise as shown and drive inner yoke
down to remove remaining bearing caps.
Disassembly
1. Remove internal or external snap ring from all
bearing caps.
CAUTION
Always wear eye protection.
4. Force U-joint cross to one side and lift out of inner

yoke.
NOTE: If yoke or bearing is removed, cross bearing

must be replaced. Note orientation of grease fitting
and mark inner and outer yoke for correct re-
positioning during installation.
2. Support inner yoke as shown and drive outer yoke

down (bearing cap out) with a soft face hammer.
7
7.9
FINAL DRIVE
Assembly 5. Install outer yoke, aligning marks made before
disassembly.
1. Install new bearing caps in yoke by hand. Carefully
install U-joint cross with grease fitting properly
positioned inward toward center of shaft. Take care
not to dislodge needle bearings upon installation of
cross joint. Tighten vise to force bearing caps in.
6. Repeat Steps 1-4 to install bearing caps on outer

yoke.
7. Seat all bearing caps against snap rings by supporting

cross shaft and tapping on each corner as shown.
2. Using a suitable arbor, fully seat bearing cap in one
side.
3. Continually check for free movement of bearing cross

as bearing caps are assembled.
8. When installation is complete, yokes must pivot freely

in all directions without binding. If the joint is stiff or
binding, tap the yoke lightly to center the joint until it
pivots freely in all directions.
4. Install snap ring to contain bearing cap just installed.

Repeat procedure for other side.

FINAL DRIVE
FRONT GEARCASE - CENTRALIZED HILLIARD
Centralized Hilliard Exploded View
9 ft-lbs
(12 Nm)
9 ft-lbs
(12 Nm)
9 ft-lbs
(12 Nm)
REF # DESCRIPTION QTY REF # DESCRIPTION QTY

1 O-Ring 1 19 Hub Sub-Assembly (Female) 1
2 O-Ring 1 20 Hub Sub-Assembly (Male) 1
3 Dowel Pin 1 21 Rollers 20 7
4 Vent Hose Fitting 1 22 Torsion Spring 1
5 Ball Bearing 2 23 Spring, Wireform 2
6 Ball Bearing (Double Row) 1 24 H-Clip Spring 20
7 Bushing 1 26 Nylon Spacer 2
8 Bushing 1 27 Torsion Spring Retainer 1
9 Oil Seal 2 28 Backlash Spacer 1
10 Oil Seal 1 29 Ring Gear Spacer 1
11 Retaining Ring, Internal 1 30 Pinion Gear 1
12 Cover Screws, M6 (T30 Torx) 7 31 Armature Plate 1
13 Cover Plate Assembly 1 32 AWD Coil 1
14 Gearcase Housing 1 35 Fill Plug 1
15 Clutch Housing (Ring Gear) 1 36 Drain Plug, Magnetic 1
16 Roll Cage 1 38 Retaining Ring, External 1
18 Hub / Race Assembly 2

7.11
FINAL DRIVE
Operation
Ring Gear
The AWD switch may be turned on or off while the vehicle
is moving, however, AWD will not enable until the vehicle Roll Cage
speed drops below an indicated 8 MPH. 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
Rollers
Switching to AWD while the rear wheels are
spinning or slipping may cause severe drive CAUTION
shaft and gearcase damage. Always switch to
AWD while the rear wheels have traction or are
Switching to AWD while the rear wheels are
at rest.
spinning or slipping may cause severe drive
shaft and gearcase damage. Always switch to
With the AWD switch off, the vehicle drives through the AWD while the rear wheels have traction or are
rear wheels only (2 wheel drive). When the AWD is at rest.
enabled, the front drive acts as an on-demand AWD
system. This means, the front drive will engage once the AWD Disengagement: Once the rear wheels regain
rear wheels have lost traction, and will remain engaged traction, the front wheels will return to the “over-running”
until the torque requirement goes away (i.e. rear wheels condition. The vehicle is now back to rear wheel drive until
regain traction). the next loss of rear wheel traction occurs.
Roll Cage Output

Centers Hubs and
Roll Cage Armature Plate AWD Diagnosis
Rollers in Ring Gear Output
Hub Symptom: AWD Will Not Engage
1. Check the gearcase coil resistance. To test the coil

resistance, measure between the Grey and Brown/
White wires. The measurement should be within
specification.
Roll Cage
& Rollers
Armature
Plate Ring Torsion
Ring Gear Gear Spring
Magnetic Coil
AWD Engagement: When the AWD switch is activated,

the AWD coil is powered by a 12 Vdc input which creates
a magnetic field. This magnetic field attracts an armature
plate that is keyed to the roll cage. When the ring gear and
roll cage are spinning (vehicle is moving), the energized
coil and armature plate will apply drag to the roll cage that
indexes the rollers inside the ring gear to an engagement
position. While in the engagement position, the front drive
will be in an “over-running” condition (not engaged), until
the rear wheels lose traction. Once the rear wheels begin Front Gearcase Coil Resistance:
to lose traction, the front drive will engage by coupling the 21.6 - 26.4 Ohms
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).

FINAL DRIVE
2. Turn the ignition switch and AWD switch on and place 6. Inspect the rollers for nicks and scratches. The rollers
gear selector in High or Low gear. Check for minimum must slide up, down, in and out freely within the roll
battery voltage at the Gray and Brown/White chassis cage sliding surfaces and H-springs.
wires that power the coil. A minimum of 11 Vdc should
be present.
Rollers
3. If electrical tests are within specification, remove
gearcase (see “Gearcase Removal”) and inspect
components.
4. Inspect the armature plate for a consistent wear

pattern. There should be two distinct wear bands (one
band inside the other). If only one band of wear is
present (or if there is wear between the two bands),
inspect the coil area as indicated in Step 5. A wear
band with an interrupted wear mark may indicate a Roll Cage
warped plate, which may cause intermittent operation. Assembly
Armature Plate
7. Inspect the roll cage assembly for cracks or excessive
wear. If damaged, replace the roll cage assembly.
Gearcase Removal
1. Stop engine, place machine in gear and set parking
brake.
2. Elevate front of vehicle and safely support machine

under the frame area.
Check for Wear Bands CAUTION

5. Check to make sure the coil is seated in the U-shaped
insert that is pressed into the gearcase cover. The top
of the coil should be seated below the U-shaped
insert. The U-shaped insert controls the pole gap. If
the top of the coil is above the surface of the U-shaped
tips or falls.
7
insert it raises the armature plate, thereby increasing 3. Remove both front drive shafts from the front
pole gap. If the pole gap increases, the coil will not be gearcase (see “FRONT DRIVE SHAFT - Removal”).
strong enough to engage the AWD system. If this is
4. Remove the front propshaft from the front gearcase
found, replace the cover plate assembly.
(see “FRONT PROPSHAFT - Removal”).
Gearcase Cover Plate Asm. 5. Remove the LH wheel well panel and disconnect the
AWD wire harness. Cut the plastic tie strap to free the
connector end from the main harness to allow
Coil gearcase removal.
U-shaped insert
Side cutaway view of
Centralized Hilliard cover
7.13
FINAL DRIVE
6. Remove the (4) bolts securing the bottom of the Gearcase Disassembly / Inspection
gearcase to the skid plate frame.
1. Drain and properly dispose of gearcase fluid.
Remove any metal particles from the drain plug
Vent line magnet.
Disconnect AWD
ire harness Clamp
2. Remove the (7) cover screws and remove the cover
plate assembly.
Remove bolts from

skid plate fame
7. Remove the vent line from the gearcase.
8. Remove the gearcase from the front left-hand wheel

well area and pull it out between the upper and lower
A-arms.

FINAL DRIVE
3. Remove the LH output hub assembly from the clutch 5. Remove the torsion spring retainer and torsion spring
housing or outer cover plate assembly. from the top of the ring gear.
Spring Retainer
LH Output Hub
Non-serviceable Torsion Spring

DO NOT Remove
LH Output Hub
NOTE: Nylon spacer is non-serviceable and should 6. Remove the clutch housing / ring gear and roll cage
not be removed. assembly from the gearcase housing.
4. Remove and inspect the armature plate. Refer to

Remove as
7
“AWD Diagnosis” for detailed inspection process.
an assembly
Armature Plate
7.15
FINAL DRIVE
7. Remove the RH output hub assembly from the 10. Inspect the AWD coil located in the outer cover plate
gearcase housing. assembly. Refer to “AWD Diagnosis” for detailed
inspection process. Replace the cover plate seal and
O-ring.
Inspect
Coil
Replace
O-Ring & Seal
8. Remove pinion seal, internal retaining ring and pinion
gear assembly from the gearcase housing. Inspect
and clean the gearcase housing and replace all oil 11. Remove the roll cage assembly and rollers from the
seals and O-rings. clutch housing. Use a shop towel to cover the housing
in order to retain all the rollers.
Pinion
Shaft NOTE: Rollers are spring loaded. Take care not to
allow them to fall out or lose them upon removal of
External
the roll cage.
Snap Ring
12. Thoroughly clean all parts and inspect the rollers (A)
for nicks and scratches. The rollers must slide up and
Replace down and in and out freely within the roll cage (B)
Seal sliding surfaces and H-springs.
C
Bearing
Internal
Snap Ring B
9. Inspect the pinion gear for chipped, broken or missing

teeth. Inspect the pinion bearing for signs of wear and
the pinion shaft seal surface for pitting.
IMPORTANT: Refer to the “Electronic Parts Catalog”

for individual part availability. Most parts are to be
replaced as an assembly or as a complete kit.
13. Inspect clutch housing ring gear (C) for a consistent

wear pattern. Inspect the ring gear for chipped,
broken, or missing teeth.
Inspect

FINAL DRIVE
14. Inspect the roll cage assembly (B) sliding surfaces 3. Install a new pinion shaft seal into the pinion gear
and H-springs. The sliding surfaces must be clean and housing. Using a universal seal installer, press the
free of nicks, burrs or scratches. If damaged, replace new seal into the housing until the seal is just below
the roll cage assembly. the housing chamfer.
H-Spring B Press in oil seal

just past chamfer
15. Inspect both output hub assemblies. Inspect the 4. Install the RH output hub into the gearcase housing.
bearings and replace if needed.
RH Output Hub
Thrust
Bearing
Bearing
Spacer
Roller
Surface
7
5. Carefully install the rollers into the roll cage assembly
while installing the assembly into the clutch housing.
16. Clean and inspect all remaining front gearcase
components. Check each for excessive wear or NOTE: Install the roll cage so that the ring gear
damage. grooves line up with the roll cage slots (see below).
Gearcase Assembly
1. As mentioned during gearcase disassembly section,
replace all O-rings, seals and worn components.
2. Install pinion shaft assembly and install internal snap

ring.
Align during
NOTE: If bearing replacement was required, press installation
new bearing onto the pinion shaft and install a new
external snap ring.
7.17
FINAL DRIVE
6. Install the torsion spring by wrapping each leg of the 9. Be sure the armature plate tabs are fully engaged into
spring around the dowel pin on the ring gear. the roll cage assembly and are resting on the cut-
grooves of the ring gear.
Engage
Tabs
7. Align the spring retainer dowel pin with the ring gear
dowel pin and install the retainer on top of the torsion NOTE: Verify armature plate tabs are in the slots on
spring. the roll cage and are resting in the ring gear grooves.
10. Carefully install the ring gear and roll cage assembly
into the gearcase housing.
Align during
installation
8. Check the action of the torsion spring by rotating in

both directions to ensure the spring and retainer are
installed properly.
11. Install a new O-ring on the cover plate assembly.
NOTE: Be sure the square O-ring is placed flat on

the cover surface. If the O-ring is twisted fluid
leakage may occur.

FINAL DRIVE
12. Carefully install the LH output hub assembly into the Gearcase Installation
cover plate. Take care not to damage the new cover
plate seal while installing the output hub. 1. Install the gearcase through the front left-hand wheel
well area between the upper and lower A-arms.
LH Hub
13. Install the output cover assembly onto the gearcase 2. Install the vent line to the gearcase and ensure it’s
housing. Install the (7) cover plate screws and torque routed properly up top under the hood.
to specification.
3. Install propshaft onto the front gearcase.
Torque Screws
4. Install new mounting bolts and torque to specification.
7
=T
Cover Plate Screws:
9 ft-lbs (12 Nm)
=T
Gearcase Mounting Bolts:
30 ft-lbs (40 Nm)
5. Drive a new roll pin into the front propshaft (see

“FRONT PROPSHAFT - Installation”).
6. Install the drive shafts into the front gearcase (see

“FRONT DRIVE SHAFT - Installation”).
7. Connect the AWD harness and tie the harness to the

main harness using a plastic tie strap.
8. Reinstall the LH wheel well panel.
7.19
FINAL DRIVE
9. Add the proper lubricant to the front gearcase. Check REAR BEARING CARRIER
drain plug for proper torque. Refer to Chapter 2 for
fluid fill and change information. Inspection
1. Support the machine securely with rear wheels
elevated.
CAUTION

tips or falls.
2. Check the bearings for side play. Grasp the top and
bottom of the wheel or wheel hub and check for
movement.
3. If movement is detected, inspect wheel hub, castle nut

torque and bearing condition. The tire should rotate
smoothly without binding or rough spots. Correct as
necessary.
Removal
1. Elevate the rear end of the vehicle and safely support
the vehicle under the main frame area.
2. Remove wheel nuts, washers and wheel.
3. Remove the cotter pin, castle nut and washers.
Castle Nut
Washers
Cotter Pin

FINAL DRIVE
4. Remove the two brake caliper mounting bolts and Disassembly
remove the caliper from the bearing carrier.
1. Remove the retaining ring from the bearing carrier.
2. From the back side, tap on the outer bearing race with
CAUTION a drift punch in the reliefs as shown.
Do not hang the caliper by the brake line. NOTE: Drive bearing out evenly by tapping on outer
race only. Once bearing is at bottom of casting,
5. Slide the wheel hub out from the bearing carrier and support casting on outer edges so bearing can be
drive shaft. removed.
6. Remove the upper and lower A-arm fasteners from

the bearing carrier.
3. Inspect the bearing.
NOTE: Due to extremely close tolerances and

minimal wear, the bearings must be inspected
visually, and by feel. While rotating bearings by
hand, inspect for rough spots, discoloration, or
corrosion. The bearings should turn smoothly and
quietly, with no detectable up and down movement
and minimal movement sideways between inner and
outer race.
7. Remove the bearing carrier. Inspect the bearing again
for smoothness and side to side movement, replace 4. Inspect bearing housing for scratches, wear or
as needed. damage. Replace housing if damaged.
5. Replace the bearing carrier bushings if worn or

damaged.
7.21
FINAL DRIVE
Assembly 4. Install a new retaining ring into the bearing carrier
groove.
1. Thoroughly clean the bearing carrier housing and
prepare the components for assembly. Installation
1. Place the bearing carrier over the drive shaft.
2. Align the bottom of the bearing carrier with the lower

A-arm. If previously removed, install new lower A-arm
bushings. Install the lower bearing carrier fastener.
3. With the drive shaft placed in the bearing carrier, align

the top of the bearing carrier with the upper A-arm. If
previously removed, install new upper A-arm
bushings. Install the upper bearing carrier fastener.
2. Support the bottom of the bearing carrier housing.

Start the bearing (A) in the bearing carrier housing (B).
Use an arbor press to install the bearing.
NOTE: The lower shock bolt may need to be

removed to allow the upper A-arm to move freely.
4. Torque the upper and lower bearing carrier fasteners

to specification.
3. Press the bearing into place until the outer bearing
race bottoms in housing. =T
CAUTION Bearing Carrier Fasteners:

30 ft-lbs (41 Nm)
Use an arbor and press only on the outer race,
as bearing damage may occur. 5. Install the wheel hub assembly onto the drive shaft.
6. Install the washers (domed side out) and the wheel

hub castle nut hand tight.

FINAL DRIVE
7. Install the wheel, washers and wheel nuts. Torque REAR DRIVE SHAFT
wheel nuts to specification.
Removal
=T 1. Perform the “REAR BEARING CARRIER - Removal”
procedure, steps 1-5.
Wheel Nut:
Steel Wheels: 35 ft-lbs (47 Nm) 2. Remove the lower shock fastener to free the upper A-
Aluminum Wheels: 30 ft-lbs + 1/4 Turn arm.
(41 Nm + 1/4 Turn)
8. Carefully lower the vehicle. Torque the wheel hub

castle nut to specification. Install a new cotter key. Remove
=T
Rear Hub Castle Nut:
110 ft-lbs (150 Nm)
3. Remove the upper bearing carrier fastener and

separate the bearing carrier from the upper A-arm.
7.23
FINAL DRIVE
4. Carefully slide the drive shaft out by pulling the Installation
bearing carrier outward and tipping it down to remove
the shaft. 1. Install a new circlip on the end of the drive shaft
output shaft. Apply an anti-seize compound to the
splines.
2. Align the splines of the drive shaft with the

transmission and reinstall the drive shaft. Use a
rubber mallet to tap on the outboard end of the drive
5. Remove the drive shaft using short, sharp jerks to free shaft if necessary.
the circlip.
3. Install the drive shaft into the bearing carrier.
4. Perform the “REAR BEARING CARRIER -

Installation” procedure to properly reassemble the
vehicle.
6. Refer to the “DRIVE SHAFT SERVICE” section if

repairing the drive shaft.

FINAL DRIVE
DRIVE SHAFT SERVICE 2. Remove the large end of the boot from the CV joint
and slide the boot down the shaft.
Drive Shaft / CV Joint Handling Tips
Care should be exercised during drive shaft removal or
when servicing CV joints. Drive shaft components are
precision parts.
Cleanliness and following these instructions is very

important to ensure proper shaft function and a normal
service life.
• The complete drive shaft and joint should be

handled by getting hold of the interconnecting
shaft to avoid disassembly or potential damage to
the drive shaft joints.
• Over-angling of joints beyond their capacity could
result in boot or joint damage. 3. Clean the grease from the face of the joint.
• Make sure surface-ground areas and splines of
shaft are protected during handling to avoid 4. Place the drive shaft in a soft-jawed vise.
damage.
5. Using a soft-faced hammer, or brass drift, strike the
• Do not allow boots to come into contact with sharp inner race of the joint to drive the joint off the drive
edges or hot engine and exhaust components. shaft. Be sure to tap evenly around the joint to avoid
binding.
• The drive shaft is not to be used as a lever arm to
position other suspension components.
Brass Drift Shown
• Never use a hammer or sharp tools to remove or
to install boot clamps.
• Be sure joints are thoroughly clean and that the
proper amount and type of grease is used to refill
when joint boots are replaced and when joints are
cleaned. Refer to text for grease capacity of CV
joints and CV joint boots.
7
Outer CV Joint / Boot Replacement
1. Using a side cutters, cut away and discard the boot
clamps.
IMPORTANT: Tap on inner race only!
7.25
FINAL DRIVE
6. Make sure the circlip is on the shaft and not left in the NOTE: Shiny areas in ball tracks and on the cage
joint. spheres are normal. Do not replace CV joints
because parts have polished surfaces. Replace CV
Circlip joint only if components are cracked, broken, worn
or otherwise unserviceable.
10. Clean the splines on the end of the shaft and apply a
light coat of grease prior to reassembly.
11. Slide the small boot clamp and boot (small end first)
onto the drive shaft and position the boot in it’s groove
machined in the shaft.
12. Install a NEW circlip on the end of the shaft.
13. Grease the joint with the special CV joint grease

provided in the boot replacement kit. Fill the cavity
behind the balls and the splined hole in the joint’s inner
7. Remove the CV boot from the shaft. race. Pack the ball tracks and outer face flush with
grease. Place any remaining grease into the boot.
CAUTION
CAUTION
Complete disassembly of the CV joint is NOT
recommended. The internal components are The grease provided in the replacement kit is
precision fit and develop their own characteristic specially formulated for wear resistance and
wear patterns. Intermixing the internal durability. DO NOT use substitutes or mix with
components could result in looseness, binding, other lubricants.
and/or premature failure of the joint.
NOTE: The amount of grease provided is pre-
IMPORTANT: If the grease in the joint is obviously measured. Use the entire package contents.
contaminated with water and/or dirt, the joint should
be replaced. 14. Slide the joint onto the drive shaft splines and align the
circlip with the lead-in chamfer on the inner race of the
joint.
8. Thoroughly clean the joint with an appropriate solvent

and dry the joint to prevent any residual solvent from
being left in the joint upon reassembly. 15. Use a soft-faced hammer to tap the joint onto the drive
shaft until it locks into place.
9. Visually inspect the joint by tilting the inner race to one
side to expose each ball. Severe pitting, galling, play 16. Pull on the joint to make sure it is securely locked in
between the ball and its cage window, any cracking place.
or damage to the cage, pitting or galling or chips in
raceways call for joint replacement. 17. Remove excess grease from the CV joint's external
surfaces and place the excess grease in the boot.

FINAL DRIVE
18. Pull the boot over the joint and position the boot lips Inner Plunging Joint / Boot Replacement
into the grooves on the joint housing and shaft. Make
sure the boot is not dimpled or collapsed. 1. Using a side cutters, cut away and discard the boot
clamps.
19. Install and tighten the large clamp using the Axle Boot
Clamp Tool (PU-48951).
2. Remove the large end of the boot from the plunging

joint and slide the boot down the shaft.
Axle Boot Clamp Tool:
8700226 or PU-48951
20. While pulling out on the CV shaft, fully extend the CV

joint and slide a straight O-ring pick or a small slotted
screw driver between the small end of the boot and
the shaft. This will allow the air pressure to equalize
in the CV boot in the position that the joint will spend
most of its life. Before you remove your instrument,
be sure the small end of the boot is in its correct
location on the shaft.
21. Install and tighten the small clamp on the boot using
the Axle Boot Clamp Tool (PU-48951).
7
3. Clean the grease from the face of the joint.
4. Place the drive shaft in a soft-jawed vise.
7.27
FINAL DRIVE
5. Using a soft-faced hammer, or brass drift, strike the 8. Thoroughly clean the joint with an appropriate solvent
inner race of the joint to drive the joint off the drive and dry the joint to prevent any residual solvent from
shaft. Be sure to tap evenly around the joint to avoid being left in the joint upon reassembly.
binding.
Brass Drift Shown
9. Visually inspect the joint for damage. Replace if

IMPORTANT: Tap on inner race only! needed.
6. Make sure the circlip is still on the shaft and not left in 10. Clean the splines on the end of the shaft and apply a
the joint. light coat of grease prior to reassembly.
Circlip 11. Slide the small boot clamp and boot (small end first)
onto the drive shaft and position the boot in its groove
machined in the shaft.
12. Install a NEW circlip on the end of the shaft.
13. Grease the joint with the special CV joint grease

provided in the boot replacement kit. Fill the cavity
behind the balls and the splined hole in the joint’s inner
race. Pack the ball tracks and outer face flush with
grease. Place any remaining grease into the boot.
CAUTION
7. Remove the boot from the shaft. The grease provided in the replacement kit is
specially formulated for wear resistance and
durability. DO NOT use substitutes or mix with
CAUTION other lubricants.
Complete disassembly of the plunging joint is NOTE: The amount of grease provided is pre-
NOT recommended. The internal components measured. Use the entire package contents.
are precision fit and develop their own
characteristic wear patterns. Intermixing the 14. Fully compress the joint and push the drive shaft firmly
internal components could result in looseness, into the inner race.
binding, and/or premature failure of the joint.
IMPORTANT: If the grease in the joint is obviously

contaminated with water and/or dirt, the joint should
be replaced.

FINAL DRIVE
15. Align the circlip with the lead-in chamfer. 21. Pull out on the drive shaft to center the joint in the
housing. Slide a straight O-ring pick or a small slotted
screw driver between the large end of the boot and the
joint housing and lift up to equalize the air pressure in
the boot.
22. Position the boot lip in its groove. Install and tighten
the large clamp using the Axle Boot Clamp Tool
(8700226 or PU-48951).
16. Use a soft-faced hammer to tap the joint onto the drive
shaft until you reach the end of the splines and the
joint locks in place.
17. Pull on the joint to test that the circlip is seated and
that the joint is securely fastened to the shaft.
18. Remove excess grease from the plunging 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 small clamp using the Axle Boot
Clamp Tool (8700226 or PU-48951).
Axle Boot Clamp Tool:

8700226 or PU-48951
7.29
FINAL DRIVE
Drive Shaft Exploded View REAR PROPSHAFT
FRONT SHAFT Removal
Spring Ring
1. Drive the roll pin from the rear propshaft yoke located
at the transmission.
Plunging
Joint
Gear Side
Boot Kit
Wheel Side
Boot Kit
Roll Pin Removal Tool:

PN 2872608
CV Joint 2. Remove the parking brake caliper assembly from the

caliper mount bracket to allow the rear propshaft to
slide back on the rear gearcase input shaft.
REAR SHAFT
Rear 4x4 Shown
Spring Ring
Plunging
Joint
Remove
Gear Side
Boot Kit
3. Slide the rear propshaft back on the rear gearcase

Wheel Side input shaft, remove the propshaft from the
Boot Kit transmission and remove the propshaft from the
vehicle.
CV Joint

FINAL DRIVE
Installation REAR GEARCASE
1. Install the rear propshaft onto the rear gearcase input
General Operation
shaft and slide back fully to allow yoke installation on
the transmission output shaft. The RANGER rear gearcase has three traction
operational modes: AWD, Differential Lock, and
2. Slide the rear propshaft forward onto the transmission Differential Unlock. Locking the rear differential is
output shaft. beneficial in low traction and rough terrain conditions.
Unlocking the rear differential makes maneuvering easier
3. Align the rear propshaft pin hole with the pin hole on and minimizes damage to turf and sensitive terrains.
the transmission rear output shaft. Drive a NEW roll
pin into the propshaft yoke. NOTE: ‘Turf’ or ‘Differential Unlock’ mode is
disabled above 10 MPH indicated ground speed.
4. Install the parking brake caliper assembly. Tighten the
two mounting bolts in increments and torque to
specification.
18 ft-lbs
(24 Nm)
When “Differential-Unlock” is selected on the switch, the

rear differential becomes unlocked for tighter turns. An
electrical solenoid mounted in the rear gearcase housing
actuates the shift yoke. The solenoid plunger extends out
=T to move the shift yoke and slides the clutch gear away from
the engagement dogs that are attached to the differential
Parking Brake Caliper - Mounting Bolts:
18 ft-lbs (24 Nm)
gear assembly. This unlocks the rear differential.
7
When switch position is set
to “Unlock”, the solenoid is
powered and the
plunger extends
to disengage the
clutch gear and
unlock the
differential.
7.31
FINAL DRIVE
When the clutch gear is unlocked the rear drive shafts are
dependent on the differential allowing tighter turns. When
Differential - Unlock it’s locked it becomes a solid rear axle increasing traction.
Clutch Gear
Differential
Shift Yoke
Clutch Gear
When “Differential-Lock” is selected on the switch, power
is removed from the electrical solenoid allowing the
solenoid plunger to retract. Spring tension moves the shift
yoke back into place and engages the clutch gear into the
engagement dogs that are attached to the differential gear
assembly, locking the rear differential as a solid rear axle. Locked Mode
Clutch Gear
When switch position is set
to “Lock”, power is removed
Locked
from the solenoid and
the plunger retracts Axle Shaft Axle Shaft
to engage the
clutch gear
and lock the
differential.
Unlocked Mode
Differential - Lock Clutch Gear

IRS Axle
Clutch Gear
Unlocked
Shift Yoke
Axle Shaft Axle Shaft

FINAL DRIVE
Gearcase Removal Gearcase Disassembly
1. Follow the “REAR DRIVE SHAFT - Removal” IMPORTANT: The pinion gear assembly is NOT
procedure to remove the rear drive shafts from each intended to be disassembled from the case, as it
side of the rear gearcase. requires special OEM tooling in order to properly
reassemble. If there is any damage to the pinion gear,
2. Disconnect the differential solenoid 2-wire harness. bearings or case, the assembly must be replaced.
Pinion and ring gear shimming information is NOT
3. Completely drain the lubricant from the rear gearcase. provided due to OEM manufacturing requirements.
1. Remove the differential solenoid from the gearcase

cover if servicing the solenoid, shift lever, shift lever
spring, or shift yoke. If none of these items are being
serviced, the solenoid can remain installed in the
gearcase cover.
Drain Plug
4. Remove the (4) bolts that secure the rear gearcase to

the frame.
2. Remove the bolts that secure the cover to the

housing.
Remove Cover Bolts

Remove the (2)
7
fasteners from
each side.
5. Remove the (3) fasteners retaining the parking brake

caliper bracket to the rear gearcase and carefully pull
the rear gear case assembly from the frame. Allow the
rear propshaft to slide off of the rear gearcase shaft.
Bracket
(3)
Propshaft
7.33
FINAL DRIVE
3. Remove the differential assembly from the housing. 6. Remove the shims from the differential assembly. Be
sure to keep the shims together for reassembly.
4. Inspect the bevel gear teeth for chipped, worn, or

broken teeth. 7. Remove the large bearing from the differential
assembly. Inspect the bearing for smoothness and
wear.
Inspect Teeth
5. Remove the small bearing from the differential

assembly. Inspect the bearing for smoothness and
wear. 8. Remove the shims from the differential assembly. Be
sure to keep the shims together for reassembly.

FINAL DRIVE
9. If the solenoid was removed for servicing, inspect the 12. Loosen the lock assembly pin.
tip of the solenoid for wear. If the tip of the solenoid is
flattened the solenoid must be replaced.
13. Remove the pin from the gearcase cover.

10. Remove the clutch gear from the gearcase cover.
14. Carefully remove the shift yoke assembly from the

11. Inspect the shift lever (A), shift lever spring (B), shift
return springs (C), and shift yoke (D) for excessive
gearcase cover.
7
wear or damage. If disassembly is required proceed
to the next step. If no disassembly is required proceed
to “Rear Gearcase Assembly.”
C
D
A
B
7.35
FINAL DRIVE
15. Inspect the shift lever (A), shift lever spring (B), shift
return springs (C), shift yoke (D), and lock pin bushing
(E). Inspect the components for excessive wear or
damage and replace as needed.
Do Not Disassemble.
D Replace as an assembly
if damaged or worn.
C
E B
Rear Gearcase Assembly 2. Replace the drive shaft oil seals located in the main
gearcase and gearcase cover
NOTE: Grease all seals and O-rings with Polaris All
Season Grease (PN 2871322) upon assembly.
1. Remove the pinion shaft oil seal using a seal puller

and replace with a new seal.
NOTE: The pinion gear assembly is NOT intended to

be disassembled from the case, as it requires
special OEM tooling in order to properly reassemble.
If there is any damage to the pinion gear, bearings or
case, the assembly must be replaced.
3. Replace all worn components.

FINAL DRIVE
4. Install the original shims (A) onto the differential 6. If previously removed; assembly the shift lever (A),
assembly (B) on both sides. Install the bearings (C), shift lever spring (B), shift return springs (C), shift yoke
replace with new bearings if needed. (D), and lock pin bushing (E).
B
C
A
A
C
C
E B
7. Carefully install the shift yoke assembly into the

B gearcase cover.
5. Install the differential assembly into the carrier

housing.
7
8. Install the lock assembly pin and tighten.
7.37
FINAL DRIVE
9. Install the new lightly greased O-ring onto the carrier 11. If previously removed, install the differential solenoid
cover. into the carrier cover. Torque solenoid to specification.
O-Ring
38 ft-lbs
(52 Nm)
10. Assemble the gearcase halves and install the (7) bolts
that secure the cover to the housing. Torque the bolts =T
in a criss cross pattern to specification.
Gearcase Cover Bolts: 30 ft-lbs (41 Nm)
Differential Solenoid: 38 ft-lbs (52 Nm)
30 ft-lbs
(41 Nm)

FINAL DRIVE
Rear Gearcase Installation
1. Place the rear gearcase assembly into the frame.
Slide the rear propshaft onto the rear gearcase input
shaft.
2. Install the (4) gearcase mounting fasteners and

torque the fasteners to specification.
3. Install the parking brake caliper bracket fasteners and

torque the fasteners to specification.
Fill Plug
Bracket
25 ft-lbs
(34 Nm)
17 ft-lbs
(23 Nm)
Propshaft
40 ft-lbs
(54 Nm)
4. Connect the differential solenoid 2-wire harness.

Drain Plug
5. Follow the “REAR DRIVE SHAFT - Installation” 38 in-lbs
procedure to reinstall the rear drive shafts. (4 Nm)
6. Torque drain plug to specification.
7. Add Polaris ATV Angle Drive Fluid (PN 2876160) to =

rear carrier. Refer to maintenance information in
Chapter 2 for more details. Rear Gearcase Lubricant / Capacity: 7
ATV Angle Drive Fluid / 22 fl. oz. (650 ml)
8. Torque fill plug to specification.
=T
Gearcase Mounting Fasteners: 40 ft-lbs (54 Nm)
Park Brake Bracket Fasteners: 17 ft-lbs (23 Nm)
Gearcase Drain Plug: 38 in-lbs (4 Nm)
Gearcase Fill Plug: 25 ft-lbs (34 Nm)
NOTE: The rear gearcase lubricant must be checked

and filled when the gearcase is properly mounted in
the vehicle and the vehicle resting on level ground.
7.39
FINAL DRIVE
Rear Gearcase Exploded View
38 in-lbs
(4 Nm)
80 ft-lbs
288 ft-lbs (108 Nm)
(390 Nm)
25 ft-lbs
(34 Nm)
30 ft-lbs
(41 Nm)
38 ft-lbs
(52 Nm)
REF DESCRIPTION QTY REF DESCRIPTION QTY REF DESCRIPTION QTY
1 Hypoid Gear Assembly 1 15 Bearing Cone - Diff 1 29 Pinion Nut 1

2 Carrier Housing Half 1 16 Bearing Cup - Diff 1 30 Oil Seal - Pinion 1
3 Carrier Cover Half 1 17 Bearing - Roller 1 31 Pinion Thrust- AR
4 Diff Case Half 1 18 Bearing - Cup 1 32 Lock Pin Bushing 1
5 Diff Case Cover Half 1 19 Hex Head Plug 1 33 Shift Return Spring 2
6 Diff Side Gear 2 20 Clutch Gear 1 34 Drain Plug 1
7 Diff Pinion Mate Gear 2 21 O-Ring - Housing Halves 1 35 Oil Seal - Shaft 2
8 Pinion Mate Thrust- 2 22 Lock Assembly Pin 1 36 Fill Plug 1
9 Diff Cross Pin 1 23 Vent Tube 1 37 Shift Yoke 1
10 Diff Roll Pin 1 24 Flanged Hex Bolt - Housing 7 38 Shift Lever 1
11 Hex Bolt - Ring Gear 8 25 Diff Solenoid 1 39 Shift Lever Spring 1
12 Diff Case Thrust-Washer AR 26 Spacer - Kit AR 40 Pinion Spacer 1
13 Side Gear Thrust-Washer 1 27 Bearing Cup - Pinion 2
14 Diff Case Thrust-Washer AR 28 Bearing Cone - Pinion 2

TRANSMISSION
CHAPTER 8
TRANSMISSION
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
TRANSMISSION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
LUBRICATION SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
SHIFT CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
TRANSMISSION SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
TRANSMISSION SHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
COMPENSATOR SHAFT PRELOAD CHECK AND ADJUSTMENT PROCEDURE . . . 8.10
TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16
TROUBLESHOOTING CHECKLIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
TRANSMISSION EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20

8.1
TRANSMISSION
SPECIAL TOOLS SHIFT LEVER
Special Tools Removal
SPX Corp: 1-800-328-6657 or http://polaris.spx.com 1. Remove the (2) push rivets retaining the dash panel
and remove the panel from the dash to access the
TRANSMISSION SPECIFICATIONS shift lever.
Torque Specifications 2. Remove the shift knob cover, retaining screw and shift
knob from the shift lever.
ITEM TORQUE VALUE
Transmission Fill Plug 12 ft-lbs (16 Nm)
Transmission Drain Plug 12 ft-lbs (16 Nm)
Transmission Case Screws 18 ft-lbs (24 Nm)
Oil Deflector Plate Screws 9 ft-lbs (12 Nm)
Bell Housing Screws 55 ft-lbs (75 Nm)
Bellcrank Nut 15 ft-lbs (20 Nm)
Shift Detent Plug 20 ft-lbs (27 Nm)
Transmission Coupler Nut 120 ft-lbs (163 Nm)
Lubrication Specifications
TRANSMISSION CAPACITY
Synthetic AGL plus
Transmission Fluid 32 oz. (946 ml)
(PN 2878068) (Quart)
3. Remove the grommet around the shift lever from the

dash.
4. Remove the clip and washer retaining the shift cable

to the shift lever and disconnect the cable end from
the lever.
5. Remove the retaining ring, outer washer, and both

bushings from the shift lever.
6. Slide the shift lever off the mounting bracket and out
from the frame.
Installation
1. Repeat the steps in reverse order to install the gear
shift lever.

TRANSMISSION
SHIFT CABLE 2. Locate the shift cable adjustment point located on the
RH side of the frame, by the air filter housing.
Inspection
3. With two open-end wrenches, loosen the outside jam
Shift cable adjustment is necessary when symptoms nut counterclockwise. Turn the outside jam nut 1 1/2
include: turns.
• Noise on deceleration
• Inability to engage a gear Inside Jam Nut
• Excessive gear clash (noise)
• Gear selector is moving out of desired range
Inspect shift cable, clevis pins, and pivot bushings and

replace if worn or damaged.
1. Place gear selector in neutral. Make sure the

transmission bell crank is engaged in the neutral
position detents.
Bell Crank in Neutral Position
Outside Jam Nut
4. After turning the outside jam nut 1 1/2 turns. Hold the
outside jam nut with a wrench and tighten the inside
jam nut clockwise, until it is tight against the bracket.
5. Repeat Step 3 and Step 4 until the proper adjustment

is made to the shift cable.
6. Use this procedure to loosen or tighten the shift

linkage cable as needed.
Adjustment
Point
8
8.3
TRANSMISSION
TRANSMISSION SERVICE 11. Remove the crankshaft sensor.
Transmission Removal
2. Thoroughly clean the engine, transmission and

chassis.
3. Tilt the cargo box.
4. Remove the seat base and seat back (see Chapter 5).
Remove
5. Disconnect the negative (-) battery cable 
(see Chapter 2).
6. Drain the transmission fluid (see Chapter 2).

12. Disconnect the speed sensor located on the lower
7. Remove the outer PVT cover:
right-hand side of the transmission.
13. Disconnect the gear position switch from the top of the
transmission.
14. Disconnect the shift cable from the gear selector on

the transmission.
Remove
8. Remove the drive and driven clutch assemblies (refer

to Chapter 6).
9. Remove the PVT intake and outlet ducts from the

transmission. 15. Remove the shift cable bracket. This creates the room
necessary for transmission removal.
16. Remove the parking brake to prepare for propshaft

removal (refer to Chapter 9).
10. Remove the inner PVT cover (see Chapter 6).

TRANSMISSION
17. Remove the rear propshaft from the transmission 21. While pushing on the forward end of the engine to
output shaft. Refer to Chapter 7. create separation, grab the clutch shaft and carefully
work the transmission away from the engine. Allow the
front propshaft to slide off the front transmission shaft.
18. Remove the transmission vent lines.
22. Once you have cleared the engine coupler, lift the
transmission assembly out of vehicle with the aid of
an assistant or hoist.
Transmission Disassembly
1. Remove the drive belt, drive clutch and driven clutch
(see Chapter 7 “PVT SYSTEM SERVICE -
Disassembly”).
2. If attached, remove the screws that secure the inner

PVT cover to the transmission case and remove the
cover.
19. Remove the 13mm and (2) 15mm bolts retaining the
transmission to the engine (shown).
15mm
8
20. From under the vehicle, remove the fasteners that

retain the transmission mounts to the frame on each
side.
3. Remove (2) retaining bolts from the transmission
cover (see Step 7). These are thread forming bolts
that can be used to hold the coupler during removal
and installation.
8.5
TRANSMISSION
4. Thread the (2) bolts into the transmission case pin 8. Carefully lift up on the cover. Use a soft-faced hammer
holes to hold the coupler. to tap on the input shaft and rear output shaft to ease
cover removal.
Coupler Output Shaft
Thread bolts
in pin holes.
Primary Shaft Input Shaft
9. Lift up on the rear output shaft assembly and remove

the front output shaft assembly.
5. Remove the retaining nut and transmission coupler.
6. Place the transmission in neutral by moving the

bellcrank.
7. Lay the transmission down with the cover facing up

and remove the bolts retaining the transmission cover.
Front Rear
Output Shaft Output Shaft
10. Remove the (2) screws retaining the oil deflector

plate.

TRANSMISSION
11. Lift up on the rear output shaft assembly enough to 14. Lift up on each end of the shift fork and rotate the fork
remove the compensator assembly. out of the shift shaft cam.
Compensator
Assembly
Rear
Output Shaft
12. Remove the rear output shaft assembly and silent 15. Repeat the previous step to remove the lower shift
chain from the transmission. fork.
13. Remove the springs, shift shaft rail and park shaft rail. 16. Remove the input shaft assembly and reverse shaft
assembly together from the transmission.
8
Park Shaft
Rail
Shift Shaft
Rail
17. If servicing either shaft assembly, remove the reverse

silent chain and separate the shaft assemblies.
8.7
TRANSMISSION
18. Inspect all bearings, gear teeth, engagement dogs Transmission Shaft Service
and silent chain.
Use the exploded views within this section when servicing
the transmission shafts.
Shaft bearings can be serviced using an arbor press.
Input Shaft
19. Remove the detent plug, snap ring, washer and gear
selector switch.
Washer Snap Ring
Detent
Plug
Primary Shaft
20. Remove the retaining ring and washer from the cam
shift shaft. Remove the nut, bellcrank and washer
from the bellcrank shift shaft.
Washer
Bellcrank
Washer
Retaining
Ring
21. Remove both shift shafts from the transmission as an

assembly. Lightly tap on each shaft to ease removal.

TRANSMISSION
Rear Output Shaft Compensator Shaft
Reverse Shaft
NOTE: Stack the belleville washers and place them

into the belleville cup upon assembly as shown. The
“UP” stamping on each washer should face out
when assembling the washer stack.
“UP” Marking
Belleville
Washers
8
Cup
8.9
TRANSMISSION
Cam Shift Shaft Compensator Shaft Preload Check and
Adjustment Procedure
NOTE: The compensator shaft preload must be
checked and/or adjusted for proper transmission
operation.
1. Place the transmission compensator shaft assembly

on a suitable work bench with the retaining ring facing
up.
2. By hand, press down on the belleville cup to remove

the slight spring tension from the preload shims and
retaining ring. Remove retaining ring and spacers.
Make note of the order and positioning of the shim(s)
as they are removed.
Press Belleville Remove Retaining

Cup Down Ring and Spacers
Bellcrank Shift Shaft
3. Remove the belleville cup.
4. Remove the belleville cup preload coil spring from the

center of the belleville washers.
Remove Spring
5. Reinstall the belleville cup onto the compensator

shaft. Be sure the belleville washer stack is installed
in the proper order/position if they were removed.

TRANSMISSION
6. Reinstall the retaining ring onto the compensator shaft
using the proper retaining ring pliers.
Install
VALUE A
Retaining Ring
Be sure these are

not installed
at this time
10. Add 0.020 in. (0.508 mm) to “VALUE A” and record

7. Hold the compensator shaft and rotate the belleville this number below as “VALUE B”.
cup as much as possible clockwise and counter 
clockwise to properly position belleville washers and VALUE B: _________ (VALUE A + 0.020 in. / 0.508
seat the retaining ring. Repeat this step 2-3 times. mm)
8. Position the compensator cam lobes centered into the

flats as shown below. 11. Use the thickest preload shims available out of Shim
Kit 2204264 or use the existing shims to equal or be
within ±.005 in. (0.127 mm) of the measurement
recorded as “VALUE B”.
12. Check the thickness of the preload shim(s) with a

caliper to be sure they are equal to or within ± 0.005
in. (0.127 mm) of “VALUE B” from steps 10-11.
Cam Lobe Centered

in Flat / Low Spot
9. Using an appropriate feeler gauge, measure and

record the distance between the top of the belleville
8
cup and the bottom of the retaining ring.

Record this measurement as “VALUE A”.

VALUE A: __________
13. Remove the retaining ring from the compensator shaft
using a proper retaining ring pliers.
14. Remove the belleville cup from the compensator

shaft.
15. Install the belleville cup preload coil spring. Be sure it

is seated properly and did not catch on a belleville
washer.
16. Install the belleville cup.
8.11
TRANSMISSION
17. Install and center the preload shims selected from
step 11. Be sure the THICKEST of the preload shims
is installed last so it will be resting against the retaining
ring.
THICKEST
Preload Shim on Top
18. By hand, press the belleville cup down and install the
retaining ring using a proper retaining ring pliers. Be
sure the retaining ring is seated properly in the
compensator shaft slot.
19. The compensator shaft preload has now been

properly set, proceed with transmission assembly /
service.
Compensator Preload Shims

(Included in Shim Kit 2204264)
.015” (.381 mm) Qty. 1
.020” (.508 mm) Qty. 2
.025” (.635 mm) Qty. 1
.031” (.787 mm) Qty. 1
.050” (1.27 mm) Qty. 2

TRANSMISSION
Transmission Assembly
1. Thoroughly clean the transmission case halves and 4. If the bellcrank shift shaft was disassembled, install
shafts. the gear sector with the step facing the O-ring.
2. Inspect all seals and O-rings for damage. If

Replace
transmission was disassembled, seal and O-ring Step O-Ring
replacement is recommended (see exploded view
above).
3. If the cam shift shaft was disassembled, install the

detent gear with the step facing the O-ring.
8
Step
5. Install new O-rings on both shift shafts and lubricate

prior to installation.
Replace
O-Ring
NOTE: Both shift shafts have skip-tooth keyed

splines for assembly purposes.
8.13
TRANSMISSION
6. Align the timing marks on the cam shift shaft and 9. Install the retaining nut and torque to specification.
bellcrank shift shaft.
Align =T
Marks
Bellcrank Retaining Nut:
15 ft-lbs (20 Nm)
10. Install the washer and a new retaining ring onto the
cam shift shaft. The retaining ring should be tight on
the shaft.
11. Install the transmission switch, washer and snap ring.
Washer Snap Ring
7. Place the two shafts into the transmission as an

assembly.
Detent
Plug
12. Install the detent plug and torque to specification.
=T
Detent Plug:
20 ft-lbs (27 Nm)
IMPORTANT: Gently rock or twist the shift shafts
upon installation to prevent from damaging the new
13. Assemble the input shaft and reverse shaft with the
O-rings. Forcing the shift shafts straight into the
lower shift fork and park pawl installed.
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.
Shift Fork
Skip-Tooth
Splines
Bellcrank
Park Pawl
14. Place the assembly into the transmission housing

making sure to move the park pawl arm behind the
shift shaft cam during installation.

TRANSMISSION
15. Lift up on the lower shift fork and rotate the end into 18. Install the oil deflector plate and install new retaining
the cam. screws. Torque screws to specification.
=T
Deflector Plate Retaining Screws:
9 ft-lbs (12 Nm)
19. Install the rear output shaft assembly and silent chain.
20. Lubricate all seal lips to prevent damage upon

assembly.
21. Lift up slightly on the rear output shaft and install the
compensator shaft and front output shaft assemblies.
22. If primary shaft was serviced, reinstall shaft assembly

16. Install the upper shift fork and rotate the end into the into the transmission case. Apply grease to the
cam. primary shaft shim(s) and place them into the
transmission cover.
23. Carefully install the transmission cover onto the

transmission. Apply even pressure to cover while
setting into place. A soft-faced hammer can be used
once the cover is started and aligned.
IMPORTANT: Take care not to damage seals during

cover installation.
24. Install the retaining bolts and torque to specification.

Leave (2) bolts out to use later when tightening the
coupler.
=T
17. Install both rails and springs.
Transmission Cover Bolts:
18 ft-lbs (24 Nm)
25. Install a new O-ring onto the compensator shaft prior

to installing the transmission coupler. 8
Park Shaft
Rail
Shift Shaft
Rail
NOTE: Make sure the spring is flush with the top of

the shift shaft rail. If not flush, the rail may not be
fully seated. O-Ring
8.15
TRANSMISSION
IMPORTANT: Be sure to install the O-ring all the way Transmission Installation
down onto the shaft, past the groove.
26. Install the transmission coupler and cone washer
(dome facing up). 2. Thoroughly clean the engine, transmission and
chassis.
27. Apply Loctite™ 2760 to the shaft threads and install
the coupler retaining nut. 3. Install the rubber coupler into the engine coupler. Be
sure rubber coupler is properly mounted. Lubricate
28. Hold the transmission coupler using the (2) the rubber with a soap/water solution to aid
transmission cover bolts that were left out. Thread the installation.
bolts into the transmission case and torque the
coupler nut to specification.
120 ft-lbs
(163 Nm)
4. Install a new gasket onto the engine mounting plate.
5. With the aid of an assistant or hoist, carefully place the

=T transmission assembly into the chassis.
Transmission Coupler Retaining Nut: 6. Slide the front propshaft onto the front transmission
120 ft-lbs (163 Nm) shaft.
29. Remove the (2) bolts holding the coupler and install 7. While pushing on the forward end of the engine, grab
them in the transmission cover. Torque the bolts to the clutch shaft of the transmission and carefully work
specification (see Step 24). the transmission to the engine. Verify the front
propshaft stays installed on the front transmission
shaft.

TRANSMISSION
8. Align the engine and transmission coupler as shown. 12. Install the transmission vent lines.
Engine Transmission
Coupler Coupler
13. Install the rear propshaft to the transmission output

shaft. (Refer to Chapter 7). Install a NEW roll pin.
NOTE: Verify the front propshaft is properly

attached to the transmission shaft before installing
the bolts.
9. Install the 13mm and (2) 15mm bolts that retain the
transmission to the engine.
15mm
14. Install the parking brake assembly and tighten

fasteners to specification (Refer to Chapter 9).
10. Torque the transmission-to-engine bolts in two steps

to the specified torque value using a cross pattern.
8
=T
Transmission-to-Engine Retaining Bolts:
18 ft-lbs (24 Nm)
11. Align the (2) transmission mount fasteners on each

side of the frame and torque to specification.
=T
Transmission Mount Fasteners:
18 ft-lbs (24 Nm)
8.17
TRANSMISSION
15. Install the shift cable bracket. Torque the fasteners to 20. Install the PVT intake and outlet ducts from the
specification. transmission.
Install
16. Install the shift cable to the gear selector on the

transmission.
21. Refer to Chapter 6 for PVT system installation.
Install 22. Add the recommended amount of lubricant through

the fill plug hole. Maintain the lubricant level at the
bottom of the fill plug hole when filling the
transmission. Do not overfill.
Fill Plug
12 ft-lbs
(16 Nm)
17. Install the gear position switch connector at the top of
the transmission.
18. Install the speed sensor connector located on the

lower right-hand side of the transmission.
19. Install the crankshaft sensor. Torque the fastener to

specification.
Gearcase lubricant
flush with the bottom
of thread area.
Transmission Lubricant:
Synthetic AGL Plus
Install (PN 2878068) (Quart)

TRANSMISSION
23. Reinstall fill plug with a new O-ring and torque to
specification.
=T
Drain/Fill Plug:
12 ft-lbs (16 Nm)
Troubleshooting Checklist
Check the following items when shifting difficulty is
encountered.
• Engine idle speed is above specification

• Transmission fluid type/quality
• Loose or worn linkage
• Worn linkage at the transmission bellcrank
• Bent bellcrank
• Worn, broken or damaged internal transmission
components
• Mis-aligned clutches
NOTE: To determine if shifting difficulty is caused
by an internal transmission problem, isolate the
transmission by disconnecting linkage from
transmission bellcrank. Manually select each gear
range at the transmission bellcrank and test ride
vehicle. If it functions properly, the problem is
outside the transmission.

If transmission problem remains, disassemble
transmission and inspect all gear dogs for wear
(rounding), or damage. Inspect all bearings, circlips,
thrust washers and shafts for wear.
8.19
TRANSMISSION
Transmission Exploded View
120 ft-lbs
(163 Nm)
FOR REASSEMBLY
15 ft-lbs
(20 Nm) Apply Polaris
Crankcase Sealant.
Apply LoctiteTM 2760

to the bolt threads.
55 ft-lbs
(75 Nm)
9 ft-lbs
(12 Nm)
12 ft-lbs
(16 Nm)
20 ft-lbs
(27 Nm)
12 ft-lbs
(16 Nm)
9 ft-lbs
(12 Nm)
18 ft-lbs
12 ft-lbs
(24 Nm)
(16 Nm)

TRANSMISSION
Exploded View, Continued
REF # DESCRIPTION QTY REF # DESCRIPTION QTY
1 Plug, Hex 2 49 Cup, Belleville 1
2 Plug, Hex 1 50 Thrust Spacer 1
3 Plug, Hex, Magnetic 1 51 Sprocket, 47 T 1
4 Screw 2 52 Reverse Shaft, 53T 1
5 Screw 19 53 Input Shaft, 25T 1
6 Screw 4 54 Compensator Cam 1
7 Nut 1 55 Helical Gear, 42T 1
8 Nut 1 56 Compensator Gear, 54T 1
9 Thrust Washer 1 57 Output Shaft 1
10 Thrust Washer 1 58 Bellcrank 1
11 Belleville Washer 1 59 Vent Tube 2
12 Dowel Pin 2 60 Gear, 67 T 1
13 Dowel Pin 2 61 Sprocket, 48 T 1
14 Snap Ring 1 62 Shift Shaft 1
15 Retaining Ring 2 63 Shift Rail 1
16 Retaining Ring 1 64 Detent Plug 1
17 Retaining Ring 1 65 Engagement Dog 1
18 Retaining Ring 1 66 Engagement Dog 1
19 Retaining Ring 1 67 Compensator Shaft 1
20 Retaining Ring 1 68 Shift Fork 1
21 Retaining Ring 1 69 Dowel 2
22 Thrust Washer 1 70 Shift Fork 1
23 Thrust Washer 1 71 Engagement Dog 1
24 Shim 2 72 Sprocket, 19T 1
25 Shim 1 73 Output Asm. 1
26 Thrust Washer 1 74 Primary Shaft Asm. 1
8
27 Belleville Washer 6 75 Compensator Shim Pack 1
28 Thrust Washer 1 76 Primary Shim pack 1
29 Collar 1 77 Switch Shaft 1
30 Ball Bearing 3 78 Oil Deflector 1
31 Ball Bearing 1 79 Bearing Cover Asm. 1
32 Ball Bearing 1 81 Silent Chain 1
33 Ball Bearing 1 82 Silent Chain 1
34 Needle Bearing 1 83 Gear Switch 1
35 Ball Bearing 1 84 O-Ring 1
36 Needle Bearing 1 85 O-Ring 1

8.21
TRANSMISSION
37 Needle Bearing 1 86 O-Ring 1
38 Ball Bearing 1 87 Seal, Triple Lip 2
39 Flanged Bearing 1 88 O-Ring 1
40 Compression Spring 1 89 O-Ring 1
41 Wave Spring 1 90 Seal 1
42 Compression Spring 1 91 Seal, Triple Lip 2
43 Compression Spring 1 93 Transmission Coupler 1
44 Gearcase Cover 1 94 Speed Sensor 1
45 Gearcase, Main 1 95 Ball Bearing
46 Bell Housing 1 100 Collar
47 Sector Gear, 38T 1
48 Detent Bullet 1

BRAKES
CHAPTER 9
BRAKES
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
BRAKE SYSTEM GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
BRAKE SYSTEM SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
BRAKE NOISE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
HYDRAULIC BRAKE SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
BRAKE SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
FOOT BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
PEDAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
PEDAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
BRAKE BLEEDING / FLUID CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
FRONT CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
CALIPER EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
CALIPER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
REAR BRAKE PADS (NON CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
REAR CALIPER SERVICE (NON CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
REAR CALIPER EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
REAR CALIPER SERVICE (CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
REAR CALIPER EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
FRONT BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
REAR BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
9
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
CABLE TENSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
PARKING BRAKE CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.28
CALIPER DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
NEW BRAKE PAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
PARKING BRAKE DISC SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.30
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.31

9.1
BRAKES
GENERAL SPECIFICATIONS
Specifications and Service Limits
FRONT BRAKE SYSTEM

Item Standard Service Limit
Front Brake Pad Thickness .298 ± .007" / 7.56 ± .178 mm .180" (4.6 mm)
Front Brake Disc Thickness .188" ( 4.78 mm) .170" (4.32 mm)
Front Brake Disc Runout - .010" (.254 mm)
REAR BRAKE SYSTEM

Rear Brake Pad Thickness .298 ± .007"/ 7.56 ± .178 mm .180" (4.6 mm)
Rear Brake Disc Thickness .188" (4.78 mm) .170" (4.32 mm)
Rear Brake Disc Runout - .010" (.254 mm)
PARK BRAKE SYSTEM

Inboard - .304” (7.72 mm) .240" (6.1 mm)
Park Brake Pad Thickness
Outboard - .360” (9.14 mm) .310” (7.87 mm)
Park Brake Disc Thickness 0.161” - 0.177” (4.09 - 4.50 mm) .150" (3.81 mm)
TORQUE SPECIFICATIONS SPECIAL TOOLS

Torque Specifications Special Tools
Torque Torque PART NUMBER DESCRIPTION

Item
ft-lbs Nm
2870975 Mity Vac™ Pressure Test Tool
Front Caliper Mounting Bolts 30 41
Rear Caliper Mounting Bolts 30 41
Park Brake Caliper to Mount
18 24
Bracket Bolts
Park Brake Lever Mount Bolts 13 18
Brake Line Flare Fittings 14 19
Brake Line Banjo Bolts (All) 15 20
Front Brake Disc to Hub Bolts 18 24
Rear Brake Disc to Hub Bolts 28 38
Park Brake Disc Mounting Bolt 18 24
Brake Switch 14 19
Master Cylinder Mount Bolts 15 20

BRAKES
BRAKE SYSTEM GENERAL INFORMATION
Brake System Service Notes
Disc brake systems are light weight, low maintenance, and perform well in the conditions this vehicle will routinely
encounter. There are a few things to remember when replacing disc brake pads or performing brake system service to
ensure proper system function and maximum pad service life.
• Optional pads are available to suit conditions in your area. Select a pad to fit riding style and environment.
• Do not over-fill the master cylinder fluid reservoir.
• Make sure the brake pedal returns freely and completely.
• Adjust stop pin on front caliper after pad service.
• Check and adjust master cylinder reservoir fluid level after pad service.
• Make sure atmospheric vent on reservoir is unobstructed.
• Test for brake drag after any brake system service and investigate cause if brake drag is evident.
• Make sure caliper moves freely on guide pins (where applicable).
• Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely.
• Perform a brake burnishing procedure after installing new pads to maximize service life.
• DO NOT lubricate or clean the brake components with aerosol or petroleum products. Use only approved brake
cleaning products.
Brake Noise Troubleshooting

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

Possible Cause Remedy
Spray disc and pads with CRC Brakleen™ or an
equivalent non-flammable aerosol brake cleaner. Remove
Dirt, dust, or imbedded material on pads or disc
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 (front calipers)
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 Inspect. Repair as necessary
Caliper piston(s) not returning Clean piston(s) seal 
Operator error (riding the brake) Educate operator
Loose wheel hub or bearings Check wheel and hub for abnormal movement.
Brake disc warped or excessively worn Replace disc
9
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
Wrong pad for conditions Change to a softer or harder pad

9.3
BRAKES
Hydraulic Brake System Operation
The Polaris brake system consists of the following components or assemblies: brake pedal, master cylinder, hydraulic
brake lines, brake calipers, brake pads, and brake discs, which are secured to the drive line.
When the foot activated brake lever is applied it applies pressure on the piston within the master cylinder. As the master
cylinder piston moves inward it closes a small opening (compensating port) within the cylinder and starts to build pressure
within the brake system. As the pressure within the system is increased, the pistons located in the brake calipers move
outward and apply pressure to the moveable brake pads. These pads contact the brake discs and move the calipers in
their floating bracket, pulling the stationary side pads into the brake discs. The resulting friction reduces brake disc and
vehicle speed.
The friction applied to the brake pads will cause the pads to wear. As these pads wear, the piston within the caliper moves
further outward and becomes self adjusting. Fluid from the reservoir fills the additional area created when the caliper
piston moves outward.
Brake fluid level is critical to proper system operation. Too little fluid will allow air to enter the system and cause the brakes
to feel spongy. Too much fluid could cause brakes to drag due to fluid expansion.
Located within the master cylinder is the compensating port which is opened and closed by the master cylinder piston
assembly. As the temperature within the hydraulic system changes, this port compensates for fluid expansion or
contraction. Due to the high temperatures created within the system during heavy braking, it is very important that the
master cylinder reservoir have adequate space to allow for fluid expansion. Never overfill the reservoir! Do not fill the
reservoir beyond the MAX LEVEL line!
When servicing Polaris brake systems use only Polaris DOT 4 Brake Fluid (PN 2872189). WARNING: Once a bottle
is opened, use what is necessary and discard the rest in accordance with local laws. Do not store or use a partial bottle
of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture. This causes the boiling temperature of
the brake fluid to drop, which can lead to early brake fade and the possibility of serious injury.

BRAKES
Brake System Exploded View
NON CREW LH Front Caliper

Brake 2
LH Front
LH Rear Line 3 Switch Brake Line
(2011)
LH Rear Caliper Master Cylinder Top View

2 1
1
RH Front Caliper
3
MC Rear RH Front
2 Brake Line 1 Brake Line
1 2
1 Brake
Switch
(2012-2013) 1
RH Rear Caliper Caliper Banjo Style Fittings:

1
15 ft-lbs (20 Nm).
All Caliper Bleed Screws:
2 47 in-lbs (5.3 Nm)
RH Rear Line 1 1
Master Cylinder All Flare Style Fittings:
Side View 3 14 ft-lbs (19 Nm)
CREW
LH Rear Line 2 LH Front Caliper
Brake LH Front
3 Switch Brake Line
(2011)
LH Rear Caliper
Master Cylinder Top View
1 2 1
3 MC Rear
1 RH Front Caliper
Brake Line 2
RH Front
1 1
2 1 Brake Line
Brake
Switch
(2012-2013)
9
RH Rear Caliper Master Cylinder
Side View Caliper Banjo Style Fittings:
1
15 ft-lbs (20 Nm).
All Caliper Bleed Screws:
RH Rear Line 1 2 47 in-lbs (5.3 Nm)
1
All Flare Style Fittings:
3 14 ft-lbs (19 Nm)
9.5
BRAKES
MASTER CYLINDER FOOT BRAKE PEDAL
Removal Pedal Removal
1. Remove the retaining clip (A) from the clevis pin (B) 1. Remove the E-clip from the end of the brake pedal
that attaches the master cylinder to the brake pedal mount bracket.
lever.
Master Brake Pedal
2. Remove LH wheel well panel to access master Cylinder Mount Bracket
cylinder.
C Clevis Pin
Clip
B
Bushing
E-Clip
Bushing
15 ft-lbs
(20 Nm) A Brake Pedal
2. Remove the retaining clip and clevis pin from the

master cylinder to free it from the brake pedal.
3. Slide the brake pedal and bushings off the mount
E bracket.
15 ft-lbs 15 ft-lbs
D (20 Nm) (20 Nm) Pedal Installation
(x2 2011) (2012-2013)
1. Reverse Steps 1-3 for foot brake installation.
3. Remove the two mounting bolts (C) that secure the
master cylinder to the frame. 2. Use a new E-clip upon installation.
4. Remove master cylinder and place a fluid catch

container under the master cylinder brake line banjo
bolt (D) and pressure switch (E).
CAUTION
Brake fluid will damage finished surfaces. Do not
allow brake fluid to come in contact with finished
surfaces.
5. Loosen the brake line banjo bolt (D) and pressure

switch (E), allow the fluid to drain.
NOTE: Make note of front and rear brake line
orientation on the master cylinder.
6. Dispose of brake fluid properly and do not re-use.
Installation
1. Reverse Steps 1-5 for master cylinder installation.
Refer to the torque specifications in the
illustration.

BRAKES
BRAKE BLEEDING / FLUID CHANGE
Brake Bleeding Procedure
NOTE: When bleeding the brakes or replacing the Bleeder
fluid always start with the furthest caliper from the Screw
master cylinder.
CAUTION
Always wear safety glasses.
CAUTION
Brake fluid will damage finished surfaces. Do not 8. Place a small amount of fresh brake fluid into a small,
allow brake fluid to come in contact with finished clear container and place the other end of bleeder
surfaces. hose into the container.
1. Locate master cylinder reservoir in the front LH wheel 9. Have an assistant slowly pump the brake pedal until
well area (Figure 1-6). Clean reservoir cover pressure builds and then hold.
thoroughly. 10. Quickly open and close the bleed screw while holding
2. Remove cover from reservoir. pressure on the brake pedal.
3. If changing fluid, remove old fluid from reservoir with NOTE: Do not release brake pedal before bleeder
a Mity Vac™ pump or similar tool. screw is tight or air may be drawn into master
cylinder.
Mity Vac™: 11. Release brake pedal pressure. Check level of fluid in
PN 2870975 reservoir and add if necessary (Figure 1-6).
12. Repeat Steps 9, 10, and 11 until brake pedal is firm
4. Add brake fluid to the indicated MAX level of reservoir
and no air can be seen moving through the clear hose.
(Figure 1-6).
Add fluid as necessary to maintain level in reservoir.
Add Fluid Master Cylinder Fluid Level

HERE
Between the MIN and MAX line.
IMPORTANT: Maintain at least 1/2” (1.27 cm) of brake

fluid in the reservoir to prevent air from entering the
master cylinder.
13. Tighten bleeder screw and remove bleeder hose.
Torque bleeder screw to specification.
Level Indicator 14. Repeat Steps 9 - 13 for the remaining brake calipers.
Figure 1-6 15. Install master cylinder reservoir cover.
16. Field test machine at low speed before putting into
service. Check for proper braking action and pedal
9
Polaris DOT 4 Brake Fluid:
P/N 2872189 reserve. With pedal firmly applied, pedal reserve
should be no less than 1/2” (1.3 cm).
5. Begin bleeding procedure with caliper furthest from 17. Check brake system for fluid leaks.
master cylinder.
6. Install a box-end wrench on caliper bleeder screw. =T
7. Attach a tight-fitting, clear hose to the bleeder fitting.
Brake Bleeder Screw:
47 in-lbs (5.3 Nm)
9.7
BRAKES
FRONT BRAKE PADS 5. Push the mounting bracket inward and the slip outer
brake pad out between the bracket and caliper body.
Pad Removal
1. Elevate and support front of vehicle.
CAUTION
tips or falls.
2. Remove the wheel nuts, washers and front wheel.

Loosen pad adjuster screw.
6. Remove the inner pad from the bracket and caliper.
Pad Inspection
1. Measure the thickness of the pad material. Replace
Pad
pads if worn beyond the service limit.
Adjuster
3. Remove the upper and lower caliper mounting bolts

and remove the caliper from the front hub.
NOTE: When removing caliper, use care not to
damage brake line. Support caliper so to avoid
kinking or bending brake line.
4. Push caliper piston into caliper bore slowly using a
C-clamp or locking pliers with pads installed.
Measure
Thickness
in. / ft.
1
= 1 2 3
mm / cm
NOTE: Brake fluid will be forced through
compensating port into master cylinder fluid Front Brake Pad Thickness:
reservoir when piston is pushed back into caliper. New: .298 ± .007” (7.56 ± .178 mm)
Remove excess fluid from reservoir as required. Service Limit: .180” (4.6 mm)

BRAKES
Pad Assembly / Installation 5. Install the pad adjuster set screw and turn clockwise
until stationary pad contacts disc, then back off 1/2
1. Lubricate mounting bracket pins with a light film of disc turn (counterclockwise).
brake caliper lube, and install rubber dust boots.
1/2 Turn
Apply disc brake caliper lube
Pad
Adjuster
6. Verify fluid level in reservoir is up to MAX line inside

2. Compress mounting bracket and make sure dust reservoir and install reservoir cap.
boots are fully seated. Install pads with friction
material facing each other.
Master Cylinder Fluid
WARNING Up to MAX line inside reservoir
If brake pads are contaminated with grease, oil,

7. Install wheel and torque wheel nuts to specification
or liquid soaked do not use the pads.
(see “Chapter 2 - Maintenance”).
Use only new, clean pads.
3. Install caliper onto front hub and torque mounting Brake Burnishing Procedure
bolts.
It is required that a burnishing procedure be performed
after installation of new brake pads to extend service life
and reduce noise.
Start machine and slowly increase speed to 30 mph.
Gradually apply brakes to stop machine. Allow pads and
disc to cool sufficiently during the procedure. Do not allow
pads or disc to become hot or warping may result. Repeat
this procedure 10 times.
30 ft-lbs
(41 Nm)
=T
9
Front Caliper Mounting Bolts:
30 ft-lbs (41 Nm)
4. Slowly pump the brake pedal until pressure has been

built up. Maintain at least 1/2, (12.7 mm) of brake fluid
in the reservoir to prevent air from entering the brake
system.
9.9
BRAKES
FRONT CALIPER SERVICE
Caliper Exploded View
Apply Polaris DOT 4 Brake

C
Fluid to Components
B 47 in-lbs
(5.3 Nm)
Apply disc brake caliper
lube D A
E D
F
G
A. Socket Set Screw 

B. Bleeder Screw 
C. Caliper Assy.  H
D. Boots 
E. Square O-rings I
F. Pistons 
G. Caliper Mount 
H. Brake Pads
I. Brake Scraper J
J. Bolts
Caliper Removal 5. Loosen brake pad adjustment set screw to allow brake
pad removal after the caliper is removed.
1. Elevate and safely support the front of the vehicle.
2. Remove the (4) wheel nuts and the front wheel.
CAUTION
Use care when supporting vehicle so that it does not
tip or fall. Serious injury may occur if vehicle tips or Pad
falls. Adjuster
3. Clean caliper area before removal.

4. Place a container below the caliper to catch brake fluid
when removing the line. Remove brake line from
caliper.
Remove
Brake Line

BRAKES
6. Remove the two caliper mounting bolts and the IMPORTANT: Do not remove the caliper pistons with
caliper. a standard pliers. The piston sealing surfaces will
become damaged if a standard pliers is used.
4. Once the pistons are removed, use a pick to carefully
remove the square O-rings from the caliper. O-rings
should be replaced during caliper service.
Remove
Caliper Disassembly
1. Remove both brake pads from the caliper (see
“FRONT BRAKE PADS - Pad Removal”).
2. Remove the mount bracket assembly and the dust
5. Clean the caliper body, piston, and retaining bracket
boots from caliper. Thoroughly clean the caliper
with brake cleaner or alcohol.
before disassembly and prepare a clean work area for
disassembly.
Clean
Components
IMPORTANT: Be sure to clean the seal grooves in

caliper body.
3. Use a commercially available caliper piston pliers to
extract the pistons from the caliper.
9.11
BRAKES
Caliper Inspection Caliper Assembly
1. Inspect caliper body for nicks, scratches, pitting or 1. Install new O-rings in the caliper body. Be sure the
wear. Measure bore size and compare to grooves are clean and free of residue or brakes may
specifications. Replace if damaged or worn beyond drag upon assembly.
service limit.
Seal
Grooves
New
O-Rings
2. Coat pistons with clean Polaris DOT 4 Brake Fluid.

Install pistons with a twisting motion while pushing
in. / ft.
1 inward. Piston should slide in and out of bore
= 1 2 3
smoothly, with light resistance.
mm / cm
3. Lubricate the mounting bracket pins with disc brake

Caliper Piston Bore ID: caliper lube, and install the rubber dust seal boots.
Std: 1.373” (34.87 mm)
Service Limit: 1.375” (34.93 mm)
Apply disc brake caliper lube
2. Inspect piston for nicks, scratches, pitting or wear.
Measure piston diameter and replace if damaged or
worn beyond service limit.
4. Compress the mounting bracket and make sure the

dust seal boots are fully seated. Install the brake pads.
Clean the disc and pads with brake parts cleaner or
denatured alcohol to remove any dirt, oil or grease.
in. / ft.
1
= 1 2 3
mm / cm
Caliper Piston OD:

Std: 1.370” (34.80 mm)
3. Inspect the brake disc and pads as outlined in this

chapter.

BRAKES
Caliper Installation 3. Install the pad adjustment screw and turn until
stationary pad contacts disc, then back off 1/2 turn.
1. Install caliper and torque mounting bolts to
specification.
1/2 Turn
IMPORTANT: If brake disc scraper was removed, be
sure to reinstall it upon caliper installation.
Disc
Scraper Pad
Adjuster
30 ft-lbs
(41 Nm)
4. Perform brake bleeding procedure as outlined earlier

in this chapter.
5. Install wheel and torque wheel nuts to specification
(see Chapter 2).
=T 6. Field test unit for proper braking action before putting

into service. Inspect for fluid leaks and firm brakes.
Front Caliper Mounting Bolts: Make sure the brake is not dragging when pedal is
30 ft-lbs (41 Nm) released. If the brake drags, re-check assembly and
installation.
2. Install brake line and torque the banjo bolt to the NOTE: If new brake pads are installed, brake
proper torque specification. burnishing is required (see “FRONT BRAKE PADS -
Brake Burnishing Procedure”).
15 ft-lbs
(20 Nm)
=T
Banjo Bolt:
9
15 ft-lbs (20 Nm)
9.13
BRAKES
REAR BRAKE PADS (NON CREW) 6. Remove the brake pads.
Pad Removal
1. Elevate and support rear of machine.
CAUTION
tips or falls.
2. Remove the rear wheel. Loosen pad adjuster screw

2-3 turns.
Pad Inspection
1. Clean the caliper with brake cleaner or alcohol.
2. Measure the thickness of the pad material. Replace
pads if worn beyond the service limit.
3. Clean caliper area before removal.

4. Remove caliper mounting bolts and lift caliper off of
disc.
NOTE: When removing caliper, be careful not to
damage brake line. Support caliper so as not to kink Measure
or bend brake line. Thickness
in. / ft.
1
= 1 2 3
mm / cm
Rear Brake Pad Thickness:

New: .298 + .007” (7.56 + .178 mm)
Service Limit: .180” (4.6 mm)
Remove Caliper Bolts
5. Push caliper piston into caliper bore slowly with pads

installed.
NOTE: Brake fluid will be forced through
compensating port into master cylinder fluid
reservoir when piston is pushed back into caliper.
Remove excess fluid from reservoir as required.

BRAKES
Pad Installation Brake Burnishing Procedure
1. Install new pads in caliper body. It is required that a burnishing procedure be performed
and reduce noise.
disc to cool sufficiently during the procedure. Do not allow
pads or disc to become hot or warping may result. Repeat

specification.
30 ft-lbs
(41 Nm)
=T
Rear Brake Caliper Mounting Bolts:
30 ft-lbs (41 Nm)
3. Turn adjuster screw back in finger tight using a hex

wrench.
4. Slowly pump the brake pedal until pressure has been
built up. Maintain at least 1/2” (12.7 mm) of brake fluid
in the reservoir to prevent air from entering the master
cylinder.
9.15
BRAKES
REAR CALIPER SERVICE (NON
CREW)
Rear Caliper Exploded View
Apply Polaris DOT 4 Brake G

Fluid to Component
Apply disc brake caliper

lube
E F
D
H
A. Socket Set Screw  B E

B. Bleeder Screw  47 in-lbs
C. Caliper Assy.  (5.3 Nm)
D. Boot 
E. Square O-rings
F. Piston 
G. Caliper Mount 
H. Brake Pads C
Caliper Removal 3. After the fluid has drained into the container, remove
the two caliper mounting bolts and remove caliper.
1. Safely support the rear of the machine.
CAUTION
tips or falls.
2. Place a container under brake line to catch brake fluid

draining from brake lines. Use a wrench to remove the
brake line.
4. Clean disc, caliper body, and pistons with brake

cleaner or alcohol.

BRAKES
Caliper Disassembly Caliper Inspection

1. Remove brake pad adjuster screw (A). 1. Inspect caliper body for nicks, scratches or wear.
Measure bore size and compare to specifications.
2. Push upper pad retainer pin inward and slip brake
Replace if damage is evident or if worn beyond
pads past edge, if pads are still installed.
service limit.
3. Remove mounting bracket (B) and dust boot (C).
B Pads
C
F D
A
in. / ft.
4. Remove piston (D) and square O-rings (E) from the 1
= 1 2 3
caliper body (F). mm / cm
Caliper Piston Bore ID:

Std: 1.505” (38.23 mm)
2. Inspect piston for nicks, scratches, wear or damage.

Measure diameter and replace if damaged or worn
beyond service limit.
5. Clean the caliper body, piston, and retaining bracket

with brake cleaner or alcohol.
NOTE: Be sure to clean seal grooves in caliper body.
=
in. / ft.
1 2
1
3
9
mm / cm
Caliper Piston OD:

Std: 1.500” (38.10 mm)
3. Inspect the brake disc and pads as outlined for brake

pad replacement in this chapter.
9.17
BRAKES
Caliper Assembly Caliper Installation
1. Install new square O-rings (A) in the caliper body. Be 1. Install the rear caliper onto the mounting bolts. Torque
sure that the grooves are clean and free of residue or mounting bolts to specification.
brakes may drag.
2. Install brake line banjo bolt. Torque banjo bolt to
specification.
A
30 ft-lbs
(41 Nm)
Lubricate With B
Brake Fluid
15 ft-lbs
(21 Nm)
2. Coat the piston with clean DOT 4 Brake Fluid
(PN 2872189). Install piston (B) with a twisting motion
while pushing inward. Piston should slide in and out
=T
of bore smoothly, with light resistance.
3. Lubricate the mounting bracket pins with disc brake Brake Caliper Mounting Bolts: 30 ft-lbs (41 Nm)
caliper lube, and install the rubber dust seal boots. Brake Line Banjo Bolt: 15 ft-lbs (21 Nm)
3. Install the rear wheel and wheel nuts. Carefully lower

the vehicle.
4. Field test unit for proper braking action before putting
Make sure the brake is not dragging when pedal is
released. If the brake drags, re-check assembly and
installation.
NOTE: If new brake pads are installed, brake
burnishing is required (see “REAR BRAKE PADS -

dust seals are fully seated. Install the brake pads.

BRAKES
REAR CALIPER SERVICE (CREW)
Rear Caliper Exploded View
Apply Polaris DOT 4 Brake 47 in-lbs B

Fluid to Component (5.3 Nm)
A
E
Apply Silicone Grease
F
H
D
I
A. Socket Set Screw 

B. Bleeder Screw 
C. Caliper Assy. 
D. Boot 
E. Square O-rings (large)
F. Square O-rings (small)
G. Piston 
H. Caliper Mount 
I. Brake Pads
Caliper Removal 4. Place a container below the caliper to catch brake fluid
when removing the line. Remove brake line from
1. Elevate and safely support the rear of the vehicle. caliper.
CAUTION
Use care when supporting vehicle so that it does not
tip or fall. Serious injury may occur if vehicle tips or
falls.
2. Remove the (4) wheel nuts, (4) washers and rear

wheel.
3. Clean caliper area before removal. Remove
Brake Line
9.19
BRAKES
5. Loosen brake pad adjustment set screw to allow brake 3. Use a commercially available caliper piston pliers to
pad removal after the caliper is removed. extract the pistons from the caliper.
Pad
Adjuster
6. Remove the two caliper mounting bolts and the

caliper.
IMPORTANT: Do not remove the caliper pistons with
a standard pliers. The piston sealing surfaces will
become damaged if a standard pliers is used.
4. Once the pistons are removed, use a pick to carefully
remove the square O-rings from the caliper. O-rings
should be replaced during caliper service.
Remove
Caliper Disassembly
1. Remove both brake pads from the caliper.
2. Remove the mount bracket assembly and the dust
boots from caliper. Thoroughly clean the caliper
before disassembly and prepare a clean work area for 5. Clean the caliper body, piston, and retaining bracket
disassembly. with brake cleaner or alcohol.
Clean
Components
IMPORTANT: Be sure to clean the seal grooves in

caliper body.

BRAKES
Caliper Inspection Caliper Assembly
1. Inspect caliper body for nicks, scratches, pitting or 1. Install new O-rings in the caliper body. Be sure the
wear. Measure bore size and compare to grooves are clean and free of residue or brakes may
specifications. Replace if damaged or worn beyond drag upon assembly.
service limit.
Seal
Grooves
New
O-Rings
2. Coat pistons with clean Polaris DOT 4 Brake Fluid.

Install pistons with a twisting motion while pushing
in. / ft.
1 inward. Piston should slide in and out of bore
= 1 2 3
smoothly, with light resistance.
mm / cm
3. Lubricate the mounting bracket pins with silicone

Caliper Piston Bore ID: grease and install the rubber dust seal boots.
Std: 1.192” (30.28 mm)
Apply Grease to Each
2. Inspect piston for nicks, scratches, pitting or wear. Bracket Pin
Measure piston diameter and replace if damaged or
worn beyond service limit.

dust seal boots are fully seated. Install the brake pads.
in. / ft.
1
9
= 1 2 3
mm / cm
Caliper Piston OD:

Std: 1.186” (30.12 mm)
3. Inspect the brake disc and pads as outlined in this

chapter.
9.21
BRAKES
Caliper Installation 4. Perform brake bleeding procedure as outlined earlier
in this chapter.
specification. 5. Install wheel and torque wheel nuts to specification.
=T
Wheel Nuts:
Steel Wheels: 35 ft-lbs (47 Nm)
Aluminum Wheels: 30 ft-lbs + 90° (1/4 turn)
30 ft-lbs
(41 Nm) 6. Field test unit for proper braking action before putting
installation.
NOTE: If new brake pads are installed, brake
burnishing is required (see “REAR BRAKE PADS -
=T
Rear Caliper Mount Bolt:
30 ft-lbs (41 Nm)
2. Install brake line and torque the banjo bolt to the

proper torque specification.
15 ft-lbs
(20 Nm)
3. Install the pad adjustment screw and turn until

stationary pad contacts disc, then back off 1/2 turn.
1/2 Turn
Pad
Adjuster

BRAKES
FRONT BRAKE DISC Disc Inspection
1. Visually inspect disc for scoring, scratches, or gouges.
Disc Runout
Replace the disc if any deep scratches are evident.
1. Mount dial indicator as shown to measure disc runout. 2. Use a 0-1” micrometer and measure the disc
Slowly rotate the disc and read total runout on the dial thickness at eight different points around the pad
indicator. Replace the disc if runout exceeds contact surface. Replace disc if worn beyond service
specification. limit.
Measure
Thickness
Front
Disc
in. / ft.
1
= 1 2 3
mm / cm
Brake Disc Thickness:

New: .188” (4.78 mm)
Brake Disc Thickness Variance:

in. / ft.
1 Service Limit: .002” (.051 mm)
= 1 2 3
difference between measurements
mm / cm
Brake Disc Runout: Disc Removal / Replacement

Service Limit: .010” (.254 mm)
1. Remove front brake caliper (see “Front Caliper
Service”).
2. Remove cotter pin, castle nut and washers.
3. Remove the wheel hub assembly from the vehicle and
remove the (4) bolts retaining the disc to the hub.
(4) Bolts
Washers
Nut
Cotter Pin
9.23
BRAKES
4. Clean the wheel hub mating surface and install new REAR BRAKE DISC
disc on wheel hub. Torque new bolts to specification.
Disc Runout
18 ft-lbs
(24 Nm) 1. Mount a dial indicator and measure disc runout.
Slowly rotate the disc and read total runout on the dial
indicator. Replace the disc if runout exceeds
specification.
80 ft-lbs
(108 Nm)
=T
Brake Disc Retaining Bolts:
18 ft-lbs (24 Nm)
CAUTION
5. Install wheel hub assembly, washers, and castle nut. in. / ft.
1
Torque castle nut to specification and install a new = 1 2 3
mm / cm
cotter pin.
Brake Disc Runout:
=T Service Limit: .010” (.254 mm)
Wheel Hub Castle Nut:

80 ft-lbs (108 Nm)
6. Install front brake caliper (see “Front Caliper

Service”). Follow bleeding procedure outlined earlier
in this chapter.
7. Field test unit for proper braking action before putting
installation.

BRAKES
Disc Inspection 4. Clean the wheel hub mating surface and install new
disc on wheel hub.
1. Visually inspect disc for scoring, scratches, or gouges.
Replace the disc if any deep scratches are evident. 5. Install new bolts and torque to specification.
2. Use a 0-1” micrometer and measure disc thickness at 28 ft-lbs

8 different points around perimeter of disc. Replace (38 Nm)
disc if worn beyond service limit.
Rear
Disc
110 ft-lbs
(150 Nm)
Measure
Thickness CAUTION
in. / ft.
1 is destroyed upon removal. Always use new
= 1 2 3
mm / cm fastener upon assembly.
Brake Disc Thickness 6. Install wheel hub assembly, washers, and castle nut.
New: .188” (4.78 mm) Torque castle nut to specification and install a new
Service Limit: .170” (4.32 mm) cotter pin.
Brake Disc Thickness Variance =T

Service Limit: .002” (.051 mm)
difference between measurements Brake Disc Retaining Bolts: 28 ft-lbs (38 Nm)
Wheel Hub Castle Nut: 110 ft-lbs (150 Nm)
Disc Removal / Replacement
7. Install rear brake caliper (see “REAR CALIPER
1. Remove rear brake caliper (see “Rear Caliper SERVICE”). Follow the bleeding procedure outlined
Service”). earlier in this chapter.
2. Remove cotter pin, castle nut and washers. 8. Field test unit for proper braking action before putting
3. Remove the wheel hub assembly from the vehicle and
remove the (4) bolts retaining the disc to the hub.
(4) Bolts installation.
Brake Burnishing Procedure

It is required that a burnishing procedure be performed
9
and reduce noise.
Washers disc to cool sufficiently during the procedure. Do not allow
Nut pads or disc to become hot or warping may result. Repeat
Cotter
Pin
9.25
BRAKES
PARKING BRAKE
Exploded View
Parking Brake
Lever
Bolts
14 ft-lbs
(19 Nm)
Clevis
Pin
13 ft-lbs
Nuts
(18 Nm)
Parking Brake
Caliper
Clevis
Pin Screw 18 ft-lbs
Nut
(24 Nm)
Clip Clip
Washer
Bolt
Mount Bracket
Cable
18 ft-lbs
Nut
(24 Nm)
Rear Propshaft Bolts

w/Parking Brake Disc
Rear Gearcase

BRAKES
Inspection Adjustment Procedure
1. Inspect the parking brake cable and brake pads on the 1. Place the vehicle in neutral on a flat level surface.
caliper assembly. Refer to the appropriate “Parking 2. Carefully lift the rear of the vehicle off the ground and
Brake Caliper Service” procedure for brake pad stabilize on jack stands.
replacement information.
3. Locate the parking brake cable adjustment area
where the cable attaches to the caliper mount bracket.
Inboard Pad
Outboard Pad
Parking Brake
Cable Adjustment
Propshaft
Cable Tension Adjustment

4. Use two open-end wrenches and loosen the outer jam
When the parking brake is fully engaged and the parking nut (D). Back out the outer jam nut (D) 1 1/2 turns.
brake indicator is illuminated, engine speed is limited to
1300 RPM in all gears, including neutral. If throttle is
applied, this limiting feature prevents operation, which 5. Now hold the outer jam nut (D) and turn in the inner
protects the parking brake pads from excessive wear. jam nut (C) clockwise, until the jam nut is tight against
the bracket.
NOTE: Inspect the parking brake cable tension after
the first 25 hours of operation and every 100 hours of 6. Repeat Step 4 and Step 5 until the proper adjustment
operation afterwards to ensure proper cable tension. is obtained for the parking brake.
Loss of tension in the parking brake cable will cause NOTE: See Chapter 10 for more information on the
illumination of the parking brake light and activation of the parking brake switch.
limiting feature. If this occurs, inspect and adjust parking
brake cable tension. If performing this service is difficult
due to conditions or location, open the hood and
temporarily disconnect the parking brake connector.
Reconnect the parking brake connector as soon as it is
practical and adjust the parking brake cable to proper
tension.
1. Pull back on the parking brake lever (located in the
dash).
2. After 3-5 clicks the “(P)” brake light should illuminate
on the instrument cluster and the wheels of the vehicle
should not rotate when turning by hand. After 8 full
clicks of lever travel, the vehicle should not roll while
9
parked.
3. If the vehicle moves, adjustment is necessary.
4. Adjust the parking brake cable where the cable
attaches to the caliper mount bracket. The mount
bracket is located on the left-hand side of the
transmission behind the outer PVT cover (4x4) or on
the rear gearcase (6x6).
9.27
BRAKES
PARKING BRAKE CALIPER SERVICE
Exploded View
Hex Nut
Pad & Holder
Pad & Holder Plain Washer
18 ft-lbs
(24 Nm)
Sleeve Thrust Washer
Hex Head
Mount Bolt
Shim Pack Lever

Nut (4 Shims)
Asm. Bolt
35 ft-lbs
(34 Nm)
Stationary Actuator
Spring Pin
Compression Spring Steel Balls (3)
Caliper Removal 2. If replacing the brake pads, slightly loosen the caliper
assembly bolts before removing the complete caliper
NOTE: Do not get oil, grease, or fluid on the parking assembly. This will ease the caliper disassembly
brake pads. Damage to or contamination of the pads procedure later.
may cause the pads to function improperly.
1. Remove the clip pin and pin (A) from the parking brake
cable.
NOTE: Be sure the parking brake is not engaged.

BRAKES
3. Loosen the two brake caliper mounting bolts (B) in 6. Measure the thickness of the rear caliper parking
equal increments. brake pads. Replace assembly or pads as needed.
See illustration below for proper readings.
B Inboard Pad
New .304” (7.72 mm)
Limit: 0.24” (6.1 mm)
Outboard
Inboard Pad
Pad
Outboard Pad
New 0.360” (9.14 mm)
Limit: 0.31” (7.87 mm)
4. Remove the mounting bolts from the mount bracket Installed Disc to Park Brake
and lift the parking brake caliper assembly out of the 0.375” (0.953 cm)
vehicle. New Rotor Disc Thickness
0.169 +/- .008”
(4.29 +/- .20mm)
Caliper Disassembly / Inspection Replace at .150” (3.81mm) or less
NOTE: Refer to the “Electronic Parts Catalog” for

parking brake caliper replacement information.
1. Remove the two caliper assembly nuts (C) that were
previously loosened during Step 2 of “Caliper
Removal”.
New Brake Pad Installation
NOTE: Parking Brake Pads can be replaced by
ordering one of the following kits:
PN 2203148 - Brake Pad and Shim Kit
PN 2203147 - Brake Pad Kit
There may be more parts in the service kit than your
C brake requires. Check the parts list included with the
kit for the exact quantities.
1. Using the stationary actuator, assemble the caliper
components as shown below. Do not install the
springs or shims yet. Measure the gap for the brake
disc. Disassemble and add shims between thrust
washer and the inside brake pad as needed to close
the gap to .203” - .193” (5.16 - 4.90 mm).
2. Slide the brake pads and springs from the assembly.
Add shims until gap
NOTE: Retain the lever and ball bearings for measures .203” - .193”
reassembly. (5.16 - 4.90 mm)
3. Inspect brake pads for excessive wear. Replace as
needed.
9
4. Check the three steel balls for any signs of cracking.
Replace as needed.
5. Check ball seats in lever and stationary actuator. If
excessively worn, replace parts as needed.
9.29
BRAKES
2. Once you have determined the correct amount of PARKING BRAKE DISC SERVICE
shims to use, install the assembly bolts through the
sleeves. Install the nuts and the correct amount of Disc Inspection / Removal
shims, the inner brake pad, springs, and outer brake
pad. Torque the assembly nuts to specification. 1. Measure the brake disc with a micrometer. If the
thickness of the disc is less than specified, replace the
rear propshaft assembly.
=T
2. Follow the rear prop shaft removal procedure listed in
Parking Brake Caliper - Assembly Bolts: Chapter 7 to remove the rear propshaft assembly.
25 ft-lbs (34 Nm) Remove Bolts
3. Ensure the parking brake assembly functions properly
by actuating the lever before reinstallation.
in. / ft.
1
= 1 2 3
mm / cm
Caliper Installation Parking Brake Disc:

New: .161” - .177” (4.09-4.50 mm)
1. Install the parking brake assembly into place. Tighten
the two mounting bolts in increments for proper
installation. 3. Refer to Chapter 7 to reinstall the rear propshaft
assembly.
18 ft-lbs
(24 Nm)
2. Torque the two mounting bolts to specification.
=T
Parking Brake Caliper - Mounting Bolts:
18 ft-lbs (24 Nm)
3. Install the cable, pin, and clip pin. Test the park brake
for proper function.

BRAKES
TROUBLESHOOTING
Brakes Squeal / Poor Brake Performance
• Air in system
• Water in system (brake fluid contaminated)
• Caliper/disc misaligned
• Caliper dirty or damaged
• Brake line damaged or lining ruptured
• Worn disc and/or friction pads
• Incorrectly adjusted stationary pad
• Worn or damaged master cylinder or components
• Damaged break pad noise insulator
Pedal Vibration
• Disc damaged
• Disc worn (runout or thickness variance exceeds
service limit)
Caliper Overheats (Brakes Drag)

• Compensating port plugged
• Pad clearance set incorrectly
• Parking brake lever incorrectly adjusted
• Brake pedal binding or unable to return fully
• Parking brake left on
• Residue build up under caliper seals
• Operator riding brakes
Brakes Lock
• Alignment of caliper to disc
• Caliper pistons sticking
• Improper assembly of brake system components
9.31
BRAKES
NOTES

ELECTRICAL
CHAPTER 10
ELECTRICAL
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
BATTERY CONDUCTANCE ANALYZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
COMPONENTS UNDER SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
COMPONENTS BEHIND DASH PANEL / UNDER HOOD . . . . . . . . . . . . . . . . . . . . . . 10.3
SWITCHES / CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
HEADLIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
AWD / 2WD / TURF SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
DIFFERENTIAL SOLENOID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
BRAKE LIGHT SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
PARKING BRAKE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
INSTRUMENT CLUSTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
RIDER INFORMATION DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
STANDARD DISPLAY MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
DIAGNOSTIC DISPLAY MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
INSTRUMENT CLUSTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
INSTRUMENT CLUSTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
INSTRUMENT CLUSTER TROUBLESHOOTING TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
ALL WHEEL DRIVE (AWD) COIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
GEAR POSITION INDICATOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
HEADLIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
TAIL LIGHT / BRAKE LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
COOLING SYSTEM BREAK-OUT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
FAN CONTROL CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
FAN CONTROL CIRCUIT BYPASS TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
COOLING FAN ON/OFF & HOT LIGHT ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
FUEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
FUSES / CIRCUIT BREAKER / RESISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27
VEHICLE CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
FUEL SOLENOID WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
CHARGING SYSTEM RATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
CHARGING SYSTEM “BREAK EVEN” TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
CHARGING SYSTEM ALTERNATOR WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . 10.31
BATTERY SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
BATTERY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
BATTERY REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
CONVENTIONAL BATTERY TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34
BATTERY CONDUCTANCE ANALYZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34
CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
STARTER SYSTEM AND WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36
10
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36
VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36

10.1
ELECTRICAL
GENERAL INFORMATION Battery Conductance Analyzer
Conductance describes the ability of a battery to conduct
Special Tools
current. A conductance tester functions by sending a low
frequency AC signal through the battery and a portion of
Part Number Tool Description
the current response is captured, from this output a
PV-43568 Fluke™ 77 Digital Multimeter conductance measurement is calculated. Conductance
testing is more accurate than voltage, specific gravity, or
PV-43526 Connector Test Kit
load testing.
2870630 Timing Light Authorized Polaris dealers/distributors are required to use
2870836 Battery Hydrometer the conductance analyzer when testing 12V Polaris
batteries.
2460761 Hall Sensor Probe Harness
2871745 Static Timing Light Harness
MDX-610P Battery / Conductance Tester
Electrical Service Notes

Keep the following notes in mind when diagnosing an
electrical problem:
• Refer to wiring diagram for stator and electrical
component resistance specifications.
• When measuring resistance of a component that
has a resistance value under 10 Ohms, remember
to subtract meter lead resistance from the reading.
Connect the leads together and record the
resistance. The resistance of the component is
equal to tested value minus the lead resistance.
• Become familiar with the operation of your meter.
Be sure leads are in the proper jack for the test
being performed (i.e. 10A jack for current
readings). Refer to the Owner’s Manual included
Polaris MDX-610P - PN:
with your meter for more information. PU-50296
• Voltage, amperage, and resistance values
included in this manual are obtained with a
Fluke™ 77 Digital Multimeter (PV-43568). This
meter is used when diagnosing electrical
problems. Readings obtained with other meters
may differ.
• Pay attention to the prefix on the multimeter
reading (K, M, etc.) and the position of the decimal
point.
• For resistance readings, isolate the component to
be tested. Disconnect it from the wiring harness or
power supply.

ELECTRICAL
Components Under Seat SWITCHES / CONTROLS
The following components can be accessed under the
Headlight Switch
seat:
• Alternator 1. Remove the dash panel from the dash (see Chapter
5).
• Battery
2. Disconnect the headlight switch harness by
• Battery Cables
depressing the connector lock and pulling on the
• Terminal Block connector. Do not pull on the wiring.
• Starter 3. Inspect the switch connections and test the switch for
• Glow Plugs continuity.
• Fuel Solenoid • When the headlight switch is turned to ‘low beam’,
there should be continuity between terminals 5
• Fuel Pump and 3.
• Fuel Sender
• When the headlight switch is turned to ‘high
beam’, there should be continuity between
Components Behind Dash Panel / Under terminals 5 and 6.
Hood
The following components can be accessed with the dash
panel removed (see Chapter 5 for removal) or under the
hood:
• Speedometer
• Speedometer Mode Switch
• AWD/2WD/TURF Switch
• Headlight Switch
• 12 VDC Accessory Power Points
• Ignition Switch
• Parking Brake Switch
• Relays
• Fuses
• VCM
10
10.3
ELECTRICAL
AWD / 2WD / TURF Switch Differential Solenoid
1. Remove the dash panel from the dash (see Chapter The differential solenoid is located on the left side of the
5). rear gear case. The solenoid actuates an engagement
dog, which locks and unlocks the rear differential. Refer to
2. Disconnect the switch harness by depressing the
Chapter 7 for more information on the rear differential
connector lock and pulling on the connector. Do not
mechanical operation.
pull on the wiring.
3. Inspect the switch connections and test the switch for
continuity.
• When the switch is in position #1 (AWD), there
should be continuity between terminals 2 and 3.
• When the switch is in position #3 (TURF), there
should be continuity between terminals 2 and 1.
• Refer to the AWD/TURF Diagram in this chapter
for more information.
Differential Solenoid Circuit Operation

The Rear Diff Solenoid Relay is located on the frame
under the rear cargo box.
When the switch is pushed to activate “TURF” mode, a
power signal is provided to the VCM from the AWD / 2WD
/ TURF Switch.
Depending on engine speed, gear position criteria and
parking brake input, the VCM energizes the Rear Diff
Solenoid Relay, allowing it to enable the differential
solenoid. The Rear Diff Solenoid Relay will not engage
at speeds above 8 MPH.
The differential will return to 2wd anytime the parking
brake is applied. NOTE: The rear differential will not
unlock if the parking brake is set.
If the rear differential fails to switch from operational
modes:
• Check the solenoid and relay connectors. Look for
loose wires or bad connections.
• Check the AWD / 2WD / TURF Switch wires for
loose connections.
• Remove solenoid from rear differential and ensure
the solenoid plunger is actuating.
• Check for a signal from the VCM to ensure the
solenoid has power to be activated.
• If all other components are verified, try a known
working VCM.

ELECTRICAL
Brake Light Switch Parking Brake Switch
2011 - The brake light switch is located on the rear portion The parking brake switch is located within the parking
of the frame below the drive. The brake pressure switch is brake lever. Follow the parking brake lever under the dash
installed into a junction block. to locate the internally mounted switch.
2012-2013 - The brake light switch is located on the front
brake line banjo bolt of the master cylinder. The brake
switch can be accessed through the RH or LH wheel well
opening with the wheel well panel removed.
1. Disconnect the wire harness from the brake switch.
2011
Brake Switch
2012-
2013
The switch remains in the “open” position when the park

brake lever is not applied.
When the parking brake lever is applied, the switch makes
contact and sends a signal to the VCM on Pin #15, which
disables ‘TURF’ mode and to the park relay, which
Brake Switch activates and illuminates the “Park Brake Indicator - (P)”
light near the top-center of the instrument cluster.
NOTE: No feature exists to prevent drive-away with
2. Connect an ohmmeter across switch contacts.
the parking brake applied. An alarm will sound when
Reading should be infinite (OL).
the transmission is shifted into gear with the parking
3. Apply foot brake and check for continuity between brake applied.
switch contacts. If there is no continuity or greater than
.5 ohms resistance when the brake is applied with
slight pressure, first clean the switch contacts and re-
test. Replace switch if necessary.
10
10.5
ELECTRICAL
Testing The Parking Brake Switch INSTRUMENT CLUSTER
1. Disconnect the harness connector at the parking
brake switch (Orange/Red and Red/White wires). Overview
2. Place the ohmmeter leads onto the switch terminals. The RANGER Diesel instrument cluster senses vehicle
The reading should be infinite (OL). speed from the transmission and RPM from the flywheel.
The instrument cluster measures distance in miles as well
as and hours of operation.
Park Brake
Indicator Speedometer
Speedometer
Needle
3. Apply the parking brake. Continuity should now exist

between the switch terminals. If no continuity exists
when the parking brake is applied, try to clean the
switch terminals and re-test. Replace switch if
necessary.
4. If the switch functions properly, check the Park Relay
and VCM for proper function.
Rider
Information
Display
NOTE: In addition to showing vehicle speed, the

speedometer needle flashes when a low fuel
condition exists.
NOTE: Use the “Mode Button” shown below to toggle
between Instrument Cluster display screens.
Key Mode Instrument

Switch Button Cluster

ELECTRICAL
Rider Information Display Standard Display Modes
The rider information display is located in the instrument Use the yellow mode button located under the
cluster. All segments will light up for 2.5 seconds at start- speedometer to toggle through the mode options.
up.
Odometer Mode
NOTE: If the instrument cluster fails to illuminate, a The odometer records the miles traveled by the vehicle.
battery over-voltage may have occurred and the
instrument cluster may have shut off to protect the Trip Meter Mode
electronic speedometer. The trip meter records the miles or kilometers traveled by
3 4 5 6 7 the vehicle on each trip if it's reset before each trip. To
reset the trip meter, select the trip meter mode. Press and
8 hold the mode button until the display reads 0.
NOTE: In the Rider Information Display, the trip meter
display contains a decimal point, but the odometer
displays without a decimal point.
2
Hour Meter Mode
This mode logs the total hours the engine has been in
1 operation.
Tachometer Mode
1. Gear Indicator - This indicator displays gear shifter
position. The engine RPM is displayed digitally.
H = High Gear NOTE: Small fluctuations in the RPM from day to day
L = Low Gear may be normal because of changes in humidity,
N = Neutral temperature and elevation.
R = Reverse Gear
2. AWD Indicator - This indicator illuminates when the Diagnostic Display Mode
AWD switch is in the AWD position.
The wrench icon will display when the gauge is in the
3. Engine Hour Display Indicator diagnostic mode. To exit the diagnostic mode, turn the key
4. Service Interval / Diagnostic Mode Indicator switch off and on. Any movement of the tires will also
cause the gauge to exit the diagnostic mode.
5. Low Battery and Over Voltage - This warning
usually indicates that the vehicle is operating at an To enter the diagnostics mode:
RPM too low to keep the battery charged. It may also 1. Turn the key switch off and wait 10 seconds.
occur when the engine is at idle and high electrical
2. Lock the parking brake.
load (lights, cooling fan, accessories) is applied. Drive
at a higher RPM or recharge the battery to clear the 3. Place the transmission in neutral.
warning. 4. Hold the mode button and turn the key switch to the
6. Odometer / Tachometer / Tripmeter / Hour Meter “ON” position. Release the mode button as soon as
the display is activated.
7. Fuel Gauge - The segments of the fuel gauge show
the level of fuel in the fuel tank. When the last segment 5. Use the mode button to toggle through the diagnostic
clears, a low fuel warning is activated. All segments screens.
will flash, FUEL will display in the LCD, and the
speedometer needle will blink. Refuel immediately.
8. Check Engine Warning Indicator - The word HOT
displays if the engine overheats. Do not operate the
vehicle if this warning appears. Serious engine
damage could result. It will also display if there is an
electrical fault with a sensor or system.
10
10.7
ELECTRICAL
Battery Voltage Screen Gear Circuit Diagnostic Screen
View this screen to check battery voltage level. This screen displays the resistance value (in ohms) being
read at the gear switch input of the gauge.
Tachometer Screen
View the tachometer to check engine speed.
AWD Diagnostic Screen

The gauge indicates whether or not current is flowing
through the AWD coil.
NOTE: A 10 - 20% variance from these readings is

within normal parameters.

ELECTRICAL
Programmable Service Interval Miles / Kilometers Toggle
When the hours of engine operation equal the The display in the tripmeter and odometer can be changed
programmed service interval setting, the wrench icon will to display either standard or metric units of measurement.
flash for 5 seconds each time the engine is started. When
1. Enter the diagnostic mode.
this feature is enabled, it provides a convenient reminder
to perform routine maintenance. 2. Toggle to the screen that displays either kilometers
(KM) or miles (MP).
3. Press and hold the mode button until the letters flash,
then press and release the button once. When the
display stops flashing, the mode has been set.
NOTE: The service interval is programmed to 50

hours at the factory.
To enable or disable the service interval:
2. Toggle to the service interval screen.
3. Press and hold the mode button for about seven (7)
seconds, until either ON or OFF appears in the Rider
Information Display, depending on your preference.
To reset the service interval:

2. Toggle to the service interval screen.
3. Press and hold the mode button for 2-3 seconds, until
the wrench icon flashes. Release the button.
4. Press and release the mode button once to advance
the setting by one hour. Press and hold the mode
button to advance the hours quickly.
NOTE: If you scroll past the intended number, press
and hold the button until the hours cycle back to zero.
5. When the desired setting is displayed, wait until the
wrench icon stops flashing. The new service interval 10
is now programmed.
10.9
ELECTRICAL
Instrument Cluster Removal Instrument Cluster Installation
NOTE: Do not allow alcohol or petroleum products to Spray a soap and water mixture onto the outer surface
come in contact with the instrument cluster lens. area of the instrument cluster. This will help the instrument
cluster slide into the rubber mount more easily.
1. Remove the dash panel from the dash (see Chapter
5).
2. Disconnect the wire connectors from the back side of
the instrument cluster.
4. Be sure the rubber mount inside the dash panel is fully

installed and that the indexing key on the rubber
mount is lined up with the keyway in the dash panel.
3. Push the instrument cluster out from the back side of 5. Hold the dash panel securely and insert the
the dash panel, while securely holding the panel and instrument cluster into the dash panel. Twist the
rubber mount. instrument cluster gently in a clockwise motion to
properly seat the instrument cluster. Apply pressure
on the bezel while pressing down on the instrument
cluster.

ELECTRICAL
INSTRUMENT CLUSTER TROUBLESHOOTING TESTS
Test 1 - No All Wheel Drive
*Diesel: AWD disabled above 8 MPH ground speed
10

10.11
ELECTRICAL
TEST 2 - No Display
TEST 3 - Speed Sensors (MPH & RPM)

ELECTRICAL
TEST 4 - No AWD Hub Safety Limiter
10

10.13
ELECTRICAL
TEST 5 - Fuel Gauge Display Not Working
TEST 6 - Shift Indicator Not Working (Transmission Switch)

ELECTRICAL
ALL WHEEL DRIVE (AWD) COIL GEAR POSITION INDICATOR SWITCH
Operation Overview Test Diagram
• When the AWD switch is “ON”, 12 VDC power is NOTE: Also see “INSTRUMENT
present at the hub coil. CLUSTER TROUBLESHOOTING”
• If the criteria is met, the instrument cluster
TRANSMISSION SWITCH
provides a ground path at pin #16 (Brown/White
wire). When this occurs the AWD icon should High / Low / Neutral / Reverse
display in the instrument cluster.
• The AWD system must be grounded to operate.
Diagnosing System Failures

• Verify the AWD switch is functional and that a
minimum of 11 volts is present at the hub coil.
High Range
• Verify the AWD hub coil is functional. Test the Low Range
AWD hub coil using an ohm meter. See
Neutral
specifications below:
Reverse
Green/White Brown/Red
Violet White/Blue
Blue/Red
AWD Hub Coil Resistance:

24  ± 5%
• Verify the wiring harness, wiring, connectors,

connector pins and grounds are undamaged,
clean and connected properly.
• Verify continuity of wire connections with a volt/
ohm meter.
IMPORTANT: Verify all wires and wiring connections
have been tested properly with a known good volt/
ohm meter before suspecting a component failure.
80% of all electrical issues are caused by bad/failed
connections and grounds.
10
10.15
ELECTRICAL
HEADLIGHTS 6. Once the beam is set to the position, tighten the
adjustment screw. Repeat the procedure to adjust the
Headlight Adjustment other headlight.
The RANGER headlights are adjustable.

WARNING
1. Place the vehicle on a level surface with the headlight
approximately 25 ft. (7.6 m) from a wall. Due to the nature of light utility vehicles and
where they are operated, headlight lenses
become dirty. Frequent washing is necessary to
25 ft. (7.6 m) maintain lighting quality. Riding with poor
X1 X2 lighting can result in severe injury or death.
8 in. (20 cm)
Headlight Bulb Replacement

1. Open the hood.
2. Locate the bulb on the back side of headlight.
Bulb
2. Measure the distance from the floor to the center of
the headlight (X1) and make a mark on the wall at the
same height (X2).
3. With the machine in Neutral and parking brake
applied, start the engine and turn the headlight switch
on.
4. The most intense part of the headlight beam should
be aimed 8 in. (20 cm) below the mark placed on the
wall in Step 2.
NOTE: Rider weight must be included in the seat
while performing this procedure.
5. Locate the T25 Torx-head adjustment screw through 3. Turn the bulb counterclockwise to remove it.
the wheel well (see illustration). Adjust the beam to the
desired position by loosening the adjustment screw
and moving the lamp to the appropriate height.
4. Unplug the headlight bulb from the wiring harness. Be

sure to pull on the connector, not on the wiring.
5. Install the wire harness into the new headlight bulb.
6. Install the bulb into the housing and rotate it clockwise
90° to lock it in place.
NOTE: Make sure the tab on the bulb locates properly
in the housing.

ELECTRICAL
Headlight Housing Removal 5. Remove the O-rings (A) from each side of the
headlight housing. Remove the adjustment screw (B)
1. Open the hood. and pull the headlight from the brackets.
2. Remove the front facia to access the headlight
housing.
3. Carefully pull the fascia out far enough to access the

headlight housing.
Headlight
Housing
4. Remove the bulb from the headlight housing (see

“Headlight Bulb Replacement”).
10
10.17
ELECTRICAL
Headlight Housing Installation
1. Install the headlight housing by pressing the headlight
tabs back into the brackets.
2. Secure the headlight housing with the rubber O-rings
on each side (A). Install the adjustment screw (B).
NOTE: Be sure to twist the O-rings upon installation
as shown below.
3. Reinstall the bulb into the housing and rotate it

clockwise 90° to lock it in place.
4. Reinstall the front fascia and securely tighten all
fasteners.
Install
5. Adjust headlights using the “Headlight Adjustment”

procedure.

ELECTRICAL
RANGER Diesel Lighting System Diagram (simplified)
Ranger Diesel Lighting System
10

10.19
ELECTRICAL
TAIL LIGHT / BRAKE LIGHT
LED Lamp Replacement
1. From the rear of the LED lamp, remove the (2) T20
Torx-head screws retaining the lamp assembly.
T20 Screws
2. Remove the lamp from the cargo box and disconnect

the tail light / brake light wire harness.
NOTE: Before replacing the LED lamp assembly, use
a digital multi-meter to test the harness to ensure the
lamp is receiving 12 volts and that a ground path is
present.
3. If the LED still does not work, replace the LED lamp
assembly with the recommended lamp.
4. Reinstall the assembly by reversing this procedure.
5. Test the tail light / brake light after installation to verify
proper function.

ELECTRICAL
COOLING SYSTEM
Cooling System Break-Out Diagram
Park Brake Relay
10

10.21
ELECTRICAL
Fan Control Circuit Operation Coolant Temperature Sensor
Power is supplied to the fan via the Orange/Black wire The coolant temperature sensor can be tested using an
when the relay is energized. The Brown wire provides the ohmmeter or voltmeter.
ground path for the fan motor. Refer to “RELAYS” later in
1. With the engine and temperature sensor at room
this chapter for more information on fan functions.
temperature (77°F = 25°C), disconnect the harness
connector.
CAUTION 2. With the meter in the ohms mode, place the meter
leads onto the sensor contacts.
Keep hands away from fan blades during
operation. Serious personal injury could result. 3. Use the following table to determine if the sensor
needs to be replaced.
NOTE: The fan may not function or operation may be
delayed if coolant level is low or if air is trapped in the Temperature ° F (° C) Resistance
cooling system. Be sure cooling system is full and
77 ° F (25 ° C) 29.9 k  ± 2%
purged of air. Refer to Chapter 2 “Maintenance” for
cooling system filling information. 176 ° F (80 ° C) 3.93 k  ± 2%
248 ° F (120 ° C) 1.22 k  ± 2%
Fan Control Circuit Bypass Test
1. Disconnect harness from coolant temperature sensor malfunctions the radiator fan will default “ON”.
on engine.
2. With the parking brake applied, turn the ignition key Cooling Fan on/off & HOT Light on/off
“ON”. The fan should start running.
The fan on/off and hot lamp on/off are both controlled by
3. If the fan runs with the sensor harness disconnected, the VCM via the coolant temp sensor.
but will not turn on when the engine is hot, check the
coolant temperature sensor and connector terminals. Fan HOT Light
If the fan does not run or runs slowly, check the fan
ON 194 ° F (90 ° C) ON 221° F (105° C)
motor wiring, ground, motor condition and mechanical
relay for proper operation. Repair or replace as OFF 179 ° F (82 ° C) OFF 212° F (100° C)
necessary.
malfunctions the radiator fan will default “ON”.

ELECTRICAL
FUEL SENDER RELAYS
NOTE: Refer to the “Electronic Power Steering (EPS)”
Testing
section in this chapter for information on EPS relays.
1. Drain the fuel tank and remove it from the chassis. The relays assist with items such as fan, chassis, park
2. Set the fuel tank on a flat surface. light, glow plugs and rear differential operation.
3. Attach an ohm meter to the fuel sender harness Violet/
White wire (B) and Brown wire (C). Fan Relay
4. Allow the sender float to sit in the empty position and The Fan Relay, controlled by the VCM and Engine Coolant
compare to specification. Temp Sensor, operates the fan motor.
Fuel Sender - Empty: 5  ± 5%
5. Slowly tilt the tank so that gravity moves the sender

float to the full position and compare to specification.
Fuel Sender
Empty: 5 ± 5% 
Half 57 ± 5% 
Full 90  ± 5%
Fuel Sender - Full: 90± 5%
6. If the readings are not to specification, or if the reading

is erratic or LCD display “sticks”, check the following
before replacing the fuel pump assembly.
Color Function
• Loose float
Orange B1 VCM controlled input at pin #4
• Float contact with tank
• Bent Float Rod Key-On 12V power supply, provides
Orange B2
power to operate the relay.
If none of the conditions exists, the sender assembly is
faulty. Fuel sender assembly replacement is required. 15 Amp circuit breaker protected, 12V
Red / White B3
relay power supply.
Relay switched 12V power to the fan
Orange / Black
motor. 20 amp circuit breaker
B5
protected.
10
10.23
ELECTRICAL
Chassis Relay Start Relay
The Chassis Relay, controlled by the VCM and key switch, The Start Relay, located in the fuse block, is controlled by
powers the Chassis components. the brake switch and key switch, and powers the relay for
starter operation.
Color Function
Brown D1 Relay ground.
Key-On 12V power supply, provides
Orange D2 Color Function
power to operate the relay.
White / Red D1 Key-On Ground
Red D3 12V relay power supply, B+.
Power From 20A In-line Circuit
Output connects relay 12V power to the Red / White C1
White D5 Breaker
fuse box buss.
Input from the brake switch
Orange C3
to energize the solenoid.
Relay switched power to the starter
White / Red D3
solenoid.

ELECTRICAL
Park Relay Glow Plug Relay
The Park Relay, controlled by the park brake switch and The Glow Plug Relay, controlled by the VCM, operates the
VCM, operates the park brake lamp and disables turf glow plug duration based on coolant temperature.
mode to 2-wheel drive.
Color Function
Key-On 12V power supply, provides
Orange A1 the relay power supply and voltage to Color Function
operate the relay. Yellow / Violet E1 Ground controlled by VCM Pin #1.
Key-On 12V power supply, provides Orange E2 Key-On 12V power.
Orange A3 the relay power supply and voltage to
operate the relay. 12V power 30 amp fuse-protected for
Red E3
glow plugs.
Ground input via the park brake switch
Orange / Red B1 to energize the solenoid. Also signals Relay switched power to the glow
Black / Red E5
VCM Pin #15 for Turf Mode to 2wd. plugs.
Relay switched power to illuminate the

Orange / Red B3 park lamp on Pin #10 of the Instrument
Cluster.
10
10.25
ELECTRICAL
Fuel Pull-In Coil Relay
The Fuel Pull-In Coil Relay, controlled by the VCM at pin
#12, operates the engine fuel pull in coil capability.
Color Function
VCM controlled relay ground at Pin
Green A1
#12
Orange A2 Key-On 12V power.
12V power 30 amp fuse-protected
Red A3
for pull-in coil operation.
Relay switched power to the pull-in
Orange / Black A5
coil.

ELECTRICAL
FUSES / CIRCUIT BREAKER / RESISTOR
Operation
The fuses, located in the fuse boxes under the hood, provide current protection for components such as the VCM, main
harness, lights, accessories and power steering (If equipped - EPS Models Only).
A 20 Amp circuit breaker, located under the hood near the relay/fuse box, protects the fan motor circuit.
10
10.27
ELECTRICAL
VEHICLE CONTROL MODULE
Operation
The Vehicle Control Module (VCM) controls or monitors the following functions on the RANGER Diesel: Fan operation
via the coolant sensor, Turf mode operation, Park Relay, High-Temp Indicator, Ground Speed, Wait to Start lamp and glow
plug operation. See complete wiring diagram for more detail.

ELECTRICAL
FUEL SOLENOID WIRING DIAGRAM
10

10.29
ELECTRICAL
CHARGING SYSTEM Charging System “Break Even” Test
Charging System Rating

CAUTION
The RANGER Diesel alternator is rated 12v, 55A, 742
watts (at 13.5v nominal voltage). Do not allow the battery cables to become
disconnected while the engine is running. Follow
Current Draw - Key Off the steps below as outlined to reduce the chance
of damage to electrical components.
CAUTION The “break even” point of the charging system is the point
at which the alternator overcomes all system loads (lights,
Do not connect or disconnect the battery cable etc.) and begins to charge the battery. Depending on
or ammeter with the engine running. Damage will battery condition and system load, the break even point
occur to electrical components. may vary slightly. The battery should be fully charged
before performing this test.
Connect an ammeter in series with the negative battery
cable. Check for current draw with the key off. If the draw
is excessive, loads should be disconnected from the WARNING
system one by one until the draw is eliminated. Check
Never start the engine with an ammeter
component wiring as well as the component for partial
connected in series. Damage to the meter or
shorts to ground to eliminate the draw.
meter fuse will result.
Do not run test for extended period of time.
Current Draw Inspection Do not run test with high amperage accessories.
Key Off 1. Using an inductive amperage metering device, (set to
DC amps) connect to the negative battery cable.
2. With engine off, and the key switch and lights in the
ON position, the ammeter should read negative amps
(battery discharge). Reverse meter lead if a positive
reading is indicated.
3. Shift transmission into neutral with the parking brake
30 Amp applied and start the engine. With the engine running
at idle, observe meter readings.
4. Increase engine RPM while observing ammeter and
tachometer.
5. Note RPM at which the battery starts to charge
(ammeter indication is positive).
Current Draw - Key Off:
Maximum of .01 DCA (10 mA) 6. With lights and other electrical loads off, the “break
even” point should occur at approximately just above
idle RPM.
7. With the engine running, turn the lights on and engage
brake to keep the brake lights on.
8. Repeat test, observing ammeter and tachometer.
With lights on, ‘break even’ charging should occur
below 2000 RPM.

ELECTRICAL
Charging System Alternator Wiring Diagram
Refer to Chapter 11 - Yanmar Engine Service, for alternator repair procedures.
10

10.31
ELECTRICAL
BATTERY SERVICE Low Maintenance Battery Inspection
The low maintenance battery is located under the seat.
Battery Information
Polaris Diesel RANGERs are equipped with a Low-
Maintenance Battery.
Diesel Battery Specs:
575 CCA @ 0 degrees F.
10HR @ 40 AH Battery
WARNING
Battery electrolyte is poisonous. It contains acid!
Serious burns can result from contact with the
skin, eyes, or clothing.
ANTIDOTE • Inspect the battery case for obvious damage such

as cracks or leaks. Look for discoloration, warping
External: Flush with water. or raised top, which may indicate the battery has
 overheated or been overcharged.
Internal: Drink large quantities of water or milk. • Make sure the battery top is clean and dry. A dirty
Follow with milk of magnesia, beaten egg, or battery actually discharges across the grime on
vegetable oil. Call a physician immediately. top of the case. Use a soft brush and a baking
 soda solution.
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.
WARNING
The gases given off by a battery are explosive.
Any spark or open flame near a battery can
cause an explosion which will spray battery acid
on anyone close to it. Should there be contact
• Inspect the battery terminals, screws and cables
with battery acid, wash the affected area with
for breakage, corrosion or loose connections.
large quantities of cool water and seek Clean the terminals and cable ends with a wire
immediate medical attention. brush and coat terminals with Nyogel™.
IMPORTANT: Don’t add acid, or distilled water to a
WARNING low maintenance battery!
CALIFORNIA PROPOSITION 65 WARNING:

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

ELECTRICAL
Battery Terminal Blocks Battery Terminals / Bolts
A terminal block is located under the seat next to the Use Polaris corrosion resistant Nyogel™ grease (PN
battery. Another terminal block under the hood provides 2871329) on battery terminals.
easy hookup for accessories.
Under Hood
Terminal Block
Under Seat
Terminal Block
=T
Battery Terminal Pinch Bolt:
13 ft-lbs (18 Nm)
Battery Removal / Installation

See Chapter 2 “Maintenance” for battery service
procedures.
=T
Terminal Block Nuts:
23 in-lbs (2.6 Nm)
10
10.33
ELECTRICAL
Conventional Battery Testing OCV - Open Circuit Voltage Test
Whenever a service complaint is related to either the Battery voltage should be checked with a digital
starting or charging systems, the battery should be multimeter. Readings of 12.6 volts or less require further
checked first. battery testing and charging. See the following chart.
Following are three tests which can easily be made on a
battery to determine its condition: OCV Test, Specific
Gravity Test and Load Test.
Battery Conductance Analyzer

Conductance describes the ability of a battery to conduct
current. A conductance tester functions by sending a low
frequency AC signal through the battery and a portion of
the current response is captured, from this output a
conductance measurement is calculated. Conductance
testing is more accurate than voltage, specific gravity, or
load testing.
Authorized Polaris dealers/distributors are required to use
the conductance analyzer when testing 12V Polaris NOTE: Lead-acid batteries should be kept at or as
batteries. near a full charge as possible. Electrolyte level should
be kept between the low and full marks. If the battery
is stored or used in a partially charged condition, or
with low electrolyte levels, hard crystal sulfation will
form on the plates, reducing the efficiency and service
life of the battery.
OPEN CIRCUIT VOLTAGE

State of Charge YuMicron™ Type
100% Charged 12.70 V
75% Charged 12.50 V
50% Charged 12.20 V
25% Charged 12.0 V
0% Charged 11.9 V or less
Load Test
A battery may indicate a full charge condition in the OCV
Polaris MDX-610P: test and the specific gravity test, but still may not have the
PN: PU-50296 storage capacity necessary to properly function in the
electrical system. For this reason, a battery capacity or
load test should be conducted whenever poor battery
performance is encountered.
This is the best test of battery condition under starting
load. Use a load testing device that has an adjustable load.
Apply a load of three times the ampere-hour rating.
At 14 seconds into the test, check battery voltage. A good
12V battery will have at least 10.5 Volts. If the reading is
low, charge the battery and retest.

ELECTRICAL
Charging Procedure
1. Remove the battery to prevent damage from leaking
or spilled acid during charging.
2. Charge the battery with a charging output no larger
than 1/10 of the battery’s amp/hr rating. Charge as
needed to raise the specific gravity to 1.270 or greater.
3. Install battery in vehicle. Coat threads of battery bolt
with a corrosion resistant dielectric grease.
Dielectric Grease:
PN 2871329
4. Connect battery cables.
WARNING
Improperly connecting or disconnecting battery
cables can result in an explosion and cause
serious injury or death. When removing the
battery, always disconnect the negative (black)
cable first. When reinstalling the battery, always
connect the negative (black) cable last.
5. After connecting the battery cables, install the cover

on the battery and attach the hold down strap.
6. Install clear battery vent tube from vehicle to battery
vent. Vent tube must be free from obstructions and
kinks and securely installed. If not, battery gases
could accumulate and cause an explosion. Vent
should be routed away from frame and body to
prevent contact with electrolyte. Avoid skin contact
with electrolyte, as severe burns could result. If
electrolyte contacts the vehicle frame, corrosion will
occur.
Off Season Storage

See Chapter 2 “Maintenance” for battery service
procedures.
10
10.35
ELECTRICAL
STARTER SYSTEM AND WIRING Voltage Drop Test
DIAGRAM The Voltage Drop Test is used to test for bad connections.
Refer to Chapter 11 - Yanmar Engine Service, for When performing the test, you are testing the amount of
starter repair procedures. voltage drop through the connection. A poor or corroded
connection will appear as a high voltage reading. Voltage
NOTE: Only torque starter B+ cable nut to 5-8 ft-lbs.
shown on the meter when testing connections should not
exceed .1 VDC per connection or component.
5-8 ft-lbs To perform the test, place the meter on DC volts and place
the meter leads across the connection to be tested. Refer
to the voltage drop tests in the “Starter System Testing
Flow Chart”.
Voltage should not exceed

.1 DC volts per connection
Troubleshooting
Starter Motor Does Not Run
• Battery discharged - Low specific gravity
• Loose or faulty battery cables or corroded
connections (see Voltage Drop Tests)
• Related wiring loose, disconnected, or corroded
• Poor ground connections at battery cable, starter
motor or starter solenoid (see Voltage Drop Tests)
• Faulty key switch
• Faulty starter solenoid or starter motor
• Engine problem - seized or binding (can engine be
rotated easily)
Starter Motor Turns Over Slowly
• Battery discharged - low specific gravity

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

ELECTRICAL
Starter Motor Wiring Diagram
10

10.37
ELECTRICAL
NOTES

2011 - 2012 RANGER DIESEL
PAGE 1 OF 2
2011-2012 RANGER DIESEL
PAGE 2 OF 2
2012 RANGER DIESEL CREW
PAGE 1 OF 2
PAGE 2 OF 2
2011-2012 RANGER DIESEL / DIESEL CREW (CARGO BOX)
PAGE 1 OF 1
2013 RANGER DIESEL
2013 RANGER DIESEL
2013 RANGER DIESEL / DIESEL CREW (CARGO BOX)

2011 2013 Ranger Diesel SM 02840

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GENERAL INFORMATION

9924084 - 2011-2013 RANGER DIESEL / CREW

Vehicle Identification Number (VIN) Designation

Vehicle Descriptors Vehicle Identifiers

1.2 9924084 - 2011-2013 RANGER DIESEL / CREW

Vehicle and Engine Serial Number Locations

Figure 1-1 Figure 1-2

Engine Serial Number

9924084 - 2011-2013 RANGER DIESEL / CREW

Model Model No. Owner’s Manual PN Parts Manual PN

NOTE: Polaris factory publications can be found at www.polarisindustries.com or purchased from

Series# Part Number

1.4 9924084 - 2011-2013 RANGER DIESEL / CREW

Bore & Stroke (mm) 72 x 74 mm Transmission Lubricant Polaris AGL plus

1.6 9924084 - 2011-2013 RANGER DIESEL / CREW

1.8 9924084 - 2011-2013 RANGER DIESEL / CREW

12V Outlets Ignition Switch

Wait-to-start (Glow plug)

Head lamp Speedometer

Ignition Switch MFD

9924084 - 2011-2013 RANGER DIESEL / CREW

1.10 9924084 - 2011-2013 RANGER DIESEL / CREW

Only the YANMAR TNM engine series 3TNM72 may

• EN14214 (European standard) and/or ASTM D-

°C to °F: 9/5(°C + 32) = °F °F to °C: 5/9(°F - 32) = °C

1.12 9924084 - 2011-2013 RANGER DIESEL / CREW

Grade 2 Grade 5 Grade 8

Grade 2 Grade 5 Grade 8

Metric Bolt Torque Specification

Bolt Size 4.6 4.8 8.8/8.9 10.9 12.9

Metric Tap / Drill Sizes

1.14 9924084 - 2011-2013 RANGER DIESEL / CREW

Severe Use Definition

• Frequent immersion in mud, water or sand

Maintenance Chart Key

 Transmission Fluid 100 H 12 M 1000 (1600) Change fluid

Grease Lubrication Points

Item Recommended Lube Method Frequency

Part No. Description Part No. Description

III. # Item Lube Rec. Method Frequency*

1. Engine Oil 2. Brake Fluid Reservoir

3. Engine Coolant* Radiator cap

View level through

III. # Item Lube Rec. Method Frequency*

4 Front Gearcase Polaris Demand Drive Plus

4. Front Gearcase 6. Transmission

Check / Fill plug

Check / Fill plug

• Wheels - check for tightness of wheel nuts and

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

Make sure lines are not kinked or pinched.

2. Replace all fuel lines every two years.

1. Lift the rear cargo box to access the airbox cover.

4. Loosen the adjuster lock nut.

4. Remove intake baffle box from the vehicle.

. Polaris All Purpose Grease to

Be sure tab and notch A

6. Reinstall the air filter into the airbox container. Be sure

5. Remove the filter element from the baffle box. Be

6. If the filter element is dirty, clean it with a high flash

7. Reinstall the filter element into the air baffle box.

8. Reinstall the baffle box, hose clamp and headlamp

2. Remove the filter element (A) from the baffle box.