Polaris Ranger 500 2017

2017-2021 RANGER 500 / 570
Service Manual
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer® technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.
Publication Printed January 2021 (PN 9850043 R01)

© Copyright 2021 Polaris Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting
or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
SAFETY WARNINGS
The following signal words and symbols appear throughout this manual and on the vehicle. Your safety is involved
when these words and symbols are used. Become familiar with their meanings before reading the manual.
DANGER
DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.
WARNING
SAFETY ALERT WARNING indicates a hazardous situation which, if not avoided, COULD result in death or serious
injury.
CAUTION
SAFETY ALERT CAUTION indicates a hazardous situation which, if not avoided, COULD result in minor to moderate
injury.
NOTICE
NOTICE provides key information by clarifying instructions.
IMPORTANT
IMPORTANT provides key reminders during disassembly, assembly and inspection of components.
TRADEMARKS
POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:
Loctite, Registered Trademark of the Loctite Corporation
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity-Vac, Registered Trademark of Neward Enterprises, Inc.
Torx, Registered Trademark of Textron
Hilliard, Trademark of the Hilliard Corporation
Warn, Trademark of Warn Industries
FOX, Registered Trademark of FOX RACING SHOX
RydeFX, Registered Trademark of ArvinMeritor
Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from
www.purepolaris.com or by contacting the nearest Polaris dealer.
REVISION INDEX
REV DATE CHANGES
R01 01/13/2021 Initial release
FEEDBACK FORM
A feedback form has been created for the technician or consumer to provide Polaris
with an overall satisfaction rating for this service manual, provide comments on your
experience or upload pictures/video. This feedback form is viewable on a mobile
device by scanning the QR code or by clicking HERE if viewing this document
electronically.
2017-2021 RANGER 500 / 570
Service Manual
Chapter Summary
CHAPTER 1 : GENERAL INFORMATION

CHAPTER 2 : MAINTENANCE
CHAPTER 3 : ENGINE / COOLING SYSTEM
CHAPTER 4 : ENGINE ELECTRICAL
CHAPTER 5 : FUEL SYSTEM
CHAPTER 6 : PVT SYSTEM
CHAPTER 7 : TRANSMISSION
CHAPTER 8 : FINAL DRIVE
CHAPTER 9 : STEERING / SUSPENSION
CHAPTER 10 : BRAKE SYSTEM
CHAPTER 11 : BODY / FRAME
CHAPTER 12 : ELECTRICAL
GENERAL INFORMATION
CHAPTER 1 1
GENERAL INFORMATION
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
MODEL NUMBER DESIGNATION (2015 +) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION (2015+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
VIN / ENGINE NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
REFERENCE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
PUBLICATION PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
MASTER SPECIAL TOOLS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
MASTER TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.17
CLUTCHING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.19
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.20
2017-2018 RANGER 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.20
2017-2018 RANGER 570 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.22
2017-2018 RANGER 570 4X4 (INTL.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.24
2017-2018 RANGER 570 4X4 TRACTOR (INTL.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.26
2017-2018 RANGER 570 CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.28
2019 RANGER 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.30
2019 RANGER 570 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.32
2019 RANGER 570 4X4 (INTL.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.34
2019 RANGER 570 4X4 TRACTOR (INTL.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.36
2019 RANGER 570 CREW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.38
2020 RANGER 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.40
2020 RANGER 570 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.42
2020 RANGER 570 CREW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.44
2021 RANGER 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.46
2021 RANGER 570 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.48
2021 RANGER 570 CREW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.50
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.52
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.52
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.53
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.54
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.55
GENERAL DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.57
GENERAL DIAGNOSTICS INFORMATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.57
GUIDED SYMPTOM DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.57
GUIDED SYMPTOM REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.58
ENGINE AND DRIVABILITY DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.59
ENGINE CRANKS BUT DOES NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.62
NO CRANK NO START OR SLOW CRANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.64
OVER HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.65
9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual

© Copyright Polaris Inc. 1.1
GENERAL INFORMATION
WARNING LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.66

ENGINE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.67
COOLING TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.69
DIGITAL WRENCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.70
DIGITAL WRENCH® SOFTWARE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.70
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.70
GUIDED DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.70
DIGITAL WRENCH® SOFTWARE INSTALLATION AND UPDATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.71
DIGITAL WRENCH® COMMUNICATION ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.72
DIGITAL WRENCH® - DIAGNOSTIC CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.72
DIGITAL WRENCH® SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.72
DIGITAL WRENCH® FEATURE MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.73
ENGINE CONTROLLER REPROGRAMMING (REFLASH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.74
POLARIS MOBILE DIGITAL WRENCH® (PMDW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.74
ENGINE ELECTRICAL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.75
DIAGNOSTIC TROUBLE CODES OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.75
MASTER TROUBLE CODE LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.76
CYLINDER MISFIRE DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.87
FLUID LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.88
FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.88
FUEL SYSTEM DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.89
FUEL SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.89
PVT SYSTEM DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.91
PVT SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.91
PVT SYSTEM OVERHEATING / DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.93
TRANSMISSION DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.94
HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.94
TRANSMISSION ISOLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.94
FINAL DRIVE DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.95
ALL WHEEL DRIVE (AWD) CONCERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.95
DRIVESHAFT (HALF SHAFT) DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.95
BRAKE SYSTEM DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.96
BRAKE NOISE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.96
BRAKE VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.96
CALIPER OVERHEATS (BRAKES DRAG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.97
POOR BRAKE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.97
BRAKES LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.97
STEERING / SUSPENSION DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.98
EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL ON) . . . . . . . . . . . . . . . . .1.98
EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL OFF) . . . . . . . . . . . . . . . .1.99
EPS TROUBLESHOOTING (USING DIGITAL WRENCH®) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.100
SHOCK ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.101
ELECTRICAL DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.102
ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.102
DIGITAL MULTI-METER (DMM) NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.102
STATIC AND DYNAMIC TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.102
CONNECTOR PROBING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.103
TESTING CONTINUITY / RESISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.104

1.2 © Copyright Polaris Inc.
GENERAL INFORMATION
TESTING FOR A SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.104

TESTING FOR A SHORT TO VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.105 1
TESTING FOR INTERMITTENT CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.106
TESTING CURRENT FLOW (AMPERAGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.106
CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.107
TESTING VOLTAGE DROP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.107

GENERAL INFORMATION
VEHICLE INFORMATION
MODEL NUMBER DESIGNATION (2015 +)
Example: R15RUE57AC
GROUP MODEL YEAR MAKE / CHASSIS CODE ENGINE CODE REGION OPTION
1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th 10th**
R 1 5 R U E 5 7 A C
* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively
** = 10th digit will be used on color/featured versions of models (not including the base)
First 3 digits and 10th digit are used in model number only. They are not used with the 17 digit VIN.
Digits 1 through 8 determine Digital Wrench calibration.
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION (2015+)

Example: 4XARUE573FG000000
VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS

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

Whenever corresponding about a Polaris RANGER utility vehicle, be sure to refer to the Vehicle Identification Number
(VIN) and the engine model and serial number.
The VIN q can be found stamped on the upper frame rail on the rear LH side of the vehicle below the cargo box.
The engine model and serial number w can be found on a decal applied to the engine’s magneto cover.

GENERAL INFORMATION
REFERENCE INFORMATION
REPLACEMENT KEYS 1
Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the
original key and refer to the chart to the right for the proper part number.
(i.e. In this example, the first two digits are 31 which would use key blank PN 4110141.)
SERIES# PART NUMBER

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

GENERAL INFORMATION
PUBLICATION PART NUMBERS

MODEL MODEL NUMBER OWNER’S MANUAL
2017 RANGER 500 2x4 R17RM250A1
R17RMA50A1 9927885
2017 RANGER 500
R17RMA50A4
R17RMA57A1
2017 RANGER 570 / EPS R17RMA57A9
R17RME57AK
2017 RANGER 570 HD R17RMH57A4
9927170
2017 RANGER 570 CREW R17RNA57A1
R17RNA57A9
2017 RANGER 570 CREW EPS R17RNE57AM
R17RNE57NM
2017 RANGER 570 (Intl.) R17RMA57F1

R17RMA57N1
9927385
2017 RANGER 570 EPS (Intl.) R17RME57F1
R17RMS57F1
2017 RANGER 570 Tractor (Intl.) R17RMT57C1

R17RMT57E1
R17RMS57C1 9927386
2017 RANGER 570 EPS Tractor (Intl.) R17RMS57CK
R17RMS57E1
R17RMS57EK
2018 RANGER 500 2x4 R18RM250B1
R18RMA50B1 9928588
2018 RANGER 500
R18RMA50B4
R18RMA57B1
2018 RANGER 570 / EPS R18RMA57B9
R18RME57BV
2018 RANGER 570 HD (Intl.) R18RME57N4
9928587
2018 RANGER 570 CREW R18RNA57B1
R18RNA57B9
2018 RANGER 570 CREW EPS R18RNE57BV
R18RNE57NV

R18RMA57L1 9928409
2018 RANGER 570 EPS (Intl.) R18RMS57F1
R18RMT57C1
2018 RANGER 570 Tractor (Intl.) R18RMT57E1
R18RMS57EV
9928410
R18RMS57C1
2018 RANGER 570 EPS Tractor (Intl.) R18RMS57CV
R18RMS57E1
2019 RANGER 500 2x4 R19RM250B1
R19RMA50B1
2019 RANGER 500
R19RMA50B4
9928852
R19RMA57B1
2019 RANGER 570 / EPS R19RMA57B9
R19RME57BX

GENERAL INFORMATION
MODEL MODEL NUMBER OWNER’S MANUAL

2019 RANGER 570 HD (Intl.) R19RME57D7 1
2019 RANGER 570 CREW R19RNA57B1
R19RNA57B9
2019 RANGER 570 CREW EPS
R19RNE57BX

R19RMA57L7 9929233
2019 RANGER 570 EPS (Intl.) R19RMS57F1
2019 RANGER 570 Tractor (Intl.) R19RMS57E1
9929235
2019 RANGER 570 EPS Tractor (Intl.) R19RMS57C1
R20MAA50B1
2020 RANGER 500 R20MAA50B7
R20MAA50J7
R20MAA57B1
2020 RANGER 570 / EPS R20MAA57B9
R20MAE57BH
2020 RANGER 570 HD (Intl.) R20MAE57D7 9931336
R20M4A57B1
2020 RANGER 570 CREW R20M4A57B9
R20M4A57L1
2020 RANGER 570 CREW EPS R20M4E57BH
2020 RANGER 570 (Intl.) R20MAA57K1
R21MAA50B1
2021 RANGER 500 R21MAA50B7
R21MAA50J7
R21MAA57B1
2021 RANGER 570 / EPS R21MAA57B9
R21MAE57BX 9931254
2021 RANGER 570 HD (Intl.) R21MAE57D7
R21M4A57B1
2021 RANGER 570 CREW
R21M4A57B9
2021 RANGER 570 CREW EPS R21M4E57BX
2021 RANGER 570 (Intl.) R21MAA57F1

R21MAA57F9
9931411
2021 RANGER 570 EPS (Intl.) R21MAS57F1
R21MAS57F9
R21MAS57C1
2021 RANGER 570 EPS Tractor (Intl.) R21MAS57C9 9931412
R21MAS57CK
NOTICE
When ordering service parts be sure to use the correct parts manual.
Polaris factory publications can be found at www.polaris.com or purchased from www.purepolaris.com.

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

GENERAL INFORMATION
MASTER SPECIAL TOOLS TABLE

ENGINE / COOLING SYSTEM 1
GENERAL
Bench Mount Engine Stand Adapter Rolling Engine Stand Engine Stand Adapter
PW-47053 PU-50624 (Mounts To The Engine)
PU-50824-A
Engine Stand Sleeve Adapter Engine Stand Sleeve Adapter Flywheel Puller
(Use With 2” Bore Stand) (Use With 2.375” Bore Stand) PA-49316
PU-50625 PW-47054
Stator Cover Removal Handles Valve Spring Compressor Water Pump Seal Installation Tool
PA-49317 PV-1253 PU-50869

GENERAL INFORMATION
ENGINE / COOLING SYSTEM

GENERAL
Crankshaft Removal / Installation Oil Filter Wrench Oil Pressure Gauge
Tool Kit PU-50105 PV-43531
PU-50784
Oil Pressure Gauge Adapter (2017 Oil Pressure Gauge Adapter (2018 Valve Spring Compressor Adapter
and earlier models) and later models) PV-43513-A
PU-50569 PU-52502
570 ONLY
Cylinder Holding &
Camshaft Timing Plate
PU-50563

GENERAL INFORMATION
FUEL SYSTEM
Digital Wrench Kit Digital Wrench Smart *Serial Number Registration Card 1
PU-47063-C Link Module Kit PU-48731-A
PU-47471
(Includes: PU-47470, PU-47469,
PU-47468)
*Digital Wrench® PC Interface Cable *Digital Wrench® Vehicle *Digital Wrench® SmartLink Module
PU-47470 Interface Cable PU-47468
PU-47469
Digital Wrench® Wireless Fuel Pressure Gauge Kit Fuel Pressure Gauge Adapter
Vehicle Link PU-43506-A PV-48656
PU-51435

GENERAL INFORMATION
FUEL SYSTEM
Fuel Pressure Gauge Adapter Fluke 77 Digital Multi-Meter Throttle Position Sensor Tester Kit
PS-48762 (Fluke 77: PV-43568) 2201519-A
(Includes: 547927, PU-47466)
Laptop or Desktop Computer USB/

Serial Adaptor: Saelig RS-232
Commercially Available (refer to
diagnostic software user manual or
HELP section for minimum
requirements)

GENERAL INFORMATION
PVT SYSTEM
Clutch Bushing Replacement Drive Clutch Puller - Short Drive Clutch Holding Tool 1
Tool Kit PA-48595 9314177-A
2871226
Drive Clutch Spider Removal Piston Pin Puller Roller Pin Tool
and Install Tool 2870386 2870910-A
2870341
Universal Clutch Compressor Tool Standard Clutch Alignment Tool Clutch Center Distance Tool
PU-50518-A 2870654 PU-50658-A

GENERAL INFORMATION
TRANSMISSION
Bearing Seal Driver (50 mm) Backlash Setting Tool Rear Driveshaft Seal Guide
2871282 2871695 (Part of 2871702 Kit) 2871699 (Part of 2871702 Kit)
Rear Output Seal Driver Snorkel Tool Transmission Nut Socket

2871698 (Part of 2871702 Kit) PA-50231 PU-50566
FINAL DRIVE
1 3/4” Straight Wrench ADC Gearcase Piston CV Boot Clamp Pliers
2870772 Installation Tool 8700226 or PU-48951
PA-48542
Roller Pin Removal Tool

2872608

GENERAL INFORMATION
STEERING / SUSPENSION
Ball Joint Removal / Installation Tool Strut Compression Tools Shock Absorber Spring 1
2870871 2871573, 2871574 Compression Tool
2870623
BRAKES
Mity Vac® Pressure Test Tool
2870975
BODY / FRAME
Multi-Function Pliers
2876389

GENERAL INFORMATION
ELECTRICAL
Battery Conductance Analyzer Battery Hydrometer Fluke® 77 Digital Multimeter
PU-50296 PU-50338 PV-43568
Hall Sensor Probe Harness Static Timing Light Harness Timing Light
2460761 2871745 2870630
Relay Bypass Connector Test Kit

PU-49466 PV-43526

GENERAL INFORMATION
MASTER TORQUE TABLE ITEM TORQUE

ITEM TORQUE Apply light coat of 1
Ball Joint Nut 30 ft-lbs (41 Nm) engine oil to bolt
threads and under bolt
Ball Joint Retaining Plate 8 ft-lbs (11 Nm) head
Screws
Torque in sequence for
Bearing Carrier Fasteners 40 ft-lbs (54 Nm) all steps
Body Screws (T-40) 8 ft-lbs (11 Nm) Step 1: 18 ft-lbs (25
N·m)
Brake Disc Mounting Bolts
18 ft-lbs (25 Nm)
(front) Step 2: 30 ft-lbs (41
N·m)
Brake Disc Mounting Bolts
27 ft-lbs (36 Nm)
(rear) Step 3: Loosen all
Cylinder Head Bolts - Silver fasteners until they are
Brake Bleed Screws 47 in-lbs (5 Nm) unseated
Brake Caliper Mounting Bolts 46 ft-lbs (62 Nm) Step 4: 15 ft-lbs (20
Brake Line Banjo Bolts 15 ft-lbs (20 Nm) N·m)
Brake Line Flare Fittings 14 ft-lbs (19 Nm) Step 5: 26 ft-lbs (35
N·m)
Brake Switch 15 ft-lbs (20 Nm)
Step 6: Additional 180°
Cam Chain Tensioner RGR 37 ft-lbs (50 Nm) Step 7: Additional 180°
500
Cam Chain Tensioner RGR Torque the Outer M6
30 ft-lbs (40 Nm) Head Bolts 89 ± 9 in-lbs
570
(10 ± 1 Nm)
Cam Chain Guide Fasteners 9 ft-lbs (12 Nm)
Differential Cover Screws 22 ft-lbs (30 Nm)
Camshaft Carrier Bolts 8 ft-lbs (10 Nm)
Drive Clutch Retaining Bolt 45 ft-lbs (61 Nm)
Camshaft Sprocket BoltsRGR 45 ft-lbs (60 Nm)
500 Driven Clutch Retaining Bolt 38 ft-lb (52 Nm)
Camshaft Sprocket BoltsRGR 14 ft-lbs (19 Nm) Drive Clutch Cover Plate
570 8 ft-lbs (10 Nm)
Screw
Chassis Ground Fastener 54 in-lbs (6 Nm) Drive Clutch Spider 290 ft-lbs (393 Nm)
Control Arm Fasteners Drive Clutch Spring Retaining
40 ft-lbs (54 Nm) 12 ft-lbs (16 Nm)
(front and rear) Ring Bolts
Coolant Bleed Screw 72 in-lbs (8 Nm) Driven Clutch Retaining Bolt 38 ft-lbs (51 Nm)
Coolant Temperature Sensor 17 ft-lbs (23 Nm) ETC Fasteners 7 ft-lbs (10 N·m)
CPS Retaining Bolt 9 ft-lbs (12 Nm) ECU Mounting Screws 10 in-lbs (1 Nm)
Crankcase Bolts 22 ft-lbs (30 Nm) Engine Oil Plug 12 ft-lbs (16 Nm)
Crankshaft Bearing Retainer Engine Oil Gallery Plug 14 ft-lbs (18 Nm)
8 ft-lbs (11 Nm)
(PTO)
Engine Mount (front) 40 ft-lbs (54 Nm)
Torque in sequence for In Sequence:
all steps Engine/Transmission
55 ft-lb (75 Nm)
Mounting Bolts (570)
Step 1: 21 ft-lbs (28 *see procedure for sequence
N·m) Exhaust Head Pipe Bolts 18 ft-lbs (25 Nm)
Cylinder Head Bolts - Black Step 2: 26 ft-lbs (35
Flywheel Nut 133 ft-lbs (180 Nm)
N·m)
Frame Bolts (front to rear) 40 ft-lbs (54 Nm)
CREW
Torque the Outer M6 Front Bumper / Fender
Head Bolts 89 ± 9 in-lbs 5 ft-lbs (7 Nm)
Screws
(10 ± 1 Nm)
Front Gearcase Cover Plate 11 ft-lbs (15 Nm)
Screws

GENERAL INFORMATION
ITEM TORQUE ITEM TORQUE

Front Gearcase Drain/Fill Steering Rack Mounting Bolts 16 ft-lbs (22 Nm)
10 ft-lbs (14 Nm)
Plugs
Steering Shaft to EPS Unit 20 ft-lbs (27 Nm)
Front Gearcase Mounting 33 ft-lbs (56 Nm)
Bolts Steering Shaft to Steering 46–51 ft-lbs (62-69 Nm)
Rack
Fuel Pump PFA Nut 70 ft-lbs (90 Nm)
Steering Wheel Nut 65 ft-lbs (88 Nm)
Fuel Rail Mounting Screws 7 ft-lbs (10 Nm)
Strut Casting Pinch Bolt 17 ft-lbs (23 Nm)
Fuel Tank Mounting Screw 17 ft-lbs (23 Nm)
Strut Mounting Nut (top) 15 ft-lbs (21 Nm)
Hub Castle Nut (front) 90 ft-lbs (122 Nm)
Thermostat Cover Bolts 8 ft-lbs (10 Nm)
Hub Castle Nut (rear) 110 ft-lbs (150 Nm)
Throttle Pedal Mounting Nuts 8 ft-lbs (11 Nm)
IAC Mount Screw 18 in-lbs (2 Nm)
Tie Rod End to Knuckle 40 ft-lbs (54 Nm)
Master Cylinder Mount Bolts 17 ft-lbs (23 Nm)
Tie Rod Jamb Nuts 14 ft-lbs (19 Nm)
Oil Pump Cover Bolt 9 ft-lbs (12 Nm)
TMAP Retaining Bolt 24 in-lbs (3 Nm)
Power Steering Bracket to 15 ft-lbs (20 Nm)
Frame Nuts TPS Mounting Screws 18 in-lbs (2 Nm)
Power Steering Unit to Mount Transmission Bell Crank Nut 15 ft-lbs (20 Nm)
30 ft-lbs (41 Nm)
Bracket
Transmission Case Screws 18 ft-lbs (24 Nm)
Prop Shaft Support Bearing 36 ft-lbs (49 Nm)
Fasteners Transmission Drain / Fill
14 ft-lbs (19 Nm)
Plugs
Prop Shaft Support Bearing 35 in-lbs (4 Nm)
Set Screws Transmission Isolator Bolt
40 ft-lbs (54 Nm)
(rear)
PVT Inner Cover Screws
50 in-lbs (5 Nm)
(Phillips) Transmission Rear Mount 17 ft-lbs (23 Nm)
Bracket Fasteners
PVT Inner Cover Screws
12 ft-lbs (16 Nm) Transmission Joint Bracket
(Hex) ft-lbs ( Nm)
Bolts
PVT Outer Cover Screws 50 in-lbs (5 Nm)
Transmission Park Flange 8 ft-lbs (11 Nm)
Seat Belt Mounting Fasteners 40 ft-lbs (54 Nm) Screws
Shift Cable Bracket Bolts 37 ft-lbs (50 Nm) Transmission Sector Gear 11 ft-lbs (15 Nm)
Cover
Shock Mounting Fasteners
40 ft-lbs (54 Nm) Transmission Shift Fork
(rear) 10 ft-lbs (14 Nm)
Screws
Skid Plate Fasteners 8 ft-lbs (11 Nm)
Transmission Snorkel Bearing
8 ft-lbs (11 Nm)
15ft-lbs (20 Nm) Retaining Plate Screws
Spark Plug
Do Not Apply Anti-Seize
Transmission Snorkel Tube
8 ft-lbs (11 Nm)
9ft-lbs (12 Nm) Locking Screw
Spark Plug
Do Not Apply Anti-Seize
TRS Retaining Nuts 7 ft-lbs (10 Nm)
Speed Sensor Screw 10 ft-lbs (14 Nm)
TPS Mounting Screws 18 in-lbs (2 Nm)
Stabilizer Bar Linkage (rear) 17 ft-lbs (23 Nm)
Valve Cover Bolts 8 ft-lbs (10 Nm)
Stabilizer Bar Mounting
17 ft-lbs (23 Nm) Finger Tight
Bracket Bolts (rear) Water Pump Impeller
*LH threads
Starter Mounting Bolts 8 ft-lbs (10 Nm) 9 ft-lbs (12 Nm)
Starter Power Wire Nut 54 in-lbs (6 Nm) Water Pump Cover Bolts (Apply Loctite® 204™ to
bolt threads)
Starter One-Way Clutch Bolts 9 ft-lbs (12 Nm)
Wheel Lug Nuts (Steel
9 ft-lbs (12 Nm) 36 ft-lbs (49 Nm)
Stator Cover Screws Wheels)
Stator Mounting Bolts 9 ft-lbs (12 Nm) Wheel Lug Nuts (Aluminum
30 ft-lbs + 90º (41 Nm + 90º)
Wheels)
Stator Wire Retainer 6 ft-lbs (9 Nm)

GENERAL INFORMATION
CLUTCHING CHART
RANGER 500 1
SHIFT DRIVE
ALTITUDE
WEIGHT SPRING
0-1800 25–52G Black
Meters (0-6000) (5632409) (7043594)
(Feet) 1800-3700 25-48 Black
(6000 - 12000) (5633217) (7043594)
RANGER 570
SHIFT DRIVE
ALTITUDE
WEIGHT SPRING
0-1800 25–52G Black
Meters (0-6000) (5632409) (7043594)
(Feet) 1800-3700 25-48 Black
(6000 - 12000) (5633217) (7043594)
RANGER CREW 570
SHIFT DRIVE
ALTITUDE
WEIGHT SPRING
0-1800 25-52G Black
Meters (0-6000) (5632409) (7043594)
(Feet) 1800-3700 25-48 Black
(6000 - 12000) (5633217) (7043594)

GENERAL INFORMATION
GENERAL SPECIFICATIONS
2017-2018 RANGER 500
MODEL NUMBER:
2017 2x4: R17RM250A1
2017 4x4: R17RMA50A4
2018 2x4: R18RM250B1
2018 4x4: R18RMA50B1
DIMENSION /
CATEGORY
CAPACITY
Length 110″ / 279.4 cm
Width 58″ / 147.3 cm
Height 73″ / 185 cm
Wheel Base 73″ / 185 cm
Ground Clearance 10″ / 25.4 cm
Turning Radius 150″ / 381 cm
Dry Weight 1080 lbs. / 490 kg
Cargo Box Capacity 500 lbs. / 227 kg
Cargo Box Dimensions L- 42″ x W-32″ x H-11.5″
(inside dimensions) (107 x 81 x 29 cm)
1000 lbs. / 454 kg
(Includes weight of
Vehicle Payload
riders, cargo and
accessories)
Towing Capacity 1500 lbs. / 680.4kg
Hitch Tongue Capacity 150 lbs. / 68 kg

GENERAL INFORMATION
MODEL SPECIFICATIONS DRIVETRAIN
ENGINE
Front Gearcase Lubricant
Requirement
Demand Drive
6.7–7.6 oz. (200–225 ml) 1
Single overhead cam, 2 valve
Platform 4 stroke single cylinder. Transmission Lubricant Full Synthetic AGL
Requirement 33.8 oz. (1000 ml)
Engine Displacement 500cc
Bore & Stroke 93 mm x 73.6 mm Toe Out 1/8 − 1/4″ (3.20 − 6.35 mm)
Compression Ratio 10:1
Front Suspension Strut / A-arm
Engine Idle Speed 1250 ±200 RPM
Front Travel 9″ (20.3 cm)
Engine Max Speed 7000 RPM
Rear Suspension Independent (IRS), Dual A-
0.006 ± 0.002" (0.152 ± 0.051 arm, Anti-Sway Bar
Valve Clearance (Intake)
mm)
Rear Travel 10″ (22.9 cm)
0.010 ± 0.002" (0.254 ± 0.051
Valve Clearance (Exhaust) Spring Adjustment Cam adjustment (rear)
mm)
Oil Requirements PS4 synthetic WHEELS / BRAKES
Front Wheel Size / Type 12 x 8 / Steel
Oil Capacity 2.0 qts. (1.9 l)
Rear Wheel Size / Type 12 x 9 / Steel
Coolant Capacity 120 Oz (3.5 L)
Front Tire Model / Size AT489 / 24 x 8 - 12
FUEL SYSTEM
Rear Tire Model / Size AT489 / 24 x 9 - 12
Type Bosch ME17 EFI
Front: 10 psi (69 kPa)
Fuel Delivery Electronic Fuel Pump (in- Tire Air Pressure Rear: 10 psi (69 kPa)
tank)
Brake System 4 Wheel Hydraulic Disc
Fuel Pressure 58 ± 2 PSI (400 ± 14 kPa)
Brake Fluid DOT 4
Fuel Capacity / Requirement 8.8 gal. (33.3 L) 87 Octane
Parking Brake Transmission - Park Lock
(minimum)
ELECTRICAL
Alternator Max Output 560 W @ 3000 RPM
Headlights 2 single beam
50W quartz/halogen
Taillights / Brake Lights 10 LED 0.28 Watt / 3.1 Watt
Indicator Light 1.0 W
Ignition Timing ECU Controlled
Spark Plug / Gap Autolite 5923 / 0.030” - 0.037”
(0.85 +/- 0.08 mm)
Battery / Amp Hr Yuasa Conventional 14 Amp
Hr / 12 Volt
DC Outlet Standard 12 Volt
Relays EFI / Chassis / Fan / Fuel
Pump / Headlight / EPS (EPS
model only)
Circuit Breaker Fan Motor: 20 Amp
Fuses Brake Light: 5 Amp
EFI: 20 Amp
Fuel Pump: 10 Amp
EPS (EPS model only): 20
Amp
Accessory: 20 Amp
Drive: 10 Amp
Lights: 20 Amp
DRIVETRAIN
Transmission Type Polaris Automatic PVT
Shift Type In Line Shift - P/ H / L / N / R

GENERAL INFORMATION
2017-2018 RANGER 570 4X4

MODEL NUMBER:
2017: R17RMA57A1/A9, R17RME57AK
2018: R18RMA57B1/B9
DIMENSION /
CATEGORY
CAPACITY
Length 110″ / 279.4 cm
Width 58″ / 147.3 cm
1075 lbs. (488 kg) (570)
1100 lbs. (499 kg) (570
Dry Weight EPS)
1140 lbs. (517 kg) (570
w/park
1000 lbs. / 454 kg
(Includes weight of
Vehicle Payload
riders, cargo and
accessories)

GENERAL INFORMATION
ENGINE
Transmission Type
Shift Type
Polaris Automatic PVT
1
Domestic Single Cyl., Liquid In Line Shift - P/ H / L / N / R
Platform Cooled, 4–Stroke, DOHC Front Gearcase Lubricant Demand Drive
Engine Displacement 567cc Requirement 6.7–7.6 oz. (200–225 ml)
Bore & Stroke 99 x 73.6 mm Transmission Lubricant Full Synthetic AGL
80-120 psi (compression
Compression Pressure Toe Out 1/8 − 1/4″
release)
(3.20 − 6.35 mm)
Engine Idle Speed 1200 +/- 100 RPM
0.005-0.007″ (0.125–0.175
Valve Clearance (Intake) Rear Suspension Independent (IRS)
mm)
0.008 ± 0.002″ (0.152–0.254 Rear Travel 9″ (22.9 cm)
Valve Clearance (Exhaust)
mm) Spring Adjustment Cam adjustment (rear)
Oil Capacity 2 qts. (1.9 L) Front Wheel Size / Type 12 x 6 / Steel
Coolant Capacity 120 Oz (3.5 L) Rear Wheel Size / Type 12 x 8 / Steel
FUEL SYSTEM Front Tire Model / Size AT489 / 25 x 8 R12
Type Bosch ME17 EFI Rear Tire Model / Size AT489 / 25 x 11 R12
Fuel Delivery Electronic Fuel Pump (in- Front: 10 psi (69 kPa)
Tire Air Pressure Rear: 10 psi (69 kPa)
tank)
Fuel Pressure 58 ± 2 PSI (400 ± 14 kPa) Brake System 4 Wheel Hydraulic Disc
Fuel Capacity / Requirement 8.8 gal. (33.3 L) 87 Octane Brake Fluid DOT 4
(minimum) Parking Brake Transmission - Park Lock
ELECTRICAL
50W quartz/halogen
Indicator Light 1.0 Watt
Spark Plug / Gap NGK MR7F / 0.0276 −
0.0315″
(0.7 – 0.9 mm)
Hr / 12 Volt
model only)
EFI: 20 Amp
Fuel Pump: 10 Amp
Amp
Accessory: 20 Amp
Drive: 10 Amp
Lights: 20 Amp

GENERAL INFORMATION
2017-2018 RANGER 570 4X4 (INTL.)

MODEL NUMBER:
2017: R17RMA57N1, R17RMT57C1, R17RME57F1, R17RMS57F1
2018: R18RMS57F1
DIMENSION /
CATEGORY
CAPACITY
Length 110″ / 279.4 cm
Width 58″ / 147.3 cm
1075 lbs. (488 kg) (570)
1100 lbs. (499 kg) (570
Dry Weight EPS)
1140 lbs. (517 kg) (570
w/park)
1000 lbs. / 454 kg
(Includes weight of
Vehicle Payload
riders, cargo and
accessories)

GENERAL INFORMATION
ENGINE
Transmission Type
Shift Type
1
Compression Pressure Toe Out 1/8 − 1/4″ (3.20 − 6.35 mm)
release)
Engine Idle Speed 1200 +/- 100 RPM Front Suspension Strut / A-arm
Engine Max Speed 7750 RPM Front Travel 8″ (20.3 cm)
0.005-0.007″ (0.125–0.175 Rear Suspension Independent (IRS)

mm) Rear Travel 9″ (22.9 cm)
0.008 ± 0.002″ (0.152–0.254 Spring Adjustment Cam adjustment (rear)
mm)
WHEELS / BRAKES
Oil Requirements PS4 synthetic Front Wheel Size / Type 12 x 6 / Steel
Oil Capacity 2 qts. (1.9 L) Rear Wheel Size / Type 12 x 8 / Steel
Coolant Capacity 120 Oz (3.5 L) Front Tire Model / Size AT489 / 25 x 8 R12
FUEL SYSTEM Rear Tire Model / Size AT489 / 25 x 11 R12
Type Bosch ME17 EFI Front: 10 psi (69 kPa)
Fuel Delivery Electronic Fuel Pump (in-
tank) Brake System 4 Wheel Hydraulic Disc
Fuel Pressure 58 ± 2 PSI (400 ± 14 kPa) Brake Fluid DOT 4
Fuel Capacity / Requirement 8.8 gal. (33.3 L) 87 Octane Parking Brake Transmission - Park Lock
(minimum)
ELECTRICAL
50W quartz/halogen
0.0315″
(0.7 – 0.9 mm)
Hr / 12 Volt
model only)
EFI: 20 Amp
Fuel Pump: 10 Amp
Amp
Accessory: 20 Amp
Drive: 10 Amp
Lights: 20 Amp

GENERAL INFORMATION
2017-2018 RANGER 570 4X4 TRACTOR

(INTL.)
MODEL NUMBER:
2017: R17RMT57C1, R17RMS57C1, R17RMS57CK
2018: R18RMS57C1, R18RMS57CV, R18RMT57C1
DIMENSION /
CATEGORY
CAPACITY
Length 110″ / 279.4 cm
Width 58″ / 147.3 cm
1075 lbs. (488 kg) (570)
1100 lbs. (499 kg) (570
Dry Weight EPS)
1140 lbs. (517 kg) (570
w/park)
1000 lbs. / 454 kg
(Includes weight of
Vehicle Payload
riders, cargo and
accessories)

GENERAL INFORMATION
ENGINE
Transmission Type
Shift Type
1
release)

mm)
WHEELS / BRAKES
(minimum)
ELECTRICAL
50W quartz/halogen
0.0315″
(0.7 – 0.9 mm)
Hr / 12 Volt
model only)
EFI: 20 Amp
Fuel Pump: 10 Amp
Amp
Accessory: 20 Amp
Drive: 10 Amp
Lights: 20 Amp

GENERAL INFORMATION
2017-2018 RANGER 570 CREW

MODEL NUMBER:
2017: R17RNA57A1
EPS: R17RNE57AM, R17RNE57NM, R17RNA57A9
2018: R18RNA57B1
R18RNA57B9
EPS: R18RNE57BV
R18RNE57NV
CATEGORY DIMENSION / CAPACITY

Length 140″ / 355.6 cm
Width 60″ / 152.4 cm
Wheel Base 105″ / 266.7 cm
1352 lbs. / 613 kg (W /
EPS)
Vehicle Payload 1250 lbs. / 567 kg
(Includes weight of
riders, cargo and
accessories)
Towing Capacity 1500 lbs. / 680.4 kg

GENERAL INFORMATION
MODEL SPECIFICATIONS ELECTRICAL
ENGINE
Circuit Breaker
Fuses
Fan Motor: 20 Amp
Brake Light: 5 Amp
1
Domestic Single Cyl., Liquid
Platform Cooled, 4–Stroke, DOHC EFI: 20 Amp
Fuel Pump: 10 Amp
Engine Displacement 567cc EPS (EPS model only): 20
Number of Cylinders 1 Amp
Accessory: 20 Amp
Bore & Stroke 99 x 73.6 mm Drive: 10 Amp
Compression Ratio 10:1 Lights: 20 Amp
80-120 psi (compression DRIVETRAIN
Compression Pressure
release) Transmission Type Polaris Automatic PVT
Engine Idle Speed 1200 +/- 100 RPM Shift Type In Line Shift - P/ H / L / N / R
Engine Max Speed 7750 RPM Front Gearcase Lubricant Demand Drive
0.005–0.007″ (0.125–0.175 Requirement 8.97 oz. (265 ml)
mm) Transmission Lubricant Full Synthetic AGL
0.008 ± 0.002″ (0.152–0.254 Requirement 33.8 oz. (1000 ml)
mm) STEERING / SUSPENSION
Lubrication Pressurized Dry Sump Toe Out 1/8 − 1/4″ (3.20 − 6.35 mm)
Oil Requirements PS4 synthetic Front Suspension Strut / A-arm
Oil Capacity 2 qts. (1.9 L) Front Travel 8″ (20.3 cm)
Coolant Capacity 170 Oz (5 L) Rear Suspension Independent (IRS)
FUEL SYSTEM Rear Travel 9″ (23 cm)
Type Bosch M17 EFI Spring Adjustment Cam Adjustment (rear)
Fuel Delivery Electronic Fuel Pump (in- WHEELS / BRAKES
tank)
Front Tire Model / Size AT489 / 25 x 8 R12
(minimum)
Rear Tire Model / Size AT489 / 25 x 11 R12
ELECTRICAL
Tire Air Pressure Front: 10 psi
Alternator Max Output 560 W @ 3000 RPM Rear: 14 psi
Headlights 2 single beam Brake System 4 Wheel Hydraulic Disc
50W quartz/halogen
Brake Fluid DOT 4
Parking Brake Transmission — Park Lock
Indicator Lamp 1.0 Watt
0.0315″
(0.7 – 0.8 mm)
Hr / 12 Volt
Instrumentation Multifunction Instrument
Cluster
model only)

GENERAL INFORMATION
2019 RANGER 500

MODEL NUMBER:
2x4: R19RMA50B1
4x4: R19RMA50B4
DIMENSION /
CATEGORY
CAPACITY
Length 110″ / 279.4 cm
Width 58″ / 147.3 cm
1000 lbs. / 454 kg
(Includes weight of
Vehicle Payload
riders, cargo and
accessories)

GENERAL INFORMATION
ENGINE
Requirement
Demand Drive
6.7–7.6 oz. (200–225 ml) 1
0.006 ± 0.002" (0.152 ± 0.051 arm, Anti-Sway Bar
mm)
0.010 ± 0.002" (0.254 ± 0.051
mm)
FUEL SYSTEM
Type Bosch ME17 EFI
tank)
Brake Fluid DOT 4
(minimum)
ELECTRICAL
50W quartz/halogen
(0.85 +/- 0.08 mm)
Hr / 12 Volt
model only)
EFI: 20 Amp
Fuel Pump: 10 Amp
Amp
Accessory: 20 Amp
Drive: 10 Amp
Lights: 20 Amp
DRIVETRAIN

GENERAL INFORMATION
2019 RANGER 570 4X4

MODEL NUMBER:
R19RCA57A1, R19RCA57A4, R19RCA57B1, R19RCA57B4
DIMENSION /
CATEGORY
CAPACITY
Length 110″ / 279.4 cm
Width 58″ / 147.3 cm
1075 lbs. (488 kg) (570)
1100 lbs. (499 kg) (570
Dry Weight EPS)
1140 lbs. (517 kg) (570
w/park)
1000 lbs. / 454 kg
(Includes weight of
Vehicle Payload
riders, cargo and
accessories)

GENERAL INFORMATION
ENGINE
Transmission Type
Shift Type
1
release)
(3.20 − 6.35 mm)
0.005-0.007″ (0.125–0.175
mm)
0.008 ± 0.002″ (0.152–0.254 Rear Travel 9″ (22.9 cm)
tank)
ELECTRICAL
50W quartz/halogen
0.0315″
(0.7 – 0.9 mm)
Hr / 12 Volt
model only)
EFI: 20 Amp
Fuel Pump: 10 Amp
Amp
Accessory: 20 Amp
Drive: 10 Amp
Lights: 20 Amp

GENERAL INFORMATION
2019 RANGER 570 4X4 (INTL.)

MODEL NUMBER:
R19RMA57F1
DIMENSION /
CATEGORY
CAPACITY
Length 110″ / 279.4 cm
Width 58″ / 147.3 cm
1075 lbs. (488 kg) (570)
1100 lbs. (499 kg) (570
Dry Weight EPS)
1140 lbs. (517 kg) (570
w/park
1000 lbs. / 454 kg
(Includes weight of
Vehicle Payload
riders, cargo and
accessories)

GENERAL INFORMATION
ENGINE
Transmission Type
Shift Type
1
release)

mm)
WHEELS / BRAKES
(minimum)
ELECTRICAL
50W quartz/halogen
0.0315″
(0.7 – 0.9 mm)
Hr / 12 Volt
model only)
EFI: 20 Amp
Fuel Pump: 10 Amp
Amp
Accessory: 20 Amp
Drive: 10 Amp
Lights: 20 Amp

GENERAL INFORMATION
2019 RANGER 570 4X4 TRACTOR (INTL.)

MODEL NUMBER:
R19RMS57C1
DIMENSION /
CATEGORY
CAPACITY
Length 110″ / 279.4 cm
Width 58″ / 147.3 cm
1075 lbs. (488 kg) (570)
1100 lbs. (499 kg) (570
Dry Weight EPS)
1140 lbs. (517 kg) (570
w/park
1000 lbs. / 454 kg
(Includes weight of
Vehicle Payload
riders, cargo and
accessories)

GENERAL INFORMATION
ENGINE
Transmission Type
Shift Type
1
release)

mm)
WHEELS / BRAKES
(minimum)
ELECTRICAL
50W quartz/halogen
0.0315″
(0.7 – 0.9 mm)
Hr / 12 Volt
model only)
EFI: 20 Amp
Fuel Pump: 10 Amp
Amp
Accessory: 20 Amp
Drive: 10 Amp
Lights: 20 Amp

GENERAL INFORMATION

MODEL NUMBER:
R19RNA57B1
EPS: R19RNE57BX
R19RNA57B9

Length 140″ / 355.6 cm
Width 60″ / 152.4 cm
1352 lbs. / 613 kg (W /
EPS)
(Includes weight of
riders, cargo and
accessories)

GENERAL INFORMATION
ENGINE
Circuit Breaker
Fuses
Fan Motor: 20 Amp
Brake Light: 5 Amp
1
Fuel Pump: 10 Amp
Accessory: 20 Amp
tank)
(minimum)
ELECTRICAL
50W quartz/halogen
Brake Fluid DOT 4
0.0315″
(0.7 – 0.8 mm)
Hr / 12 Volt
Cluster
model only)

GENERAL INFORMATION
2020 RANGER 500

MODEL NUMBER:
2x4: R20RMAA50B1
DIMENSION /
CATEGORY
CAPACITY
Length 110″ / 279.4 cm
Width 58″ / 147.3 cm
1000 lbs. / 454 kg
(Includes weight of
Vehicle Payload
riders, cargo and
accessories)

GENERAL INFORMATION
ENGINE
Requirement
Demand Drive
6.7–7.6 oz. (200–225 ml) 1
0.006 ± 0.002" (0.152 ± 0.051 arm, Anti-Sway Bar
mm)
0.010 ± 0.002" (0.254 ± 0.051
mm)
FUEL SYSTEM
Type Bosch ME17 EFI
tank)
Brake Fluid DOT 4
(minimum)
ELECTRICAL
50W quartz/halogen
(0.85 +/- 0.08 mm)
Hr / 12 Volt
model only)
EFI: 20 Amp
Fuel Pump: 10 Amp
Amp
Accessory: 20 Amp
Drive: 10 Amp
Lights: 20 Amp
DRIVETRAIN

GENERAL INFORMATION
2020 RANGER 570 4X4

MODEL NUMBER:
R20MAA57B1, R20MAA57B9, R20MAA57L7
EPS: R20MAE57BH, R20MAE57D7
DIMENSION /
CATEGORY
CAPACITY
Length 110″ / 279.4 cm
Width 58″ / 147.3 cm
1075 lbs. (488 kg) (570)
1100 lbs. (499 kg) (570
Dry Weight EPS)
1140 lbs. (517 kg) (570
w/park)
1000 lbs. / 454 kg
(Includes weight of
Vehicle Payload
riders, cargo and
accessories)

GENERAL INFORMATION
ENGINE
Transmission Type
Shift Type
1
release)
(3.20 − 6.35 mm)
0.005-0.007″ (0.125–0.175
mm)
0.008 ± 0.002″ (0.152–0.254 Rear Travel 9″ (22.9 cm)
tank)
ELECTRICAL
50W quartz/halogen
0.0315″
(0.7 – 0.9 mm)
Hr / 12 Volt
model only)
EFI: 20 Amp
Fuel Pump: 10 Amp
Amp
Accessory: 20 Amp
Drive: 10 Amp
Lights: 20 Amp

GENERAL INFORMATION

MODEL NUMBER:
R20M4A57B1, R20M4A57B9, R20M4A57L1
EPS: R20M4E57BH

Length 140″ / 355.6 cm
Width 60″ / 152.4 cm
1352 lbs. / 613 kg (W /
EPS)
(Includes weight of
riders, cargo and
accessories)

GENERAL INFORMATION
ENGINE
Circuit Breaker
Fuses
Fan Motor: 20 Amp
Brake Light: 5 Amp
1
Fuel Pump: 10 Amp
Accessory: 20 Amp
tank)
(minimum)
ELECTRICAL
50W quartz/halogen
Brake Fluid DOT 4
0.0315″
(0.7 – 0.8 mm)
Hr / 12 Volt
Cluster
model only)

GENERAL INFORMATION
2021 RANGER 500

MODEL NUMBER:
2x4: R21MAA50B1, R21MAA50B7, R21MAA50J7, R21RM250A1
DIMENSION /
CATEGORY
CAPACITY
Length 110″ / 279.4 cm
Width 58″ / 147.3 cm
1000 lbs. / 454 kg
(Includes weight of
Vehicle Payload
riders, cargo and
accessories)

GENERAL INFORMATION
ENGINE
Requirement
Demand Drive
6.7–7.6 oz. (200–225 ml) 1
0.006 ± 0.002" (0.152 ± 0.051 arm, Anti-Sway Bar
mm)
0.010 ± 0.002" (0.254 ± 0.051
mm)
FUEL SYSTEM
Type Bosch ME17 EFI
tank)
Brake Fluid DOT 4
(minimum)
ELECTRICAL
50W quartz/halogen
(0.85 +/- 0.08 mm)
Hr / 12 Volt
model only)
EFI: 20 Amp
Fuel Pump: 10 Amp
Amp
Accessory: 20 Amp
Drive: 10 Amp
Lights: 20 Amp
DRIVETRAIN

GENERAL INFORMATION
2021 RANGER 570 4X4

MODEL NUMBER:
R21MAA57B1, R21MAA57B9
EPS: R21MAE57BX, R21MAE57D7
DIMENSION /
CATEGORY
CAPACITY
Length 110″ / 279.4 cm
Width 58″ / 147.3 cm
1075 lbs. (488 kg) (570)
1100 lbs. (499 kg) (570
Dry Weight EPS)
1140 lbs. (517 kg) (570
w/park)
1000 lbs. / 454 kg
(Includes weight of
Vehicle Payload
riders, cargo and
accessories)

GENERAL INFORMATION
ENGINE
Transmission Type
Shift Type
1
release)
(3.20 − 6.35 mm)
0.005-0.007″ (0.125–0.175
mm)
0.008 ± 0.002″ (0.152–0.254 Rear Travel 9″ (22.9 cm)
tank)
ELECTRICAL
50W quartz/halogen
0.0315″
(0.7 – 0.9 mm)
Hr / 12 Volt
model only)
EFI: 20 Amp
Fuel Pump: 10 Amp
Amp
Accessory: 20 Amp
Drive: 10 Amp
Lights: 20 Amp

GENERAL INFORMATION

MODEL NUMBER:
R21M4A57B1, R21M4A57B9
EPS: R21M4E57BX

Length 140″ / 355.6 cm
Width 60″ / 152.4 cm
1352 lbs. / 613 kg (W /
EPS)
(Includes weight of
riders, cargo and
accessories)

GENERAL INFORMATION
ENGINE
Circuit Breaker
Fuses
Fan Motor: 20 Amp
Brake Light: 5 Amp
1
Fuel Pump: 10 Amp
Accessory: 20 Amp
tank)
(minimum)
ELECTRICAL
50W quartz/halogen
Brake Fluid DOT 4
0.0315″
(0.7 – 0.8 mm)
Hr / 12 Volt
Cluster
model only)

GENERAL INFORMATION
MISC. SPECIFICATIONS AND CHARTS

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

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

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

GENERAL INFORMATION
SAE TAP / DRILL SIZES

THREAD SIZE DRILL SIZE THREAD SIZE DRILL SIZE 1
#0–80 3/64 1/2–13 27/64
#1–64 53 1/2–20 29/64
#1–72 53 9/16–12 31/64
#2–56 51 9/16–18 33/64
#2–64 50 5/8–11 17/32
#3–48 5/64 5/8–18 37/64
#3–56 45 3/4–10 21/32
#4–40 43 3/4–16 11/16
#4–48 42 7/8–9 49/64
#5–40 38 7/8–14 13/16
#5–44 37 1–8 7/8
#6–32 36 1–12 59/64
#6–40 33 1 1/8–7 63/64
#8–32 29 1 1/8–12 1 3/64
#8–36 29 1 1/4–7 1 7/64
#10–24 24 1 1/4–12 1 11/64
#10–32 21 1 1/2–6 1 11/32
#12–24 17 1 1/2–12 1 27/64
#12–28 4.6 mm 1 3/4–5 1 9/16
1/4–20 7 1 3/4–12 1 43/64
1/4–28 3 2–4 1/2 1 25/32
5/16–18 F 2–12 1 59/64
5/16–24 I 2 1/4–4 1/2 2 1/32
3/8–16 O 2 1/2–4 2 1/4
3/8–24 Q 2 3/4–4 2 1/2
7/16–14 U 3–4 2 3/4
7/16–20 25/64

GENERAL INFORMATION
METRIC TAP / DRILL SIZES

TAP SIZE DRILL SIZE DECIMAL EQUIVALENT NEAREST FRACTION
3 x .50 #39 0.0995 3/32
3 x .60 3/32 0.0937 3/32
4 x .70 #30 0.1285 1/8
4 x .75 1/8 0.125 1/8
5 x .80 #19 0.166 11/64
5 x .90 #20 0.161 5/32
6 x 1.00 #9 0.196 13/64
7 x 1.00 16/64 0.234 15/64
8 x 1.00 J 0.277 9/32
8 x 1.25 17/64 0.265 17/64
9 x 1.00 5/16 0.3125 5/16
9 x 1.25 5/16 0.3125 5/16
10 x 1.25 11/32 0.3437 11/32
10 x 1.50 R 0.339 11/32
11 x 1.50 3/8 0.375 3/8
12 x 1.50 13/32 0.406 13/32
12 x 1.75 13/32 0.406 13/32

GENERAL INFORMATION
DECIMAL EQUIVALENTS
FRACTION DECIMAL MM TO INCHES 1
1/64 0.0156″
1/32 0.0312″ 1 mm = 0.0394″
3/64 0.0469″
1/16 0.0625″
5/64 0.0781″ 2 mm = 0.0787″
3/32 0.0938″
7/64 0.1094″ 3 mm = 0.1181″
1/8 0.1250″
9/64 0.1406″
5/32 0.1563″ 4 mm = 0.1575″
11/64 0.1719″
3/16 0.1875″ 5 mm = 0.1969″
13/64 0.2031″
7/32 0.2188″
15/64 0.2344″ 6 mm = 0.2362″
1/4 0.25″
17/64 0.2656″ 7 mm = 0.2756″
9/32 0.2813″
19/64 0.2969″
5/16 0.3125″ 8 mm = 0.3150″
21/64 0.3281″
11/32 0.3438″ 9 mm = 0.3543″
23/64 0.3594″
3/8 0.375″
25/64 0.3906″ 10 mm = 0.3937″
13/32 0.4063″
27/64 0.4219″ 11 mm = 0.4331″
7/16 0.4375″
29/64 0.4531″
15/32 0.4688″ 12 mm = 0.4724″
31/64 0.4844″
1/2 0.500″ 13 mm = 0.5118″
33/64 0.5156″
17/32 0.5313″
35/64 0.5469″ 14 mm = 0.5512″
9/16 0.5625″
37/64 0.5781″ 15 mm = 0.5906″
19/32 0.5938″
39/64 0.6094″
5/8 0.625″ 16 mm = 0.6299″

GENERAL INFORMATION
FRACTION DECIMAL MM TO INCHES

41/64 0.6406″
21/32 0.6563″ 17 mm = 0.6693″
43/64 0.6719″
11/16 0.6875″
45/64 0.7031″ 18 mm = 0.7087″
23/32 0.7188″
47/64 0.7344″ 19 mm = 0.7480″
3/4 0.750″
49/64 0.7656″
25/32 0.7813″ 20 mm = 0.7874″
51/64 0.7969″
13/16 0.8125″ 21 mm = 0.8268″
53/64 0.8281″
27/32 0.8438″
55/64 0.8594″ 22 mm = 0.8661″
7/8 0.875″
57/64 0.8906″ 23 mm = 0.9055″
29/32 0.9063″
59/64 0.9219″
15/16 0.9375″ 24 mm = 0.9449″
61/64 0.9531″
31/32 0.9688″ 25 mm = 0.9843″
63/64 0.9844″
1 1.000″

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

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

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

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

GENERAL INFORMATION
Refer to, Engine Cranks but

does Not Start page 1.62 or
→
No Crank No Start or Slow
Crank page 1.64.
Is the concern Starting Pay close attention to what is
Related? noted in the Occurrence
Yes Checklist for conditions when
concern is present. This will
help in determining cause of
concern.
No ↓ Refer to Engine and

Drivability Diagnostic
Is the concern related to

Engine Performance or a
Running concern?
→Yes
Procedures page 1.59.
Pay close attention to what is
noted in the Occurrence
Checklist for conditions when
concern is present. This will
help in determining cause of
concern.
No ↓
Have any concerns in the
Transmission / Final Drive
Category been selected? → Refer to the Transmission or
Final Drive Chapters for
further diagnostic information.
No ↓
Is the concern related to a
Noise? →Yes
Refer to necessary service
information for pin-pointing
noise location and diagnosis.
GUIDED SYMPTOM REFERENCES

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

GENERAL INFORMATION
ENGINE AND DRIVABILITY DIAGNOSTIC PROCEDURES

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

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

– Connect to Digital Wrench®. Check codes and continue with Digital
Wrench® Guided diagnosis.
– Certain failures may not display a CEL / MIL on the instrument cluster. In
this instance record CEL’s from the instrument cluster and refer to the
necessary section in the Service Manual.
– Refer to Warning Lights page 1.66.
•For ENGINE HOT WARNING
– Check Coolant level. If not full, fill to correct level.
– Check Oil level. If not full, fill to correct level.
– Visually inspect for Oil or Coolant leaks. If any leaks are present repair
e Are there any Yes
before continued diagnosis.
warning lights or – Refer to Warning Lights page 1.66.
messages on – Refer to Over Heating page 1.65.
vehicle? (Reference
• For EPS WARNING (if applicable) Refer to STEERING - EPS
necessary manual
TROUBLESHOOTING.
for light
identification) – Check battery voltage and connections.
– Check connections at EPS unit. If any connection or wiring damage is
found, repair before proceeding.
– Refer to EPS Troubleshooting (Using Digital Wrench®) page 1.100.
Check codes and continue with diagnosis.
– If no codes are present, refer to EPS Troubleshooting (Power Steering
Non-Functional with MIL OFF) page 1.99
– If codes are present, refer to EPS Troubleshooting (Power Steering Non-
Functional with MIL ON) page 1.98
• Connect to Digital Wrench®. Check codes and continue with Digital

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

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

• Check Fuel Level. (Check tank using flash light - gauge may not be accurate
Yes - add fuel if needed)
• Check Coolant level. If not full, fill to correct level.
Continue to step t
• Check Oil level. If oil is low concern may be caused by lack of oil or oil
r Does the engine pressure. Suspect internal engine issue. Refer to Chapter 3 Engine / Cooling
crank? System.
• Check for battery power. Voltage should be ~ 12.6 V.
No • Load test battery. If battery fails the load test, charge / replace battery as
needed. Retest for concern before proceeding.
• Check Ignition Switch and connections. Concern may be caused by faulty
Ignition Switch.
• Refer to No Crank No Start or Slow Crank page 1.64 for further diagnostic
procedures
Yes • Continue to step y
• Check air filter for blockage.

• Check for spark. Refer toEngine Cranks but does Not Start page 1.62 for
t Does the engine quick check.
stay running?
• Check fuel supply using fuel pressure gauge. Is fuel pressure within
No
specification?
• Check exhaust for blockage.
• After checking for air supply and fuel pressure, perform leakdown test.
• Refer to Engine Cranks but does Not Start page 1.62 for more information.

GENERAL INFORMATION
Yes • Continue to step u 1

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

refer to the applicable section in the service manual.
• If the concern is electrical systems related, refer to Electrical
Troubleshooting.
• If the concern is overheating or related to the cooling system, first refer to
u Test drive vehicle Over Heating page 1.65 , then Cooling Troubleshooting page 1.69.
for concern.
• If the concern is driveability related (lack of power, misfire, etc.), refer to Fuel
System Troubleshooting page 1.89, or Cylinder Misfire Detection page 1.87.
These concerns may also be caused by a mechanical failure.
• If the concern can not be diagnosed or repaired using normal diagnostic
means, please contact Polaris Technical Service Team.

GENERAL INFORMATION
ENGINE CRANKS BUT DOES NOT START 6. Check fuses or fuel system relays (where applicable).
1. Check battery voltage while cranking. If voltage is • If any fuel related system fuses are blown, replace
below 10.8V, vehicle may not start. fuses and recheck. Wiring concern or faulty parts may
• Perform Voltage Drop Test on Starter Circuit. Refer cause fuse to blow.
to Testing Voltage Drop page 1.107 for more • It is advisable to try swapping a relay with a known
information. Acceptable drop is 0.1V per good relay to check operation. Swap relay with like
connection, if too much drop is detected concern relay and see if vehicle starts.
may be caused by faulty starter, or solenoid.
• Charge battery. 7. Check fuel lines and fittings for leaks or damage.
• If equipped with a serviceable battery, check • If leak or damage is found repair, replace as
battery electrolyte level. Fill following procedure if necessary and recheck concern.
low. • If no concerns are found proceed with fuel pressure
• If battery voltage is not ~12.6 V charge battery at testing.
recommended rate. Attempt starting after charging.
8. Perform a fuel pressure test during engine cranking.
• If battery still does not reach ~12.6 V, battery may
require replacement. • Verify that battery voltage is present at the fuel
pump. A low voltage concern may cause the pump
2. Visually inspect vehicle for any electrical connectors to be inoperable.
or wiring that may be loose or damaged. Check • Check using fuel pressure gauge to see that fuel
connectors for water intrusion or corrosion. pressure is within specification.
• If connections are found to be loose, repair • If not within specification, if equipped check fuel
connector as necessary. filter / screen for restriction.
• If connector is found to have corrosion or water • If no concern is found with filter or pressure is still
within connectors, clean, dry, and reconnect. low after filter replacement, suspect weak or faulty
• Repair any damage to wiring. fuel pump.
3. Check vehicle for trouble codes. Refer to Digital 9. Inspect spark plug wiring, spark plug, and check for
Wrench® Diagnostic. spark.
• If codes are present proceed with testing per Digital • Check to make sure that spark plug is tight.
Wrench®. • Inspect spark plug for fouling. Inspect plug gap
using feeler gauge or similar tool. Adjust to
4. Check air box and filter for debris or moisture.
specification if needed.
• If debris is found clear debris and recheck for
concern. • Disconnect plug wire and install an inline spark
tester between the spark plug wire and spark plug.
• If water is found within air box, dry box and filter. It Check for spark. If a spark tester is not available,
is possible that engine may have ingested water. remove the spark plug and reinstall wire to plug
This could cause engine failure, refer to Engine connection. Using caution crank engine while
Troubleshooting page 1.67 watching spark plug for spark.
5. Check fuel level and condition in vehicle. CAUTION
• Possible to have incorrect reading from fuel gauge.
DO NOT TOUCH SPARK PLUG DURING TEST.
Using a flashlight, check for fuel in tank. If no fuel is
TOUCHING SPARK PLUG COULD RESULT IN
visible, fill with fuel before further diagnostic.
ELECTRIC SHOCK.
• Check fuel quality, pull fuel sample or drain tank
and refill with fresh fuel from a reliable source.
• If plug does not spark in previous test, check
IMPORTANT connections at ignition coil. Ensure that the ignition
coil has power and is receiving signal from the
When filling with fuel, ensure that the fuel being used
ECU. Concern may be caused by faulty ignition coil
meets the correct octane rating specific to the vehicle.
or electrical concern.
• If filled with fuel, vehicle starts, and gauge still is not 10. Listen for unusual noises while cranking.
reading test the fuel sending unit.

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

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

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

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

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

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

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

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

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

• Power steering fault has been detected.
• Check for codes using Digital Wrench. If no codes
present refer to EPS System – Troubleshooting
• Check connections at battery, could be caused by
voltage concern.
• Visually inspect connections at EPS Unit.
• For further diagnosis refer to Steering System –
Steering Assembly EPS
3. ENGINE HOT
• Over temperature condition detected.
• Check coolant level. If not full fill to correct level.
Bleed the cooling system to ensure there are no air
pockets present.
• Visually inspect hoses and radiator for coolant
leaks. Repair as necessary.
• Pressurize cooling system and look for pressure
losses. This indicates a leak in the cooling system.
Inspect for external leaks, if none are found it is
possible there is an internal leak.
• Check cooling system using combustion leak tester
for any combustion gasses entering the cooling
system. This could indicate possible Head /
Headgasket failure.
• Check oil level. Verify that oil is filled to the correct
level. Engine oil that is low, or overfull can cause
overheating concerns. Check maintenance history
to see if oil needs to be changed.
• Visually inspect for oil leaks.
• Refer to Over Heating page 1.65 for more info.
4. PERFORMANCE LIMITED
• Check for codes using Digital Wrench. Refer to
Guided Diagnostic for further diagnosis.
5. BRAKE WARNING
• Detects brake system failure.
• Inspect brake system for leaks, damage, etc. Refer
to Brake System chapter for more information.

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

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

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

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

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

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

• Thermostat opening too soon

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

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

GENERAL INFORMATION
DIGITAL WRENCH® SOFTWARE INSTALLATION AND UPDATES

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

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

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

Version.

GENERAL INFORMATION
4. Once the installation is complete, launch the Digital DIGITAL WRENCH® - DIAGNOSTIC
Wrench® software and verify the information in the CONNECTOR
lower, right-hand corner matches the new Base
The diagnostic connector q is located under the hood as
Version you just installed.
shown.
DIGITAL WRENCH® COMMUNICATION

ERRORS
If you experience problems connecting to a vehicle, or
any other Digital Wrench® software-related problem, visit
the Digital Wrench® home page (www.polaris.diagsys.
com) and locate the following information under
Knowledge Base:
• Errors and Troubleshooting
• Frequently Asked Questions (FAQs)
• Procedures and Solutions
DIGITAL WRENCH® SERIAL NUMBER

LOCATION
To locate the Digital Wrench® serial number, do the
following:
1. Launch the Digital Wrench® software.
2. On the Digital Wrench® main screen, select the
‘Configure the Diagnostic System Software’ menu
icon.
3. Locate the serial number on the right side of the

System Configuration screen.

GENERAL INFORMATION
DIGITAL WRENCH® FEATURE MAP

1
View and / or clear trouble

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

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

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

record functions. Configuration screen.
Perform specialized testing

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

form. formatted printout.

GENERAL INFORMATION
ENGINE CONTROLLER REPROGRAMMING (REFLASH)

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

(PMDW)
Polaris Mobile Digital Wrench® (PMDW) is a diagnostic
software application (app) designed specifically for
Android™ devices. When paired with the Wireless
Vehicle Link (WVL) (PU-51435), the PMDW app provides
many of the same features and functions as the Digital
Wrench® software.

GENERAL INFORMATION
ENGINE ELECTRICAL DIAGNOSTICS

DIAGNOSTIC TROUBLE CODES OVERVIEW 1
NOTICE
The diagnostic mode is accessible only when the check
engine MIL has been activated.
If there is a diagnostic problem with the power steering
system, the power steering MIL will illuminate and blink
in place of the check engine MIL.
Use the following procedure to display diagnostic trouble

codes that were activated during current ignition cycle
causing the MIL to illuminate. Error codes are not stored.
When the key is turned OFF, the code and message is
lost, but will reappear if the fault reoccurs after restarting
the engine.
If the CHECK ENGINE lamp or the EPAS lamp
illuminates, retrieve the active error codes from the
display.
1. Press and hold the MODE button to enter the settings

menu.
You can download the PMDW app on your Android 2. Press either toggle button to cycle to the
device from the Polaris dealer website. From the Service “DIAGCODE” option. Press MODE to select.
and Warranty drop-down, select Digital Wrench, and
then click Mobile Digital Wrench App Download. 3. More than one diagnostic code may be present.
Press the toggle UP button to see if more codes are
MINIMUM SPECIFICATIONS FOR ANDROID present. Press MODE to select a code.
DEVICES 4. Record the three numbers displayed.
• Minimum operating system: Android 3.1 “Honeycomb”
or higher (Android 4.0 or higher preferred)
NOTICE
The PMDW app will not work on Microsoft Windows 8™
or Apple IOS™ products.
• Dual core processor / 2 GB internal memory / external

micro SD (32 or 64 GB) slot / 500 MB RAM
• Rear facing camera with minimum 3.0 mega pixel
resolution with auto / continuous focus
• Video, microphone, and voice-to-text capable
• The first number (located top) can be 1 to 2 digits in
• Internet and Bluetooth wireless technology capable length. This number equates to the fault mode
(FMI).
• Device must be set to allow the installation of non-
market applications • The second number (located middle) can be 2 to 6
digits in length. This number equates to the
ADDITIONAL INFORMATION suspected area of fault (SPN).
• An electronic user’s guide is provided within the • The third number (located bottom) can range from
PMDW app. To access the user’s guide, launch the 0 to 9. This number represents the total number of
app, and then click “Help” under the Settings / trouble code present (example: 2 means there are
Preferences menu. 3 codes present).
• Only CAN-based vehicles are compatible with the 5. Press MODE to exit to the settings menu.
PMDW app and the WVL. See the user’s guide for a
complete list of compatible vehicles.

GENERAL INFORMATION
MASTER TROUBLE CODE LIST

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

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

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

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

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

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

GENERAL INFORMATION

10
0
Abnormal Rate Of Change
Data Valid But Above Normal Operational Range - Most Severe Level
P0109
P1111
1
Intake Air Temperature Sensor (T-
105 MAP) 4 Voltage Too Low P0112
0 Data Valid But Above Normal Operational Range P110B
1 Data Valid But Below Normal Operational Range P110A
106 Intake Air Pressure Sensor 2 Data Erratic, Intermittent Or Incorrect P1109
0 Data Valid But Above Normal Operational Range - Most Severe Level P1280
Engine Air Filter 1 Differential 4 Voltage Too Low P1283

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

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

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

GENERAL INFORMATION

3 Voltage Too High C1063 / P0563 / C1820
168 System Power 4 Voltage Too Low P0562

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

523 Gear Sensor Signal 4 Voltage Too Low P0916

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

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

GENERAL INFORMATION

4
5
Voltage Below Normal, Or Shorted To Low Source
Current Below Normal Or Open Circuit
P1738
P1737
1
4 Voltage Below Normal / Shorted To Low Source / Driver Circuit P1262
651 Injector 1 (MAG) Grounded.
5 Current Below Normal / Open Circuit / Driver Circuit Open / Grounded P0261
3 Voltage Above Normal, Or Shorted To High Source / Driver Circuit Short P0265
to B+
652 Injector 2 (PTO) 4 Voltage Below Normal, Or Shorted To Low Source / Driver Circuit P1265
Grounded
5 Current Below Normal Or Open Circuit / Driver Circuit Open / Grounded P0264
677 Starter Solenoid Driver Circuit 4 Voltage Below Normal, Or Shorted To Low Source P0616
731 Knock Sensor 1
3 Driver Circuit Short to B+ P1692
746 Rear Differential Output (Turf) 4 Driver Circuit Grounded P1693

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

GENERAL INFORMATION

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

1127 Boost Pressure Sensor 3 Voltage Above Normal P0238

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

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

1557 Fan Driver 2

GENERAL INFORMATION

5
13
Out Of Calibration
P0481
C1261
1
1809 Lateral Acceleration Sensor 19 Received Network Data In Error U25CA
13 Out Of Calibration C1262
1810 Longitudinal Acceleration Sensor
19 Received Network Data In Error U25CB
1888 PTO Solenoid Driver Circuit 4 Voltage Below Normal, Or Shorted To Low Source P1312
2584 Brake Pressure Switches 13 Out Of Calibration C1263

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

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

GENERAL INFORMATION

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

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

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

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

GENERAL INFORMATION

4
5
Voltage Below Normal, Or Shorted To Low Source
P1683
P1681
1
520207 All Wheel Drive Control Circuit 4 Voltage Below Normal, Or Shorted To Low Source P1834
520208 Chassis Relay 4 Voltage Below Normal, Or Shorted To Low Source P1613
520211 Idle Speed
520219 Accessory Relay 4 Voltage Below Normal, Or Shorted To Low Source P1645
3 Voltage Above Normal, Or Shorted To High Source P163D
520220 Battery Charge Relay 4 Voltage Below Normal, Or Shorted To Low Source P163A
5 Current Below Normal Or Open Circuit P163C
6 Current Above Normal Or Grounded Circuit C1050
520221 Steering Over Current Shut Down
12 Bad Intelligent Device Or Component C102E
520222 Steering Excessive Current Error 6 Current Above Normal Or Grounded Circuit C1051
520223 Steering Torque Partial Failure 31 Condition Exists C1052
520224 Steering Torque Full Failure 31 Condition Exists C1053

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

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

GENERAL INFORMATION

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

13 Out Of Calibration C1141
520265 ABS Module 7 Mechanical System Not Responding Or Out Of Adjustment C1042
520266 ABS Brake Switch (Front/Rear)
520272 Glow Plug Relay Driver Circuit 4 Voltage Below Normal, Or Shorted To Low Source P1383
Fuel Pull Solenoid Relay Driver 4 Voltage Below Normal, Or Shorted To Low Source P125C
520273 Circuit (Low Side)
5 Current Below Normal Or Open Circuit P125A
Accelerator Position/Brake Position 31 Condition Exists P150A / U1007

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

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

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

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

GENERAL INFORMATION
520305
Throttle Body Control - Requested
Throttle Angle Not Plausible
1
520306 ECU ADC Fault - No Load 31 Condition Exists P1531
520307 ECU ADC Fault - Voltage 31 Condition Exists P1532
Accelerator Sensor Sync Fault - 31 Condition Exists P1533

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

520331 Knock Sensor Positive Line
3 Voltage Above Normal, Or Shorted To High Source P132A
520332 Knock Sensor Negative Line
4 Voltage Below Normal, Or Shorted To Low Source P132B
520341 Wastegate Solenoid Driver 4 Voltage Below Normal, Or Shorted To Low Source P0246
520342 Idle Fuel Correction Bank 1 15 Data Valid But Above Normal Operating Range - Least Severe Level P116C
15 Data Valid But Above Normal Operating Range - Least Severe Level P116E
520343 Idle Fuel Correction Bank 2
17 Data Valid But Below Normal Operating Range - Least Severe Level P116F
520344 Adaptive Fuel Correction Bank 1
Internal fault - Chassis Output 31 Condition Exists P1618

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

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

GENERAL INFORMATION

Hydraulic Oil Pressure Sensor/ 17 Data Valid But Below Normal Operating Range - Least Severe Level P150F
524075
Switch
524076 Engine Oil Pressure Sensor/Switch 17 Data Valid But Below Normal Operating Range - Least Severe Level P151F
524085 EPS Fault Lamp Driver Circuit 12 Bad Intelligent Device Or Component C106C
3 Voltage Above Normal, Or Shorted To High Source C106D
524086 EPS SEPIC Voltage Error
4 Voltage Below Normal, Or Shorted To Low Source C106E

GENERAL INFORMATION
CYLINDER MISFIRE DETECTION If a misfire code has been set and there is no observed
misfire, cycle the key and allow 4000 engine revolutions
NOTICE to see if the check engine light turns off. If it does not turn 1
This process only applies to some MY15 and later off, diagnose by verifying the following items:
models.
• Low battery voltage (loose connection, low charge,
Refer to this procedure only if one of the codes shown
bad battery)
below is displayed in Digital Wrench.
• Faulty voltage regulator
The ECU monitors crankshaft speed via the crankshaft • Ignition Coil and connections are good
position sensor. A misfire will cause a fluctuation in
crankshaft speed. A code will set and turn on the check • Spark plugs wires are secure
engine light after an engine misfire threshold/rate is • The correct spark plugs are installed and the plugs are
detected that is above a pre-determined limit. This not fouled
threshold varies based on engine speed.
• Crankshaft Position Sensor tests good
One or more of the following codes will be set if a misfire
occurs: • Wiring to the Crankshaft Position Sensor, ECU and
Ignition Coil are not damaged. Chassis ground is clean
• P0301 (SPN 65591/FMI 7) Misfire Detected, Cylinder and tight
1 (MAG)
• Fuel pressure is within specification
• P0302 (SPN 65592/FMI 7) Misfire Detected, Cylinder
2 (PTO) • Fresh/good quality fuel is in the fuel tank
• P0314 (SPN 65590/FMI 7) Misfire Detected, Cylinder • Engine mechanical is good (leak down, timing)
Not Identified • Confirm the belt is in good condition, specifically
looking for signs of hour-glassing
Once a cylinder misfire code is set, the following events • Confirm primary clutch operation (worn/incorrect
will occur: weights, loose spider/jam nut)
• Check Engine Light illuminates • Confirm secondary clutch operation (sliders, rollers,
• If the cylinder can be detected by the ECU (code helix)
P0301 or P0302), the ECU will deactivate the fuel
injector for that cylinder. This will remain in effect until
the key is cycled off and back on.
• If the cylinder with the misfire cannot be detected
(code P0314), the ECU will limit available power by
limiting how far the throttle plate opens.
One the key is cycled, the trouble code(s) will show
current but there will be no fuel injector deactivation or
throttle limitation unless the misfiring continues to occur.
The check engine light will remain illuminated until there
are 4000 engine revolutions (i.e. 4000 RPM for one
minute) without a significant misfire being detected.
Once this condition is met, the check engine light will turn
off and the code(s) will show as historic.

GENERAL INFORMATION
FLUID LEAKS
Fluid leaks can apply to multiple different systems used in the vehicle. Leaks can be a common cause of concerns
within these systems. Procedures that are used for checking leaks can apply to multiple systems.
When diagnosing fluid leaks, refer to the appropriate “Level Inspection” procedure, Fluid Inspection page 1.88, or the
appropriate chapter in the Service Manual before proceeding with any repairs or parts replacement.
FLUID INSPECTION
OVERVIEW
Multiple vehicle systems will contain different fluids or lubricants within the system.
These fluids should be inspected for condition and level. Refer to Fluid Condition and the appropriate level check
within the Service Manual for more information.
Most of these systems should be inspected for leaks using the same methods. Refer to Fluid Leak for more
information.
FLUID LEAK
Perform the following inspection prior to replacement of any seals or gaskets.
1. Inspect the fluid level prior to any checks to verify that the system is currently leaking.
NOTICE
If the system is not low at this time, clean and continue to monitor. It is possible that the fluid is residual from
manufacturing or previous repairs.
2. Thoroughly clean the area using an appropriate cleaner (Brake cleaner, Throttle Body cleaner, Soap, etc.) prior to
diagnosing the leak.
3. Operate the vehicle under the condition that the leak presented and re-inspect for leak.
4. Pinpoint location of leak. Check for any damage to parts and repair the leak as necessary.
NOTICE
If the leak can not be pin-pointed using this method, the leak may require dye to be added to the system, operated
and inspected for leaks using a UV light.
FLUID CONDITION
Refer to the appropriate “Level Check” procedure for the fluid being inspected. When the fluid is inspected it should
be compared to NEW recommended replacement fluid.
INSPECTION ITEMS CAUSE

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

GENERAL INFORMATION
FUEL SYSTEM DIAGNOSTICS

FUEL SYSTEM TROUBLESHOOTING 1
FUEL STARVATION / LEAN MIXTURE
SYMPTOMS CAUSES
• Hard start or no start • No fuel in tank

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

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

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

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

GENERAL INFORMATION
PVT SYSTEM DIAGNOSTICS

PVT SYSTEM TROUBLESHOOTING 1
SITUATION PROBABLE CAUSE REMEDY
Wrong or broken drive clutch spring. Replace with recommended spring.
Engine RPM
below specified Install correct shift weight kit to match engine
Drive clutch shift weight too heavy.
operating range, application.
although engine
is properly tuned. Driven clutch spring broken or installed in Replace spring; refer to proper installation
wrong helix location. location.
Disassemble drive clutch; inspect shift weights
for wear and free operation.
Drive clutch binding. Clean and polish stationary shaft hub;
reassemble clutch without spring to determine
Erratic engine problem area.
operating RPM
during Belt worn unevenly - thin / burnt spots. Replace belt.
acceleration or
load variations. Replace ramp buttons.
Driven clutch malfunction. Inspect movable sheave for excessive bushing
clearance.
Sheave face grooved. Replace the clutch.
Incorrect drive clutch spring (too high of Install correct recommended spring.
rate).
Drive clutch shift weights incorrect for Install correct recommended shift weights.
application (too light).
Disassemble and clean clutch, inspecting shift
Engine RPM weights and rollers. Reassemble without the
Drive clutch binding.
above specified spring and move sheaves through entire range
operating range. to further determine probable cause.
Disassemble, clean, and inspect driven clutch,
Driven clutch binding. noting worn sheave bushing and ramp buttons
and helix spring location.
Converter sheaves greasy; belt slipage. Clean sheaves with denatured alcohol or brake
cleaner, install new belt.
Drive belt worn too narrow. Replace belt.
Harsh drive clutch
engagement. Excessive belt / sheave clearance with new Perform belt / sheave clearance adjustment with
belt. shim washers beneath spider.
Drive belt turns Wrong belt for application. Replace with correct belt.
over
Abuse (continued throttle application when Caution operator to operate machine within
vehicle is stationary, excess load) guidelines.
Belt burnt, thin Dragging brake Inspect brake system.
spots
Slow, easy clutch engagement Fast, effective use of throttle for efficient
engagement.

GENERAL INFORMATION

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

GENERAL INFORMATION
PVT SYSTEM OVERHEATING / DIAGNOSIS

During routine maintenance, or whenever PVT system overheating is evident, it’s important to check the inlet and
outlet duct for obstructions. Obstructions to air flow through the ducts will significantly increase PVT system operating
1
temperatures. The vehicle should be operated in Low when extended low vehicle speed operation is anticipated.
CLUTCH DRIVE BELT & COVER RELATED ISSUES: DIAGNOSIS

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

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

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

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

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

GENERAL INFORMATION
FINAL DRIVE DIAGNOSTICS

ALL WHEEL DRIVE (AWD) CONCERNS 1
All Wheel Drive (AWD) concerns are generally caused by a mechanical concern within the front gearcase, or electrical
concern. The following chart will help finding the root cause and assist with basic checks of the front gearcase and
AWD system. Refer to the proper chapter in the service manual for additional vehicle specific information.
SYMPTOM CAUSE
AWD stays engaged even when switch is OFF
• Rollers flat-spotted. Remove all and roll across a table
to check for flat spots
• Inside of ring gear is dimpled from harsh engagement.
Check the ramps and low spots inside ring gear.
Should be smooth.
• Output Hub races are flat spotted/dimpled. Run your
finger along the outer surface that goes inside of the
cage. Should be uniform with no high points.
• Armature plate or coil magnetized. Rule out armature
plate by putting it close to something metal to see if it
tries to stick.
• Drivetrain wedged. Often caused by torsion spring
coming out of place.
AWD Does not engage

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

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

GENERAL INFORMATION
BRAKE SYSTEM DIAGNOSTICS

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

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

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

GENERAL INFORMATION
CALIPER OVERHEATS (BRAKES DRAG)

CALIPER OVERHEATS (BRAKES DRAG) 1
• Compensating port plugged • Parking brake left on (If Equipped)
• Pad clearance set incorrectly • Residue build up under caliper seals
• Parking brake lever incorrectly adjusted (If Equipped) • Incorrect operation of brakes
– Operator using the throttle and brakes at the same
• Brake pedal or brake lever binding or unable to return
time.
fully
– Excessive use of the brakes.
• Incorrect brake fluid level (Overfilled Fluid Reservoir)
POOR BRAKE PERFORMANCE

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

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

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

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

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

IMPORTANT 1
READ BEFORE YOU REPLACE THE EPS UNIT!
Verify the EPS unit has the latest software version and calibration loaded before replacing the EPS unit. If not, update
to the latest version for each and follow the guided diagnostic procedure(s) available in Digital Wrench®.
Power
Steering
Non
Functional,
MIL is OFF
↓ Determine
Is Battery
Voltage >11
and
<16VDC?
→ No
cause of
incorrect
battery
voltage and
repair
Yes ↓
Is EPS Fuse
OK?
→ No
Replace
EPS Fuse.
Yes ↓
12 VDC and
GND across
2 Pin EPS
Connector
with Key
→ No
Check EPS
Power
Relay and
Circuit
On?
Yes ↓
Check
12 VDC on
Pin 3 of the
8 pin EPS
Connector?
→ No
wiring from
Connector
to Ignition
Switch
Circuit
Yes ↓ MIL Lamp

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

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

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

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

GENERAL INFORMATION
SHOCK ANALYSIS
Shock “misting” q or “weepage” w is common and should be present during normal vehicle operation. All Shock
Absorber Seals are designed to allow a thin film of oil to pass into and out of the shock. This thin film of oil lubricates
1
the Seal to ensure low friction and reduces the corrosion rate of the Piston Rod.
Vehicle operating conditions have a high impact on how much shock oil might be present on the seal and shock body
(i.e. road conditions and operating temperature). It is important to properly identify the difference between normal
operation (weepage or misting) and a shock that has a leak. Below are some images to help determine what is normal
and what could be identified as a bad shock.
MISTING OR WEEPAGE LEAKAGE

GENERAL INFORMATION
ELECTRICAL DIAGNOSTICS STATIC AND DYNAMIC TESTING

There are many methods for testing a DC circuit. These
ELECTRICAL SERVICE NOTES methods fall into one of two categories, either static or
Keep the following notes in mind when diagnosing an dynamic.
electrical problem.
STATIC TESTING
• Refer to wiring diagram for stator and electrical The two most common forms of static testing are:
component resistance specifications.
• Resistance testing (the Ohms setting on your DMM)
• When measuring resistance of a component that has a
low resistance value (under 10 Ohms), remember to • Measuring voltage with the circuit open, such as when
subtract meter lead resistance from the reading. the harness connector is off a sensor you are testing.
Connect leads together and record the resistance. The This is commonly referred to as measuring “Available
resistance of the component is equal to tested value Voltage”.
minus the lead resistance.
• Become familiar with the operation of your meter. Be These two tests will help you find the majority of electrical
sure leads are in the proper jack for the test being issues. If they do not, we must remember that static
performed (i.e. 10A jack for current readings). Refer to circuit testing does not take into account how current
the Owner’s Manual included with your meter. actually flows in that circuit. That is only accomplished
with dynamic testing.
• Voltage, amperage, and resistance values included in
this manual are obtained with a Fluke™ 77 Digital Before attempting dynamic testing (as it is intrusive on
Multimeter (PV-43568). This meter is acceptable for sealed connectors and damage could be done if not
use when diagnosing electrical problems. Readings careful), verify the following:
obtained with other meters may differ. • Static voltage testing advised for that circuit has been
• Pay attention to the prefix on the meter reading (K, M, completed, and is in spec.
etc.) and the position of the decimal point. • All associated circuits have under 1 ohm of resistance
• For resistance readings, isolate component to be from end to end. Testing Continuity / Resistance page
tested. Disconnect wire harness or power supply. 1.104
• All associated circuits have no shorts to ground.
Testing For A Short To Ground page 1.104
DIGITAL MULTI-METER (DMM) NOTES • All associated circuits have no shorts to voltage.
Testing For A Short To Voltage page 1.105
Polaris advises to only use a high quality DMM that
meets the same standards as the Fluke™ 77 (PV-43568)
for electrical testing. DYNAMIC TESTING
Unless you are very familiar with Ohm’s Law, and have There are two types of dynamic testing we will advise to
complete information about the circuit you are trying to use when diagnosing electrical concerns:
diagnose, test lights are likely to provide results that • Current flow testing (Amperage) Testing Current Flow
would be misleading. This is especially true if any solid (Amperage) page 1.106. Measuring Amperage is not a
state component is involved, where you will almost common practice, as you will not typically have a spec
certainly not have complete circuit information. to compare your reading to. Also, many components
Polaris also specifically advises against the use of other on this machine flow over 10 Amps, which will blow the
circuit testing devices, including but not limited to: majority of DMM fuses. The exception to this is a
parasitic draw test refer to Current Draw - Key Off
• Short finders page 1.107.
• Simplified circuit testers • Measuring voltage drop. Performing this test correctly
will give you understanding of how electrical pressure
• Fuse piggy-back devices
(voltage) varies in a circuit as current is flowing.
Testers beside a DMM will only work in one scenario, Testing Voltage Drop page 1.107
and slight variables can provide you with misleading
results. The testing practices described in this chapter
are more certain and rely only on the DMM and your
knowledge.

GENERAL INFORMATION
CONNECTOR PROBING GUIDELINES For a video demonstration, scan the QR code below, or
right click it and select “open in new tab”.
FRONT PROBING 1
Front probing is accomplished by pulling the harness
connector from the component, and then taking a
measurement from the terminal face. This is the
measurement taken in most situations.
The terminals in electrical connectors are small and
fragile. Do not probe directly with your meter leads, as
the meter leads are larger than almost all terminals.
Probing with a meter lead will likely damage the terminal
by spreading it beyond it’s design limits, causing no
tension. If there is no tension, you will have either no
connection or a poor connection.
BACK PROBING
To avoid causing damage, use of the appropriate
Back probing is typically not advisable on sealed
adapters is required. Most terminals used on Polaris
connectors, as it can easily cause damage to the wire,
machines can be tested using terminal test kit PV–
terminal, connector body, or body to wire seal.
43526. It includes male and female adapters that can be
plugged into banana connectors to adapt to your meter.
NOTICE
There are commercially available back probe kits. Fine,
narrow needles with no coating to block current flow
also work well for back probing.
If back probing must be done to see voltage drop while

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

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

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

Testing using the Ohmmeter function of your DMM is one Shorts to ground happen when the current flowing in a
of the first things you will do when troubleshooting an given circuit bypasses the load. The current flowing from
electrical issue. It is especially convenient when the B+ finds an easier way to return to ground (B-), so much
wiring diagram provides a resistance spec for the more of it can flow than the circuit is designed for. This
component in the circuit you are diagnosing. It can causes the circuit’s protection device (either a fuse or
quickly give you a good idea if you simply need to circuit breaker) to open, protecting the circuit from
replace a part, or if there might be another circuit issue. damage.
Using the following points in conjunction with your DMM There are many possible causes of a short to ground,
owner’s manual will ensure your resistance testing is here are some:
always accurate:
• The harness rubbing against a component that is
• Only measure resistance on an isolated part of the grounded, such as the frame, chassis component, or
circuit. This means if you are testing internal resistance engine.
of a component, it cannot be connected to the
• A component’s internal circuitry contacting its case.
harness. If you are measuring a wire (typically from the
ECU to a sensor) both the sensor and ECU would • Wire-to-wire chaffing causing contact with the
need to be unplugged. Most Ohmmeters provides a conductor of a ground side circuit.
precise amount of current to determine resistance. Any
other sources will make your reading inaccurate. • Corrosion/moisture in a component providing a ground
path.
• Ensure you are making good contact by using the
proper terminal adapters. Connector Probing • Moisture in a connector body providing a ground path.
Guidelines page 1.103
• If you are not using a self ranging meter, double check NOTICE
your range setting. This test is typically done right after checking continuity
• If your continuity is under 1 ohm, leave the harness from sensor to ECU when diagnosing an EFI DTC. It
disconnected and move on to Testing For A Short To can also be used to help diagnose concerns about
Ground page 1.104 and Testing For A Short To Voltage blowing fuses. Ensure you are able to duplicate the
page 1.105. concern before testing so that your results point you in
the right direction.Testing for Intermittent Conditions
For a video demonstration, scan the QR code below, or page 1.106
right click it and select “open in new tab.”
TESTING PROCEDURE
1. Consult the wiring diagram. Determine which circuit
you will be testing.
2. Ensure that any static voltage checks advised in
relation to the DTC or concern you are diagnosing
have been performed and are in spec.
3. Ensure you have checked continuity of the circuit.
Testing Continuity / Resistance page 1.104
4. Ensure that neither end of the circuit is connected.
5. Set your DMM to Ohms.
6. Connect one meter lead securely to the battery
negative post.
7. Connect the other lead to either end of the
disconnected circuit. Ensure you are using the correct
adapter.Connector Probing Guidelines page 1.103
8. If there is continuity, the harness is damaged and
should be repaired or replaced.
9. If the DMM reads OL, there is no short to ground.
Leave the harness disconnected on both sides, and
proceed to check for a short to voltage. Testing For A
Short To Voltage page 1.105

GENERAL INFORMATION
For a video demonstration, scan the QR code below, or TESTING FOR A SHORT TO VOLTAGE
right click it and select “open in new tab”. There are three possible short to voltage causes: 1
1. Internal electronic component short.
2. Harness chaffing leading to contact of the circuit
being diagnosed to one with B+ or a different
reference voltage.
3. Moisture in a connector or component.
TESTING PROCEDURE
1. Consult the wiring diagram. Determine which circuit
you will be testing.
2. Ensure that any static voltage checks advised in
relation to the DTC or concern you are diagnosing
have been performed and are in spec.
3. Ensure you have checked continuity of the circuit.
Testing Continuity / Resistance page 1.104
4. Ensure you have checked for a short to ground.
Testing For A Short To Ground page 1.104
5. Ensure that neither end of the circuit is connected.
6. Set your DMM to DC volts.
7. Connect one meter lead securely to the battery
negative post.
8. Connect the other lead to either end of the
disconnected circuit. Ensure you are using the correct
adapter.Connector Probing Guidelines page 1.103
9. If there is voltage present, the harness is damaged
and should be repaired or replaced. You may need to
remove the protective tape and tubing to inspect.
10. If the DMM reads 0 volts, the concern may be in a
component related to the circuit. If so, checking
internal continuity of non-electronic components may
reveal the concern, but diagnosis at this point may
require using known good parts.

GENERAL INFORMATION
TESTING FOR INTERMITTENT CONDITIONS TESTING CURRENT FLOW (AMPERAGE)

Intermittent conditions are very difficult to diagnose, as Performing a current flow test requires the meter leads
when you are testing the circuit, you may not have the be inserted into the correct cavities in the meter, and be
circuit failing to indicate where the issue is. Intermittent placed in series in the circuit to be tested. Refer to your
electrical failures are almost always related to a poor Digital Multi Meter’s owner’s manual for potential model
connection that only goes open in specific situations, specific instructions. Ensure you are using acceptable
such as going over a certain kind of bump, at a certain adapters to avoid damaging the connector terminals.
temperature, or when the machine is torque loaded in See Connector Probing Guidelines page 1.103.
one way.
NOTICE
Here is a list of possible failures that can be associated
with an intermittent electrical failure: Amperage specs are generally not provided for circuits/
components. Please only perform this test when
• Loose female terminal in an electrical connector. advised in the manual.
NOTICE
If the terminals in question are the correct size/series, IMPORTANT
always use PV–43526 to test the drag when inserting Many circuits on this machine will exceed the 10 Amp
and removing the test terminal adapters. Compare the fuse in most Digital Multi Meters in normal operation.
effort to the drag against the known good tester
terminal for reference.
• Poor terminal to wire crimp.

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

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

GENERAL INFORMATION
CURRENT DRAW - KEY OFF 7. Wait 10 minutes before checking the value. Vehicles
will vary, but electronic components will take time to
Parasitic draw is when there is excessive current flow
with the key off. fully go to sleep after switched power is removed. 1
While the most common causes of draws are improperly 8. Maximum allowable is 10 milliamps. If your meter is
installed accessories (tapping into un-switched B+ ranged to the 10 Amp scale, this will appear as 0.010
instead of switched) there can be electronic component Amps.
failures that can cause this as well.
Current Draw - Key Off:
IMPORTANT Maximum of .01 DCA (10 mA)
Do not connect or disconnect the battery cable, or
ammeter with the engine running. Damage will occur to 9. If over 10 milliamps, go to the fuse block and start
electrical components. systematically removing one fuse at a time until the
value drops, indicating the circuit that requires
attention.
IMPORTANT
Charging system damage will occur if incompatible
components are installed. Always reference the Polaris TESTING VOLTAGE DROP
Electronic Parts Catalog for the proper part numbers.
NOTICE
NOTICE If you disconnect the connector at the load, and
measure voltage with one lead on the power supply
Wait ten minutes with the key off for the ECU to power wire, and one to ground, you will be measuring
down. This will avoid a faulty readout while testing available voltage. This is a static test and not dynamic
amperage draw. voltage drop testing. Refer to Static and Dynamic
Testing page 1.102.
TESTING PROCEDURE
1. Remove the negative cable from the battery. The measurement of voltage is the DIFFERENCE in
electrical pressure between the two points your DMM
2. Connect a jumper from the negative battery cable leads are touching.
terminal to the negative battery post.
Most circuits will have one load. The load is the
3. Ensure your meter leads and selector dial are set to component in the circuit that uses the current flow to do
measure amperage. work, such as move a solenoid or light a bulb.
4. Connect your red lead to the battery negative cable Voltage coming into the load should be near battery
terminal. voltage with current flowing. There will be some loss from
moving through electrical contacts in connectors and
relays, but it will be minimal.
NOTICE
You will need to backprobe to perform this test. For
information about doing this safely, refer to Connector
Probing Guidelines page 1.103.
Voltage should be near fully depleted by the load. This

means that when measuring on the ground side of the
circuit, immediately after the load, back to battery
negative, you should have near zero pressure difference
(voltage).
If you do have a difference in pressure, this means there
is something adding resistance to the circuit such as
5. Connect your black lead to the battery negative post. corrosion.
6. Momentarily key the ignition switch on, then off.
IMPORTANT
Ensure all electrical components are switched off, or
damage to your jumper and/or meter will occur.

GENERAL INFORMATION


MAINTENANCE
CHAPTER 2
MAINTENANCE
2
PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
COLD WEATHER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
VEHICLE BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
ENGINE AND DRIVETRAIN BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
BRAKE SYSTEM BREAK-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
PVT BREAK-IN (CLUTCHES / BELT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
PERIODIC MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
GREASE LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
COMPONENT QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
STORAGE TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10
LUBRICANTS / SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12
COMPRESSION AND LEAKDOWN TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12
ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12
OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12
BREATHER HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13
BREATHER VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13
500 SOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14
VALVE CLEARANCE - SOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14
570 DOHC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14
VALVE CLEARANCE - DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16
COOLING SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16
COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16
50/50 EXTENDED-LIFE ENGINE ANTIFREEZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18
COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19
COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19
RADIATOR INSPECTION / CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20
COOLANT DRAIN / RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20
FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
FUEL PUMP / FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
VENT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
THROTTLE PEDAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
ENGINE AIR INTAKE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

MAINTENANCE
PVT AIR INTAKE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

TRANSMISSION AND GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
SHIFT CABLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
SHIFT CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
FRONT GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
FINAL DRIVE / WHEEL / TIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27
WHEEL AND HUB TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27
CV SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27
WHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27
WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28
TIRE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28
STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29
STEERING INSPECTION NOTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29
TIE ROD END / STEERING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29
WHEEL TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30
TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30
CAMBER AND CASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32
SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32
SPRING PRE-LOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32
STABILIZER BAR PIVOT LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32
SUSPENSION PIVOT POINT LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.33
SHOCK ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.34
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.35
BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.35
BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.35
BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.35
BRAKE DISC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.36
ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.37
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.37
BATTERY FLUID LEVEL (CONVENTIONAL BATTERY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.37
BATTERY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.37
BATTERY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38
BATTERY STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38
BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38
500 SOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38
SPARK PLUG SERVICE - 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38
570 DOHC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.39
SPARK PLUG SERVICE - 570 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.39
MAIN FRAME/ENGINE GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.40

MAINTENANCE
PERIODIC MAINTENANCE CHART

PRE-RIDE / DAILY INSPECTION
Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.
• Tires - check condition and pressures

• Fuel and oil tanks - fill both tanks to their proper level; do not overfill oil tank 2
• Engine oil — check for proper level; do not overfill oil tank
• All brakes - check operation and adjustment (includes auxiliary brake)
• Throttle - check for free operation and closing
• Headlight/Taillight/Brakelight - check operation of all indicator lights and switches
• Ignition switch - check for proper function
• 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
• Engine coolant - check for proper level at the recovery bottle
• Check all rear suspension components for wear or damage
COLD WEATHER OPERATION

If the vehicle is used year-round, check the oil level frequently. A rising oil level could indicate the accumulation of
contaminates such as water or excess fuel in the bottom of the crankcase. Water in the bottom of the crankcase can
lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases.

MAINTENANCE
BREAK-IN PERIOD PVT BREAK-IN (CLUTCHES / BELT)

A proper break-in of the clutches and drive belt will
VEHICLE BREAK-IN PERIOD ensure a longer life and better performance. Break in the
The break-in period is the first 25 hours of operation. clutches and belt by operating at slower speeds during
Careful treatment of a new engine and drive components the break-in period as recommended. Pull only light
causes satisfactory performance and a longer life for loads. Avoid aggressive acceleration and high speed
these components. operation during the break-in period.
IMPORTANT If a belt fails, always clean away all debris when
replacing the belt.
Too much heat build-up during the first three hours of
operation damages the close-fitted engine parts and
drive components. Do not operate at full throttle at or
high speeds during the first three hours of operation.
Never substitute or mix oil brands. Serious engine
damage and voiding of warranty can result. Polaris
recommends you use Polaris PS-4 Synthetic Engine
Oil.
ENGINE AND DRIVETRAIN BREAK-IN

PERIOD
1. Fill the fuel tank. Use unleaded gasoline with
minimum 87 octane and maximum 10% ethanol
content.
2. Check the engine oil level. Add the recommended oil
as needed.
3. Refer the customer to the New Operator Driving
Procedures outlined in the Owner’s Manual.
4. Avoid aggressive use of the brakes.
5. Vary throttle positions. Do not operate at sustained
idle or sustained high speed.
6. Pull only light loads.
7. Perform regular checks on fluid levels, controls, and
areas outlined in the Pre-Ride Inspection checklist.
8. Perform a break-in oil and filter change at 25 hours /
250 miles (whichever comes first); change every 100
hours thereafter. Change more frequently during cold
weather operation.
9. Perform a transmission break-in fluid level check at
25 hours / 250 miles (whichever comes first); check
every 25 hours thereafter. Change fluid at 200 hours /
2000 miles.
10. Perform a front gearcase break-in fluid change at 25
hours / 250 miles (whichever comes first); change
every 200 hours / 2000 miles thereafter.
BRAKE SYSTEM BREAK-IN

Apply only moderate braking force for the first 50 stops.
Aggressive or overly forceful braking when the brake
system is new could damage brake pads and rotors.

MAINTENANCE
PERIODIC MAINTENANCE CHART KEY

SYMBOL DESCRIPTION
► Perform these operations more often for vehicles subjected to severe use.
E Emission-related Control System Service (California)
Failure to conduct this maintenance will not void the emissions warranty but may affect
emissions 2
■ Have an authorized POLARIS dealer perform these services.
SEVERE USE ITEM: Severe Use is defined as frequent vehicle immersion in mud, water or sand, racing or race-style
high rpm use, prolonged low speed - heavy load operation or extended idle. More preventative maintenance is
required under these conditions. Fluid changes, cable and chassis lubrication are required more frequently. For engine
oil, short trip cold weather riding also constitutes severe use. Pay special attention to oil level. A rising oil level in cold
weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately and monitor level. If
oil level begins to rise, discontinue use and determine cause.
NOTICE
Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.
WARNING
Improperly performing the procedures marked with a ■ could result in component failure and lead to serious injury or
death. Have an authorized Polaris dealer perform these services.
PERIODIC MAINTENANCE CHART

MAINTENANCE INTERVAL
(WHICHEVER COMES FIRST)
HOUR- CALEN-
ITEM S DAR MILES (KM) REMARKS
Steering - Pre-Ride -
Front-suspension - Pre-Ride -
Rear-suspension - Pre-Ride -
Tires - Pre-Ride -
Brake fluid level - Pre-Ride -
Make adjustments as needed.
Brake pedal travel - Pre-Ride -
Brake systems - Pre-Ride -
Wheels /fasteners - Pre-Ride -
Frame fasteners - Pre-Ride -
Engine Oil Level - Pre-Ride -
▶
Air filter, pre-filter - Daily - Inspect; clean often; replace as needed
E
Coolant - Daily - Check level
Power Steering unit (if
▶ equipped) - Daily - Inspect daily; clean often
Head lamp / tail lamp / Check operation; apply dielectric grease to

- Daily -
worklight electrical connections if replacing lamps
▶ Weekly
Air filter - - Inspect; replace as needed
E
▶ Brake pad wear Monthly - Inspect periodically
10 H
D
Battery 20 H Monthly - Check terminals; clean; test

MAINTENANCE
HOUR- CALEN-
▶ Engine breather Monthly
25 H - Inspect; replace as needed
E filter (if equipped)
Inspect; Cycle the Key to pressurize the fuel
Fuel System 25 H Monthly - pump; check lines and fittings for leaks and
abrasion.
Front Gearcase oil (if
▶ equipped) 25 H Monthly - Perform a break-in oil level check
Middle Gearcase oil (if
▶ equipped) 25 H Monthly - Perform a break-in oil level check
Rear gearcase oil (if
▶ 25 H Monthly - Perform a break-in oil level check
equipped)
▶ Transmission fluid 25 H Monthly - Perform a break-in oil level check
Engine oil change
▶ (break-in) 25 H Monthly - Perform a break-in oil change at one month
▶ General lubrication 50 H 3M - Lubricate all grease fittings, pivots, cables, etc.

Shift Linkage 50 H 6M - Inspect, lubricate, adjust
D Steering 50 H 6M - Lubricate
▶ Front Suspension 50 H 6M - Lubricate
▶ Rear Suspension 50 H 6M - Lubricate
D Throttle Cable/ 500 (800) Inspect; adjust; lubricate; replace if necessary
50 H 6M
E Release Switch
Throttle body air intake
E ducts/ 50 H 6M 500 (800) Inspect ducts for proper sealing/air leaks
flange
Drive belt 50 H 6M 500 (800)
Inspect coolant strength seasonally; pressure
▶ Cooling system 50 H 6M -
test system yearly
Engine oil and filter Change oil and filter; (perform a break-in oil
▶ change 100 H 6M 1000 (1600)
change at one month)
▶ Oil lines and fasteners 100 H 6M - Inspect for leaks and loose fittings
Front Gearcase oil (if
▶ equipped) 100 H 6M - Inspect level; change yearly
Middle Gearcase oil (if

Rear gearcase oil (if

▶ Transmission fluid 100 H 6M 1000 (1600) Change fluid

Cycle the key to prime and pressurize the fuel
D Fuel System 1000 (1600) system. Check for leaks at fuel cap, fuel line /
100 H 12 M
E rail, and fuel pump; Replace lines every 2 years
Radiator
▶ (if applicable) 100 H 12 M - Inspect; clean external surfaces
▶ Cooling Hoses 100 H 12 M - Inspect for leaks; clean external surfaces

▶ Engine mounts 100 H 12 M - Inspect
Exhaust muffler /pipe 100 H 12 M - Inspect

MAINTENANCE
HOUR- CALEN-
D Spark plug 1000 (1600) inspect; replace as needed
100 H 12 M
E
Inspect for wear, routing, security; apply
2
▶ Wiring 100 H 12 M - dielectric grease to connectors subjected to
water, mud, etc.
D Clutches 100 H 12 M 1000 (1600) Inspect; clean; replace worn parts
D Front wheel bearings 100 H 12 M - Inspect; replace as needed
D Brake fluid 200 H 24 M - Change every two years
Spark arrestor - 60 M - Clean out
D - 2000 (3200) Inspect; adjust
Valve clearance 200 H
E
Idle speed - Adjust as needed.
Inspect periodically; adjust when parts are
D Toe adjustment -
replaced
Auxiliary brake (if
D▶ - Inspect daily; adjust as needed
equipped)
Headlight aim - Adjust as needed
▶ = Perform these procedures more often for vehicles subjected to severe use.
E= Emission Control System Service (California)
D = Have an authorized POLARIS dealer perform these services.
*Service Note: Under extreme use, change demand drive fluid every 25 hours. "Extreme Use" is defined as constant
ADC operation on hilly or mountainous terrain, or if ADC is the primary mode of AWD operation.

MAINTENANCE
GREASE LUBRICATION POINTS

There is a grease fitting on the front propshaft yoke. Apply a maximum of 3 pumps of grease.
ITEM RECOMMENDED LUBE METHOD FREQUENCY

Grease before long periods
Grease fittings of storage, and after
Front Propshaft Yoke Polaris Premium U-Joint Grease (3 pumps maximum) pressure washing or
submerging the vehicle. **
Front A-Arm Polaris All Season Grease Locate fitting and grease. Semi-annually **
Rear A-Arm Polaris All Season Grease Locate fitting and grease Semi-annually **
Rear Stabilizer Bar
Bushings (If equipped Polaris All Season Grease Locate fitting and grease Semi-annually **
with grease fittings)
** Semi-annually or 50 hours of operation. Refer to Maintenance Schedule for additional information. Service more
often under severe conditions (i.e. operating in water or hauling heavy loads).

MAINTENANCE
COMPONENT QUICK REFERENCE

III. # ITEM LUBE REC. METHOD FREQUENCY*
Change after first month
or first 25 hours of
operation, 100 hours
1 Engine Oil
Polaris PS-4 Performance Add oil to proper level on thereafter; Change more 2
Synthetic 4-Cycle Oil dipstick often (25 hours) in
severe duty conditions or
short trip cold weather
operation
Check level daily,
Engine Coolant Maintain coolant level in change coolant every 2
2 Polaris 60/40 Coolant
coolant reservoir bottle. years
Maintain fluid level
Check level at pre-ride
between “MAX and
3 Brake Fluid Polaris DOT 4 Brake Fluid inspection; change fluid
“MIN” lines on the
every two years
master cylinder reservoir
* More often under severe use, such as operated in water or under severe loads.

MAINTENANCE
STORAGE TIPS OIL AND FILTER

STABILIZE THE FUEL Change the oil and filter.
1. Fill the fuel tank. AIR FILTER / AIR BOX
2. Add Polaris Premium Carbon Clean or Polaris Fuel 1. Inspect and clean (or replace) the pre-cleaner and air
Stabilizer. Follow the instructions on the container for filter.
the recommended amount. Carbon Clean removes
2. Clean the air box.
water from fuel systems, stabilizes fuel and removes
carbon deposits from pistons, rings, valves and 3. Inspect the air box drain.
exhaust systems.
BATTERY STORAGE
3. Allow the engine to run for 15-20 minutes to allow the
Refer to Body Electrical chapter for off season storage
stabilizer to disperse through the entire fuel delivery
procedures.
system.
FOG THE ENGINE CLEAN THE EXTERIOR
Make any necessary repairs and clean the vehicle as
1. After stabilizing the fuel, remove the spark plugs and recommended.
add 2-3 tablespoons of engine oil. To access the plug
holes, use a section of clear 1/4” hose and a small STORAGE AREA / COVERS
plastic squeeze bottle filled with the pre-measured Set the tire pressure and safely support the ATV with the
amount of oil. tires slightly off the ground. Be sure the storage area is
2. Reinstall the spark plugs. Torque to specification. well ventilated. Cover the vehicle with a genuine Polaris
cover. Do not use plastic or coated materials. They do
3. Apply dielectric grease to the inside of the spark plug not allow enough ventilation to prevent condensation,
cap and reinstall the caps onto the plugs. and may promote corrosion and oxidation.
4. Turn the engine over several times using electric
start. Oil will be forced in and around the piston rings
and ring lands, coating the cylinder with a protective
film of fresh oil.
5. If Polaris fuel system additive is not used, the fuel
tank, fuel lines, and injectors should be completely
drained of gasoline.
NOTICE
Starting the engine during the storage period will disturb
the protective film created by fogging and damage
could occur. Never start the engine during the storage
period.
INSPECT AND LUBRICATE

Inspect all cables and lubricate all areas of the vehicle as
recommended in the maintenance interval charts.
FLUID LEVELS
Inspect the fluid levels. Add or change fluids as
recommended in the maintenance interval charts
• Demand drive unit (front gearcase)

• Rear gearcase (if equipped)
• Transmission
• Brake fluid (change every 2 years and any time the
fluid looks dark or contaminated)
• Coolant (test strength / fill)

MAINTENANCE
LUBRICANTS / SERVICE PRODUCTS

POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS
PART NO. DESCRIPTION
2870791 Fogging Oil (12 oz. Aerosol)
2876244 PS-4 Syn. 4-Cycle Engine Oil (Quart)
Engine Lubricant 2876245 PS-4 Syn. 4-Cycle Engine Oil (Gallon / 3.8 l)
2
2878920 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (qt./.95 l)
2878919 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (gal./3.8 l)
2878068 AGL Gearcase Lubricant (1 Qt. / .95 l) (12 Count)
2878069 AGL Gearcase Lubricant (1 Gal. / 3.8 l) (4 Count)
Gearcase / Transmission 2878070 AGL Gearcase Lubricant (2.5 Gal. / 9.5 l) (2 Count)
Lubricants 2877922 Demand Drive fluid (Quart / .95 l)
2877923 Demand Drive fluid (2.5 Gallon / 9.5 l)
2870465 Oil Pump for 1 Gallon Jug
2880514 50/50 Extended Life 1 US Quart (0.9 L), 12 per case
Coolant 2880513 50/50 Extended Life 1 US Gallon (3.8 L), 4 per case
2880512 50/50 Extended Life 55 US Gallon Drum (208 L)
2871312 Grease Gun Kit
2871322 Premium All Season Grease (3 oz. cartridge) (24 Count)
2871423 Premium All Season Grease (14 oz. cartridge) (10 Count)
Grease / Specialized Lubricants
2871460 Premium Starter Grease
2871515 U-Joint Grease (3 oz.) (24 Count)
2871551 U-Joint Grease (14 oz.) (10 Count)
2871326 Premium Carbon Clean (12 oz.) (12 count)
2870652 Fuel Stabilizer (16 oz.) (12 count)
2872189 DOT 4 Brake Fluid (12 count)
Miscellaneous 2871950 Loctite™ Threadlock 242 (6 ml.) (12 count)
2871956 Loctite™ 565 Thread Sealant
2871557 Crankcase Sealant, 3-Bond 1215 (5 oz.)
2859044 POLARIS Battery Tender™ Charger
NOTICE
Each item can be purchased separately at your local
Polaris dealer.
NOTICE
The number count indicated by each part number in the
table above indicates the number of units that are
shipped with each order.

MAINTENANCE
ENGINE
COMPRESSION AND LEAKDOWN TEST 4. Reinstall dipstick completely.
NOTICE NOTICE
This Polaris 4-Stroke engine is equipped with an The dipstick must be screwed completely in to ensure
automatic decompressor. Compression readings will accurate measurement.
vary in proportion to cranking speed during the test.
Average compression (measured) is about 80-120 psi
during a compression test.
Smooth idle generally indicates good compression. Low

engine compression is rarely a factor in running condition
problems above idle speed. Abnormally high
compression can be caused by a decompressor
malfunction, or worn or damaged exhaust cam lobes.
Inspect camshaft and automatic decompression
mechanism if compression is abnormally high.
A cylinder leakage test is the best indication of engine
condition on models with automatic decompression.
Follow manufacturer’s instructions to perform a cylinder
leakage test (never use high pressure leakage testers as
crankshaft seals may dislodge and leak).
5. Remove dipstick and check the oil level. The oil level
Cylinder Compression should be between the top line and the bottom line on
80 - 120 PSI the dipstick. Add oil as indicated by the level on the
Cylinder Leakage dipstick. Do not overfill.
Service Limit: 10%
Inspect for cause if leakage exceeds 10% NOTICE
Rising oil level between checks in cool weather driving,
can indicate moisture collecting in the oil reservoir. If
the oil level is over the full mark, change the oil.
ENGINE OIL LEVEL
Access the oil dipstick and fill tube from the right side of
the vehicle. A rising oil level between checks in cool
weather driving can indicate contaminants such as gas OIL AND FILTER CHANGE
or moisture collecting in the crankcase. If the oil level is
over the full/safe mark, change the oil immediately. Oil Filter Torque:
Lubricate oil filter gasket with engine oil
Turn by hand until filter gasket contacts sealing
surface, then turn an additional 3/4 turn
Oil Filter Wrench:

PV-50105
Recommended Engine Oil:

Polaris PS–4
Synthetic 5W-50
NOTICE: Care must be taken to ensure that the fluids

are contained. Be prepared to collect the fluid with
suitable containers before opening any compartment
or disassembly of any component containing fluids.
1. Set machine on a level surface.
CAUTION
2. Clean the area around the dip stick.
Personal injury can occur when handling used oil. Hot
3. Remove dipstick and wipe dry with a clean cloth. oil can cause burns or skin damage.

MAINTENANCE
1. Place vehicle on a level surface. 16. Add oil as necessary to bring the oil level to the upper
mark on the dipstick. Do not over fill the engine, the
2. Place the transmission in PARK (P). maximum oil capacity is 2 qts(1.9 l).
3. Clean area around drain plug at bottom of oil pan.
NOTICE
4. Start the engine. Allow it to warm up at idle for two to
three minutes. The dipstick must be screwed completely in to ensure
accurate measurement. 2
5. Stop the engine.
6. Place a drain pan under the crank case. 17. Reinstall the upper fill cap (if removed) and tighten
the dipstick.
7. Remove the drain plug w. Allow oil to drain
completely. 18. Place the transmission in PARK (P).
19. Verify that the transmission is still positioned in PARK
(P).
20. Start the engine. Allow it to idle for two minuets.
21. Stop the engine and check for leaks.
22. Check the oil level on the dipstick and add oil as
necessary to bring the level to the upper mark on the
dipstick.
23. Dispose of used filter and oil properly.
BREATHER HOSE
Be sure breather line is routed properly and secured in
place.
8. Replace sealing washer on drain plug.
CAUTION
NOTICE
Make sure line(s) are not kinked or pinched.
The sealing surfaces on the drain plug and the oil tank
should be clean and free of burrs, nicks or scratches.
9. Reinstall the drain plug and torque it to specification. BREATHER VALVE INSPECTION
This engine is equipped with a breather valve q. The
TORQUE valve is located on the front of the engine. The valve
Engine Oil Plug: should only allow air to pass from the engine to the
12 ft-lbs (16 Nm) breather hose w and finally to the intake e and NOT
from the air intake to the engine. Replace as necessary.
10. Place a drain pan under the oil filter.

11. Place shop towels beneath oil filter q. Use Oil Filter
Wrench (PV-50105), turn filter counterclockwise to
remove.
12. Using a clean dry cloth, clean filter sealing surface on
the crankcase.
13. Lubricate the o-ring on new filter with a thin film of
engine oil. Check to make sure the O-ring is in good
condition.
14. Install the new filter and turn it by hand until the filter
gasket contacts the sealing surface, then turn an
additional 3/4 of a turn.
15. Remove dipstick.

MAINTENANCE
500 SOHC 5. Measure the valve clearance of each valve using a

feeler gauge. Record the measurement if clearance is
VALVE CLEARANCE - SOHC out of specification.
NOTICE MEASUREMENT
Valve clearance inspection should be performed on a Intake Valve Clearance:
cold engine, at room temperature.
0.006 ± 0.002" (0.152 ± 0.051 mm)
1. Tilt the cargo box. Exhaust Valve Clearance:

0.010 ± 0.002" (0.254 ± 0.051 mm)
2. Remove the PVT cover to access the drive clutch.
3. Remove the rocker cover bolts q, cover w and
gasket. 6. Record the results of each measurement for future
reference.
7. Reinstall all components that were removed.
570 DOHC
VALVE CLEARANCE - DOHC
Inspect and adjust valve clearance while the engine is
cold and the piston positioned at Top Dead Center (TDC)
on compression stroke.
1. Tilt the cargo box.
2. Remove the spark plug high tension lead q and
remove the spark plug w. CAUTION: Place a clean
shop towel into the spark plug cavity to prevent dirt
NOTICE from entering.
It may be necessary to tap the cover lightly with a soft-
faced hammer to loosen it from the cylinder head.
4. Use drive clutch to rotate the crankshaft until the cam

chain sprocket timing marks are aligned with the
gasket surface as shown.
3. Remove the valve cover bolts e, cover r and

gasket.
NOTICE
It may be necessary to tap the cover lightly with a soft-
faced hammer to loosen it from the cylinder head.
NOTICE
Isolators must be replaced after each use.
4. Remove the PVT cover to access the drive clutch.

MAINTENANCE
5. Use drive clutch to rotate the crankshaft until the cam

chain sprocket timing marks are aligned with the
gasket surface as shown.
IMPORTANT
Intake cam sprocket should have “I” marks aligned with
the gasket surface and the exhaust cam sprocket
should have “E” marks aligned with the gasket surface.
6. Measure the valve clearance of each valve using a

feeler gauge. Record the measurement if clearance
is out of specification.
MEASUREMENT
Intake Valve Clearance:
0.006 ± 0.002" (0.15 ± 0.05 mm)
Exhaust Valve Clearance:

0.008 ± 0.002" (0.20 ± 0.05 mm)

MAINTENANCE
COOLING SYSTEM
COOLING SYSTEM OVERVIEW COOLANT LEVEL INSPECTION
The engine coolant level is controlled, or maintained, by The recovery bottle q and radiator pressure cap w are
the recovery system. The recovery system components located under the hood.
are the recovery bottle, radiator filler neck, radiator
pressure cap and connecting hose.
As coolant operating temperature increases, the
expanding (heated) excess coolant is forced out of the
radiator past the pressure cap and into the recovery
bottle. As engine coolant temperature decreases the
contracting (cooled) coolant is drawn back up from the
bottle, past the pressure cap, and into the radiator.
NOTICE
Some coolant level drop on new vehicles is normal as
the system is purging itself of trapped air. Observe
coolant level often during break-in period.
IMPORTANT With the engine at operating temperature, the coolant

level should be between the “MAX” and “MIN” marks on
Overheating of engine could occur if air is not fully
the recovery bottle. If not, perform the following:
purged from system.
1. Position the vehicle on a level surface.
Polaris recommends the use of Polaris 50/50 Extended 2. The coolant level must be maintained between the
Life Antifreeze or a 50/50 mixture of high quality “MAX” and “MIN” levels indicated on the recovery
aluminum compatible anti-freeze/coolant and distilled bottle
water.
NOTICE
Polaris 50/50 Extended Life Antifreeze 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.
NOTICE
If overheating is evident, allow system to cool
completely and check coolant level in the radiator and
inspect for signs of trapped air in system.
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.

MAINTENANCE
4. Remove the pressure cap. Using a funnel, add

coolant to the top of the radiator filler neck.
5. Reinstall the pressure cap.
NOTICE
Use of a non-standard pressure cap will not allow the
recovery system to function properly. 2
6. Remove the recovery bottle cap.
7. Fill the recovery bottle to the “MAX” mark with Polaris
Premium 50/50 Anti-Freeze/Coolant or a 50/50
mixture of antifreeze/coolant and distilled water as
required for freeze protection in your area.
8. Reinstall the recovery bottle cap.
9. If coolant was required, start engine and check for
leaks. Make sure radiator fins are clean to prevent
overheating.

MAINTENANCE
50/50 EXTENDED-LIFE ENGINE ANTIFREEZE

All liquid-cooled Polaris vehicles use 50/50 Extended Life antifreeze, which has a 5-year service life.
It’s important to note that conventional, 60/40 antifreeze can be mixed with 50/50 Extended Life antifreeze. However,
mixing the two will affect the service interval. To receive the full 5-year service interval benefit, the cooling system must
be fully drained and replenished with the Extended Life antifreeze.
To determine if a vehicle is using 60/40 or 50/50 Extended Life antifreeze, note the color: 60/40 antifreeze is green,
while 50/50 Extended Life antifreeze is yellow.
50/50 EXTENDED- LIFE ANTIFREEZE PART NUMBERS

PART NUMBERS DESCRIPTION
2880514 1 US Quart (0.9 L) / 12 per case
2880513 1 US Gallon (3.8 L) / 6 per case
2880512 55 US Gallon Drum (208 L)

MAINTENANCE
COOLANT STRENGTH / TYPE COOLING SYSTEM HOSES

Test the strength of the coolant using an antifreeze
hydrometer.
• A 50/50 or 60/40 mixture of antifreeze and distilled

water will provide the optimum cooling, corrosion
protection, and freeze protection.
• Do not use tap water, straight antifreeze, or straight
water in the system. Tap water contains minerals and
impurities which build up in the system. Straight water
or antifreeze may cause the system to freeze, corrode, REF DESCRIPTION
or overheat.
q Clamp
FLUID CAPACITY
w Hose to Thermostat
Recommended Anti-Freeze/Coolant:
Polaris 50/50 Anti-Freeze/Coolant e Radiator
2871534 (Quart)
r Recovery Bottle
t Hose to Water Pump
y Retainer
u Bolt
1. Inspect all hoses for cracks, deterioration, abrasion

or leaks. Replace if necessary.
2. Check tightness of all hose clamps.
CAUTION
Do not over-tighten hose clamps at radiator, or radiator
fitting may distort.
TORQUE
Radiator Hose Clamp:
36 in-lbs (0.4 Nm)

MAINTENANCE
RADIATOR INSPECTION / CLEANING COOLANT DRAIN / RADIATOR

REMOVAL
1. Allow the vehicle to cool down if recently operated.
2. Place a suitable drain pan underneath the right hand
side of the radiator.
3. Open the hood and slowly open the radiator
pressure cap to relieve system pressure.
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.
4. Open the drain valve q on the front side of the

REF DESCRIPTION radiator and allow the coolant to completely drain.
Properly dispose of the used coolant.
q Fan Motor
w Shroud
e Radiator
1. Check radiator air passages for restrictions or

damage.
2. Carefully straighten any bent radiator fins.
3. Remove any obstructions with compressed air or low
pressure water.
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 5. Remove the screws that retain the recovery bottle to
recommended. the frame bracket. Set the recovery bottle out of the
way.

MAINTENANCE
6. Remove the upper and lower coolant lines from the Installation
radiator. 11. Reverse previous procedures for installation.
12. Upon installation, be sure the lower radiator mounts
are placed properly in the frame support.
7. Remove the recovery bottle return line.

8. Remove the two mounting screws w that secure the
upper portion of the radiator to the frame. 13. After the radiator is installed, verify the rubber
mounts e have remained in place.
14. After installation and reassembly, remove the
pressure cap and fill the radiator and recovery bottle
with coolant.
15. Refer to the cooling system bleeding procedure in
Chapter 3, under “Engine Installation Notes”.
9. Carefully lift the radiator straight up and out of the

vehicle. Take care not to damage the cooling fins.
10. Remove the four bolts that retain the fan motor and
shroud to the radiator.

MAINTENANCE
FUEL SYSTEM AND AIR INTAKE

FUEL SYSTEM VENT LINES
1. Check fuel tank vent line for signs of wear,
WARNING deterioration, damage or leakage. Replace every two
Gasoline is extremely flammable and explosive under years.
certain conditions. 2. Be sure vent line is routed properly and secured with
Always stop the engine and refuel outdoors or in a well cable ties. CAUTION: Make sure line is not
ventilated area. obstructed.
Do not smoke or allow open flames or sparks in or near
the area where refueling is performed or where THROTTLE PEDAL INSPECTION
gasoline is stored. This vehicle is equipped with Pedal Position Sensor q
Do not overfill the tank. Do not fill the tank neck. used to detect when the throttle pedal w is pushed or
If you get gasoline in your eyes or if you swallow released.
gasoline, seek medical attention immediately. Do not
induce vomiting.
If you spill gasoline on your skin or clothing,
immediately wash it off with soap and water and
change clothing.
Never start the engine or let it run in an enclosed area.
Engine exhaust fumes are poisonous and can result
loss of consciousness or death in a short time.
Never drain the fuel when the engine is hot. Severe
burns may result.
FUEL LINES
1. Check fuel lines for signs of wear, deterioration,
damage or leakage. Replace if necessary.
The throttle pedal should move freely and always return
2. Be sure fuel lines are routed properly and secured back to its idle position when released.
with cable ties. CAUTION: Make sure lines are not
kinked or pinched. Check throttle pedal periodically.
3. Replace all fuel lines every two years.
FUEL PUMP / FILTER AIR FILTER SERVICE

It is recommended that the air filter be replaced annually.
The fuel pump components on the RANGER are not When riding in extremely dusty or wet conditions, or at
serviceable. If a component requires replacement, the wide open throttle for extended periods, replacement is
fuel pump assembly must be replaced. required more often.
The filter should be inspected periodically before each
NOTICE
ride, using the following procedure.
See the “Online Electronic Parts Catalog” for correct
parts information. Removal
For all other information related to the Fuel System, 1. Lift the rear cargo box to access the airbox cover.
refer to Chapter 4.

MAINTENANCE
2. Unhook the two clips q from airbox cover and 4. Clean airbox of any oil or water deposits and apply a
remove cover. Inspect the cover seal. It should small amount of grease to the sealing surfaces of the
adhere tightly to the cover. filter.
5. Reinstall the air filter into the airbox container. Be
sure the filter fits tightly in the air box and engage the
(2) clips.
2
ENGINE AIR INTAKE INSPECTION
1. Remove the cover from the outer side of the seat
base q and remove the pre-filter element.
3. Remove the air filter assembly. Inspect the air filter

and replace if necessary.
NOTICE
If the filter has been soaked with fuel or oil it must be
replaced. Do not attempt to wash the air filter. If
cleaning is required, replace the filter.
2. If the pre-filter element is dirty, clean it with hot,

soapy water. Rinse and dry the filter element
thoroughly. Inspect element for tears or damage.
Replace if necessary.
3. Reinstall the pre-filter element into the seat frame
and install the cover.
PVT AIR INTAKE INSPECTION

1. Remove the PVT intake cover q.
REF. DESCRIP- NOTES

TION
w Cover
e Filter
r Seal
t Clamp
y Airbox 2. Verify there is no debris obstructing the airway.
u Boot 3. Reinstall the cover.
Installation

MAINTENANCE
TRANSMISSION AND GEARCASE

SHIFT CABLE INSPECTION TRANSMISSION LUBRICATION
Shift cable adjustment is necessary when symptoms NOTICE
include:
It is important to follow the transmission maintenance
• Noise on deceleration intervals described in the Periodic Maintenance Chart.
Regular fluid level inspections should be performed as
• Inability to engage a gear well.
• Excessive gear clash (noise)
The transmission lubricant level should be checked and
• Gear selector is moving out of desired range changed in accordance with the maintenance schedule.
Inspect shift cable, clevis pins, and pivot bushings and • Be sure vehicle is positioned on a level surface when
replace if worn or damaged checking or changing the lubricant.
• Check vent hose to be sure it is routed properly and
unobstructed.
SHIFT CABLE ADJUSTMENT
NOTICE Transmission Lubricant Level Check
The shift cable should be adjusted at the rear Maintain the fluid level even with the bottom threads of
adjustment point near the transmission. If further the fill plug hole.
adjustment is needed, remove dash panel to access the 1. Position vehicle on a level surface.
shift cable adjustment point under the shift lever.
2. Remove the fill / check plug q and check the
lubricant level.
1. Place gear selector in neutral. Make sure the
transmission bell crank is engaged in the neutral
position detent.
2. Locate the shift cable adjustment point at the engine-
to-transmission mount bracket.
3. With two open-end wrenches, loosen the outside jam
nut q counterclockwise. Turn outside jam nut 1 1/2
turns.
3. If lubricant level is not level with the bottom threads,

add the recommended lubricant as needed. Do not
overfill.
4. Reinstall the fill plug and torque to specification.
TORQUE
Transmission Drain / Fill Plug:
14 ft-lbs (19 Nm)
4. After turning the outside jam nut 1 1/2 turns, hold the
outside jam nut with a wrench and tighten the inside
jam w nut clockwise, until it is tight against the Transmission Lubricant Change
bracket. Access the drain plug from underneath the vehicle
5. Repeat Step 3 and Step 4 until the proper through the access hole in the skid plate.
adjustment is made to the shift cable. 5. Remove the fill plug (refer to “Transmission Lubricant
Level Check”).
6. Place a drain pan under the transmission drain plug.

MAINTENANCE
7. Remove the drain plug and allow lubricant to drain FRONT GEARCASE LUBRICATION
completely.
NOTICE
NOTICE It is important to follow the front gearcase maintenance
On some 2012 vehicles, a commercially available long intervals described in the Periodic Maintenance Chart.
ball end hex bit socket may be needed to remove the Regular fluid level inspections should be performed as
drain plug. well. 2
8. Clean the drain plug magnetic surface. Reinstall The front gearcase fluid level should be checked and
drain plug with a new O-ring and torque to changed in accordance with the maintenance schedule.
specification. • Be sure vehicle is positioned on a level surface when
9. Add the recommended amount of lubricant through checking or changing the fluid.
the fill plug hole. Maintain the lubricant level at the • Check vent hose to be sure it is routed properly and
bottom of the fill plug hole when filling the unobstructed.
transmission. Do not overfill.
Front Gearcase Fluid Level Check
The fill plug is located on the front-right side of the front
gearcase. Access the fill plug from the side of the
vehicle. Maintain the fluid level even with the bottom
threads of the fill plug hole.
1. Position vehicle on a level surface.
2. Open the hood to gain access to the gearcase area.
3. Remove the fill plug q and check the fluid level.
REF. DESCRIP- NOTES

TION
w Fill Plug 14 ft-lbs (19
Nm)
e Drain Plug 14 ft-lbs (19

Nm)
FLUID CAPACITY
4. If fluid level is not even with the bottom threads, add
Recommended Transmission Lubricant: the recommended fluid as needed. Do not overfill.
Full Synthetic AGL (PN 2878068) (Quart)
Capacity: 41 oz. (1200 ml) 5. Reinstall the fill plug and torque to specification.
TORQUE
10. Reinstall fill plug with a new O-ring and torque to
specification. Front Gearcase Drain / Fill Plug:
10 ft-lbs (14 Nm)
TORQUE
Transmission Drain / Fill Plug: Front Gearcase Fluid Change:
14 ft-lbs (19 Nm)
The drain plug is located on the bottom side of the
front gearcase. Access the drain plug through the
11. Check for leaks. Dispose of used lubricant properly. skid plate.
6. Remove the fill plug q (refer to “Front Gearcase
Fluid Level Check”).

MAINTENANCE
7. Place a drain pan under the front gearcase drain

plug w.
8. Remove the drain plug and allow fluid to drain
completely.
9. Clean the drain plug magnetic surface.

10. Reinstall drain plug with a new O-ring and torque to
specification.
11. Add the recommended amount of fluid through the fill
hole. Maintain the fluid level even with the bottom
threads of the fill plug hole.
FLUID CAPACITY
Recommended Front Gearcase Fluid:
Polaris Demand Drive
(PN 2877922) (Quart)
Capacity: 6.7–7.6 oz. (200–225 ml)
12. Reinstall fill plug with a new O-ring and torque to

specification.
TORQUE
Front Gearcase Drain / Fill Plug:
10 ft-lbs (14 Nm)
13. Check for leaks. Dispose of used fluid properly.

MAINTENANCE
FINAL DRIVE / WHEEL / TIRE

WHEEL AND HUB TORQUE TABLE WHEEL REMOVAL
ITEM SPECIFICATION
Torque: Steel Wheels:
Wheels Nuts
36 ft-lbs (49 Nm)
Aluminum Wheels:
2
30 ft-lbs + 90º (41 Nm +
90º)
Front Hub Nut 90 ft-lbs (122 Nm)
Rear Hub Nut 110 ft-lbs (150 Nm)
CV SHAFT BOOT INSPECTION

Inspect the CV shaft boots in the front and rear for
damage, tears, wear, or leaking grease. If the rubber RE- DESCRIP- NOTES
boot exhibits any of these symptoms, replace the boot. F. TION
Refer to Final Drive for CV boot replacement.
q Wheel Nuts Torque: Steel Wheels:
36 ft-lbs (49 Nm)
Aluminum Wheels:
30 ft-lbs + 90º (41 Nm + 90º)
w Washers
1. Stop the engine, place the transmission in gear and

chock wheels.
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.

MAINTENANCE
WHEEL INSTALLATION WARNING

1. With the transmission in gear and wheels chocked,
place the wheel in the correct position on the wheel Operating with worn tires will increase the possibility of
hub. Be sure the valve stem is toward the outside the vehicle skidding easily with possible loss of control.
and rotation arrows on the tire point toward forward Worn tires can cause an accident. Always replace tires
rotation. when the usable tread depth has worn out.
2. Install the washers (if applicable) and wheel nuts and
tighten by hand.
3. Lower the vehicle to the ground. TIRE PRESSURE
4. Torque wheel nuts to specification. CAUTION
TORQUE Maintain proper tire pressure.
Wheel Lug Nuts: Refer to the warning tire pressure decal applied to the
Steel: 27 ft-lbs (37 N·m) vehicle.
Aluminum: 30 ft-lbs (41 N·m) (plus 1/4 turn)
TIRE PRESSURE INSPECTION (PSI - COLD)
CAUTION 500 570 EFI 570 EFI CREW

If wheels are improperly installed it could affect vehicle 10 PSI Front 10 PSI Front 14 PSI Front
handling and tire wear. On vehicles with tapered wheel
nuts, make sure the tapered end of the nut goes into 10 PSI Rear 12 PSI Rear 16 PSI Rear
the taper on wheel.
TIRE INSPECTION
• Improper tire inflation may affect vehicle
maneuverability.
• When replacing a tire always use original equipment
size and type.
• The use of non-standard size or type tires may affect
vehicle handling.
MEASUREMENT
Tread Depth Service Limit:
Replace if 1/8″ (3 mm) or less.

MAINTENANCE
STEERING
STEERING INSPECTION NOTE TIE ROD END / STEERING INSPECTION
The steering components should be checked periodically • To check for play in the tie rod end, grasp the steering
for loose fasteners, worn tie rod ends, and damage. Also tie rod, pull in all directions feeling for movement.
check to make sure all cotter pins are in place. If cotter
pins are removed, they must not be re-used. Always use • Replace any worn steering components. Steering
new cotter pins. should move freely through entire range of travel 2
without binding.
Replace any worn or damaged steering components.
Steering should move freely through entire range of
travel without binding. Check routing of all cables, hoses,
and wiring to be sure the steering mechanism is not
restricted or limited.
NOTICE
Whenever steering components are replaced, check
front end alignment. Use only genuine Polaris parts.
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 Elevate front end of machine so front wheels are off
or damaged steering parts. the ground. Check for any looseness in front hub/
Use only genuine Polaris replacement parts. wheel assembly by grasping the tire firmly at top and
bottom first, and then at front and rear. Try to move the
wheel and hub by pushing inward and pulling outward.
• If abnormal movement is detected, inspect the hub and

wheel assembly to determine the cause (loose wheel
nuts or loose front hub nut).
• Refer to the Steering/Suspension or Final Drive
chapter for more information.

MAINTENANCE
WHEEL TOE ALIGNMENT INSPECTION 5. Again measure the distance between the marks and
1. Place machine on a smooth level surface and set record. Call this measurement “B” w. Subtract
steering wheel in a straight ahead position. Secure measurement “B” from measurement “A”. The
the steering wheel in this position. difference between measurements “A” and “B” is the
vehicle toe alignment. The recommended vehicle toe
tolerance is 1/8” to 1/4”, (.3 to .6 cm) toe out. This
means the measurement at the front of the tire (A) is
1/8” to 1/4” (.3 to .6 cm) wider than the measurement
at the rear (B).
MEASUREMENT
Wheel Toe-Out: (A) - (B) = 1/8 - 1/4" (.3 to .6 cm)
TOE ADJUSTMENT
If toe alignment is incorrect, measure the distance
between vehicle center and each wheel. This will tell you
which tie rod needs adjusting.
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.
NOTICE
Be sure steering wheel is straight ahead before
determining which tie rod needs adjustment.
NOTICE
It is important the height of both marks be equally
positioned to get an accurate measurement. CAUTION
During tie rod adjustment, it is very important that the
3. Measure the distance between the marks and record following precautions be taken when tightening tie rod
the measurement. Call this measurement “A” q. end jam nuts.
4. Rotate the tires 180° by moving the vehicle forward. If the rod end is positioned incorrectly it will not pivot,
Position chalk marks facing rearward, even with the and may break.
hub/axle center line.
To adjust toe alignment:
1. Hold tie rod end to keep it from rotating.

2. Loosen jam nuts at both end of the tie rod.

MAINTENANCE
3. Shorten or lengthen the tie rod until alignment is as

required to achieve the proper toe setting as specified
in “Wheel Toe Alignment”.
IMPORTANT
When tightening the tie rod end jam nuts, the rod ends
must be held parallel to prevent rod end damage and 2
premature wear. Damage may not be immediately
apparent if done incorrectly.
4. After alignment is complete, torque jam nuts to

specification.
TORQUE
Tie Rod Jam Nut:
14 ft-lbs (19 Nm)
CAMBER AND CASTER

The camber and caster are non-adjustable.

MAINTENANCE
SUSPENSION
SUSPENSION INSPECTION STABILIZER BAR PIVOT LUBRICATION
Compress and release the suspension. Damping should 1. Grease stabilizer bar pivots q with a grease gun
be smooth throughout the range of travel. until old grease is purged from the joint and new
grease appears. Inspect link isolators w for cracks.
• Check all suspension components and mounting
fasteners for wear or damage.
• Inspect each shock body for leakage.
SPRING PRE-LOAD ADJUSTMENT

The rear shock absorber springs are adjustable. Rotate
the adjuster cam q either direction to increase or
decrease spring tension. Always adjust both left and right
sides equally.
Vehicle loads effect suspension spring pre-load

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

2871095

MAINTENANCE
SUSPENSION PIVOT POINT

LUBRICATION
Grease all four front A-Arm pivot points q and all eight
rear A-Arm pivot points w. See the maintenance chart
for service intervals or grease as needed.
2
NOTICE
Wheels removed for clarification only. Procedure can be
done with wheels installed on unit.

MAINTENANCE
SHOCK ANALYSIS

MAINTENANCE
BRAKE SYSTEM
BRAKE FLUID INSPECTION BRAKE PAD INSPECTION
Always check the brake pedal travel and inspect the
1. Check the brake pads for wear, damage, or
brake fluid reservoir level before each operation. If the
looseness.
fluid level is low, add DOT 4 brake fluid only.
Brake fluid should be changed every two years. The fluid 2. Inspect the brake pad wear surface for excessive
should also be changed anytime the fluid becomes wear. 2
contaminated, the fluid level is below the minimum level,
or if the type and brand of the fluid in the reservoir is
unknown.
The brake master cylinder reservoir q can be accessed
through the front left wheel well by opening the hood..
MEASUREMENT
Brake Pad
.030″ (0.762 mm)
3. If any one pad is less than the service limit then all
1. Position the vehicle on a level surface. pads should be replaced.
2. Place the transmission in Park (P) and chock
wheels.
3. View the brake fluid level in the reservoir. The level
should be between the MAX and MIN level lines.
4. If the fluid level is lower than the MIN level line, add
brake fluid until it reaches the MAX level line.
5. Install the reservoir cap and apply the brake pedal
forcefully for a few seconds and check for fluid
leakage around the master cylinder fittings and the
brake caliper fittings.
BRAKE HOSE AND FITTING

INSPECTION
Check brake system hoses and fittings for cracks,
deterioration, abrasion, and leaks. Tighten any loose
fittings and replace any worn or damaged parts.

MAINTENANCE
BRAKE DISC INSPECTION

1. Check the surface condition of the brake discs.
2. Measure the thickness of the front and rear brake
discs.
3. The disc(s) should be replaced if thickness is less
than the specified service limit
REF PART SERVICE LIMIT

q Front Disc See the specifications
at the beginning of
w Rear Disc the Brake System
chapter.
WARNING
Do not apply WD-40 or any petroleum product to brake
discs. These types of products are flammable and may
also reduce the friction between the brake pad and
caliper.

MAINTENANCE
ELECTRICAL AND IGNITION SYSTEM

BATTERY MAINTENANCE
Keep battery terminals and connections free of
corrosion. If cleaning is necessary, remove the corrosion
with a stiff wire brush. Wash with a solution of one
tablespoon baking soda and one cup water. Rinse well
with tap water and dry off with clean shop towels. Coat 2
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 California to Add only distilled water. Tap water contains minerals that
cause cancer and birth defects or other reproductive are harmful to a battery.
harm.
WASH HANDS AFTER HANDLING.
BATTERY REMOVAL
1. Remove the seat to access the battery area.
WARNING
2. Remove the two T-27 Torx screws q retaining the
Battery electrolyte is poisonous. It contains sulfuric battery bracket to the battery box.
acid. Serious burns can result from contact with skin,
eyes or clothing. Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow
with milk of magnesia, beaten egg, or vegetable oil. Call
physician immediately.
Eyes: Flush with water for 15 minutes and get prompt
medical attention.
Batteries produce explosive gases.
Keep sparks, flame, cigarettes, etc. away.
Ventilate when charging or using in an enclosed space.
Always shield eyes when working near batteries.
KEEP OUT OF REACH OF CHILDREN.
NOTICE
3. Disconnect the black (-) (negative) battery cable.
Batteries must be fully charged before use or battery
life will be reduced by 10-30% of full potential. Charge 4. Disconnect the red (+) (positive) battery cable.
battery for 3-5 hours at a current equivalent of 1/10 of
5. Lift the battery out of the vehicle, being careful not to
the battery’s rated amp/hour capacity. Do not use the
tip and spill electrolyte.
alternator to charge a new battery.
CAUTION
To reduce the chance of sparks: Whenever removing
BATTERY FLUID LEVEL the battery, disconnect the negative (black) cable first.
(CONVENTIONAL BATTERY) When reinstalling the battery, install the negative cable
last.
A poorly maintained battery will deteriorate rapidly.
Check the battery fluid level often. Maintain the fluid level
between the upper q and lower level w marks.

MAINTENANCE
BATTERY INSTALLATION 500 SOHC

Using a new battery that has not been fully charged can
damage the battery and result in a shorter life. It can also SPARK PLUG SERVICE - 500
hinder vehicle performance. Follow the battery charging 1. Remove spark plug high tension lead q. Clean plug
procedure before installing the battery. area so no dirt and debris can fall into engine when
1. Ensure that the battery is fully charged. plug is removed.
2. Place the battery in the battery holder. NOTICE
3. Install the battery vent tube and route it down Allow engine to cool before removing the spark plug
through the battery box. wire. The wire strength is significantly reduced when
hot so it may break if not allowed to cool. If removal of
NOTICE the plug wire from a hot engine is required, ensure the
Route vent tube to prevent electrolyte from damaging wire is pulled off as straight as possible. If difficult to
critical components (i.e. wire harness, brake lines, remove, adjust the pull angle and try again.
throttle cable).
4. Coat the terminals with dielectric grease or

petroleum jelly.
5. Connect and tighten the red (+) (positive) cable first.
6. Connect and tighten the black (-) (negative) cable
last.
7. Verify that cables are properly routed and install the
hold-down strap.
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 2. Remove spark plug w.
during storage and recharge as needed to maintain a full
charge. 3. Inspect electrodes for wear and carbon buildup w.
Look for a sharp outer edge with no rounding or
NOTICE erosion of the electrodes.
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.
BATTERY CHARGING
1. Remove the battery from the vehicle to prevent
damage from leaking or spilled electrolyte 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 4. Clean with electrical contact cleaner or a glass bead
greater. spark plug cleaner only.
3. Reinstall the battery. CAUTION
A wire brush or coated abrasive should not be used.

MAINTENANCE
5. Measure gap with a wire gauge. Refer to 570 DOHC

specifications in picture below for proper spark plug
type and gap. Adjust gap if necessary by bending the SPARK PLUG SERVICE - 570
side electrode carefully. 1. Remove spark plug high tension lead q. Clean plug
area so no dirt and debris can fall into engine when
plug is removed.
2
Spark Plug Gap:

0.030-0.037 in. (0.84 +/– 0.08 mm) 2. Remove spark plug w.
3. Inspect electrodes for wear and carbon buildup w.
6. If necessary, replace spark plug with proper type. Look for a sharp outer edge with no rounding or
erosion of the electrodes.
CAUTION
Severe engine damage may occur if the incorrect spark
plug is used.
7. Install spark plugs and torque to specification.

Recommended Spark Plug:
Autolite 5924
TORQUE
Spark Plug: 15ft-lbs (20 Nm)Do Not Apply Anti-Seize
8. Install spark plug wire into spark plug / engine. 4. Clean with electrical contact cleaner or a glass bead
spark plug cleaner only.
CAUTION
A wire brush or coated abrasive should not be used.

MAINTENANCE
5. Measure gap with a wire gauge. Refer to

specifications in picture below for proper spark plug
type and gap. Adjust gap if necessary by bending the
side electrode carefully.
Spark Plug Gap:

0.028 - 0.032″ (0.7 - 0.8 mm)
6. If necessary, replace spark plug with proper type.
CAUTION
Severe engine damage may occur if the incorrect spark
plug is used.
7. Install spark plug and torque to specification.

Recommended Spark Plug:
NGK MR7F
TORQUE
Spark Plug:
9 ft-lbs (12 Nm)w/o anti-seize
MAIN FRAME/ENGINE GROUND

Inspect engine ground cable connections q. Be sure
ground wires are tight and not corroded. The main
chassis ground can be found below the fuse box under
the driver’s seat base.

CHAPTER 3
GENERAL ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 3
ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
ENGINE OIL FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
ACCESSIBLE ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
TOP-END SERVICE (ENGINE IN CHASSIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.13
ENGINE BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16
ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16
ENGINE MOUNTING AND TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17
SETTING TDC (TOP-DEAD-CENTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.18
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20
COOLING SYSTEM ASSEMBLY VIEW AND COOLANT FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . .3.20
COOLING SYSTEM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21
COOLING SYSTEM PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21
PRESSURE CAP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.22
COOLANT DRAIN / RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.22
THERMOSTAT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.23
COOLING SYSTEM BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.24
WATER PUMP COVER AND IMPELLER SERVICE (STATOR COVER REMAINS ON ENGINE) . . .3.25
WATER PUMP MECHANICAL SEAL / OIL SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.25
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.31
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.31
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.32
500CC SOHC ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.33
ENGINE DETAIL, TORQUES / SEQUENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.33
ENGINE SPECIFICATIONS, 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.33
ENGINE TORQUE SEQUENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.35
CRANKCASE SEALANT PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.37
CRANKCASE / TIMING CHAIN GUIDES / OIL PICKUP / REGULATOR VALVE . . . . . . . . . . . . . . . . . . . .3.38
CYLINDER / OIL FILTER / OIL PUMP / BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.39
CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / IDLER GEARS / STATOR COVER . . . . . . . . . . . . . .3.41
SPARK PLUGS / STARTER / THROTTLE BODY / VALVE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.43
PISTON / CRANKSHAFT / BALANCE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.45
ENGINE DISASSEMBLY / INSPECTION - TOP END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.48

VALVE COVER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.48

CAMSHAFT / CARRIER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.48
CAMSHAFT SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.49
CAMSHAFT / CAMSHAFT BORE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.49
EXHAUST CAMSHAFT DECOMPRESSION MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.50
CAM CHAIN AND GUIDE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.50
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.51
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.51
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.52
CYLINDER HEAD WARP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.52
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.52
COMBUSTION CHAMBER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.54
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.54
CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.55
CYLINDER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.56
PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.56
PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.57
PISTON / ROD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.57
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.58
ENGINE ASSEMBLY - TOP END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.59
PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.59
PISTON / CONNECTING ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.60
CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.60
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.61
VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.62
VALVE CLEARANCE CHECK / ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.62
VALVE LASH - TAPPET SELECTION MATRIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.64
CAMSHAFT INSTALLATION / TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.65
CAMSHAFT TIMING - QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.67
VALVE COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.68
ENGINE DISASSEMBLY / INSPECTION - LOWER END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.69
CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.69
STATOR COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.69
STARTER ONE-WAY CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.69
STATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.71
OIL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.72
OIL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.74
CRANKCASE BREATHER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.75
CRANKCASE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.75
BALANCE SHAFT REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.76
CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.77
CRANKSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.77
PTO SIDE CRANKCASE BEARING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.78
MAG SIDE CRANKCASE BEARING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.79
OIL PICKUP ASSEMBLY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.80
OIL PRESSURE REGULATOR (BYPASS) VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.80
CRANKCASE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.80
ENGINE ASSEMBLY - LOWER END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.81

CRANKCASE ASSEMBLY – PTO SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.81

BALANCE SHAFT INSTALLATION / TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.83
FINAL CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.83
STARTER ONE-WAY CLUTCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.85
FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.85
STATOR / STATOR COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.87
570CC DOHC ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.88
ENGINE DETAIL, TORQUES / SEQUENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.88
ENGINE FASTENER TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.88
TORQUE SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.90
3
CRANKCASE - TIMING / SEALING PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.92
ENGINE DISASSEMBLY / INSPECTION - TOP END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.93
VALVE COVER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.93
CAMSHAFT / CARRIER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.93
CAMSHAFT SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.94
CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.95
EXHAUST CAMSHAFT DECOMPRESSION MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.95
CAM CHAIN AND GUIDE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.96
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.96
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.97
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.98
CYLINDER HEAD WARP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.98
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.98
COMBUSTION CHAMBER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.99
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.100
CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.102
CYLINDER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.102
PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.103
PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.103
PISTON / ROD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.104
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.105
ENGINE ASSEMBLY - TOP END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.106
PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.106
PISTON / CONNECTING ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.107
CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.108
CYLINDER HEAD IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.108
CRANKCASE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.109
CYLINDER HEAD INSTALLATION - BLACK BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.110
CYLINDER HEAD INSTALLATION - SILVER BOLTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.111
VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.112
VALVE CLEARANCE CHECK / ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.112
VALVE LASH - TAPPET SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.115
CAMSHAFT INSTALLATION / TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.116
CAMSHAFT TIMING - QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.119
VALVE COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.120
ENGINE DISASSEMBLY / INSPECTION - LOWER END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.121
CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.121
STATOR COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.121

STARTER ONE-WAY CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.121

STATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.123
OIL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.124
OIL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.126
CRANKCASE BREATHER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.127
CRANKCASE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.127
BALANCE SHAFT REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.128
CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.129
CRANKSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.129
PTO SIDE CRANKCASE BEARING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.130
MAG SIDE CRANKCASE BEARING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.131
OIL PICKUP ASSEMBLY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.132
OIL PRESSURE REGULATOR (BYPASS) VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.132
CRANKCASE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.132
ENGINE ASSEMBLY - LOWER END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.133
CRANKCASE ASSEMBLY – PTO SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.133
BALANCE SHAFT INSTALLATION / TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.135
FINAL CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.135
STARTER ONE-WAY CLUTCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.136
FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.137
STATOR / STATOR COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.138

GENERAL ENGINE INFORMATION

GENERAL INFORMATION
SPECIAL TOOLS
PART NUMBER TOOL DESCRIPTION
PW-47053 Bench Mount Engine Stand Adapter
PU-50658 Clutch Center Distance Tool
PU-50784 Crankshaft Removal / Installation Tool Kit
PU-50563 Cylinder Holding & Camshaft Timing Plate
PU-50624 Engine Stand (2” Bore)
PU-50824 Engine Stand Adapter (Mounts To The Engine)
3
PU-50625 Engine Stand Sleeve Adapter (Use With 2” Bore Stand)
PW-47054 Engine Stand Sleeve Adapter (Use With 2.375” Bore Stand)
PA-49316 Flywheel Puller
PU-50105 Oil Filter Wrench
PV-43531 Oil Pressure Gauge
PU-50569 Oil Pressure Gauge Adapter (2017 and earlier models)
PU-52502 Oil Pressure Gauge Adapter (2018 and later models)
PA-49317 Stator Cover Removal Handles
PV-1253 Valve Spring Compressor
PV-43513-A Valve Spring Compressor Adapter
PU-50689 Water Pump Mechanical / Oil Seal Installation Kit
Bosch Automotive Service Solutions: 1-800-345-2233 http://polaris.service-solutions.com/.
ENGINE LUBRICATION SPECIFICATIONS

FLUID CAPACITY
Oil Capacity
Approx. 2 Quarts (1.9 L)
Oil Filter Wrench
PU-50105 or 2.5″ (64 mm)
Oil Type
Polaris PS-4 Synthetic Engine Oil
Oil Pressure Minimum Specification
(using Polaris PS-4 at operating temperature)
10 PSI @ 1200 RPM (Minimum)

OIL PRESSURE TEST Oil Pressure Gauge: PV-43531

1. Attach the Oil Pressure Gauge Adapter to the Oil
Pressure Gauge.
Oil Pressure Gauge Adapter (2017 and earlier models):
PU-50569
2. Remove the seats and engine service panel.

3. Clean the area around the main oil gallery plug q,
located on the oil filter adapter housing.
Oil Pressure Gauge Adapter (2018 and later models):
PU-52502
4. Remove the plug and insert the oil pressure adapter.

5. Start engine and allow it to reach operating
temperature, monitoring gauge indication.
NOTICE
Test results are based on the use of the recommended
engine oil (Polaris PS-4) at operating temperature, and
may vary considerably if any other oil is used or if
engine is not up to temperature.
6. Upon assembly, torque the crankcase gallery plug to

specification.
TORQUE
Oil Gallery Plug:14 ft-lbs (18 Nm)

ENGINE OIL FLOW CHART

ENGINE SPECIFICATIONS
CAMSHAFT / CYLINDER HEAD / CYLINDER INCHES (MM)
Cam Lobe Height - Intake 1.5704" ± 0.0038" (39.89 ± 0.097 mm)
Cam Lobe Height - Exhaust 1.5405" ± 0.0038" (39.13 ± 0.097 mm)
Camshaft Journal O.D. - All (Standard) 0.9038" - 0.9046 " (22.957 - 22.978 mm)
Camshaft Journal O.D. - All (Service Limit) 0.9034" (22.947 mm)
Camshaft Journal Bore I.D. - All (Standard) 0.9055" - 0.9063" (23.000 - 23.021 mm)
Camshaft
Camshaft Journal Bore I.D. - All (Service Limit) 0.9072" (23.044 mm)
Camshaft Oil Clearance (Standard) 0.0008" - 0.0025" (0.022 - 0.064 mm)
Camshaft Oil Clearance (Service Limit) 0.0047" (0.121 mm)
Camshaft End Play (Standard) 0.0069" - 0.0128" (0.175 - 0.325 mm)
Camshaft End Play (Service Limit) 0.0157" (0.4 mm)
Cylinder Head - Surface Warp Limit 0.0024" (0.060 mm)

Cylinder Head
Cylinder Head - Standard Height 4.745" ± 0.0020" (120.53 ± 0.05 mm)
Valve Seat - Contacting Width - Intake (Standard) 0.0393" ± 0.0039" (1.0 ± 0.10 mm)
Valve Seat - Contacting Width - Intake (Service Limit) 0.0551" (1.4 mm)
Valve Seat Valve Seat - Contacting Width - Exhaust (Standard) 0.0590" ± 0.0039" (1.5 ± 0.10 mm)
Valve Seat - Contacting Width - Exhaust (Service Limit) 0.0748" (1.9 mm)
Valve Seat Angles 30.0° ± 1.5° / 45.0° ± 0.5° / 60.0° ± 1.5°
Valve Guide Valve Guide Inner Diameter 0.2165" - 0.2171" (5.500 - 5.515 mm)
Valve Lash (Cold) - Intake 0.006" ± 0.002" (0.152 ± 0.050 mm)
Valve Lash (Cold) - Exhaust 0.008" ± 0.002" (0.203 ± 0.050 mm)
Valve Stem Diameter - Intake 0.2155" - 0.2161" (5.475 - 5.490 mm)
Valve Stem Diameter - Exhaust 0.2147" - 0.2153" (5.455 - 5.470 mm)

Valve
Valve Stem Oil Clearance - Intake 0.0003" - 0.0015" (0.010 - 0.040 mm)
Valve Stem Oil Clearance - Exhaust 0.0011" - 0.0023" (0.030 - 0.060 mm)
Valve Stem Overall Length - Intake 3.7704" (95.77 mm)
Valve Stem Overall Length - Exhaust 3.7964" (96.43 mm)
Valve Spring Free Length (Standard) 1.7263" (43.85 mm)

Valve Spring
Valve Spring Free Length (Service Limit) 1.683" (42.75 mm)
Cylinder - Surface Warp Limit (mating with cylinder

0.00098" (0.025 mm)
head)
Cylinder Bore - Standard 3.8976" ± 0.0003" (99.0 mm ± 0.008 mm)

Cylinder
Cylinder Out of Round Limit 0.001" (0.025 mm)
Cylinder Taper Limit 0.001" (0.025 mm)
Cylinder to Piston Clearance 0.00177" - 0.00295" (0.045 - 0.075 mm)

PISTON / RINGS / CONN ROD / CRANK / BALANCE SHAFT INCHES (MM)
Piston - Standard O.D. 3.8957 - 3.8968″ (98.953 - 98.980 mm)
Piston Piston Pin Bore I.D. (Standard) 0.8662 - 0.8665″ (22.004 - 22.010 mm)
Piston Pin Bore I.D. (Service Limit) 0.8677" (22.042 mm)
Piston Pin O.D. (Standard) 0.8659" - 0.8661" (21.995 - 22.000 mm)

Piston Pin
Piston Pin O.D. (Service Limit) 0.8651" (21.975 mm)
Top Ring (Standard) 0.0059" - 0.0122" (0.15 - 0.31 mm)
Top Ring (Service Limit) 0.0137" (0.35 mm) 3

Second Ring (Standard) 0.0094" - 0.0196" (0.24 - 0.50 mm)
Installed Gap
Second Ring (Service Limit) 0.0220" (0.56 mm)
Oil Control Rails (Standard) 0.0098" - 0.0401" (0.25 - 1.02 mm)

Piston Ring
Oil Control Rails (Service Limit) 0.0480" (1.22 mm)
Top Ring (Standard) 0.0011" - 0.0037" (0.030 - 0.095 mm)
Top Ring (Service Limit) 0.0042" (0.108 mm)

Ring to Groove
Clearance Second Ring (Standard) 0.0007" - 0.0029" (0.020 - 0.076 mm)
Second Ring (Service Limit) 0.0035" (0.089 mm)
Connecting Rod Small End I.D. (Standard) 0.8665" - 0.8670" (22.010 - 22.023 mm)
Connecting Rod Connecting Rod Small End I.D. (Service Limit) 0.8682" (22.053 mm)
Connecting Rod Big End I.D. See Service Procedure Listed In This Chapter
Main Journal O.D. (Service Limit) 1.6137" (40.990 mm)

Crankshaft
Crankshaft Runout Limit (PTO and MAG) See Service Procedure Listed In This Chapter
Balance Shaft Bearing Journal O.D. (Standard) 1.1798 - 1.1802″ (29.969 - 29.979 mm)

ENGINE SERVICE ENGINE REMOVAL

ACCESSIBLE ENGINE COMPONENTS NOTICE
The following components can be serviced or removed Some engine repair procedures can be performed
with the engine installed: without removing the engine assembly from the vehicle.
Refer to “Accessible Engine Components” for further
• Camshaft information.
• Camshaft Sprockets The use of an overhead or portable engine hoist is the
only recommended method for removing and installing
• Cylinder Head and Gaskets the engine.
• Cylinder and Gaskets Have an assistant help guide the engine in and out of
the vehicle while using an engine hoist to prevent
• Piston and Rings personal injury or damage to vehicle components.
• Flywheel
• Starter Motor / Idler Gear Asm CAUTION
• Stator (Alternator) Correct Drive Clutch Puller P/N PA-48595
• Thermostat
• Valve Cover
• Water Pump
• Camshaft Timing Chain and Guides
• Crankshaft Seal (PTO)
• Oil Pump / Oil Pump Sprocket or Chain
The following components require engine removal for

service:
• Counterbalance Shaft and Bearings

• Crankshaft and Bearings
• Crankcase
• Oil Pressure Regulator WARNING
• Oil Pump Pickup Assembly Always wear safety glasses and proper shop clothing
when performing the procedures in this Service
Manual.
Failing to do so may lead to possible injury.
TOP-END SERVICE (ENGINE IN CHASSIS)
ALL of the top-end engine components can be serviced 1. If vehicle was recently operated, allow it to cool down
while the engine is mounted in the chassis. before attempting to perform any work.
2. Thoroughly clean the engine and chassis.

3. Drain the engine oil and engine coolant prior to 11. Disconnect the ETC (Item 1), T-MAP sensor (Item 2),
engine removal (see Chapter 2). harness leads from the throttle body.
4. Remove the seat. 12. Disconnect the fuel injector harness lead from the
fuel injector.
5. Disconnect the (-) negative battery cable from the
battery. 13. Place a shop to beneath the fuel line quick connector
to catch any fuel. Disconnect the fuel line (Item 3)
6. Remove the rear cargo box as an assembly (see from the fuel rail by pressing in on the quick
Body / Frame Chapter). Remove the box tilt shock connector tabs.
lower mount pin and remove the box tilt shock from
the frame.
7. Loosen the clamps securing the intake duct to air
box rubber boot and the throttle body to the engine.
Disengage the assembly from the boots and place
off to the left side.
NOTICE
Be sure dirt and debris do not enter the engine, air box
or throttle body. Use clean shop towels to plug engine
and air box intake holes.
8. Remove the outer clutch cover, driven clutch, drive

belt, drive clutch and inner clutch cover. (see PVT
System Chapter).
NOTICE 14. Move fuel line to the left-hand side of the engine
compartment. Make note of line routing for
Be sure to use the correct Drive Clutch Puller (PA- installation.
48595) to prevent damage to crankshaft.
15. Remove the spark plug wire from the engine.
9. Disconnect the stator wire connector and cut the tie 16. Remove (+) positive cable (Item 4) from the starter
strap securing the wiring to the front engine mount motor. If desired, remove the remaining starter motor
bracket. Replace tie strap for engine installation. bolt and remove the starter motor from the engine.
10. Remove the CPS sensor from the stator cover on the
right-hand side of the engine. Plug CPS hole with
clean shop towel. Inspect CPS O-ring and replace if
needed.

17. Remove (-) negative cable (Item 5) from the starter 25. With the help of an assistant and the engine hoist,
mounting nut. raise the engine vertically out of the vehicle frame.
NOTICE
Have an assistant help guide the engine in and out of
personal injury or damage to the vehicle components.
26. Install the engine stand adapter (PU-50824) onto the

engine PTO side mounting ears as shown below.
18. Disconnect the upper engine coolant hose, bypass

hose, T-MAP, and ECT harness connector.
19. Remove the two bolts securing the muffler to the
frame. Remove the (3) hex bolts securing the
exhaust head pipe to the engine. Maneuver the
exhaust assembly out of the mounting grommet and
remove the exhaust assembly as one.
20. Place a support between the main frame and
transmission case. Do not pinch any lines.
27. Select the proper engine stand sleeve adapter and
21. Use an overhead or portable engine hoist and install it onto the engine stand adapter.
suitable engine straps to secure the engine in its
current position. • Sleeve adapter for a 2” bore engine stand:
22. Remove the (4) bolts and nuts (Item 8) securing the • (PU-50625)
engine to the front motor mount bracket.
• Sleeve adapter for a 2.375” bore engine stand:
23. Remove the (8) bolts (Item 7) securing the coupler
brackets to the engine and transmission. • (PW-47054)
24. Loosen the (2) bolts and nuts (Item 6) so the engine 28. Place engine onto the engine stand (PU- 50624) for
mount bracket can be slightly tilted away from service.
engine.

ENGINE INSTALLATION 6. Install the Clutch Center Distance Tool (PU-50658 or

Use the following procedure to reinstall the engine PU-50658-A) onto the crankshaft and transmission
assembly. input shaft. The pictures below show a properly
installed tool (PU-50658).
1. Attach engine with suitable lifting straps to an
overhead or portable engine hoist.
2. Remove the engine stand adapter plate.
3. Use the overhead or portable engine hoist and
suitable engine straps to lower the engine into the
vehicle frame.
NOTICE 3
Have an assistant help guide the engine in and out of
personal injury or damage to vehicle components.
4. By hand, install the (4) front engine mount bolts and

nuts (Item 1). Do not tighten at this time.
5. Install the four engine to transmission coupler plates
(Item 2) and instal the (8) bolts and washers (Item 3).
Do not tighten fasteners at this time.
NOTICE
Images for Reference only. The tool shown should only
NOTICE be used to check center to center distance.
The location the tool rests on the shafts may vary.
DO NOT torque fasteners at this time.
PU-50658–A
HOLE YEAR VEHICLE DESCRIPTION
1 2012 RZR 570
2011-14 RZR 900
2 2014-15 RZR XP 1000
2013 RANGER 900
2014-16 ACE
2015-19 ACE 570
2015-16 RGR ETX
3
2013–19 RZR 570
2014–19 RANGER 500/570
2015-19 RANGER 570 Full-Size
4 2014-19 RANGER 900/1000

HOLE YEAR VEHICLE DESCRIPTION 9. Torque the two front center isolator bolts (Item 4) to
2015-19 RZR 900 specification.
2016-19 RZR 1000
2016–19 ACE 900
2016–19 GENERAL
5 2015-18 RANGER Diesel
TORQUE
Isolator Center Bolt:
40 ft-lbs (54 Nm)
i.e. 2015 RZR 900 uses the holes marked with a
4
10. Remove the lifting straps and overhead or portable
7. In sequence, torque the (8) engine coupler bracket engine hoist and remove the support previously
fasteners to specification. installed under the transmission case during the
engine removal process.
11. Reposition the head pipe assembly in the chassis
and install new muffler and head pipe seals (Item 5).
Install the (3) head pipe bolts (Item 6) and torque to
specification.
TORQUE
Rear Engine Coupler Fastener (In Sequence):
In Sequence:55 ft-lb (75 Nm)
8. In a criss-cross pattern, torque the (4) front engine TORQUE

mount fasteners to specification.
Exhaust Head Pipe Bolts:
TORQUE 18 ft-lbs (25 Nm)
Front Engine Mount Fasteners:
40 ft-lbs (54 Nm) 12. Install the (2) springs (Item 7) securing the muffler to
the head pipe.
13. Install the (3) coolant hoses onto the engine.
14. Install the throttle body and air box. Tighten the hose
clamps that secure the throttle body to the intake
duct, intake boot and air box.

15. Install the lower stater motor bolt through the lower 27. Install the rear bumper and cargo box assembly (See
starter motor mounting boss. Body / Frame chapter).
16. Instal the starter motor onto the engine. 28. Install the left-hand rear wheel and torque wheel nuts
to specification.
17. Install the starter motor and battery cables as
outlined in the Electrical Chapter. TORQUE
TORQUE Steel Wheel Nuts:
36 ft-lbs (49 Nm)
Starter Motor Fastener:
Aluminum Wheel Nuts:
3 ft-lbs (4 Nm)
30 ft-lbs + 90º (41 Nm + 90º)
18. Connect the harness leads to the ETC (Item 8) and
3
T-MAP sensor (Item 9). Verify routing is correct. 29. Remove the pressure cap and fill the cooling system
through the filler neck with properly mixed anti-freeze
/ coolant.
30. If the engine oil was completely drained, add
approximately 2 quarts (1.9 L) of Polaris PS-4
Synthetic Engine Oil into the crankcase.
31. Install a new oil filter. Lubricate the seal with engine
oil prior to installation (see Maintenance chapter).
32. Connect the (-) negative battery cable to the battery.
33. Install the engine service panel and seats.
34. Follow the “Cooling System Bleeding Procedure” as
outlined in this chapter.
35. Start engine and check for any oil or coolant leaks.
36. Check the engine oil level (see Maintenance
19. Connect the fuel injector harness lead to the fuel
chapter).
injector.
37. Refer customer to “Engine Break-In Period” upon
20. Connect the fuel line to the fuel rail.
returning vehicle to customer.
21. Connect the ignition coil harness connector and
install the spark plug wire.
22. Install the CPS and mounting bolt into the stator
cover and torque to specification.
TORQUE
CPS Fastener:
9 ft-lbs (12 Nm)
23. Connect the stator wire connector and install a new

tie strap to secure the wiring to the front engine
mount bracket.
24. Install the inner clutch cover (See PVT System
chapter).
25. Install the drive clutch, driven clutch, belt and outer
clutch cover as outlined in the PVT System chapter.
Be sure all hose and wire routing is correct. Torque
all fasteners to specification as outlined in the PVT
System chapter.
26. Install the intake baffle assembly. Secure the 3
clamps that attach the assembly to the crankcase
vent, air box lid and inner clutch cover.

ENGINE BREAK-IN PERIOD ENGINE LUBRICATION SPECIFICATIONS

The break-in period consists of the first 25 hours of
operation, or the time it takes to use 15 gallons (57 liters) FLUID CAPACITY
of fuel. Careful treatment of a new engine and drive Oil Capacity
components will result in more efficient performance and Approx. 2 Quarts (1.9 L)
longer life for these components.
Oil Filter Wrench
CAUTION PU-50105 or 2.5” (64 mm)
Use only Polaris PS-4 Synthetic Engine Oil.
Never substitute or mix oil brands. Oil Type
Serious engine damage and voiding of warranty can Polaris PS-4 Synthetic Engine Oil
result.
Do not operate at full throttle or high speeds for Oil Pressure
extended periods during the first three hours of use. Minimum Specification
Excessive heat can build up and cause damage to (using Polaris PS-4 at operating temperature)
close fitted engine parts. 10 PSI @ 1200 RPM (Minimum)
40 PSI @ 7000 RPM(Minimum)
1. Fill fuel tank with unleaded fuel which has a minimum
pump octane number of 87 = (R+ M)/2.
2. Refer to Chapter 2. Check oil level indicated on the
dipstick. Add oil if necessary.
3. Drive slowly at first to gradually bring engine up to
operating temperature.
4. Vary throttle positions. Do not operate at sustained
idle or sustained high speed.
5. Perform regular checks on fluid levels, controls and
all important bolt torques.
6. Change oil and oil filter after break-in period at 25
hours.

ENGINE MOUNTING AND TORQUE VALUES
REF. DESCRIPTION NOTES

q Bolt Torque to 55 ft-lbs (75 Nm)
w Bolt Torque to 40 ft-lbs (54 Nm)
e Nut Torque to 25 ft-lbs (34 Nm)
r Bolt Torque to 18 ft-lbs (25 Nm)

SETTING TDC (TOP-DEAD-CENTER) 2. With the valve cover and thermostat housing
There are three ways to ensure the piston is at TDC. removed, rotate the engine so the cam lobes are
Remove the outer clutch cover to access the drive clutch facing outward and the Cylinder Holding and
to aid in engine rotation (manually turn the drive clutch Camshaft Timing Plate can be installed into the slots
counter clockwise). of the camshafts as shown below. This will set TDC
of the compression stroke.
1. With the CPS sensor removed, rotate the engine
until the “V” marked on the flywheel is aligned with
the CPS mounting hole. This will set TDC, but not
necessarily TDC of the compression stroke. View
the timing marks on the camshaft sprockets to
ensure the engine is at TDC of the compression
stroke.
Camshaft Timing Plate

PU-50563
NOTICE
gasket surface and the exhaust cam sprocket should
have “E” marks aligned with gasket surface.
3. With the stator cover and flywheel removed, rotate

the engine and position the piston at TDC by aligning
the timing hole in crank case with a timing hole in the
crankshaft.

4. Insert a 1/4” drive socket extension through the

crankcase and into the crankshaft locating hole q.
This will set TDC, but not necessarily TDC of the
compression stroke. View the timing marks on the
cam shaft sprockets to ensure the engine is at TDC
of the compression stroke.

COOLING SYSTEM
COOLING SYSTEM ASSEMBLY VIEW AND COOLANT FLOW DIAGRAM

q Radiator
w Fan Shroud
e Cooling Fan
r Recovery Bottle
t Radiator Drain Plug
y Upper Radiator Hose
u Lower Radiator Hose
i Bypass Hose
o Water Pump Hose

COOLING SYSTEM SPECIFICATIONS COOLING SYSTEM PRESSURE TEST

1. Remove the hood from the front cab.
COOLANT
CONDITION TEMPERATURE °F (°C) WARNING
Room Temperature 68° F (20° C) Never remove pressure cap when engine is warm or
hot. The cooling system is under pressure and serious
Thermostat Open 180° F (82° C) burns may result. Allow the engine to cool before
servicing.
Fan Off 192° F (89° C)
Fan On 198° F (92° C) 2. Remove pressure cap and pressure test the cooling
Thermostat Full Open Lift 203° F (95° C)

system using a commercially available pressure
tester.
3
Engine Temperature 233° F (112° C)
Overheat Indicator
Engine Protection
236° F (113° C)
Ignition Misfire
Engine Protection 257° F (125° C)
Shutdown
ITEM SPECIFICATION
Cooling 570 3.5 qts. (3.3 L)
System
Capacity 570 Crew 5.0 qts. (4.7 L)
Pressure Cap Relief 13 PSI

3. The system must maintain 10 psi for five minutes or
longer. If pressure loss is evident within five minutes,
Polaris Premium Antifreeze: check the filler neck, radiator, hoses, clamps and
2871534 - Quart water pump weep hole for leakage.
2871323 - Gallon
Recommended Coolant PRESSURE CAP TEST

Use only high quality antifreeze/coolant mixed with 1. Open the hood (see “WARNING” under “Cooling
distilled water in a 50/50 ratio, depending on freeze System Pressure Test”).
protection required in your area. 2. Remove pressure cap q and test using a pressure
CAUTION: Using tap water in the cooling system will cap tester (commercially available).
lead to a buildup of deposits which may restrict coolant
flow and reduce heat dissipation, resulting in possible
engine damage. Polaris Premium 50/50 Antifreeze/
Coolant is recommended for use in all cooling systems
and comes pre-mixed, ready to use.
3. The pressure cap relief pressure is 13 psi. Replace

cap if it does not meet this specification.

RADIATOR COOLANT DRAIN / RADIATOR REMOVAL

1. Check radiator air passages for restrictions or Coolant Drain
damage.
1. Open the hood.
WARNING
Never drain the coolant when the engine and radiator
are warm or hot. Hot coolant can cause severe burns.
Allow engine and radiator to cool.
2. Slowly remove the pressure cap to relieve any

cooling system pressure.
3. Place a suitable drain pan underneath the drain
valve on the front left side of the vehicle.
4. Drain the coolant from the radiator by opening the
drain valve q in the lower left corner of the radiator.
Properly dispose of the coolant.
2. Carefully straighten any bent radiator fins.
3. Remove any obstructions with compressed air or low
pressure water.
CAUTION
Washing the vehicle with a high-pressure washer could
damage the radiator fins and impair the radiators
effectiveness. Use of a high-pressure washer is not
recommended.
5. Allow coolant to completely drain.

6. Place a suitable drain pan underneath the lower
engine hose w on the right rear side of the vehicle.
7. Remove the hose and completely drain the engine.

Radiator Removal
8. Remove the upper engine outlet hose and recovery
hose from the top of the radiator.

9. Remove the two upper radiator retaining bolts e. THERMOSTAT REPLACEMENT

1. Open the hood.
WARNING
Allow the engine to cool before servicing. The cooling
system is under pressure and serious burns may result.
2. Remove the pressure cap to relieve any system

pressure (see “Pressure Cap Test”).
3. Drain coolant to a level below the thermostat
housing. 3
5. Remove the two bolts q retaining the thermostat
cover.
10. Disconnect the fan motor and remove the radiator
from the vehicle. Take care not to damage the
cooling fins.
11. Reverse procedure for installation.
6. Lift the cover from the engine and remove the

thermostat.
7. Reverse this procedure for installation. Replace
thermostat seal if worn or damaged. Torque
thermostat cover bolts to specification.
TORQUE
Thermostat Cover Bolts:
8 ft-lbs (10 Nm)
8. Be sure to properly fill and bleed cooling system as


COOLING SYSTEM BLEEDING 6. Open the bleed screw (Item 3) to allow any trapped
PROCEDURE air to escape.
WARNING
Always wear safety glasses and proper shop clothing
when performing the procedures in this manual. Failing
to do so may lead to possible injury or death.
CAUTION
Use caution when performing these procedures.
Coolant may be hot and may cause severe injury or
burns.
NOTICE
If the coolant level is LOW in the radiator, or if there are
leaks in the system, the coolant system will not draw 7. Fill the radiator until a steady stream of coolant
coolant from the reservoir tank. It may be necessary to begins to drain out of the bleed screw.
safely raise the front of the vehicle 12” (30 cm) to bleed 8. Tighten the bleed screw to specification, top off
the cooling system. coolant and properly install the pressure cap.
1. Allow engine and cooling system to completely cool. TORQUE

Coolant Bleed Screw:
CAUTION 72 in-lbs (8 Nm)
Be sure the engine has cooled and no pressure is built
up in the cooling system before removing the pressure 9. Start the engine and allow it to idle until the coolant
cap. The coolant may be hot and could cause severe fan has cycled.
injury or burns. 10. Allow engine and cooling system to completely cool
down (see CAUTION).
2. Open the hood.
11. Remove the pressure cap. Add the necessary
3. Remove the recovery bottle cap (Item 1) and fill the amount of Polaris Premium Antifreeze to the radiator
bottle to the MAX line. filler neck.
12. Open the bleed screw to allow any trapped air to
escape. Close the bleed screw once a steady stream
of coolant begins to drain out.
13. Tighten the bleed screw to specification, top off
coolant and properly install the pressure cap.
TORQUE
Coolant Bleed Screw:
72 in-lbs (8 Nm)
14. Fill the recovery bottle to the MAX line.

15. Reinstall the hood.
16. Reinstall cargo box access cover.
4. Remove the pressure cap (Item 2) and add the
necessary amount of Polaris Premium Antifreeze to
the radiator filler neck.
5. Remove the cargo box access cover to gain access
to the coolant bleed screw that is on top of the
thermostat housing.

WATER PUMP COVER AND IMPELLER 12. Follow this procedure in reverse to assemble the
SERVICE (STATOR COVER REMAINS ON water pump impeller and cover. Always use a new
ENGINE) water pump cover gasket. Torque all fasteners in
sequence to specification.
NOTICE
The water pump cover, gasket and impeller can be
serviced with the stator cover installed on the engine.
1. Allow engine and cooling system to completely cool.
WARNING 3
up in the cooling system before removing the pressure
cap. The coolant may be hot and could cause severe
injury or burns.
2. Disconnect the (-) negative battery cable.

3. Remove all debris and thoroughly clean water pump
area and right-hand side of engine block. TORQUE
4. Open the hood. Water Pump Cover Fastener:
5. Remove the pressure cap from the filler neck. 9 ft-lbs (12 Nm)(Apply Loctite® 204™ to bolt
threads)
6. Completely drain cooling system and engine as
outlined in this chapter. Water Pump Impeller:
7. Raise and safely support the vehicle. Remove the Finger Tight *LH threads
right rear wheel.
8. Remove the eight bolts q attaching the water pump 13. Fill and bleed cooling system as outlined in this
cover to the stator cover. chapter.
9. Remove the water pump cover w and water pump

cover gasket e. Discard the water pump gasket e. WATER PUMP MECHANICAL SEAL / OIL
10. Using an 8mm socket, remove the water pump SEAL REPLACEMENT
impeller r.
NOTICE
NOTICE The stator cover must be removed from the engine to
The water pump impeller r uses reverse (left) threads. service the water pump drive shaft, oil seal, mechanical
seal and bearing.
1. Allow engine and cooling system to completely cool.
CAUTION
up in the cooling system before removing the pressure
cap. The coolant may be hot and could cause severe
injury or burns.
2. Disconnect the (-) negative battery cable.

3. Remove all debris and thoroughly clean water pump
area and right-hand side of engine block.
4. Open the hood.
5. Remove the pressure cap from the filler neck.
11. Inspect the water pump cover and impeller for
damage. Replace as necessary. 6. Completely drain cooling system and engine as

7. Raise and safely support the vehicle. Remove the 12. Remove the water pump impeller r.
right rear wheel.
NOTICE
8. Disconnect the stator wire connector and cut the tie
strap securing the wiring to the front engine mount The water pump impeller uses reverse (left) threads.
bracket.
13. Remove the oil dipstick t.
9. Remove the CPS sensor from the stator cover on the

right-hand side of the engine. Inspect CPS O-ring 14. Remove the 13 bolts y securing the stator cover to
and replace if needed. the engine.
15. If needed, install the stator cover removal handle tool
(PA-49317) to the water pump cover bolt holes to aid
in stator cover removal.
10. Remove the eight bolts q retaining the water pump

cover to the stator cover.
CAUTION
The flywheel contains powerful magnets. Use caution
when removing the stator cover.
DO NOT place fingers between cover and crankcase at
any time during the removal process or injury could
result.
16. Remove and discard the stator cover gasket.
CAUTION
Be sure engine coolant does not contaminate the
engine oil during stator cover service.
11. Remove the water pump cover w and water pump
cover gasket e. Discard the water pump gasket.

17. Bring the stator cover assembly to a clean work 21. Thoroughly clean the stator cover.
bench.
22. Press in a new water pump drive shaft bearing a
18. Using a brass drift, remove the water pump drive until it is fully seated in the cover.
shaft u. Be sure not to damage the threads. Inspect
shaft for wear or damage, replace if necessary. CAUTION
Be sure bearing is fully seated in cover or severe
engine damage may result.
23. Clean and de-grease the water pump drive shaft (H).
24. Press in the water pump drive shaft into the bearing 3
using PU-50869 Item #1.
19. Extract the mechanical seal i and the oil seal o

from the stator cover.
20. Press out the water pump drive shaft bearing a from
the stator cover. Discard bearing and replace with
new.
Water Pump Assembly

25. Install the water pump drive shaft holding tool in kit 27. Use the water pump oil seal installation tool in kit PU-
PU-50869. Hold the tool in position and flip the 50869 to fully install the new water pump oil seal s.
assembly up-side-down so the special tool PU-
50869 is supporting the assembly. CAUTION
Be sure the oil seal is fully seated in cover or severe
engine damage may result.
28. Use the water pump mechanical seal installation tool

in kit PU-50869 to fully install the new water pump
mechanical seal d until it is fully seated in the cover.
26. Lubricate the new water pump oil seal with clean
engine oil.
29. Install a new stator cover gasket onto the engine.

30. Align the water pump drive slot as shown below.

31. Align the water pump drive shaft blade as shown 34. While installing the stator cover to the engine, slightly
below. rotate the water pump impeller to verify the
crankshaft slot and the water pump drive shaft blade
32. Apply a small amount of crankcase sealant to the
are properly engaged. Verify the stator cover is
area indicated below g.
laying flat on the engine case.
CAUTION
when installing the stator cover.
any time during the removal and installation process or
injury could result.
CAUTION
If the water pump drive shaft blade and slot in the crank
shaft are not in alignment during the installation
process, severe engine damage may result.
REF. DESCRIPTION NOTES 35. Install and torque the stator cover fasteners in
h Crankshaft
j Driveshaft
k Mechanical Seal
l Impeller
33. If needed, install the stator cover removal handles

tool PA-49317 to the water cover bolt holes to aid in
stator cover installation.
TORQUE
Stator Cover and Water Pump Cover:
9 ft-lbs (12 Nm)(Apply Loctite® 204™ to bolt
threads)

36. Measure the installed height of the new mechanical 39. Install the water pump cover to the stator cover.
seal as shown below. If not within specification, Torque all fasteners in sequence to specification.
remove and discard the mechanical seal and
properly install new mechanical seal as outlined in
this chapter.
40. Install the oil dipstick.

41. Install the coolant hose to the water pump cover and
tighten hose clamp.
42. Connect the stator wire connector and install a new
MEASUREMENT tie strap securing the wiring to the front engine mount
bracket.
Mechanical Water Pump Seal Installed Height:
0.280 - 0.287″ (7.2 +/- 0.1 mm) 43. Install the CPS sensor into the stator cover. Inspect
CPS O-ring and replace if needed.
37. Install the water pump impeller 1(. Finger Tight *LH 44. Install the right-hand rear wheel and torque the
threads wheel nuts to specification. Safely lower vehicle.
NOTICE
TORQUE
The water pump impeller 1( uses reverse (LH) threads. Steel Wheel Nuts:
36 ft-lbs (49 Nm)
30 ft-lbs + 90º (41 Nm + 90º)
45. Install both seats and the engine service panel.

46. Connect the (-) negative battery cable.
47. If the engine oil was contaminated during this service
procedure, perform an engine oil change as outlined
in Chapter 2. DO NOT run the engine until coolant
has been added to the cooling system.
48. Fill cooling system with recommend coolant and
bleed the system of air as outlined in this chapter.
49. Check for leaks.
38. Install a new water pump cover gasket.

TROUBLESHOOTING Engine Idles But Will Not Accelerate

ENGINE • Spark plug fouled/weak spark
Spark Plug Fouling • Broken throttle cable
• Spark plug cap loose or faulty • Obstruction in air intake
• Incorrect spark plug heat range or gap • Air box removed (reinstall all intake components)
• PVT system calibrated incorrectly/ components worn • Incorrect flywheel installation or sheared flywheel key.
or mis-adjusted
• Restricted exhaust system
• Fuel quality poor (old) or octane too high
• Low compression
• Cam worn excessively 3
• Restricted exhaust Engine Has Low Power
• Weak ignition (loose coil ground, faulty coil, or stator) • Spark plug fouled
• Restricted air filter (main or pre-cleaner) or breather • Cylinder, piston, ring, or valve wear or damage (check
system compression)
• Improperly assembled air intake system • PVT not operating properly
• Restricted engine breather system • Restricted exhaust muffler
• Oil contaminated with fuel • Cam worn excessively
Engine Turns Over But Fails To Start Piston Failure - Scoring

• No fuel • Lack of lubrication
• Dirt in fuel line or filter • Dirt entering engine through cracks in air filter or ducts
• Fuel will not pass through fuel valve • Engine oil dirty or contaminated
• Fuel pump inoperative/restricted
Excessive Smoke and Carbon Buildup
• Tank vent plugged or pinched
• Excessive piston-to-cylinder clearance
• Engine flooded
• Worn rings, piston, or cylinder
• Low compression (high cylinder leakage)
• Worn valve guides or seals
• No spark (Spark plug fouled) ignition component
failure • Restricted breather
• Air filter dirty or contaminated
Engine Does Not Turn Over
• Dead battery Piston Failure - Scoring
• Starter motor does not turn • Lack of lubrication
• Engine seized, rusted, or mechanical failure • Dirt entering engine through cracks in air filter or ducts
• Engine oil dirty or contaminated
Engine Runs But Will Not Idle
• Restricted fuel supply Slow Engine Cranking
• Low compression • Weak battery
• Crankcase breather restricted • Loose Electrical connections
• Decompression Mechanism not functioning properly.

Excessive Smoke and Carbon Buildup COOLING SYSTEM

• Excessive piston-to-cylinder clearance Overheating
• Wet sumping due to over-full crankcase • Low coolant level

• Worn rings, piston, or cylinder • Air in cooling system
• Worn valve guides or seals • Wrong type/mix of coolant
• Restricted breather • Faulty pressure cap or system leaks

• Air filter dirty or contaminated • Restricted system (mud or debris in radiator fins
causing restriction to air flow, passages blocked in
radiator, lines, pump, or water jacket, accident
Low Compression damage)
• Cylinder head gasket leak • Lean mixture (vents, fuel pump or fuel valve)
• No valve clearance (cam wear) • Fuel pump output weak
• Cylinder or piston worn • Electrical malfunction
• Piston rings worn, leaking, broken, or sticking • Water pump failure/ Loose impeller
• Bent valve or stuck valve • Thermistor failure
• Valve spring broken or weak • Cooling fan inoperative or turning too slowly (perform
• Valve not seating properly (bent or carbon current draw test)
accumulated on sealing surface) • Low oil level
• Rocker arm sticking • Spark plug incorrect heat range
• Faulty hot light circuit
Backfiring
• Thermostat stuck closed or not opening completely
• Fouled spark plug or incorrect plug or plug gap
• Radiator is missing its internal diverter plate not
• Exhaust system air leaks allowing coolant to flow through entire radiator
• Valve sticking
• Ignition system faulty: Temperature Too Low
• Spark plug cap cracked / broken • Thermostat stuck open

• Ignition coil faulty • Thermostat missing
• Ignition or kill switch circuit faulty

Leak at Water Pump Weep Hole
• Poor connections in ignition system
• Faulty water pump mechanical seal (coolant leak)
• Ignition timing incorrect
• Faulty pump shaft oil seal (oil leak)
• Sheared flywheel key

500CC SOHC ENGINE

ENGINE DETAIL, TORQUES /
SEQUENCES
ENGINE SPECIFICATIONS, 500
CAMSHAFT / CYLINDER HEAD / CYLINDER (IN. / MM)
Cam Lobe Height - Intake 2.0327" ± 0.0038" (51.63 ± 0.097 mm)
Cam Lobe Height - Exhaust 2.0657" ± 0.0038" (52.47 ± 0.097 mm)
MAG 1.374" - 1.375 " (34.899 - 34.920 mm)
Camshaft Journal O.D. - All (Standard)
PTO 1.256" - 1.257" (31.907 - 31.928 mm) 3
MAG 1.374" (34.889 mm)
Camshaft Journal O.D. - All (Service Limit)
PTO 1.256" (31.897 mm)
MAG 1.3780" - 1.3788" (35.000 - 35.021 mm)
Camshaft Journal Bore I.D. - All (Standard)
PTO 1.2600" - 1.2607" (32.000 - 32.021 mm)
Camshaft
MAG 1.3802" (35.056 mm)
Camshaft Journal Bore I.D. - All (Service Limit)
PTO 1.2619" (32.053 mm)
MAG 0.0031" - 0.0048" (0.080 - 0.122 mm)
Camshaft Oil Clearance (Standard)
PTO 0.0028" - 0.0045" (0.072 - 0.114 mm)
MAG 0.0066" (0.167 mm)
Camshaft Oil Clearance (Service Limit)
PTO 0.0061" (0.156 mm)
Camshaft End Play (Standard) 0.0069" - 0.0128" (0.175 - 0.325 mm)
Camshaft End Play (Service Limit) 0.0157" (0.4 mm)
Cylinder Head - Surface Warp Limit 0.0024" (0.060 mm)
Cylinder Head
Cylinder Head - Standard Height 4.745" ± 0.0020" (120.53 ± 0.05 mm)
Contacting Width - Intake (Standard) .0591" ± 0.0039" (1.5 ± 0.10 mm)
Contacting Width - Intake (Service Limit) 0.0748" (1.9 mm)
Valve Seat Contacting Width - Exhaust (Standard) 0.0787" ± 0.0039" (2.0 ± 0.10 mm)
Contacting Width - Exhaust (Service Limit) 0.0945" (2.4 mm)
Valve Seat Angles 30.0° ± 1.5° / 45.0° ± 0.5° / 60.0° ± 1.5°
Valve Guide Valve Guide Inner Diameter 0.2741" - 0.2747" (6.963 - 6.978 mm)
Valve Lash (Cold) - Intake 0.006" ± 0.002" (0.152 ± 0.050 mm)
Valve Lash (Cold) - Exhaust 0.010" ± 0.002" (0.25 ± 0.050 mm)
Valve Stem Diameter - Intake 0.2731" - 0.2737" (6.938 - 6.953mm)
Valve Stem Diameter - Exhaust 0.2724" - 0.2730" (6.918 - 6.933 mm)
Valve
Valve Stem Oil Clearance - Intake 0.0003" - 0.0015" (0.010 - 0.040 mm)
Valve Stem Oil Clearance - Exhaust 0.0011" - 0.0023" (0.030 - 0.060 mm)
Valve Stem Overall Length - Intake 4.0256" (102.25 mm)
Valve Stem Overall Length - Exhaust 4.0280" (102.31 mm)
Valve Spring Free Length (Standard) 1.8756” (47.64 mm)
Cylinder - Surface Warp Limit
0.00098" (0.025 mm)
(mating with cylinder head)
Cylinder Bore - Standard 3.6614" ± 0.0003" (93.0 mm ± 0.008 mm)
Cylinder
Cylinder Out of Round Limit 0.001" (0.025 mm)
Cylinder Taper Limit 0.001" (0.025 mm)
Cylinder to Piston Clearance 0.00138" - 0.00256" (.035 - .065 mm)

PISTON / RINGS / CONNECTING ROD / CRANKSHAFT / BALANCE SHAFT (IN. / MM)

Piston - Standard O.D. -
3.6592” - 3.6598”
Measured 90 degrees to pin,
(92.943 - 92.957 mm)
0.47 in. (12 mm) up from piston skirt.
See text.
Piston 0.8662” - 0.8665”
Piston Pin Bore I.D. (Standard)
(22.004 - 22.010 mm)
0.8677"
Piston Pin Bore I.D. (Service Limit)
(22.042 mm)
0.8659" - 0.8661"
Piston Pin O.D. (Standard)
Piston Pin (21.995 - 22.000 mm)
Piston Pin O.D. (Service Limit) 0.8651" (21.975 mm)
Top Ring 0.0059" - 0.0122"
(Standard) (0.15 - 0.31 mm)
Top Ring
0.0137" (0.35 mm)
(Service Limit)
Second Ring 0.0094" - 0.0196"
(Standard) (0.24 - 0.50 mm)
Installed Gap
Second Ring
0.0220" (0.56 mm)
(Service Limit)
Oil Control Rails 0.0098" - 0.0401"
(Standard) (0.25 - 1.02 mm)
Piston Ring
Oil Control Rails 0.0480"
(Service Limit) (1.22 mm)
Top Ring 0.0011" - 0.0037"
(Standard) (0.030 - 0.095 mm)
Top Ring 0.0042"
Ring to Groove (Service Limit) (0.108 mm)
Clearance Second Ring 0.0007" - 0.0029"
(Standard) (0.020 - 0.076 mm)
Second Ring 0.0035"
Small End I.D. 0.8665" - 0.8670"
(Standard) (22.010 - 22.023 mm)
Small End I.D. 0.8682"
Connecting Rod
See Service Procedure
Big End I.D.
Listed In This Chapter
Main Journal O.D. 1.6137"
Crankshaft
Crankshaft Runout Limit See Service Procedure
(PTO and MAG) Listed In This Chapter
Bearing Journal O.D. 1.1798” - 1.1802"
Balance Shaft
(Standard) (29.969 - 29.979 mm)

ENGINE TORQUE SEQUENCES

CAM CARRIER
CYLINDER HEAD
WATER PUMP COVER

VALVE COVER

STATOR COVER
CRANKCASE

CRANKCASE SEALANT PATH

Apply sealant as shown.
Crankcase Sealant: 2871557
NOTICE
Clean the case halves with ISOPROPYL ALCOHOL to
remove all sealant before applying new sealant.
Alignment Pins MUST be installed prior to assembly
3
IMPORTANT
Clean the case deck q of all sealant after assembly.

CRANKCASE / TIMING CHAIN GUIDES / OIL PICKUP / REGULATOR VALVE

q Oil Pickup Install until fully seated in bore/hole.
Engine oil may be used to aid installation.
w Oil Pressure Regulator Assembly Torque: 20 ft-lbs (12 Nm)
e Piston Oil Jet Torque: 35–in-lbs (4 Nm)
r Oil Pump Cover Torque: 106 in-lbs (12 Nm)

CYLINDER / OIL FILTER / OIL PUMP / BREATHER


q Cylinder Apply ENGINE OIL to bottom 50 mm of cylinder bore and to piston
rings before assembly.
w Cylinder Base Gasket Ensure tab is visible to verify assembly.
e Plug Torque: 11 ft-lbs (16 Nm)
r O-ring Ensure O-ring seals are seated in C’bores before assembly.
t Screw Torque: 20 ft-lbs (28 Nm)
y Straight Filter Adapter Torque: 20 ft-lbs (28 Nm)
u Oil Filter Lubricate seal with engine oil prior to filter installation.
i Gear Sprocket to be installed so that “OUT” is visible.
o Screw Torque: (12 Nm)

Replace if loosened or removed.
a Gear Sprocket to be installed so that “OUT” is visible.
s Screw Torque: 106 in-lbs (12 Nm)
d Oil Pump Cover Apply ENGINE OIL to bore of oil pump cover prior to assembly.
f Drain Plug Torque: 11 ft-lbs (16 Nm)
g Gerotor Inner Gerotor Slot must be visible after assembly
h Gerotor Outer Gerotor dots must not be visible after assembly.
j Piston Assembly Apply ENGINE OIL to bottom 50 mm of cylinder bore and to piston
rings before assembly.

CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / IDLER GEARS / STATOR COVER

q Screw Torque: 89 in-lbs (10 Nm)

Torque in Sequence shown in Torque Sequence topic.
w Cam Threaded hole in end of cam must be free of oil and debris prior to assembly.
Coat lobes and bearing journals with white lithium grease.
e Screw Torque: 89 in-lbs (10 Nm)
r Cylinder Head Do not tilt head assembly on this side or upside down unless camshaft and cam carrier are installed securely.
Firedeck to be protected throughout entire assembly process.
t Fitting Torque: 24 ft-lbs (33 Nm)
y ECT Sensor Torque: 17 ft-lbs (22.5 Nm)

Apply P80 rubbed lubricant to washer prior to assembly.
u Cylinder Head Gasket Ensure Tab is visible to ensure proper assembly.
i Gear
o Screw 44 ft-lb (60 Nm)

Replace camshaft sprocket bolt if loosened or removed.
a Head Bolt See: Cylinder Head Installation page 3.61
s Screw
d Timing Chain Tensioner Torque: 37 ft-lbs (50 Nm)

Ensure the sealing washer is in place prior to torquing. Replace sealing washer if loosened or removed.
f Screw Torque: 106 in-lbs (12 Nm)
g Nut Replace if loosened or removed.

Torque to spec, back off 180 degrees, re-torque to spec
Torque: 133 ft-lbs (180 Nm)
h Stator Cover Apply sealant to specified edges of cover.
j Shaft Apply Engine Oil or White lithium grease to shaft prior to assembly.
k Crank Position Sensor Apply P80 Rubber Lubricant to o-ring prior to assembly.
l Screw Torque: 9 ft-lbs (12 Nm)
1( Screw Torque: 106 in-lbs (12 Nm)

Torque in Sequence shown in Torque Sequence topic.
Replace if loosened of removed.
2) Water Pump Impeller Impeller has left hand thread, tighten to finger tight.
21 Screw Torque: 106 in-lbs (12 Nm)

SPARK PLUGS / STARTER / THROTTLE BODY / VALVE COVER


q Screw Torque: 106 in-lbs (12 Nm)
Torque in sequence shown in this chapter.
w Spark Plug Apply Anti-Seize to threads prior to assembly.
e Screw Torque: 89 in-lbs (10 Nm)
r Fuel Injector Apply P80 rubber lubricant prior to assembly.
t Screw Torque: 26 in-lbs (2.8 Nm)
y T-MAP Sensor Apply P80 rubber lubricant prior to assembly.
u Intake Boot Apply P80 rubber lubricant prior to assembly.
i Screw Torque: (22.5 Nm)
o Screw Torque: (22.5 Nm)
a Screw Torque: 89 in-lbs (10 Nm)
s Screw Torque: 89 in-lbs (10 Nm)
d Starter Motor Apply grease to starter o-ring.
f Dipstick Apply engine oil to o-ring

PISTON / CRANKSHAFT / BALANCE SHAFT


q Seal Clean crankcase bore with ISOPROPYL ALCOHOL prior to
assembly of seal.
Press until flush with crankcase. (+/- 0.25 mm)
Crankshaft must be installed prior to seal installation.
w Crankcase Clean crankcase bore and sealing surfaces with ISOPROPYL

ALCOHOL prior to assembly.
Apply ENGINE OIL or WHITE LITHIUM grease to bearing

surfaces and/or bore.
e Bearing Apply ENGINE OIL or WHITE LITHIUM grease to bearing

Install until bottomed in bore.
Bearings MUST rotate freely after assembly.
Apply load to outer race only.
r Screw Torque: 8 ft-lbs (11 Nm)

Apply Loctite® 272™
Replace if loosened or removed.
t Rod Apply ENGINE OIL or WHITE LITHIUM grease to bearing

y Crankshaft Crankshaft to be drawn through bearings in PTO case without

side loading the bearing balls. Bearing inner race to be
supported during installation. Minimum axial load to be applied
to seat the crank in bearings is 13.3 kN.
Apply ENGINE OIL or WHITE LITHIUM grease to bearing

Align gears to gear timing marks.
Crankshaft must be installed prior to seal installation.
u Bearing Apply ENGINE OIL or WHITE LITHIUM grease to bearing

Install until bottomed in bore.
Bearings MUST rotate freely after assembly.
Apply load to outer race only.
i Balance Shaft Apply ENGINE OIL or WHITE LITHIUM grease to bearing

Align gears to gear timing marks.

IMPORTANT
Orient cir-clip as shown below. The gap should be located at the 6 o’clock or 12 o’clock locations.
IMPORTANT
Orient Piston as shown. Arrow should be pointing to the exhaust valve side.
IMPORTANT
Time balance shaft and crankshaft gears as shown.

ENGINE DISASSEMBLY / INSPECTION - 2. Remove the hydraulic cam chain tensioner e from
TOP END the cylinder. Replace the sealing washer r upon
reassembly.
VALVE COVER REMOVAL
NOTICE
The valve cover, camshafts, cylinder head, cylinder and
piston can be serviced with the engine installed in the
chassis.
1. If needed, remove the spark plug wire from the

engine.
2. Remove dirt and debris from valve cover area.
3. Remove the four valve cover bolts q.
4. Carefully lift valve cover from the engine and remove
it out of the right-hand rear wheel well area.
3. Remove the camshaft sprocket bolt u while holding

engine from turning. Pull the camshaft sprocket i off
of the camshaft and remove the timing chain from the
sprocket. Carefully remove the camshaft from the
engine.
5. Replace valve cover seal w if oil leaks are evident.
CAMSHAFT / CARRIER REMOVAL

NOTICE
The camshafts can be removed with the engine
installed in the chassis.
1. Rotate the engine so the piston is at Top Dead Center

(TDC) on the compression stroke.
NOTICE
To verify TDC, see “Setting TDC (Top-Dead-Center)”.

4. Remove the 4 bolts t that retain the camshaft carrier CAMSHAFT SPROCKET INSPECTION
y and carefully lift the carrier off the camshaft. Inspect cam sprocket teeth q for wear or damage.
Replace timing chain and sprockets as a set if worn or
damaged.
NOTICE
The crankcase has a lower guide to prevent the chain
from falling off the crankshaft. TORQUE
Camshaft Sprocket Bolt
5. Attach a hook or other tool to the camshaft chain to 44 ft-lb (60 Nm)
prevent it from dropping down into the engine.
6. Carefully remove the camshafto from the engine.
CAMSHAFT / CAMSHAFT BORE
INSPECTION
Inspect all main journals and cam lobes as described
below and compare to specifications. Replace camshaft
or cylinder head if worn beyond service limit or if any
surface is pitted or damaged.
1. Visually inspect each cam lobe for wear or damage.

2. Measure the height of each cam lobe from the base 2. Replace the decompression assembly if any
circle to highest point on the lobe using a micrometer. excessive wear or binding is evident.
Compare to specification.
3. Be sure the decompression mechanism functions

NOTICE smoothly and easily returns under spring pressure to
the resting position against gravity.
Replace camshaft if damaged or if any part is worn past
the service limit.
NOTICE
If the ball or bushing are damaged the whole camshaft
MEASUREMENT needs to be replaced. If there is damage to the weight,
Camshaft Lobe Height: spring, or shaft, the service kit 2207556 can be ordered
Intake: 2.0327" ± 0.0038" (51.63 ± 0.097 mm) to replace the assembly. Decompression Kit Part
Exhaust: 2.0657" ± 0.0038" (52.47 ± 0.097 mm) Number 2207556.
CAM CHAIN AND GUIDE SERVICE

EXHAUST CAMSHAFT DECOMPRESSION
MECHANISM NOTICE
The crankcase has a removable lower cam chain drive
NOTICE
guide that prevents the chain from disengaging the
Removal of the decompression mechanism is not crankshaft during engine service.
necessary unless replacement is required. The cam chain, cam chain guides and cam chain
tensioner can be replaced with the engine installed in
the vehicle.
1. Thoroughly clean and inspect the decompression
mechanism q located on the exhaust camshaft.
1. If not already performed, remove the valve cover,
stator cover, flywheel, cam chain tensioner, cam
carrier and camshafts as outlined in this chapter.
2. Remove the two fasteners q that secure the upper
cam chain guides w to the crankcase.
3. Remove the fasteners e that secure the lower cam
chain guide r to the crankcase.
4. Inspect the cam chain guides and replace if
excessive wear is evident.

5. Upon installation, torque all fasteners to specification 5. Remove the cylinder head w and head gasket r.
and reassemble engine and vehicle as outlined in this
chapter.
TORQUE CYLINDER HEAD DISASSEMBLY

Lower Cam Chain Guide Fasteners: CAUTION
9 ft-lbs (12 N·m)
Wear eye protection during cylinder head disassembly
Upper Cam Chain Guide Fasteners: and reassembly or when working with the valve springs.
7 ft-lbs (10 N·m)
NOTICE
Keep mated parts together and in order with respect to
their location in the cylinder head for assembly
CYLINDER HEAD REMOVAL purposes. It is important to install cylinder head
components back in the same location. Mark each
NOTICE component or place them in an organized rack as you
The cylinder head can be serviced with the engine remove them.
Do not rotate head assembly up side-down until the
1. Remove the valve tappet q from the cylinder head.
valve tappets have been removed.
1. Remove and discard the two outer M6 bolts q that

retain the cylinder head w and the cylinder.
2. Loosen the four cylinder head bolts e evenly 1/8 turn
(45 degrees) at a time until all are loose.
3. Remove and discard the cylinder head bolts e.
Replace with new upon assembly.
4. Tap cylinder head lightly with a soft faced hammer
until loose. Tap only in reinforced areas or on thick
parts of the cylinder head casting.

2. Compress the valve spring by hand using valve 8. Clean the combustion chamber and head gasket
spring compressor adapter. surface.
CYLINDER HEAD INSPECTION

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

PV-43513-A
1. Lay a straight edge across the surface of the cylinder
head at several different points and measure warp by
3. Push down on the springe and remove the split inserting a feeler gauge between the straight edge
keepers q. and the cylinder head surface. If warp exceeds the
service limit, replace the cylinder head.
4. Slowly release valve spring pressure and remove the

compressor adapter. MEASUREMENT
5. Remove the valve retainer w, valve spring e, valve Cylinder Head Warp Limit:
stem seal r and valve spring seat t. Discard the .0024" (0.06 mm)
valve seal.
NOTICE
Replace valve seals whenever cylinder head is
disassembled. Hardened, cracked or worn seals will VALVE INSPECTION
cause excessive oil consumption. 1. Remove all carbon from valves with a soft wire wheel
or brush.
6. Lift up the cylinder head and push the valve y out, 2. Check valve face for excessive runout, pitting, and
keeping it in order for reassembly in the same valve burnt spots.
guide.
7. Repeat the previous steps to remove the remaining
valve.

3. To check for bent valve stems, mount valve in “V” 6. Measure diameter of valve stem with a micrometer in
blocks and measure with a dial indicator. three places, then rotate 90° and measure again
(take six measurements total). Compare to
specifications.
MEASUREMENT
Valve Stem Diameter:
Intake: 0.2731" - 0.2737" (6.938 - 6.953mm)
Exhaust: 0.2724" - 0.2730" (6.918 - 6.933 mm)
4. Check the end of the valve stem for flaring, pitting,
wear or damage.
7. Measure valve guide inside diameter at the top
middle and end of the guide using a small hole gauge
and a micrometer. Measure in two directions.
5. Inspect split keeper groove for wear or flaring in the

keeper seat area.
NOTICE
The valves can be re-faced or end ground, if necessary.
They must be replaced if extensively worn, burnt, bent
or damaged. MEASUREMENT
Valve Guide I.D.:
0.2741" - 0.2747" (6.963 - 6.978 mm)
8. Be sure to measure each guide and valve

combination individually.
NOTICE
The valve guides cannot be replaced.

COMBUSTION CHAMBER CLEANING IMPORTANT
CAUTION If the valve seat is cracked the cylinder head must be

replaced.
Wear eye protection during combustion chamber
cleaning.
Valve seat width and point of contact on the valve face is
very important for proper sealing. The valve must contact
1. Clean all accumulated carbon deposits from the valve seat over the entire circumference of the seat,
combustion chambers and valve seat area q. and the seat must be the proper width all the way
around. If the seat is uneven, compression leakage will
result. If the seat is too wide, seat pressure is reduced,
causing carbon accumulation and possible compression
loss. If the seat is too narrow, heat transfer from valve to
seat is reduced. The valve may overheat and warp,
resulting in burnt valves.
IMPORTANT
Polaris Premium Carbon Clean can be used to help
remove carbon deposits.
Do not use a metal scraper, a coarse wire brush or
abrasive cleaners to clean the cylinder head. Damage
may result. RENEWING VALVE SEATS
1. Install pilot into valve guide.
2. Visually inspect cylinder head gasket surface and
combustion chamber for cracks or damage. Pay 2. Apply cutting oil to valve seat and cutter.
close attention to the areas around spark plug and 3. Place 46° cutter on the pilot and make a light cut.
valve seats.
4. Inspect the cut area of the seat:
• If the contact area is less than 75% of the
VALVE SEAT RECONDITIONING circumference of the seat, rotate the pilot 180° and
make another light cut.
Valve seat reconditioning should be performed by a
technician proficient in cylinder head reconditioning • If the cutter now contacts the uncut portion of the
techniques. Reconditioning techniques vary, so follow seat, check the pilot. Look for burrs, nicks, or
the instructions provided by the valve reconditioning runout. If the pilot is bent it must be replaced.
equipment manufacturer. Do not grind seats more than • If the contact area of the cutter is in the same
necessary to provide proper seat surface, width, and place, the valve guide is distorted from improper
contact point on valve face. installation.
CAUTION • If the contact area of the initial cut is greater than

75%, continue to cut the seat until all pits are
Wear eye protection or a face shield during cylinder removed and a new seat surface is evident.
head disassembly and reassembly.
NOTICE
VALVE SEAT INSPECTION Remove only the amount of material necessary to
Inspect valve seat in cylinder head for pitting, burnt repair the seat surface.
spots, roughness, and uneven surface. If any of the
above conditions exist, the valve seat must be
reconditioned.

5. To check the contact area of the seat on the valve MEASUREMENT

face, apply a thin coating of Prussian Blue paste to
the valve seat. If using an interference angle (46°) Valve Seat Width:
apply black permanent marker to the entire valve face Intake:
Std.: .0591" (1.50 mm)
q. Service Limit: .0748" (1.90 mm)
Exhaust:
Std.: .0787” (2.00 mm)
Service Limit: .0945" (2.40 mm)
• If the indicated seat contact is at the top edge of the

valve face and contacts the margin area w it is too
3
high on the valve face. Use the 30° cutter to lower
the valve seat.
• If too low, use the 60° cutter to raise the seat. When
contact area is centered on the valve face,
measure seat width.
• If the seat is too wide or uneven, use both top and
bottom cutters to narrow the seat.
6. Insert valve into guide and tap valve lightly into place • If the seat is too narrow, widen using the 45° cutter
a few times. and re-check contact point on the valve face and
seat width after each cut.
7. Remove valve and check where the Prussian Blue
indicates seat contact on the valve face. The valve MEASUREMENT
seat should contact the middle of the valve face or
slightly above, and must be the proper width. Intake Seat Cutter Diameter
1.979 in. (50.26 mm)
NOTICE
When using an interference angle, the seat contact Exhaust Seat Cutter Diameter
point on the valve will be very narrow, and is a normal 1.617 in. (41.08 mm)
condition. Look for an even and continuous contact
point all the way around the valve face e.
8. Clean all filings from the area with hot soapy water.
Rinse and dry with compressed air.
9. Lubricate valve guides with clean engine oil and apply
oil or water based lapping compound to the face of
the valve.
NOTICE
Lapping is not required if an interference angle
reconditioning method is used.
10. Insert the valve into its respective guide and lap using
a lapping tool or a section of fuel line connected to the
valve stem.
11. Rotate the valve rapidly back and forth until the cut
sounds smooth. Lift the valve slightly off of the seat,
rotate 1/4 turn, and repeat the lapping process. Do
this four to five times until the valve is fully seated,
and repeat process for the other valves.
12. Thoroughly clean cylinder head and valves.
CYLINDER REMOVAL
1. Remove and discard the head gasket.

2. Position the cam chain and guides vertically. 3. Inspect cylinder for wear, scratches, or damage.
3. Tap cylinder lightly with a plastic hammer in the 4. Inspect cylinder for taper and out of round with a
reinforced areas only until loose. telescoping gauge or a dial bore gauge. Measure in
two different directions, front to back and side to side,
4. Rock cylinder forward and backward and lift it from
on three different levels (1/2" down from top, in the
the crankcase, supporting piston and connecting rod. middle, and 1/2” up from bottom).
5. Remove the cylinder from the engine.
6. Remove and discard cylinder base gasket.

NOTICE
Stuffing a clean rag around the connecting rod after
cylinder is removed is helpful in keeping foreign objects 5. Record measurements taken in Step 4. If cylinder is
from falling into the crankcase. tapered, or out of round beyond .001, cylinder must
be re-bored oversize, or replaced.
Cylinder Taper Limit:
.001″ Max. (0.025 mm)
CYLINDER INSPECTION Cylinder Out of Round Limit:
1. Remove all gasket material from the cylinder sealing .001″ Max. (.025 mm)
surfaces.
2. Inspect the top of the cylinder for warpage using a Standard Bore Size:
straight edge and feeler gauge. 3.6614 +/- 0.0003″ (93.0 +/- 0.008 mm)
PISTON REMOVAL
1. Ensure the piston arrow points toward the exhaust
side of the engine.
2. Remove piston circlip and push piston pin out of
piston. If necessary, heat the crown of the piston
slightly with a heat gun.
IMPORTANT
Do not apply heat to the piston rings, they may lose
radial tension.
Cylinder Warpage:
.00098” (.025 mm)

3. Remove top ring. 2. Subtract this measurement from the maximum

cylinder size measurement from cylinder inspection.
IMPORTANT
Using a piston ring pliers, carefully expand ring and lift it Piston to Cylinder Clearance:
off the piston. Do not expand the ring more than the .00138 - .00256″ (.035 - .065 mm)
amount necessary to remove it from the piston. Piston O.D.:
3.6592 - 3.6598″ (92.943 - 92.957 mm)
By hand, use both of your thumbs to spread the ring
open and push up on the opposite side.
PISTON / ROD INSPECTION 3

1. Measure piston pin bore inside diameter I.D.
4. Repeat steps for the second ring.

5. Remove oil control ring top rail first, then remove the
bottom rail.
6. Remove the oil control ring expander. Piston Pin Bore:
Std.: 0.8662 - 0.8665″ (22.004 - 22.010 mm)
Service Limit: 0.8651″ (21.975 mm)
PISTON-TO-CYLINDER CLEARANCE
1. Measure the outside diameter of the piston 12 mm 2. Measure piston pin O.D. Replace piston and/or piston
from the skirt and at a right angle to the direction of pin if out of tolerance.
the piston pin q.
Piston Pin O.D.:

Std.: 0.8659 - 0.8661″ (21.995 - 22.0 mm)

3. Measure connecting rod small end ID. Inspect PISTON RING INSTALLED GAP
bearing surface for damage.
1. Place each piston ring inside cylinder. Use a piston to
push the ring squarely into place 1” (25.4 mm) down
from the cylinder head gasket surface.
2. Measure installed gap with a feeler gauge at location
q.
Piston Pin Degree of Fit:

Pin should be a push-fit by hand with piston at room
temperature or warmed slightly
Connecting Rod Small End ID:
Std.: 0.8665 - 0.8670″ (22.010 - 22.023 mm)
Piston Ring Installed Gap
Top Ring:
4. Measure piston ring to groove clearance by placing Std: 0.0059 - 0.0122" (0.15 - 0.31 mm)
the ring in the ring land and measuring with a Limit: 0.0137" (0.35 mm)
thickness gauge. Replace piston and rings if ring-to-
Second Ring:
groove clearance exceeds service limits.
Std: 0.0094 - 0.0196" (0.24 - 0.50 mm)
Limit: 0.022" (0.56 mm)
Oil Ring Rails:
Std: 0.0098” - 0.0401" (0.25 - 1.02 mm)
Limit: 0.0480" (1.22 mm)
NOTICE
Always check piston ring installed gap after re-boring a
cylinder or when installing new rings.
Piston Ring-to-Groove Clearance

Top Ring:
Std.: 0.0011 - 0.0037" (0.030 - 0.095 mm)
Service Limit: 0.0042" (0.108 mm)
Second Ring:
Std.: 0.0007 - 0.0029" (.020 - 0.076 mm)

ENGINE ASSEMBLY - TOP END 3. Install upper ring with end gap positioned as shown.
PISTON RING INSTALLATION
NOTICE
Apply clean engine oil to all ring surfaces and ring lands
upon installation. Always check piston ring installed gap
before rings are installed on piston (see Piston Ring
Installed Gap page 3.105). Clean accumulated carbon
from piston ring grooves and oil ring lube holes if piston
has been in service.
3
REF DESCRIPTION
y Upper Ring Gap Position
u Lower Ring Gap Position

Spring Expander Gap Position
i (PTO Side)
4. Install second ring with marking facing top of piston.

Rotate ring to position the end gap toward intake side
of piston as shown below.
REF DESCRIPTION
5. Install top ring with mark facing top of piston. Rotate
q Top Ring (Marking up) ring to position the end gap toward exhaust side of
piston as shown below.
w Second Ring (Marking up)
e Upper Rail
r Spring Expander
t Lower Rail
1. Place oil control ring expander in oil ring groove.

Rotate expander in groove until butt ends are on PTO
side of piston (see illustration 1).
NOTICE
Ends must butt squarely together and must not overlap.
2. Install lower ring with end gap positioned as shown in

step 3.
REF DEFINITION
o Second Ring Gap Position
a Top Ring Gap Position
6. Be sure top and second rings rotate freely in their

grooves and do not bind when compressed by hand.

PISTON / CONNECTING ROD ASSEMBLY 4. Place piston q on connecting rod w. Push piston pin
1. Lubricate connecting rod small end, piston pin bore e through rod and piston until it seats against the
and piston pin with engine oil. installed circlip.
IMPORTANT NOTICE
Do NOT re-use circlips. Circlips become deformed Do not tap on pin or cause any sideways force to
during the removal process. connecting rod. Warm piston crown with a heat gun if
Do not compress the new clip more than necessary to pin cannot be installed by hand, or use a piston pin
prevent loss of radial tension. Severe engine damage installation tool.
may result if circlips are re-used or deformed during
installation. IMPORTANT
DO NOT apply heat to piston rings or a loss of radial
NOTICE tension could result.
Stuffing a clean rag around the connecting rod after
cylinder is removed is helpful in keeping foreign objects
from falling into the crankcase.
2. Install a new circlip on one side of piston with gap at

the top (12:00 position) or bottom (6:00 position).
IMPORTANT
Never re-use a piston pin circlip.
3. When installing the piston, ensure the piston marking

arrow is positioned towards the exhaust side of the
engine.
5. Install the remaining circlip r with gap at the top

(12:00 position) or bottom (6:00 position). Push the
piston pin in both directions to make sure the clips are
properly seated in the groove.
CYLINDER INSTALLATION
1. Clean base gasket sealing surface on cylinder and
crankcase to remove all oil, grease, or old sealant.
2. Install a new base gasket.
NOTICE
Base gasket and surfaces must be DRY and oil free.
Use care upon assembly to keep oil away.

3. Slide a commercially available Piston Support Block CYLINDER HEAD INSTALLATION

under piston skirt to support piston during cylinder
installation. NOTICE
Head gasket and surfaces must be DRY and oil free.
Use care during assembly to keep oil and finger prints
off of gasket.
1. Prepare cylinder head gasket sealing surfaces by

cleaning thoroughly to remove all residue. The new
head gasket must be installed clean and dry, free
from oil or grease. 3
NOTICE
Do not touch sealing surfaces of the new head gasket.
2. Guide cam chain r through a new head gasket t

and install the gasket on the cylinder, locating it on
the alignment pins.
4. Apply clean engine oil to cylinder bore and bottom
tapered portion of cylinder sleeve.
5. Verify all ring end gaps are correctly located on
piston. Place cam chain and guides in alignment with
chain room.
6. Carefully compress rings with fingers or commercially
available spring compression tool and install cylinder
with a slight front to back rocking motion until all rings
are captive in cylinder and past the taper of the
sleeve.
7. Remove support block and ring compressor.
8. Push cylinder downward until fully seated on base
gasket.
3. Carefully set the cylinder head y in place on

alignment pins.
4. Install and finger tighten the four new cylinder head
bolts u evenly.
5. Install and finger tighten the two new outer M6 bolts
i evenly.
6. Torque the new cylinder head bolts in sequence to
specification.
9. Hold the cylinder in place and rotate the engine and

position the piston at TDC.
NOTICE
If cam chain and flywheel are installed (top end work
only is being performed) hold cam chain tight while
rotating the engine to avoid damage to the chain, drive
sprocket teeth, or tensioner blade.

TORQUE 3. Repeat for exhaust valve by pouring fluid into exhaust

porte.
Cylinder Head Bolts:
Apply light coat of engine oil to bolt threads
and under bolt head
Torque in Sequence for all steps
Step 1: 18 ft-lbs (25 Nm)
Step 3: Loosen all fasteners until they are
unseated
Torque The Outer M6 Head Bolts 89 ± 9 in-lbs
(10 ± 1 Nm) VALVE CLEARANCE CHECK /
ADJUSTMENT
NOTICE
Always inspect valve clearance prior to camshaft
installation or final engine assembly.
NOTICE
Valve clearance should only be checked on a cold
engine.
1. Install the cam chain guides and cam chain before

camshaft installation (if removed) as outlined in this
chapter.
2. Lubricate the camshaft bearing journal surfaces with
Polaris PS-4 engine oil prior to installation.
3. Carefully install the camshafts into the cylinder head.
VALVE SEALING TEST The camshaft lobes should face out.
1. Clean and dry the combustion chamber area q.
2. Pour a small amount of clean solvent into intake port
w and check for leakage around the valves. The
valve seats should hold fluid with no seepage.
4. Carefully install the camshaft carrier onto the

camshafts.

5. Install the four bolts that retain the camshaft carrier. 8. If any of the valve clearance measurements are out of
specification, remove the camshaft carrier and
camshaft and proceed with this procedure.
NOTICE
If all valve clearance measurements are within
specification, remove the camshaft carriers and
proceed to “Camshaft Installation / Timing”.
9. Remove the valve tappet q from a valve that was out

of specification. 3
6. Torque the camshaft carrier bolts in sequence to

specification.
NOTICE
purposes. Mark each component or place them in an
organized rack as you remove them.
TORQUE 10. Record the 3-digit number engraved on top of the

tappet.
Camshaft Carrier Bolts:
7 ft-lbs (10 N·m) 11. Reference the valve clearance measurement
recorded for that valve, along with the 3-digit tappet
number.
thickness (feeler) gauge. Record the measurement if 12. Refer to the appropriate tappet selection matrix
clearance is out of specification. (Intake or Exhaust) on the following pages and select
the proper tappet.
MEASUREMENT 13. Install the new tappet.
Intake Valve Clearance (cold):
.006 ± .002″ (0.152 ± .050 mm) NOTICE
Lubricate the outer portion of the valve bucket upon
installation.
MEASUREMENT
Exhaust Valve Clearance (cold): 14. Repeat steps until all necessary valves have been
.010 ± .002″ (0.254 ± .050 mm) adjusted.

15. Reinstall the camshafts and camshaft carriers and 16. Measure and confirm that valve clearance is now
tighten the bolts evenly to specification. within specification for each valve.
TORQUE 17. If valve clearance is not within specification, repeat
this procedure.
7 ft-lbs (10 N·m) 18. If all valve clearance measurements are now within
specification, remove the camshaft carrier and
VALVE LASH - TAPPET SELECTION MATRIX

A 440 tappet means the thickness of the tappet is 4.40 mm. Part Number: 5139458-XXX (X’s represent 3 digit tappet
size)
An Engine Valve Lash Adjustment calculator has been created and is located under Service and Warranty – News,
Forms and Links.
Click or go to https://www.polarisdealers.com/files/ServWarr/English/Engine%20Valve%20Adjustment%20Calculator.
pdf
The proper valve tappet may also be obtained by completing these steps:
IMPORTANT
The Valve Lash Specification and Measured Valve lash must be calculated in millimeters (mm)
1. Subtract the actual valve lash on the engine from the valve lash specification (i.e. 0.29 mm – 0.20 mm) = 0.09 mm.
2. Divide the 3 digit tappet number by 100 (i.e. 450 / 100) = 4.5 mm.
3. Add the results of step 1 and step 2 (i.e. 0.09 mm + 4.5 mm) = 4.59 mm.
4. Multiply that answer by 100 to obtain the correct new tappet (i.e. 4.59 mm x 100 = 459).
5. Refer to the table below to find the closest available tappet size to the result from step 4 (i.e. 459 should be
rounded to 460 since there is a 460 tappet).
AVAILABLE TAPPETS
322 325 328 330 332 335 338 340 342 345 348
350 352 355 358 360 362 365 368 370 372 375
378 380 382 385 390 392 395 398 400 402 405
408 410 412 415 418 420 422 425 428

CAMSHAFT INSTALLATION / TIMING 5. Verify that the timing marks qare in alignment as
shown below.
NOTICE
If any valve train components were replaced, refer to
“Valve Clearance Adjustment” page 3.112 prior to
“Camshaft Installation / Timing”.
1. Rotate the engine so the piston is at Top Dead Center

(TDC).
NOTICE
3
2. Lubricate all camshaft lobes and bearing journal

surfaces with Polaris PS-4 Synthetic Engine Oil prior
to installation.
camshafts.
7. Install the four bolts that retain the camshaft carrier.
Tighten the bolts evenly until snug. Do not torque at
this time.
3. Place the camshaft into the cylinder head and align

the timing marks as shown below.
8. Verify cam timing is correct and the piston is a TDC.

9. If timing marks are not aligned:
• Remove the cam carrier bolt and cam carrier.
• Correct the camshaft timing as needed.
• Reinstall the cam carrier.
• Re-check cam timing.
10. If needed, install the camshaft carrier and bolts.
4. Wrap the cam chain around the camshaft in its

current position.

11. Torque the camshaft carrier bolts in sequence to 14. Install the hydraulic cam chain tensioner w into the
specification. cylinder and torque to specification.
TORQUE TORQUE
Camshaft Carrier Bolts: Cam Chain Tensioner:
7 ft-lbs (10 N·m) 37 ft-lbs (50 Nm)
12. Install camshaft sprocket bolt and torque to 15. Rotate crankshaft through two revolutions and verify
specification. camshaft timing is correct.
TORQUE NOTICE
Camshaft sprocket Bolt Verify the valve lash after the tensioner has been
44 ft-lb (60 Nm) installed and the engine has been rotated two turns.
NOTICE
Ensure exhaust decompression mechanism still moves
freely and returns by spring force after sprocket has
been installed.
13. Insure the new sealing washer q is in place.

CAMSHAFT TIMING - QUICK REFERENCE

The camshaft sprocket should have notch marks q aligned with gasket surface.
Stator Cover/Flywheel Removed. Flywheel Key faces Stator Cover/Flywheel Installed. “V” marked on the
down and insert a 1/4” drive socket extension through flywheel is aligned with the CPS mounting hole.
the crankcase and into the crankshaft locating hole q.

VALVE COVER INSTALLATION

1. Prepare valve cover sealing surfaces by cleaning
thoroughly to remove all residue.
2. Install a new valve cover seal w.
3. Install the four valve cover bolts q.
4. Torque valve cover bolts to specification.

TORQUE
Valve Cover Bolts:
9 ft-lbs (12 Nm)

ENGINE DISASSEMBLY / INSPECTION - 6. Hold flywheel special service tool and remove
LOWER END flywheel nut and washer e. Discard the flywheel nut
and replace for assembly.
CRANKCASE DISASSEMBLY
Flywheel special service tool:
NOTICE PU-51220
The engine top end, starter motor, stator cover, starter
drive, flywheel, stator, cam chain, oil pump and NOTICE
sprockets can be serviced with the engine installed in
the vehicle. The flywheel nut has standard rotation (right hand)
threads.
3
7. Back the center screw of flywheel puller completely
STATOR COVER REMOVAL out and screw puller onto flywheel completely.
1. Remove the engine to transmission coupler through
bolts (See “Engine to Transmission Coupler
Service”).
CAUTION
result.
2. Disconnect stator harness connector.

3. Disconnect CPS connector.
4. Remove stator cover fasteners.
5. Remove starter drive gear w and shaft q. Inspect Flywheel puller:
gear teeth for damage. Inspect fit of shaft inside gear PA-49316
and replace gear assembly if clearance is excessive.
Inspect shaft and shaft bearing surfaces in case and 8. Tighten center bolt of the flywheel puller and remove
stator housing for wear. flywheel.
STARTER ONE-WAY CLUTCH INSPECTION

1. Remove flywheel as outlined in this chapter.
2. Place flywheel on work bench. Grasp gear and rotate
clockwise. It should turn smoothly without binding.
3. Rotate gear counterclockwise. The gear should
immediately lock in position and not slip.

4. Inspect inside of hub q for wear, galling, or uneven 7. Remove the three, one-way clutch retaining bolts.
surface.
8. Remove clutch and inspect both sides of drive rollers

5. Inspect crankshaft bearing surface for abnormal
wear.
w and roller contact surface e inside hub for wear,
damage, or uneven surface.
6. Remove starter gear from the flywheel assembly.

9. Inspect drive surface of starter gear r and bearing
surface t for wear, damage, or uneven surface. If
any starter clutch component is worn or damaged,
replace clutch, clutch hub, and starter gear.

STATOR REMOVAL
NOTICE
Test stator wire continuity before removing it from the
housing.
1. Remove the stator cover.
CAUTION
3
result.
CAUTION
3. Remove the three bolts e that secure the stator q

to the stator cover w.
4. Remove the two bolts that secure the stator wire

routing bracket r to the stator cover.
5. Remove the stator q from the stator cover.

OIL PUMP REMOVAL
REF DESCRPITION NOTES

q Screw
w Cover, Oil Pump
e Washer
r Pin, Solid
t Shaft, Oil Pump
y ASM., Gerotor

1. Remove the stator cover (Refer to “Stator Cover 4. Remove the upper oil pump sprocket spacer.
Removal” page 3.69)
2. Remove the two oil pump sprocket bolts and
washers. Discard the bolts and replace with new for
assembly. Remove the sprockets and chain from the
engine.
5. Remove the three bolts securing the oil pump cover

to the crankcase.
6. Grasp the oil pump shaft and pull it outward to
remove the shaft, oil pump cover and inner oil pump
geroter. This will prevent the oil pump drive pin from
3. Inspect the oil pump chain for worn or missing rollers falling out and into the crankcase.
or damage. Chain should be replaced as a set with
sprockets if sprocket teeth are worn.
NOTICE
The gerotor set has two orientation dots that must be
NOTICE installed inward upon assembly
The larger oil pump sprocket s mounts to the balance (Figure 1 on the next page).
shaft extension, the smaller oil pump sprocket d
mounts to the oil pump shaft. 7. Remove the center geroter, pin and shaft from the oil
pump cover.
NOTICE
There is a spacer f in between the inner oil pump
geroter and the oil pump cover.
8. Remove the oil pump geroter that is in the engine

case (if needed).
9. Clean the geroters to remove oil.

10. Inspect surfaces of pump cavity in crankcase and 6. Install the oil pump cover r onto the shaft assembly.
surface of pump cover for scoring or wear.
7. Grasp the complete oil pump assembly by the drive

11. Inspect gerotor for scoring or other damage. Replace shaft and install the assembly into the crankcase.
parts as a set if damaged.
8. Install the three oil pump cover bolts and torque to
specification.
9. Torque cover bolts to specification.
TORQUE
Oil Pump Cover Bolts:
9 ft-lbs (12 Nm)
FLUID CAPACITY
Oil Capacity
Oil Filter Wrench

PU-50105 or 2.5” (64 mm)
Oil Type
OIL PUMP ASSEMBLY Polaris PS-4 Synthetic Engine Oil
1. Clean and dry all parts thoroughly. Apply clean
engine oil to all parts. Do not use gasket sealer on Oil Pressure
the pump cover mating surfaces. Minimum Specification
2. Align the gerotor according to the orientation dots. (using Polaris PS-4 at operating temperature)
3. Place the drive pin q through the oil pump drive
shaft. 40 PSI @ 7000 RPM (Minimum)
4. Slide the gerotor w onto the drive shaft and lock

them into position on the drive pin.
5. Install the washer e onto the drive shaft.

CRANKCASE BREATHER SERVICE CRANKCASE SEPARATION

NOTICE NOTICE
The crankcase breather is serviceable with the engine Before the crankcase can be separated, be sure the
assembled and installed in the vehicle chassis. entire top end and oil pump assembly are removed
from the engine as outlined in this chapter.
1. Remove the crankcase vent tube (if not already
performed). 1. Rotate the engine on the engine stand so the
magneto side is facing upward.
2. Remove the two fasteners securing the engine
breather cover to the engine. 2. Remove the oil filter and the three fasteners w (20ft-
3. Remove the breather cover gasket and replace if

lbs (28Nm) apply loctite 272) that secure oil filter
adapter q to the crankcase. Discard O-rings and
3
damaged. through clean the adaptor for reassembly.
4. For reassembly, thoroughly clean the crankcase and
breather cover mating surfaces. Install a new gasket
and torque the two fasteners to specification.
TORQUE
Crankcase Breather Cover Bolts:
9 ft-lbs (12 Nm)
3. Remove and discard the fifteen flange bolts from

magneto side crankcase evenly in a criss-cross
pattern.

4. Separate crankcase by tapping with a soft faced 2. Pull upward on the balance shaft and remove it from
hammer in reinforced areas and lift MAG crankcase the crankcase.
off PTO case.
3. Inspect drive gear for broken or damaged teeth.
CAUTION 4. Inspect bearing surfaces for scoring or signs of wear.
Never strike the engine mounts with a hammer.
BALANCE SHAFT REMOVAL / INSPECTION

1. Rotate crankshaft to align the timing marks as shown
below.
5. Inspect / replace the balance shaft bearings in both

crankcase halves. See “Crankcase Bearing
Inspection / Removal” procedure in this chapter.
NOTICE
Due to extremely close tolerances and minimal wear,
counterbalance shaft ball bearings must be inspected
visually and by feel. Look for signs of discoloration,
scoring or galling. Turn the inner race of each bearing.
The bearings should turn smoothly and quietly. The
outer race of each bearing should fit tightly in the
crankcase bore. The inner race should be firm with
minimal side to side movement and no detectable up
and down (radial) movement.

CRANKSHAFT REMOVAL CRANKSHAFT INSPECTION

1. Remove the engine from the engine stand and place
the assembly on a sturdy work bench. NOTICE
The connecting rod uses plain bearings. The
2. Install the crankshaft removal / installation tool on to
connecting rod bearings are not serviceable. If ANY
the PTO side crank case.
excessive wear or movement is present or if the rod
Crankshaft Removal / Installation Tool does not rotate on the crankshaft freely, the crankshaft
PU-50784 assembly must be replaced.
1. Use a feeler gauge to measure the connecting rod

• Install plate q over adapter w. big end side clearance q.
• Evenly attach the assembly onto the PTO side
3
crankcase using the four bolts as shown below.
• Thread the crankshaft removal screw e into w.
Connecting Rod Big End Side Clearance:

0.00590-.01771″ (.15 - .45mm)
2. Measure the connecting rod small end I.D. w.
3. With the help of an assistant holding the crankshaft,

slowly tighten the screw e until the crankcase is Small End I.D. Standard:
completely separated from the crankshaft. 0.8665 - 0.8670″ (22.010 - 22.023 mm)
4. Remove all special tools from the crankcase. Service Limit: 0.08682″ (22.053 mm)

3. Place the crankshaft in a truing stand or V-blocks 4. Support the crankcase and drive, press, or extract
and measure the runout where indicated below with the three bearings with a blind bearing remover.
a dial indicator.
Maximum Runout:
Mag side (3) - 0.00118″ (0.03 mm)
PTO side (4) - 0.00590″ (0.15 mm)
PTO SIDE CRANKCASE BEARING SERVICE

Bearing Removal
NOTICE
the bearings must be inspected visually, and by feel.
Look for signs of discoloration, scoring or galling. Turn
the inner race of each bearing. The bearings should REF DESCRIPTION
turn smoothly and quietly. The outer race of each
bearing should fit tightly in the crankcase. The inner Bearing Retainer Bolt
race should be firm with minimal side to side movement
q 8 ft-lbs (11 Nm) apply loctite 272
and no detectable up and down movement.
w Bearing Retainer
Bearings are stressed during the removal process and
must not be re-used! Bearings:
Apply Loctite® 641 to the inner
1. Remove and discard the PTO side crankshaft seal. e race of each of the crank
Replace with new for assembly. bearings.
2. If not already performed, remove the screws that Bearing Spacer
secure the bearing retainer to the case. r
3. Remove the retaining ring. t Retaining Ring

Installation MAG SIDE CRANKCASE BEARING

SERVICE
NOTICE Bearing Removal
To ease bearing installation, warm the crankcase
1. Support the crankcase and drive, press, or extract
evenly with a heat gun or place in an oven and heat to
the balance shaft bearing q with a blind bearing
220-250° F. Place bearings in clean plastic wrap and
remover.
set in a freezer for 10-20 minutes.
NOTICE
5. Clean all bearings e and inspect for excessive wear.
The MAG side crankshaft plain bearing w is not
NOTICE serviceable. Crankcase replacement is required if the
Apply Loctite® 641 to the inner race of each of the
bearing is damaged or has excessive wear. The 3
crankshaft is reusable if it meets specifications and
crank bearings. MAG side bearing surface is not groved, pitted,
damaged or excessively worn.
6. Lubricate all bearings e with clean engine oil.
7. Fully seat the new balance shaft bearing until
bottomed in the bearing bore.
8. Install the retaining ring t for the crankshaft
bearings.
9. Fully seat the new outer PTO crankshaft bearing
until bottomed against the retaining ring.
10. Install the bearing spacer r.
11. Press in the new inner PTO bearing until it is
bottomed against the bearing spacer.
12. Apply Loctite® 272™ to the two bearing retainer
bolts q.
13. Install the bearing retainer w and torque the fastener
to specification.
IMPORTANT
TORQUE
Bearing Retainer Fastener: the bearings must be inspected. Look for discoloration,
8 ft-lbs (11 Nm)Apply Loctite® 272™ scoring or galling. The inner race of each bearing
should turn smoothly and quietly. The outer race of
each bearing should fit tightly in the crankcase. The
inner race should be firm with minimal side to side
movement and no detectable up and down movement.
must not be re-used!
Installation
2. Clean all bearing bores and inspect for excessive
wear.
3. Lubricate all bearing bores with clean engine oil.

OIL PICKUP ASSEMBLY INSPECTION CRANKCASE INSPECTION

The oil pickup assembly is located in the Mag side 1. Remove all traces of gasket sealer from the
crankcase q. crankcase mating surfaces. Inspect the surfaces
closely for nicks, burrs or damage.
2. Be sure alignment pins are in place where used.
3. Be sure oil passages are clean and free of any
cleaning solvent.
1. Pull and twist to remove the oil pickup assembly from

the crankcase.
2. Inspect the assembly for cracks and excessive wear.
3. Remove and discard the O-ring.
4. Thoroughly clean the pickup assembly
5. Replace the o-ring and lubricate with clean engine
oil.
6. Press the pickup assembly into the crankcase until
fully seated.
OIL PRESSURE REGULATOR (BYPASS)

VALVE INSPECTION
The oil pressure regulator (bypass) valve is located in the
Mag side crankcase w.
1. Use a brass drift to press out the oil pressure valve
from the crankcase.
2. Replace the oil pressure valve if the inner plunger
binds, sticks or does not operate smoothly.
3. Remove and discard the o-ring.
4. Thoroughly clean the valve.
oil.
6. Press the oil pressure valve into the crankcase until
fully seated.

ENGINE ASSEMBLY - LOWER END 5. Install the crankshaft removal / installation tool on to
the PTO side crankcase.
CRANKCASE ASSEMBLY – PTO SIDE
1. Lubricate all crankcase bearings with engine oil. Crankshaft Removal / Installation Tool
Clean sealing surface to remove all oil sealant. PU-50784
NOTICE
• Install plate q over adapter w.
crank bearings. • Evenly attach the assembly q onto the PTO side
crankcase flange using the four bolts provided with
2. Place crankcase on a sturdy work bench. tool.
3. Carefully set the PTO crankcase onto the PTO side • Place the nut and large washer onto the crankshaft
3
of the crankshaft. installation screwe.
4. Align the connecting rod with the cylinder area of the • Insert the crankshaft installation screw through the
crankcase. threaded portion of the adaptor w.
• Fully thread the crankshaft installation screw into the
clutch bolt threads of the crankshaft.
• With the help of an assistant holding the crankshaft,
firmly hold the crankshaft installation screw with a
wrench while tightening the large nut against the
adaptor w.
6. With the help of an assistant, slowly tighten the nut

until the crankshaft is completely seated into the
crankcase bearings.

7. Remove the crankshaft removal / installation tool 10. Use the crankshaft removal / installation tool to
from the crankcase. properly drive the crankshaft seal into the crankcase.
8. Be sure crankshaft is fully seated and rotates Crankshaft Removal / Installation Tool
smoothly. PU-50784
• Center plate q over the crankshaft so it is resting on

the crankshaft seal.
• Center adaptor w over the crankshaft end.
• Place the nut and large washer onto the crankshaft
installation screw.
• Insert the crankshaft installation screw through the
threaded portion of the adaptor.
• Firmly hold the crankshaft installation screw with a
adaptor.
NOTICE
The crankshaft seal can be replaced with the engine
installed in the chassis. The engine does not have to be
removed and the crankcase does not have to be
separated to replace the crankshaft seal.
9. Lubricate a new crankshaft seal and slide it over the

PTO end of the crankshaft with numbers facing OUT.
Be sure seal lip does not fold back when moving
over the crankshaft flange.
11. Drive seal until flush with seal bore.
12. Turn PTO crankcase over and support with

crankshaft upright.

BALANCE SHAFT INSTALLATION / TIMING FINAL CRANKCASE ASSEMBLY

1. Position balance shaft in the crankcase. 1. Prepare lower crankcase by cleaning sealing
surface. Be sure the oil pickup and oil pressure valve
2. Rotate crankshaft to align the timing marks q as
are fully installed.
shown below.
2. Apply a thin film of Crankcase Sealant (PN 2871557)
3. Fully seat the balance shaft into the crankcase and evenly to a clean and oil-free crankcase mating
verify timing marks are correct.
surface as indicated below q. Be sure alignment
pins w are in place.
Crankcase Sealant:
PN 2871557
3
3. Carefully assemble MAG crankcase to PTO
crankcase immediately. Do not allow sealant to dry.
4. Tap crankcase evenly until fully seated with a soft

sided hammer.
5. Install the new crankcase bolts finger tight in MAG

side crankcase.
6. Tighten all bolts evenly until snug.

7. Torque the new crankcase bolts to in sequence to

specification.
TORQUE
Crankcase Bolts (In Sequence):
22 ft-lbs (30 Nm)
8. Install the engine stand adapter onto the engine ears

as shown below.
Engine Stand Adapter:

PU-50824-A

install it onto the engine stand adapter.
Sleeve adapter for a 2″ bore engine stand:
PU-50625
Sleeve adapter for a 2.375″ bore engine stand:

PW-47054
10. Place engine onto the engine stand for top end
engine assembly as outlined in this chapter.
Engine Stand:
PU-50624-A

STARTER ONE-WAY CLUTCH FLYWHEEL INSTALLATION

INSTALLATION 1. Clean the threads q, taper w and flat e of
1. Install one-way clutch in clutch hub with flange of crankshaft to remove all oil or grease.
clutch q facing the flywheel.
2. Clean flywheel taper r with alcohol to remove all oil

or grease.
NOTICE
The one-way clutch can be installed into the hub
incorrectly. This will cause engine cranking issues.
2. Clean screw threads in flywheel to remove all oil or

grease.
3. Apply Loctite® 272™ on the one way clutch retaining
bolts threads w. Place hub on flywheel and install
bolts.
4. Torque screws to specification.
3. Apply a small amount of PS4 engine oil to the flat

area t on the MAG side crankshaft. DO NOT apply
engine oil to the crankshaft taper.
TORQUE
One Way Clutch Retaining Bolts:
1st: 6 ft-lbs (8 Nm)2nd: 9 ft-lbs (12 Nm) Apply
Loctite® 272™
4. Rotate crankshaft so the flywheel key y is facing

upward.

5. Fully install starter gear onto the crankshaft as 11. Torque new flywheel nut u to specification.
shown.
6. Align the flywheel keyway with flywheel key on the TORQUE

crankshaft. Flywheel Retaining Nut:
7. Thoroughly clean the crank taper with alcohol. 1st: 133 ft-lbs (180 Nm)2nd: Back off 180°3rd: Re-
torque to 133 ft-lbs (180 Nm)
8. By hand, lightly press the flywheel inward while
rotating the starter gear counter clock-wise. Fully
install the flywheel until seated on the crankshaft NOTICE
taper.
The flywheel nut has standard rotation (right hand)
threads.
12. Install starter idler gear i and shaft o.
9. Install the flywheel washer.

10. Hold flywheel with commercially available strap
wrench.

STATOR / STATOR COVER INSTALLATION 8. Install the stator cover screws and torque in
1. Clean and degrease stator screws and threads in the sequence to specification.
stator housing.
2. Clean mounting surfaces of stator q and housing w.
3. Apply crankcase sealant to edges of rubber stator
grommet.
4. Set the stator in housing and press wire grommet
into slot on housing.
5. Apply Loctite® 242™ to end (8-10 threads) of the
stator screws e and the wire routing bracket screws 3
r.
TORQUE
Stator Mounting Bolts:
9 ft-lbs (12 Nm)
6. Install a new stator cover gasket.

7. Install the stator cover.
TORQUE
Stator Wire Retainer:
6 ft-lbs (8 Nm)
CAUTION
any time during the installation process or injury could
result.

570CC DOHC ENGINE

ENGINE DETAIL, TORQUES /
SEQUENCES
ENGINE FASTENER TORQUE SPECIFICATIONS
570 Engine
Description Torque
Bearing Retainer Fastener 8 ft-lbs (11 N·m) Apply Loctite® 272
Upper Cam Chain Guide Fasteners 7 ft-lbs (10 N·m)
Cam Chain Tensioner 30 ft-lb (40 Nm)
Camshaft Carrier Bolts 7 ft-lb (10 Nm)
Camshaft Sprocket Bolts 14 ft-lb (19 Nm)
Coolant Bleed Screw 72 in-lbs (8 Nm)
Coolant Temperature Sensor 17 ft-lb (23 Nm)
CPS Retaining Bolt 9 ft-lb (12 Nm)
Crankcase Bolts 22 ft-lbs (30 N·m) Torque in Sequence Shown
Crankshaft Position Sensor (CPS) Fastener 9 ft-lbs (12 N·m)
Cylinder Head Bolts - Black Torque in sequence for all steps
Step 1: 21 ft-lbs (28 N·m)
Torque the Outer M6 Head Bolts 89 ± 9 in-lbs (10
± 1 Nm)
Cylinder Head Bolts - Silver Apply light coat of engine oil to bolt threads and
under bolt head
Torque in sequence for all steps
unseated
Torque the Outer M6 Head Bolts 89 ± 9 in-lbs (10
± 1 Nm)
ETC Fasteners 7 ft-lbs (10 N·m)

Engine Mount (front) 40 ft-lbs (54 Nm)

Engine Coupler (Rear) In Sequence:

55 ft-lb (75 Nm)
Exhaust Head Pipe Bolts 18 ft-lb (25 Nm)
IAC Mounting Screw 18 in-lbs (2 Nm)
Camshaft Sprocket Bolt 14 ft-lbs (19 N·m) Replace camshaft sprocket bolt if
loosened or removed.
Oil Gallery Plug: 11 ft-lbs (15 Nm)
Oil Filter Lubricate seal with engine oil. Turn by hand until 3
filter gasket contacts sealing surface, then turn an
additional 3/4 turn.
Oil Pan Drain Plug 12 ft-lbs (16 N·m)
Oil Pickup 9 ft-lbs (12 N·m)
Oil Pressure Regulator 20 ft-lbs (27 N·m)
Oil Pressure Regulator Valve Cover 7 ft-lbs (10 N·m)
Oil Pump Sprocket Bolt 9 ft-lbs (12 N·m)
Oil Pump Cover Bolt 8 ft-lbs (11 Nm)
Spark Plug 9 ft-lbs (12 N·m) Do Not Apply Anti-Seize
Starter Mounting Bolts 3 ft-lbs (4 Nm)
Starter One-Way Clutch Screws 9 ft-lbs (12 Nm)
Stator Cover Screws 9 ft-lb (12 Nm)
Stator Wire Routing Bolts 6 ft-lbs (9 Nm)
Thermostat Cover Bolts 7 ft-lbs (10 Nm)
T-MAP Retaining Bolt 24 in-lbs (2.8 Nm)
TPS Mounting Screws 18 in-lbs (2 Nm)
Valve Cover Bolts 9 ft-lbs (12 Nm)
Voltage Regulator Fasteners 75 in-lb (6 Nm)
Water Pump Cover Bolts 9 ft-lbs (12 Nm)
(Apply Loctite® 204™ to bolt threads)
Water Pump Impeller Finger Tight *LH threads

TORQUE SEQUENCE
CRANKCASE CYLINDER HEAD
Apply light coat of engine oil to

bolt threads and under bolt
head
Torque in sequence for all
steps
M11 Bolts: Step 2: 30 ft-lbs (41 N·m)
Must Install Step 3: Loosen all fasteners
Crankcase Bolts: 22 ft-lbs (30 Nm) NEW Bolts if until they are unseated
removed
Torque the Outer M6 Head
Bolts 89 ± 9 in-lbs (10 ± 1 Nm)
M6 Bolts: 7 ft-lbs (10 Nm)

STATOR COVER WATER COVER
9 ft-lbs (12 Nm)

Stator Cover Bolts 9 ft-lbs (12 Nm) Water Cover Bolts (Apply Loctite® 204™ to
bolt threads)
CAM CARRIER VALVE COVER
Camshaft Carrier Bolts 7 ft-lbs (10 N·m) Valve Cover Bolts 7 ft-lbs (10 N·m)

CRANKCASE - TIMING / SEALING PATH

TIMING MARKS
CRANKCASE SEALING PATH

ENGINE DISASSEMBLY / INSPECTION - CAMSHAFT / CARRIER REMOVAL

TOP END NOTICE
VALVE COVER REMOVAL The camshafts can be removed with the engine
NOTICE
The valve cover, camshafts, cylinder head, cylinder and 1. Rotate the engine so the piston is at Top Dead
piston can be serviced with the engine installed in the Center (TDC) on the compression stroke.
chassis.
1. If needed, remove the spark plug wire from the

engine. 3
2. Remove dirt and debris from valve cover area.
3. Remove the three valve cover shoulder bolts q and
isolators w using a T40 driver.
4. Carefully lift valve cover from the engine and remove
it out of the right-hand rear wheel well area.
NOTICE
2. Remove the hydraulic cam chain tensioner t from

the cylinder. Replace the sealing washer y upon
reassembly.
5. Replace isolators after each usew

6. Replace Valve cover seal eif oil leaks are evident
7. Remove the spark plug r. Stuff spark plug hole with
a shop towel to prevent anything from falling into the
combustion chamber (if further engine disassembly
is required).

3. Remove the two bolts retaining the fixed cam chain 7. Lift upward on the intake camshaft while rotating it
guide u and remove the assembly from the engine. counter-clockwise. Walk the timing chain off of the
Inspect the guide for wear and replace if necessary. sprocket. Carefully remove the intake camshaft from
the engine.
4. Remove the remaining six bolts that retain the

camshaft carrier i and carefully lift the carrier off the 8. Remove the cam chain from the exhaust camshaft
camshafts. sprocket a and remove the exhaust camshaft from
the engine.
CAMSHAFT SPROCKET INSPECTION

NOTICE
Camshaft sprocket removal is not necessary unless the
replacement of the sprockets is required.
Inspect cam sprocket teeth q for wear or damage.

Replace timing chain and sprockets as a set if worn or
damaged.
NOTICE
The crankcase has a lower guide to prevent the chain
from falling off the crankshaft.
5. Attach a hook or other tool to the camshaft chain to

prevent it from dropping down into the engine.
6. Mark the intake o and exhaust a camshafts to
ensure proper assembly.
TORQUE
Camshaft Sprocket Bolt:
14 ft-lbs (19 N·m) Replace camshaft sprocket bolt if

CAMSHAFT INSPECTION EXHAUST CAMSHAFT DECOMPRESSION

Inspect all main journals and cam lobes as described MECHANISM
below and compare to specifications. Replace camshafts
or cylinder head if worn beyond service limit or if any NOTICE
surface is pitted or damaged. Removal of the decompression mechanism is not
1. Visually inspect each cam lobe for wear or damage. necessary unless replacement is required.
2. Measure the height of each cam lobe from the base 1. Thoroughly clean and inspect the decompression
circle to highest point on the lobe using a mechanism q located on the exhaust camshaft.
micrometer. Compare to specification.
2. Replace the decompression assembly if any
excessive wear or binding is evident. 3
NOTICE
Replace camshafts if damaged or if any part is worn 3. Be sure the decompression mechanism functions
past the service limit. smoothly and easily returns under spring pressure to
the resting position against gravity.
MEASUREMENT
Camshaft Lobe Height:
Intake: 1.5704" ± 0.0038" (39.89 ± 0.097 mm)
Exhaust: 1.5405" ± 0.0038" (39.13 ± 0.097 mm)

CAM CHAIN AND GUIDE SERVICE CYLINDER HEAD REMOVAL

NOTICE NOTICE
The crankcase has a removable lower cam chain drive The cylinder head can be serviced with the engine
guide that prevents the chain from disengaging the installed in the chassis.
crankshaft during engine service. Do not rotate head assembly up side-down until the
The cam chain, cam chain guides and cam chain valve tappets have been removed.
tensioner can be replaced with the engine installed in
the vehicle. 1. Remove and discard the two outer M6 bolts q that
retain the cylinder head w and the cylinder.
1. If not already performed, remove the valve cover,
stator cover, flywheel, cam chain tensioner, cam 2. Loosen the four cylinder head bolts e evenly 1/8
carrier and camshafts as outlined in this chapter. turn (60 degrees) at a time until all are loose.
2. Remove the two fasteners q that secure the cam 3. Remove and discard the cylinder head bolts e.
chain guides w to the crankcase. Replace with new upon assembly.
3. Remove the fasteners e that secure the lower cam 4. Tap cylinder head lightly with a soft faced hammer
chain guide r to the crankcase. until loose. Tap only in reinforced areas or on thick
parts of the cylinder head casting.
4. Inspect the cam chain guides and replace if
excessive wear is evident. 5. Remove the cylinder head w and head gasket r.
5. Upon installation, torque all fasteners to specification

and reassemble engine and vehicle as outlined in
this chapter.
TORQUE
Lower Cam Chain Guide Fasteners:
9 ft-lbs (12 Nm)
Upper Cam Chain Guide Fasteners:

7 ft-lbs (10 Nm)

CYLINDER HEAD DISASSEMBLY 3. Push down on the spring and remove the split
keepers q.
CAUTION
Wear eye protection during cylinder head disassembly
and reassembly or when working with the valve springs.
NOTICE
purposes. It is important to install cylinder head
components back in the same location. Mark each
3
component or place them in an organized rack as you
remove them.
1. Remove the valve tappet q from the cylinder head.
4. Slowly release valve spring pressure and remove the

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

keeping it in order for reassembly in the same valve
guide.
2. Compress the valve spring by hand using valve
spring compressor adapter. 7. Repeat the previous steps to remove the remaining
valves.
8. Clean the combustion chamber and head gasket
surface.
Valve Spring Compressor Adapter

PV-43513-A

CYLINDER HEAD INSPECTION VALVE INSPECTION

Thoroughly clean cylinder head surface to remove all 1. Remove all carbon from valves with a soft wire wheel
traces of gasket material and carbon. or brush.
2. Check valve face for excessive runout, pitting, and
IMPORTANT burnt spots.
Use care not to damage gasket sealing surface. All 3. To check for bent valve stems, mount valve in “V”
gasket surfaces must be clean, dry and free of any oil blocks and measure with a dial indicator.
or grease upon assembly. Clean sealing surfaces with
rubbing alcohol or electrical contact cleaner. Do not
touch sealing surfaces of the new head gasket.
CYLINDER HEAD WARP INSPECTION

1. Lay a straight edge q across the surface of the
cylinder head at several different points and measure
warp by inserting a feeler gauge between the straight
edge and the cylinder head surface. If warp exceeds
the service limit, replace the cylinder head.
4. Check the end of the valve stem for flaring, pitting,

wear or damage.
MEASUREMENT
Cylinder Head Warp Limit:
.0024" (0.06 mm)
5. Inspect split keeper groove for wear or flaring in the

keeper seat area.
NOTICE
The valves can be re-faced or end ground, if necessary.
They must be replaced if extensively worn, burnt, bent
or damaged.

6. Measure diameter of valve stem with a micrometer in COMBUSTION CHAMBER CLEANING

three places, then rotate 90° and measure again
(take six measurements total). Compare to WARNING
specifications. Wear eye protection during combustion chamber
cleaning.
1. Clean all accumulated carbon deposits from

combustion chambers and valve seat area q.
MEASUREMENT
Valve Stem Diameter:
Intake: 0.2155" - 0.2161" (5.475 - 5.490 mm)
Exhaust: 0.2147" - 0.2153" (5.455 - 5.470 mm)
7. Measure valve guide inside diameter at the top

middle and end of the guide using a small hole
gauge and a micrometer. Measure in two directions. NOTICE
Polaris Premium Carbon Clean can be used to help
remove carbon deposits.
Do not use a metal scraper, a coarse wire brush or
abrasive cleaners to clean the cylinder head. Damage
may result.
2. Visually inspect cylinder head gasket surface and

combustion chamber for cracks or damage. Pay
close attention to the areas around spark plug and
valve seats.
MEASUREMENT
Valve Guide I.D.:
0.2165" - 0.2171" (5.500 - 5.515 mm)
8. Be sure to measure each guide and valve

combination individually.
NOTICE
The valve guides cannot be replaced.

VALVE SEAT RECONDITIONING Renewing Valve Seats

Valve seat reconditioning should be performed by a 1. Install pilot into valve guide.
technician proficient in cylinder head reconditioning
techniques. Reconditioning techniques vary, so follow 2. Apply cutting oil to valve seat and cutter.
the instructions provided by the valve reconditioning 3. Place 46° cutter on the pilot and make a light cut.
equipment manufacturer. Do not grind seats more than
necessary to provide proper seat surface, width, and 4. Inspect the cut area of the seat:
contact point on valve face. * If the contact area is less than 75% of the
circumference of the seat, rotate the pilot 180° and
WARNING make another light cut.
Wear eye protection or a face shield during cylinder * If the cutter now contacts the uncut portion of the
head disassembly and reassembly. seat, check the pilot. Look for burrs, nicks, or runout.
If the pilot is bent it must be replaced.
Valve Seat Inspection * If the contact area of the cutter is in the same place,
Inspect valve seat in cylinder head for pitting, burnt the valve guide is distorted from improper
spots, roughness, and uneven surface. If any of the installation.
above conditions exist, the valve seat must be * If the contact area of the initial cut is greater than
reconditioned. If the valve seat is cracked the cylinder 75%, continue to cut the seat until all pits are
head must be replaced. removed and a new seat surface is evident.
Valve seat width and point of contact on the valve face is
NOTICE
very important for proper sealing. The valve must contact
the valve seat over the entire circumference of the seat, Remove only the amount of material necessary to
and the seat must be the proper width all the way repair the seat surface.
around. If the seat is uneven, compression leakage will
result. If the seat is too wide, seat pressure is reduced, 5. To check the contact area of the seat on the valve
causing carbon accumulation and possible compression face, apply a thin coating of Prussian Blue paste to
loss. If the seat is too narrow, heat transfer from valve to the valve seat. If using an interference angle (46°)
seat is reduced. The valve may overheat and warp, apply black permanent marker to the entire valve
resulting in burnt valves. face q.
6. Insert valve into guide and tap valve lightly into place
a few times.

7. Remove valve and check where the Prussian Blue Intake Seat Cutter Diameter:
indicates seat contact on the valve face. The valve 1.567 in. (39.80 mm)
seat should contact the middle of the valve face or
slightly above, and must be the proper width.
NOTICE
When using an interference angle, the seat contact
point on the valve will be very narrow, and is a normal
condition. Look for an even and continuous contact
point all the way around the valve face e.
Exhaust Seat Cutter Diameter:

1.364 in. (34.65 mm)
MEASUREMENT
Valve Seat Width:
Intake:
Std.: .0393" (1.00 mm)
Exhaust:
Std.: .0590” (1.50 mm)
* If the indicated seat contact is at the top edge of the

valve face and contacts the margin area w it is too
high on the valve face. Use the 30° cutter to lower
the valve seat.
* If too low, use the 60° cutter to raise the seat. When 8. Clean all filings from the area with hot soapy water.
contact area is centered on the valve face, measure Rinse and dry with compressed air.
seat width.
* If the seat is too wide or uneven, use both top and 9. Lubricate valve guides with clean engine oil and
bottom cutters to narrow the seat. apply oil or water based lapping compound to the
* If the seat is too narrow, widen using the 45° cutter face of the valve.
and re-check contact point on the valve face and NOTICE
seat width after each cut.
Lapping is not required if an interference angle
reconditioning method is used.
10. Insert the valve into its respective guide and lap
using a lapping tool or a section of fuel line
connected to the valve stem.

11. Rotate the valve rapidly back and forth until the cut CYLINDER INSPECTION
sounds smooth. Lift the valve slightly off of the seat, 1. Remove all gasket material from the cylinder sealing
rotate 1/4 turn, and repeat the lapping process. Do surfaces.
this four to five times until the valve is fully seated,
2. Inspect the top of the cylinder for warpage using a
and repeat process for the other valves.
straight edge and feeler gauge.
12. Thoroughly clean cylinder head and valves.
CYLINDER REMOVAL
1. Remove and discard the head gasket.
2. Position the cam chain and guides vertically.
3. Tap cylinder lightly with a plastic hammer in the
reinforced areas only until loose.
4. Rock cylinder forward and backward and lift it from
the crankcase, supporting piston and connecting rod.
5. Remove the cylinder from the engine.
Cylinder Warpage:
.00098” (.025 mm)
3. Inspect cylinder for wear, scratches, or damage.

4. Inspect cylinder for taper and out of round with a
telescoping gauge or a dial bore gauge. Measure in
two different directions, front to back and side to
side, on three different levels (1/2" down from top, in
the middle, and 1/2” up from bottom).
6. Remove and discard cylinder base gasket.

5. Record measurements taken in Step 4. If cylinder is 6. Remove the oil control ring expander.
tapered, or out of round beyond .001, cylinder must
be re-bored oversize, or replaced.
Cylinder Taper Limit: PISTON-TO-CYLINDER CLEARANCE
.001″ Max. (0.025 mm) 1. Measure the outside diameter of the piston 12 mm
from the skirt and at a right angle to the direction of
Cylinder Out of Round Limit:
the piston pin q.
.001″ Max. (.025 mm)
Standard Bore Size:

3.8976 +/- 0.0003″ (99.0 +/- 0.008 mm) 3
PISTON REMOVAL
1. Ensure the piston arrow points toward the exhaust
side of the engine.
2. Remove piston circlip and push piston pin out of
piston. If necessary, heat the crown of the piston
slightly with a heat gun.
IMPORTANT 2. Subtract this measurement from the maximum
Do not apply heat to the piston rings, they may lose cylinder size measurement from cylinder inspection.
radial tension.
Piston to Cylinder Clearance:
.00177 - .002925″ (.045 - .075 mm)
3. Remove top ring. Piston O.D.:
3.8957 - 3.8968″ (98.953 - 98.980 mm)
IMPORTANT
Using a piston ring pliers, carefully expand ring and lift it
off the piston. Do not expand the ring more than the
amount necessary to remove it from the piston.
By hand, use both of your thumbs to spread the ring

open and push up on the opposite side.
4. Repeat steps for the second ring.

5. Remove oil control ring top rail first, then remove the
bottom rail.

PISTON / ROD INSPECTION 3. Measure connecting rod small end ID. Inspect
1. Measure piston pin bore inside diameter I.D. bearing surface for damage.
Piston Pin Bore: Piston Pin Degree of Fit:

Std.: 0.8662 - 0.8665″ (22.004 - 22.010 mm) Pin should be a push-fit by hand with piston at room
Service Limit: 0.8651″ (21.975 mm) temperature or warmed slightly
Connecting Rod Small End ID:
2. Measure piston pin O. D. Replace piston and/or Std.: 0.8665 - 0.8670″ (22.010 - 22.023 mm)
piston pin if out of tolerance.
4. Measure piston ring to groove clearance by placing
the ring in the ring land and measuring with a
thickness gauge. Replace piston and rings if ring-to-
groove clearance exceeds service limits.
Piston Pin O.D.:

Std.: 0.8659 - 0.8661″ (21.995 - 22.0 mm)
Piston Ring-to-Groove Clearance

Top Ring:
Std.: 0.0011 - 0.0037" (0.030 - 0.095 mm)
Second Ring:
Std.: 0.0007 - 0.0029" (.020 - 0.076 mm)

PISTON RING INSTALLED GAP

1. Place each piston ring inside cylinder. Use a piston
to push the ring squarely into place 1” (25.4 mm)
down from the cylinder head gasket surface.
2. Measure installed gap with a feeler gauge at location
q.
Piston Ring Installed Gap

Top Ring:
Std: 0.0059 - 0.0122" (0.15 - 0.31 mm)
Limit: 0.0137" (0.35 mm)
Second Ring:
Std: 0.0094 - 0.0196" (0.24 - 0.50 mm)
Limit: 0.022" (0.56 mm)
Oil Ring Rails:
Std: 0.0098” - 0.0401" (0.25 - 1.02 mm)
Limit: 0.0480" (1.22 mm)
NOTICE
Always check piston ring installed gap after re-boring a
cylinder or when installing new rings.

ENGINE ASSEMBLY - TOP END 3. Install upper ring with end gap positioned as shown.
PISTON RING INSTALLATION
NOTICE
Apply clean engine oil to all ring surfaces and ring lands
upon installation. Always check piston ring installed gap
before rings are installed on piston (see Piston Ring
Installed Gap page 3.105). Clean accumulated carbon
from piston ring grooves and oil ring lube holes if piston
has been in service.
REF DESCRIPTION
y Upper Ring Gap Position
u Lower Ring Gap Position

Spring Expander Gap Position
i (PTO Side)
4. Install second ring with marking facing top of piston.

Rotate ring to position the end gap toward intake
side of piston as shown below.
REF DESCRIPTION
5. Install top ring with mark facing top of piston. Rotate
q Top Ring (Marking up) ring to position the end gap toward exhaust side of
piston as shown below.
w Second Ring (Marking up)
e Upper Rail
r Spring Expander
t Lower Rail
1. Place oil control ring expander in oil ring groove.

Rotate expander in groove until butt ends are on
PTO side of piston (see illustration 1).
NOTICE
Ends must butt squarely together and must not overlap.
2. Install lower ring with end gap positioned as shown in

step 3.
REF DEFINITION
o Second Ring Gap Position
a Top Ring Gap Position
6. Be sure top and second rings rotate freely in their

grooves and do not bind when compressed by hand.

PISTON / CONNECTING ROD ASSEMBLY 4. Place piston q on connecting rod w. Push piston pin
1. Lubricate connecting rod small end, piston pin bore e through rod and piston until it seats against the
and piston pin with engine oil. installed circlip.
CAUTION NOTICE
Do not re-use circlips. Circlips become deformed during Do not tap on pin or cause any sideways force to
the removal process. connecting rod. Warm piston crown with a heat gun if
Do not compress the new clip more than necessary to pin cannot be installed by hand, or use a piston pin
prevent loss of radial tension. Severe engine damage installation tool.
may result if circlips are re-used or deformed during
installation.
CAUTION 3
2. Install a new circlip on one side of piston with gap at DO NOT apply heat to piston rings or a loss of
the top (12:00 position) or bottom (6:00 position). radial tension could result.
NOTICE
Never re-use a piston pin circlip.
3. When installing the piston, be sure the piston

marking “EX” is positioned towards the exhaust side
of the engine.
5. Install the remaining circlip r with gap at the top

(12:00 position) or bottom (6:00 position). Push the
piston pin in both directions to make sure the clips
are properly seated in the groove.

CYLINDER INSTALLATION 9. Hold the cylinder in place and rotate the engine and
1. Clean base gasket sealing surface on cylinder and position the piston at TDC.
crankcase to remove all oil, grease, or old sealant.
NOTICE
2. Install a new base gasket.
If cam chain and flywheel are installed (top end work
NOTICE only is being performed) hold cam chain tight while
rotating the engine to avoid damage to the chain, drive
Base gasket and surfaces must be DRY and oil free. sprocket teeth, or tensioner blade.
Use care upon assembly to keep oil away.
3. Slide a commercially available Piston Support Block

under piston skirt to support piston during cylinder
installation. CYLINDER HEAD IDENTIFICATION
The first image displays the cylinder head q for 2015
and earlier models. The second image displays the
cylinder head w for 2016 and later models.
4. Apply clean engine oil to cylinder bore and bottom

tapered portion of cylinder sleeve.
5. Verify all ring end gaps are correctly located on
piston. Place cam chain and guides in alignment with
chain room.
6. Carefully compress rings with fingers or
commercially available spring compression tool and
install cylinder with a slight front to back rocking
motion until all rings are captive in cylinder and past
the taper of the sleeve.
7. Remove support block and ring compressor.
8. Push cylinder downward until fully seated on base
gasket.

CRANKCASE IDENTIFICATION
The first image displays (1) crankcase dowel q for 2015
and earlier models. The second image displays (2)
crankcase dowels w for 2016 and later models.

CYLINDER HEAD INSTALLATION - BLACK 5. Install and finger tighten the four NEW cylinder head
BOLTS bolts u evenly.
NOTICE 6. Install and finger tighten the two NEW outer M6 bolts
Head gasket and surfaces must be DRY and oil free. i evenly.
Use care during assembly to keep oil and finger prints 7. Torque the NEW cylinder head bolts in sequence to
off of gasket. specification.
1. Verify the cylinder head bolts are BLACK. If TORQUE

uncertain, measured bolts in the reduced diameter Cylinder Head Bolts:
portion of the bolt shank (between A and B); verify
Torque in sequence for all steps
the are the correct color and diameter before
proceeding. Step 1: 21 ft-lbs (28 Nm)
MEASUREMENT Step 2: 26 ft-lb (35 Nm)
Diameter Between A - B: Step 3: Additional 135°
q Black: 9.00 +/- .1 mm Torque The Outer M6 Head Bolts 89 ± 9 in-lbs
w Silver: 8.20 +/- .1 mm (10 ± 1 Nm)
IMPORTANT
Torquing cylinder head bolts using the incorrect
procedure may lead to engine component damage.

cleaning thoroughly to remove all residue. The new
from oil or grease.
NOTICE
3. Guide cam chain r through a new head gasket t

and install the gasket on the cylinder, locating it on
the alignment pins.
4. Carefully set the cylinder head y in place on
alignment pins.
NOTICE
Install NEW cylinder head bolts.

CYLINDER HEAD INSTALLATION - SILVER 3. Guide cam chain r through a new head gasket t
BOLTS and install the gasket on the cylinder, locating it on
the alignment pins.
NOTICE
Head gasket and surfaces must be DRY and oil free.
Use care during assembly to keep oil and finger prints
off of gasket.
1. Verify the cylinder head bolts are SILVER. If

uncertain, measured bolts in the reduced diameter
portion of the Cylinder head bolt shank (between A 3
and B); verify the are the correct color and diameter
before proceeding.
MEASUREMENT
Diameter Between A - B:
q Black: 9.00 +/- .1 mm
w Silver: 8.20 +/- .1 mm 4. Carefully set the cylinder head y in place on
alignment pins.
5. Install and finger tighten the four NEW cylinder head
bolts u evenly.
6. Install and finger tighten the two NEW outer M6 bolts
i evenly.
7. Torque the NEW cylinder head bolts in sequence to
specification.
TORQUE
Cylinder Head Bolts:
Apply light coat of engine oil to bolt threads
and under bolt head
Torque in Sequence for all steps
IMPORTANT
Torquing cylinder head bolts using the incorrect
procedure may lead to engine component damage. Step 2: 30 ft-lbs (40 Nm)
unseated
cleaning thoroughly to remove all residue. The new Step 4: 15 ft-lbs (20 Nm)
from oil or grease. Step 5: 26 ft-lbs (35 Nm)
NOTICE
Torque The Outer M6 Head Bolts 89 ± 9 in-lbs
(10 ± 1 Nm)

VALVE CLEARANCE CHECK /

ADJUSTMENT
NOTICE
Always inspect valve clearance prior to camshaft
installation or final engine assembly.
1. Install the cam chain guides and cam chain before

camshaft installation (if removed) as outlined in this
chapter.
2. Reference the camshaft intake q and exhaust w
markings made during disassembly. If installing new
camshafts or if camshafts were not marked, you can
reference the part number stamped on the end of the
shafts.
VALVE SEALING TEST

1. Clean and dry the combustion chamber area q.
2. Pour a small amount of clean solvent into each
intake port w and check for leakage around the
valves. The valve seats should hold fluid with no
seepage.
3. Repeat for exhaust valves by pouring fluid into each
exhaust port e.
3. Lubricate the camshaft bearing journal surfaces with

Polaris PS-4 engine oil prior to installation.
4. Carefully install the camshafts into the cylinder head.
The camshaft lobes should face out.

camshafts.

6. Install the upper cam chain guide and the eight bolts 8. Install the Cylinder Holding and Camshaft Timing
that retain the camshaft carrier. Plate into the end of camshafts as shown below. The
thermostat housing must be removed to install the
timing plate PU-50563.
7. Torque the camshaft carrier bolts in sequence to

specification.
Cylinder Holding / Camshaft Timing Plate:
PU-50563

thickness (feeler) gauge. Record the measurement if
clearance is out of specification.
MEASUREMENT
Intake Valve Clearance (cold):
.006 ± .002″ (0.150 ± .050 mm)
MEASUREMENT
Exhaust Valve Clearance (cold):
.008 ± .002″ (0.200 ± .050 mm)
TORQUE
Camshaft Carrier Bolts: 10. If any of the valve clearance measurements are out
7 ft-lbs (10 N·m) of specification, remove the camshaft carrier and
camshafts and proceed with this procedure.
NOTICE
If all valve clearance measurements are within

11. Remove the valve tappet q from a valve that was

out of specification.
NOTICE
purposes. Mark each component or place them in an
organized rack as you remove them.
12. Record the 3-digit number engraved on top of the

tappet.
13. Reference the valve clearance measurement
recorded for that valve, along with the 3-digit tappet
number.
14. Refer to the appropriate tappet selection matrix
(Intake or Exhaust) on the following pages and select
the proper tappet.
15. Install the new tappet.
NOTICE
Lubricate the outer portion of the valve bucket upon
installation.
16. Repeat steps until all necessary valves have been

adjusted.
17. Reinstall the camshafts and camshaft carriers and
tighten the bolts evenly to specification.
TORQUE
7 ft-lbs (10 N·m)
18. Measure and confirm that valve clearance is now

within specification for each valve.
19. If valve clearance is not within specification, repeat
this procedure.
20. If all valve clearance measurements are now within

VALVE LASH - TAPPET SELECTION

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

CAMSHAFT INSTALLATION / TIMING 6. Carefully install the intake cam at an angle to allow
for cam chain installation. Roll the cam shaft into its
NOTICE bearing pockets and verify that the timing marks are
If any valve train components were replaced, refer to in alignment as shown below.
“Valve Clearance Adjustment” page 3.112 procedure
prior to “Camshaft Installation / Timing”.
1. Rotate the engine and position the piston at TDC.

2. Reference the intake q and exhaust w markings
made during disassembly.
3. Lubricate all camshaft lobes and bearing journal

surfaces with Polaris PS-4 engine oil prior to
installation.
4. Place the exhaust cam into the cylinder head and
align the timing marks as shown below.
NOTICE
gasket surface and the exhaust cam sprocket should
have “E” marks aligned with gasket surface.

camshafts.
5. Wrap the cam chain around the exhaust cam

sprocket and hold the exhaust cam in its current
position.

8. Install the upper cam chain guide and the eight bolts 10. Verify cam timing is correct and the piston is a TDC.
that retain the camshaft carrier. Tighten the bolts
evenly until snug. Do not torque at this time. NOTICE
For correct sprocket orientation, insure the “I” for intake
on cam and the “E” for exhaust on cam are positioned
as shown. View from mag side.
9. Install the Cylinder Holding and Camshaft Timing

Plate into the end of camshafts as shown.
11. If timing marks are not aligned:

• Remove the Camshaft Timing Plate from the end of
the camshafts.
• Remove the cam carrier bolt and cam carrier.
• Correct the camshaft timing as needed.
• Reinstall the cam carrier.
• Re-check cam timing.
12. Remove the Cylinder Holding & Camshaft Timing
Plate from the end of the camshafts.
Cylinder Holding / Camshaft Timing Plate:
Cylinder Holding / Camshaft Timing Plate: PU-50563
PU-50563
13. If needed, install the camshaft carrier and bolts.

14. Torque the camshaft carrier bolts in sequence to 16. Install the hydraulic cam chain tensioner i into the
specification. cylinder and torque to specification.
TORQUE TORQUE
Camshaft Carrier Bolts: Cam Chain Tensioner:
7 ft-lbs (10 N·m) 30 ft-lb (40 Nm)
15. Insure the new sealing washer u is in place. 17. Rotate crankshaft through two revolutions and verify
camshaft timing is correct.
18. Check the valve lash after tensioner installation and
two engine revolutions.
NOTICE
Verify the valve lash after rotating the engine.

CAMSHAFT TIMING - QUICK REFERENCE

Rotate engine so the cam lobes are facing outward and Intake cam sprocket should have “I” marks aligned with
the Cylinder Holding and Camshaft Holding Plate can be gasket surface and the exhaust cam sprocket should
installed into the slots of the camshafts as shown. have “E” marks aligned with gasket surface.
Stator Cover/Flywheel Removed. Flywheel Key faces Stator Cover/Flywheel Installed. “V” marked on the
down and insert a 1/4” drive socket extension through flywheel is aligned with the CPS mounting hole.
the crankcase and into the crankshaft locating hole q.

VALVE COVER INSTALLATION

1. Install the spark plug q and torque to specification.
TORQUE
Spark Plug:
9 ft-lbs (12 N·m) Do Not Apply Anti-Seize
2. Prepare valve cover sealing surfaces by cleaning

thoroughly to remove all residue.
3. Apply a small amount of crankcase sealant to the
cylinder head half-moon cutouts t as shown.
Crankcase Sealant: 2871557
4. Install a new valve cover seal w.

5. Install the three valve cover shoulder bolts e and
new isolators r Around each T40 fastener.
6. Torque valve cover bolts to specification.

TORQUE
Valve Cover Bolts:
7 ft-lbs (10 N·m)

ENGINE DISASSEMBLY / INSPECTION - 6. Hold flywheel special service tool and remove
LOWER END flywheel nut and washer e. Discard the flywheel nut
and replace for assembly.
CRANKCASE DISASSEMBLY
Flywheel special service tool:
NOTICE PU-51220
The engine top end, starter motor, stator cover, starter
drive, flywheel, stator, cam chain, oil pump and NOTICE
sprockets can be serviced with the engine installed in
the vehicle. The flywheel nut has standard rotation (right hand)
threads.
3
7. Back the center screw of flywheel puller completely
STATOR COVER REMOVAL out and screw puller onto flywheel completely.
1. Remove the engine to transmission coupler through
bolts (See “Engine to Transmission Coupler
Service”).
CAUTION
result.
2. Disconnect stator harness connector.

3. Disconnect CPS connector.
4. Remove stator cover fasteners.
5. Remove starter drive gear w and shaft q. Inspect Flywheel puller:
gear teeth for damage. Inspect fit of shaft inside gear PA-49316
and replace gear assembly if clearance is excessive.
Inspect shaft and shaft bearing surfaces in case and 8. Tighten center bolt of the flywheel puller and remove
stator housing for wear. flywheel.
STARTER ONE-WAY CLUTCH INSPECTION

1. Remove flywheel as outlined in this chapter.
2. Place flywheel on work bench. Grasp gear and rotate
clockwise. It should turn smoothly without binding.
3. Rotate gear counterclockwise. The gear should
immediately lock in position and not slip.

4. Inspect inside of hub q for wear, galling, or uneven 7. Remove the three, one-way clutch retaining bolts.
surface.
8. Remove clutch and inspect both sides of drive rollers

5. Inspect crankshaft bearing surface for abnormal
wear.
w and roller contact surface e inside hub for wear,
damage, or uneven surface.
6. Remove starter gear from the flywheel assembly.

9. Inspect drive surface of starter gear r and bearing
surface t for wear, damage, or uneven surface. If
any starter clutch component is worn or damaged,
replace clutch, clutch hub, and starter gear.

STATOR REMOVAL
NOTICE
Test stator wire continuity before removing it from the
housing.
1. Remove the stator cover.
CAUTION
3
result.
CAUTION
3. Remove the three bolts e that secure the stator q

to the stator cover w.
4. Remove the two bolts that secure the stator wire

routing bracket r to the stator cover.
5. Remove the stator q from the stator cover.

OIL PUMP REMOVAL
REF DESCRPITION NOTES

q Screw
w Cover, Oil Pump
e Washer
r Pin, Solid
t Shaft, Oil Pump
y ASM., Gerotor

1. Remove the stator cover (Refer to “Stator Cover 4. Remove the upper oil pump sprocket spacer.
Removal” page 3.121)
2. Remove the two oil pump sprocket bolts and
washers. Discard the bolts and replace with new for
assembly. Remove the sprockets and chain from the
engine.
5. Remove the three bolts securing the oil pump cover

to the crankcase.
6. Grasp the oil pump shaft and pull it outward to
remove the shaft, oil pump cover and inner oil pump
geroter. This will prevent the oil pump drive pin from
3. Inspect the oil pump chain for worn or missing rollers falling out and into the crankcase.
or damage. Chain should be replaced as a set with
sprockets if sprocket teeth are worn.
NOTICE
The gerotor set has two orientation dots that must be
NOTICE installed inward upon assembly
The larger oil pump sprocket s mounts to the balance (Figure 1 on the next page).
shaft extension, the smaller oil pump sprocket d
mounts to the oil pump shaft. 7. Remove the center geroter, pin and shaft from the oil
pump cover.
NOTICE
There is a spacer f in between the inner oil pump
geroter and the oil pump cover.
8. Remove the oil pump geroter that is in the engine

case (if needed).
9. Clean the geroters to remove oil.

10. Inspect surfaces of pump cavity in crankcase and 6. Install the oil pump cover r onto the shaft assembly.
surface of pump cover for scoring or wear.
7. Grasp the complete oil pump assembly by the drive

11. Inspect gerotor for scoring or other damage. Replace shaft and install the assembly into the crankcase.
parts as a set if damaged.
8. Install the three oil pump cover bolts and torque to
specification.
9. Torque cover bolts to specification.
TORQUE
Oil Pump Cover Bolts:
9 ft-lbs (12 Nm)
FLUID CAPACITY
Oil Capacity
Oil Filter Wrench

PU-50105 or 2.5” (64 mm)
Oil Type
OIL PUMP ASSEMBLY Polaris PS-4 Synthetic Engine Oil
1. Clean and dry all parts thoroughly. Apply clean
engine oil to all parts. Do not use gasket sealer on Oil Pressure
the pump cover mating surfaces. Minimum Specification
2. Align the gerotor according to the orientation dots. (using Polaris PS-4 at operating temperature)
3. Place the drive pin q through the oil pump drive
shaft. 40 PSI @ 7000 RPM (Minimum)
4. Slide the gerotor w onto the drive shaft and lock

them into position on the drive pin.
5. Install the washer e onto the drive shaft.

CRANKCASE BREATHER SERVICE CRANKCASE SEPARATION

NOTICE NOTICE
The crankcase breather is serviceable with the engine Before the crankcase can be separated, be sure the
assembled and installed in the vehicle chassis. entire top end and oil pump assembly are removed
from the engine as outlined in this chapter.
1. Remove the crankcase vent tube (if not already
performed). 1. Rotate the engine on the engine stand so the
2. Remove the two fasteners securing the engine magneto side is facing upward.
breather cover to the engine. 2. Remove the oil filter and the three fasteners w (20ft-
3. Remove the breather cover gasket and replace if lbs (28Nm) apply loctite 272) that secure oil filter
adapter q to the crankcase. Discard O-rings and
3
damaged.
through clean the adaptor for reassembly.
4. For reassembly, thoroughly clean the crankcase and
breather cover mating surfaces. Install a new gasket
and torque the two fasteners to specification.
TORQUE
Crankcase Breather Cover Bolts:
9 ft-lbs (12 Nm)
3. Remove and discard the fifteen flange bolts from

magneto side crankcase evenly in a criss-cross
pattern.

4. Separate crankcase by tapping with a soft faced 2. Pull upward on the balance shaft and remove it from
hammer in reinforced areas and lift MAG crankcase the crankcase.
off PTO case.
3. Inspect drive gear for broken or damaged teeth.
CAUTION 4. Inspect bearing surfaces for scoring or signs of wear.
Never strike the engine mounts with a hammer.
BALANCE SHAFT REMOVAL / INSPECTION

1. Rotate crankshaft to align the timing marks as shown
below.
5. Inspect / replace the balance shaft bearings in both

crankcase halves. See “Crankcase Bearing
Inspection / Removal” procedure in this chapter.
NOTICE
counterbalance shaft ball bearings must be inspected
visually and by feel. Look for signs of discoloration,
scoring or galling. Turn the inner race of each bearing.
The bearings should turn smoothly and quietly. The
outer race of each bearing should fit tightly in the
crankcase bore. The inner race should be firm with
minimal side to side movement and no detectable up
and down (radial) movement.

CRANKSHAFT REMOVAL CRANKSHAFT INSPECTION

1. Remove the engine from the engine stand and place
the assembly on a sturdy work bench. NOTICE
The connecting rod uses plain bearings. The
2. Install the crankshaft removal / installation tool on to
connecting rod bearings are not serviceable. If ANY
the PTO side crank case.
excessive wear or movement is present or if the rod
Crankshaft Removal / Installation Tool does not rotate on the crankshaft freely, the crankshaft
PU-50784 assembly must be replaced.
1. Use a feeler gauge to measure the connecting rod

• Install plate q over adapter w. big end side clearance q.
• Evenly attach the assembly onto the PTO side
3
crankcase using the four bolts as shown below.
• Thread the crankshaft removal screw e into w.
Connecting Rod Big End Side Clearance:

0.00590-.01771″ (.15 - .45mm)
2. Measure the connecting rod small end I.D. w.
3. With the help of an assistant holding the crankshaft,

slowly tighten the screw e until the crankcase is Small End I.D. Standard:
completely separated from the crankshaft. 0.8665 - 0.8670″ (22.010 - 22.023 mm)
4. Remove all special tools from the crankcase. Service Limit: 0.08682″ (22.053 mm)

3. Place the crankshaft in a truing stand or V-blocks 4. Support the crankcase and drive, press, or extract
and measure the runout where indicated below with the three bearings with a blind bearing remover.
a dial indicator.
Maximum Runout:
Mag side (3) - 0.00118″ (0.03 mm)
PTO side (4) - 0.00590″ (0.15 mm)
PTO SIDE CRANKCASE BEARING SERVICE

Bearing Removal
NOTICE
Look for signs of discoloration, scoring or galling. Turn
the inner race of each bearing. The bearings should REF DESCRIPTION
turn smoothly and quietly. The outer race of each
bearing should fit tightly in the crankcase. The inner Bearing Retainer Bolt
race should be firm with minimal side to side movement
q 8 ft-lbs (11 Nm) apply loctite 272
and no detectable up and down movement.
w Bearing Retainer
must not be re-used! Bearings:
Apply Loctite® 641 to the inner
1. Remove and discard the PTO side crankshaft seal. e race of each of the crank
Replace with new for assembly. bearings.
2. If not already performed, remove the screws that Bearing Spacer
secure the bearing retainer to the case. r
3. Remove the retaining ring. t Retaining Ring

Installation MAG SIDE CRANKCASE BEARING

SERVICE
NOTICE Bearing Removal
To ease bearing installation, warm the crankcase
1. Support the crankcase and drive, press, or extract
evenly with a heat gun or place in an oven and heat to
the balance shaft bearing q with a blind bearing
220-250° F. Place bearings in clean plastic wrap and
remover.
set in a freezer for 10-20 minutes.
NOTICE
5. Clean all bearings e and inspect for excessive wear.
The MAG side crankshaft plain bearing w is not
NOTICE serviceable. Crankcase replacement is required if the
bearing is damaged or has excessive wear. The 3
crankshaft is reusable if it meets specifications and
crank bearings. MAG side bearing surface is not groved, pitted,
damaged or excessively worn.
6. Lubricate all bearings e with clean engine oil.
8. Install the retaining ring t for the crankshaft
bearings.
9. Fully seat the new outer PTO crankshaft bearing
until bottomed against the retaining ring.
10. Install the bearing spacer r.
11. Press in the new inner PTO bearing until it is
bottomed against the bearing spacer.
12. Apply Loctite® 272™ to the two bearing retainer
bolts q.
13. Install the bearing retainer w and torque the fastener
to specification.
IMPORTANT
TORQUE
Bearing Retainer Fastener: the bearings must be inspected. Look for discoloration,
8 ft-lbs (11 Nm)Apply Loctite® 272™ scoring or galling. The inner race of each bearing
should turn smoothly and quietly. The outer race of
each bearing should fit tightly in the crankcase. The
inner race should be firm with minimal side to side
movement and no detectable up and down movement.
must not be re-used!
Installation
2. Clean all bearing bores and inspect for excessive
wear.
3. Lubricate all bearing bores with clean engine oil.

OIL PICKUP ASSEMBLY INSPECTION CRANKCASE INSPECTION

The oil pickup assembly is located in the Mag side 1. Remove all traces of gasket sealer from the
crankcase q. crankcase mating surfaces. Inspect the surfaces
closely for nicks, burrs or damage.
2. Be sure alignment pins are in place where used.
3. Be sure oil passages are clean and free of any
cleaning solvent.
1. Pull and twist to remove the oil pickup assembly from

the crankcase.
2. Inspect the assembly for cracks and excessive wear.
3. Remove and discard the O-ring.
4. Thoroughly clean the pickup assembly
oil.
6. Press the pickup assembly into the crankcase until
fully seated.
OIL PRESSURE REGULATOR (BYPASS)

VALVE INSPECTION
The oil pressure regulator (bypass) valve is located in the
Mag side crankcase w.
1. Use a brass drift to press out the oil pressure valve
from the crankcase.
2. Replace the oil pressure valve if the inner plunger
binds, sticks or does not operate smoothly.
3. Remove and discard the o-ring.
4. Thoroughly clean the valve.
oil.
6. Press the oil pressure valve into the crankcase until
fully seated.

ENGINE ASSEMBLY - LOWER END 5. Install the crankshaft removal / installation tool on to
the PTO side crankcase.
CRANKCASE ASSEMBLY – PTO SIDE
1. Lubricate all crankcase bearings with engine oil. Crankshaft Removal / Installation Tool
Clean sealing surface to remove all oil sealant. PU-50784
NOTICE
• Install plate q over adapter w.
crank bearings. • Evenly attach the assembly q onto the PTO side
crankcase flange using the four bolts provided with
2. Place crankcase on a sturdy work bench. tool.
3. Carefully set the PTO crankcase onto the PTO side • Place the nut and large washer onto the crankshaft
3
of the crankshaft. installation screwe.
4. Align the connecting rod with the cylinder area of the • Insert the crankshaft installation screw through the
crankcase. threaded portion of the adaptor w.
• With the help of an assistant holding the crankshaft,
firmly hold the crankshaft installation screw with a
adaptor w.
6. With the help of an assistant, slowly tighten the nut

until the crankshaft is completely seated into the
crankcase bearings.

7. Remove the crankshaft removal / installation tool 10. Use the crankshaft removal / installation tool to
from the crankcase. properly drive the crankshaft seal into the crankcase.
8. Be sure crankshaft is fully seated and rotates Crankshaft Removal / Installation Tool
smoothly. PU-50784
• Center plate q over the crankshaft so it is resting on

the crankshaft seal.
• Center adaptor w over the crankshaft end.
• Place the nut and large washer onto the crankshaft
installation screw.
• Insert the crankshaft installation screw through the
threaded portion of the adaptor.
• Firmly hold the crankshaft installation screw with a
adaptor.
NOTICE
The crankshaft seal can be replaced with the engine
installed in the chassis. The engine does not have to be
removed and the crankcase does not have to be
separated to replace the crankshaft seal.
9. Lubricate a new crankshaft seal and slide it over the

PTO end of the crankshaft with numbers facing OUT.
Be sure seal lip does not fold back when moving
over the crankshaft flange.
11. Drive seal until flush with seal bore.
12. Turn PTO crankcase over and support with

crankshaft upright.

BALANCE SHAFT INSTALLATION / TIMING FINAL CRANKCASE ASSEMBLY

1. Position balance shaft in the crankcase. 1. Prepare lower crankcase by cleaning sealing
surface. Be sure the oil pickup and oil pressure valve
2. Rotate crankshaft to align the timing marks q as
are fully installed.
shown below.
2. Apply a thin film of Crankcase Sealant (PN 2871557)
3. Fully seat the balance shaft into the crankcase and evenly to a clean and oil-free crankcase mating
verify timing marks are correct.
surface as indicated below q. Be sure alignment
pins w are in place.
Crankcase Sealant:
PN 2871557
3
3. Carefully assemble MAG crankcase to PTO
crankcase immediately. Do not allow sealant to dry.
4. Tap crankcase evenly until fully seated with a soft

sided hammer.
5. Install the new crankcase bolts finger tight in MAG

side crankcase.
6. Tighten all bolts evenly until snug.

7. Torque the new crankcase bolts to in sequence to STARTER ONE-WAY CLUTCH

specification. INSTALLATION
1. Install one-way clutch in clutch hub with flange of
clutch q facing the flywheel.
TORQUE
Crankcase Bolts (In Sequence):
22 ft-lbs (30 Nm) NOTICE
The one-way clutch can be installed into the hub
8. Install the engine stand adapter onto the engine ears incorrectly. This will cause engine cranking issues.
as shown below.
2. Clean screw threads in flywheel to remove all oil or
grease.
3. Apply Loctite® 272™ on the one way clutch retaining
bolts threads w. Place hub on flywheel and install
bolts.
4. Torque screws to specification.
Engine Stand Adapter:

PU-50824-A

install it onto the engine stand adapter.
Sleeve adapter for a 2″ bore engine stand: TORQUE
PU-50625 One Way Clutch Retaining Bolts:
1st: 6 ft-lbs (8 Nm)2nd: 9 ft-lbs (12 Nm) Apply
Sleeve adapter for a 2.375″ bore engine stand: Loctite® 272™
PW-47054
10. Place engine onto the engine stand for top end
engine assembly as outlined in this chapter.
Engine Stand:
PU-50624-A

FLYWHEEL INSTALLATION 5. Fully install starter gear onto the crankshaft as

1. Clean the threads q, taper w and flat e of shown.
crankshaft to remove all oil or grease.
6. Align the flywheel keyway with flywheel key on the

2. Clean flywheel taper r with alcohol to remove all oil crankshaft.
or grease. 7. Thoroughly clean the crank taper with alcohol.
8. By hand, lightly press the flywheel inward while
rotating the starter gear counter clock-wise. Fully
install the flywheel until seated on the crankshaft
taper.
3. Apply a small amount of PS4 engine oil to the flat

area t on the MAG side crankshaft. DO NOT apply
engine oil to the crankshaft taper.
9. Install the flywheel washer.

10. Hold flywheel with commercially available strap
wrench.
4. Rotate crankshaft so the flywheel key y is facing

upward.

11. Torque new flywheel nut u to specification. STATOR / STATOR COVER INSTALLATION
1. Clean and degrease stator screws and threads in the
stator housing.
2. Clean mounting surfaces of stator q and housing w.
3. Apply crankcase sealant to edges of rubber stator
grommet.
4. Set the stator in housing and press wire grommet
into slot on housing.
5. Apply Loctite® 242™ to end (8-10 threads) of the
stator screws e and the wire routing bracket screws
r.
TORQUE
Flywheel Retaining Nut:
1st: 133 ft-lbs (180 Nm)2nd: Back off 180°3rd: Re-
torque to 133 ft-lbs (180 Nm)
NOTICE
The flywheel nut has standard rotation (right hand)
threads.
12. Install starter idler gear i and shaft o.

6. Install a new stator cover gasket.
7. Install the stator cover.
TORQUE
Stator Wire Retainer:
6 ft-lbs (8 Nm)
CAUTION
any time during the installation process or injury could
result.

8. Install the stator cover screws and torque in

TORQUE
Stator Mounting Bolts:
9 ft-lbs (12 Nm)

NOTES

ENGINE ELECTRICAL
CHAPTER 4
ENGINE ELECTRICAL
ELECTRONIC CONTROL UNIT (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
ECU OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
RPM LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
ECU SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
ECU REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
ELECTRONIC THROTTLE BODY (ETC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
ETC OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 4
ETC TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
ETC REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
ETC LEARN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
TEMPERATURE / MANIFOLD ABSOLUTE PRESSURE (T-MAP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
T-MAP OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
T-MAP SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
T-MAP SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
PEDAL POSITION SENSOR (PPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
PPS TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
PPS REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
CRANKSHAFT POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
CPS OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
CPS TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
CPS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
ENGINE COOLANT TEMPERATURE SENSOR (ETC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.10
ECT OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.10
ECT SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.10
ECT SENSOR REPLACEMENT - 570 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11

ENGINE ELECTRICAL
ELECTRONIC CONTROL UNIT (ECU)

ECU OVERVIEW 570 RPM Limit:
The ECU q is the central processing computer of the Max RPM Limit - Fuel / Spark Cutoff
entire EFI fuel/ignition management system. During 7500 rpm (All Gears)
operation, sensors continuously gather data which is
relayed through the wiring harness to input circuits within
the ECU. Signals to the ECU include: ignition (on/off),
crankshaft position and speed (RPM), throttle position, ECU SERVICE
engine coolant temperature, intake air temperature,
Never attempt to disassemble the ECU. It is sealed to
intake manifold absolute pressure and battery voltage.
prevent damage to internal components. Warranty is void
The ECU compares the input signals to the programmed
if the case is opened or tampered with in any way.
maps in its memory and determines the appropriate fuel
and spark requirements for the immediate operating All operating and control functions within the ECU are
conditions. The ECU then sends output signals to set the pre-set. No internal servicing or readjustment may be
injector duration and ignition timing. performed. If a problem is encountered, and you
determine the ECU to be faulty, contact the Polaris
Service Department for specific handling instructions. Do
not replace the ECU without factory authorization.
The relationship between the ECU and the throttle
position sensor (TPS) is very critical to proper system
operation. If the TPS is faulty, or the mounting position of
the TPS to the throttle body is altered, the TPS must be
adjusted.
For the purpose of troubleshooting, a known-good ECU
from another Polaris Vehicle of the same model number
and year may be used without system or engine
component damage.
During operation, the ECU continually performs a

diagnostic check of itself, each of the sensors, and
system performance. If a fault is detected, the ECU turns
on the “Check Engine” light in the speedometer and
stores the fault code in its fault memory. Depending on
the significance or severity of the fault, normal operation
may continue, or "Fail-Safe" operation (slowed speed,
richer running) may be initiated. A technician can
determine the cause of the “Check Engine” light by
referencing the “Instrument Cluster Trouble Code
Display” and “Diagnostic Trouble Code Table” or by using
Digital Wrench®. The ECU requires a minimum of 7.0
volts to operate. The memory in the ECU is operational
the moment the battery cables are connected.
RPM LIMIT
To prevent engine over-speed and possible failure, an
RPM limiting feature is programmed into the ECU. If the
maximum RPM limit is exceeded, the ECU suppresses
the injection signals, cutting off the fuel flow and retards
the ignition timing. This process repeats it self in rapid
succession, limiting operation to the preset maximum.
500 RPM Limit:

Max RPM Limit - Fuel / Spark Cutoff
7500 rpm (All Gears)

ENGINE ELECTRICAL
ECU REPLACEMENT 4. With the ignition turned off, disconnect the wire
Although the need for ECU replacement is unlikely, a harness from the ECU. Lift the connector locking
specific replacement procedure is required to ensure that lever and rotate it up until the connector is free from
all essential data contained within the original ECU is the ECU.
transferred to the replacement ECU. This procedure
requires the use of Digital Wrench Software which is only NOTICE
available at an authorized dealer. Therefore ECU Upon removing the ECU connector, you should hear a
replacement should only be done at an authorized “click” when the connector is fully open.
dealer.
NOTICE 5. To install, reverse the procedure and tighten any
fasteners to specification.
Refer to this procedure and carefully follow all
instructions provided in Digital Wrench . NOTICE
Upon installing the ECU connector, you should hear a
1. Carefully follow the ECU replacement instructions “click” when the connector is fully closed.
provided in Digital Wrench to ensure that all
essential data contained within the original ECU is
4
transferred to the replacement ECU.
2. Remove seat and ECU cover q.
3. Remove the 4 screws w retaining the ECU.

ENGINE ELECTRICAL
ELECTRONIC THROTTLE BODY (ETC)

ETC OVERVIEW ETC REPLACEMENT
NOTICE 1. Lift the rear cargo box.
DO NOT attempt to service the ETC. The ETC is a non- 2. Remove the airbox and breather box (if equipped).
serviceable component and can only be tested using
Digital Wrench®. If the ETC is faulty, the entire 3. Disconnect the wire harness from the ETC.
assembly must be replaced. 4. Remove the bolts retaining the ETC housing to intake
.
Mounted to the intake, the ETC acts as an electronically

5. Reverse these steps for installation. Torque the ETC
controlled throttle body. The ETC controls engine throttle
housing retaining bolts and intake boot clamp to
operation to provide the proper air/fuel ratio needed for
specification.
engine operation at all RPM ranges. The ETC controls
engine RPM based off input provided by the Throttle TORQUE
Control Sensor (TCS) and Electronic Control Unit (ECU).
ETC Housing Retaining Bolts:
7 ft-lbs (10 N·m)
ETC TEST Intake Boot Clamp:
35 in-lbs (4 N·m)
Never attempt to disassemble the ETC assembly.
Warranty is void if the end cover is opened or tampered
with in any way.
All operating and control functions within the ETC are
pre-set. No internal servicing or adjustments may be ETC LEARN PROCEDURE
performed. If a problem is encountered, and you IMPORTANT
determine the ETC to be faulty, contact the Polaris
Service Department for specific handling instructions. Do This procedure MUST be performed on the vehicle
not replace the ETC under warranty without factory whenever the ECU is replaced or reflashed or the
authorization. throttle body is replaced.
Use Digital Wrench® to perform all troubleshooting of

this component. Use a Volt Ohm meter to test the vehicle 1. After the reflash / ECU replacement / throttle body
harness continuity between the ETC connector and ECU change, leave the key on (engine not running) for 60
connector. Refer to the wire diagram for pin-out details. If seconds. Do NOT crank the engine during this time.
the ETC is faulty, the entire ETC assembly must be
2. Turn the key off and wait 3 minutes. During this time,
replaced.
the ECU will write values into memory and then
completely shut down.
3. Turn key back on and start the vehicle. The vehicle
should operate normally.
4. If the procedure was interrupted at any time, start
back at step 1.

ENGINE ELECTRICAL
TEMPERATURE / MANIFOLD ABSOLUTE PRESSURE (T-MAP)

T-MAP OVERVIEW T-MAP SENSOR REPLACEMENT
Mounted on the intake manifold, the T-MAP sensor
1. Remove the seat and disconnect the negative (-)
performs two functions in one unit.
battery cable.
The temperature and pressure of the air passing through
the intake is measured by the T-MAP and relayed to the 2. Remove the cargo box access panel.
ECU. These signals are processed by the ECU and 3. Disconnect vehicle harness from T-MAP sensor.
compared to its programming for determining the fuel
and ignition requirements during operation. The T-MAP 4. Remove the retaining bolt q and remove the sensor
sensor provides the ECU with engine load data. w from the intake boot.
5. Use a light coating of soapy water on the grommet e
to aid installation of the new sensor.
T-MAP SENSOR TEST
6. Install the sensor w by inserting it with a twisting
The T-MAP sensor should be tested using Digital
Wrench. When connected to Digital Wrench, observe the
motion to properly seat the grommet e. 4
Intake Air Temperature reading and the Manifold
Absolute Pressure reading. Intake Air Temperature and
Manifold Absolute Pressure should be close to what the
temperature and pressure are in your environment when
the key is turned on, engine not running. When the
vehicle is started, manifold absolute pressure will be
around 9 PSI (cold engine) and drop to around 6 PSI
(warm engine). If unsure about the readings, compare to
a known good unit.
Wiring harness issues are more likely to be the cause of
a poor running condition than a faulty T-MAP.
The T-MAP sensor is a non-serviceable item. If it is
faulty, it must be replaced.
7. Install the retaining bolt and torque to specification.
TORQUE
T-MAP Retaining Bolt:
24 in-lbs (2.8 Nm)

ENGINE ELECTRICAL
PEDAL POSITION SENSOR (PPS)

OPERATION OVERVIEW PPS REPLACEMENT
NOTICE 1. Disconnect the PPS harness connection q located
on the accelerator pedal.
DO NOT attempt to service the PPS. The PPS is a non-
serviceable component and can only be tested using
Digital Wrench®. If the PPS is faulty, the entire throttle
pedal assembly must be replaced.
Mounted to the throttle pedal assembly, the PPS acts as

a pedal position sensor. The PPS provides accelerator
pedal position to the Electronic Control Unit (ECU) to
increase or decrease engine RPM using the Electronic
Throttle Control (ETC). The PPS is the primary input
used to control engine speed during vehicle operation.
PPS TEST
The PPS can be tested utilizing Digital Wrench® by
verifying that pedal position readout varies as the pedal
is pressed. Reference the Data Display section and be 2. Remove the seat and disconnect the negative (-)
sure the Pedal Position is displayed. With the ignition key battery cable.
on for at least 15 seconds and engine not running, the
3. Remove the bolts w securing the accelerator pedal
Pedal Position will read approximately 9.6% when the
pedal is released. With the pedal fully depressed, the assembly to the frame support.
Throttle Position will vary depending on what gear you 4. Remove the pedal assembly from the vehicle.
have selected.
• High/Neutral/Park/Invalid – 100%.
• Low – 100%
• Reverse – 100%
NOTICE
If the PPS fails, disconnect the battery power for 10
min. and retest.
The Pedal Position Sensor is calibrated to the

accelerator pedal. If the PPS is faulty, the accelerator
pedal assembly must be replaced (see "PPS
Replacement").

ENGINE ELECTRICAL
CRANKSHAFT POSITION SENSOR

CPS OVERVIEW CPS TEST
NOTICE
The CPS is a sealed, non-serviceable assembly. If fault
code diagnosis indicates a problem with this sensor
circuit, test as follows:
RESISTANCE TEST
1. Access the CPS connector.
2. Disconnect CPS from the main harness connector.
3. Measure the resistance between the CPS terminals
shown below q using an ohmmeter. Verify the
resistance at room temperature is within specification. 4
CPS Resistance Specification:
Mounted on top of the stator cover, the crankshaft 1000 Ω ± 10%
position sensor q is essential to engine operation,
constantly monitoring the rotational speed (RPM) and
position of the crankshaft.
4. If the resistance is incorrect, follow the “CPS

Replacement” procedure.
5. If the resistance is correct, thoroughly inspect the
A ferromagnetic 35-tooth encoder ring w with a missing relevant wiring connections and chassis harness. An
tooth is built onto the flywheel. The inductive speed electrical component , connection, or harness issue
sensor is mounted 1.0 ± 0.26 mm (0.059 ± 0.010″) away may persist.
from the encoder ring. During rotation, an AC pulse is
created within the sensor for each passing tooth. The 6. If all electrical connections have been verified and
ECU calculates engine speed from the time interval problems persist, proceed to the next test.
between the consecutive pulses.
7. Disconnect the ECU connector. Check continuity from
The encoder ring missing tooth creates an “interrupt” one wire at the CPS connector to the other end of the
input signal, corresponding to specific crankshaft circuit at the ECU connector. It should have less than
position. This signal serves as a reference for the control one ohm of resistance. If more than one ohm, locate
of ignition timing by the ECU. Synchronization of the the cause of high resistance and recheck.
CPS and crankshaft position takes place during the first
8. If under one ohm on both wires, leave one meter lead
two revolutions each time the engine is started. This
on one CPS circuit wires with both connectors still
sensor must be properly connected at all times. If the
disconnected. Place the other lead on the battery
sensor fails or becomes disconnected for any reason, the
negative terminal. Check both wires in this matter.
engine will stop running.
They should both read OL, indicating no shorts to
ground.

ENGINE ELECTRICAL
9. If resistance of the wires to the ECU are in spec and MEASUREMENT

not shorted to chassis ground, test the shield wire
(third pin on the CPS connector) for good continuity to CPS Air Gap:
ground (under one ohm). 1.0 ± 0.26 mm (0.059 ± 0.010″)
10. If continuity to ground on the shield is in specification,

inspect harness routing compared to a known good
vehicle, as well as for accessories that may create
interference. Routing close to ignition cables, stator
wires, or HID bulbs and other high voltage
accessories may cause issues.
NOTICE
It should be noted that dynamic operation is what is
read by the ECU, not static testing like resistance
measuring as advised here. While the static tests
advised will lead to properly diagnosing almost all
situations, there are failure modes that will not be
noticed by resistance testing and still set trouble codes.
If there are concerns, please contact Technical Service
for guidance. • If the resistance and air gap is correct proceed to
“Encoder Flywheel / Keyway Inspection”.
AIR GAP TEST • If the air gap is incorrect, compare the CPS flange
to sensor face measurement to a known good
NOTICE
sensor. If the sensor is correct proceed to “Encoder
The CPS air gap is non-adjustable, however Flywheel / Keyway Inspection”.
differences in air gap readings may indicate an
improper or damaged CPS sensorq or flywheel w. If • Is the CPS sensor is incorrect, follow the “CPS
improper components are suspected, compare the Replacement” procedure.
components to known good components.
ENCODER FLYWHEEL / KEYWAY
Measuring the air gap between the CPS sensor q and INSPECTION
flywheel encoder w must be done using multiple 1. Access the CPS.
measurements as the stator cover design does not
allow direct air gap measurement. 2. Disconnect the CPS from the main wiring harness.
3. Drain the coolant.
1. Disconnect the CPS q from the main harness. NOTICE
2. Remove the CPS. Properly dispose of the coolant.
3. Measure the distance between the sensor mounting
flange and the bottom face of the sensor. 4. Disconnect the coolant hose at the water pump.
4. Rotate the engine until a tooth of the encoder 5. Remove the fasteners retaining the stator cover.
flywheel is positioned in line with the CPS mounting
location.
5. Using a depth gauge, measure the distance from the
encoder flywheel tooth to the mounting surface of the
CPS.
6. Subtract the sensor length from the sensor mounting
point to encoder flywheel measurement. Verify that
the calculated air gap is within specification.

ENGINE ELECTRICAL
6. Inspect the flywheel for corrosion, warping, and CPS REPLACEMENT

damaged or missing components.
1. If not done already; disconnect the CPS harness
NOTICE connector.
At this time measure flywheel run-out using a dial 2. Using an 8 mm socket, remove the CPS retaining bolt
indicator near the teeth on the flywheel. If the run-out and remove the sensor from the stator cover.
causes the CPS air gap to be out of tolerance, identify
whether the flywheel is out of round, or if the crankshaft 3. Install new sensor using a light coating of oil on the
is bent. O-ring to aid installation.
4. Torque the CPS and heat shield retaining bolts (if
If the resistance test, air gap test, and flywheel equipped) to specification.
inspection all test good, remove the flywheel and
verify the keyway is in good working order. If the TORQUE
keyway is intact and problems persist, thoroughly CPS Retaining Bolt:
inspect the relevant wiring connections as a electrical
9 ft-lbs (12 Nm)
component or connection may persist.
4
7. Install the stator if removed (see Engine / Cooling
System chapter).
8. Install the stator cover if removed (see Engine /
Cooling System chapter).
9. Install a NEW or known good CPS (see the “CPS
Replacement” procedure).
10. Fill and bleed the coolant system (see Engine /
Cooling System chapter).

ENGINE ELECTRICAL
ENGINE COOLANT TEMPERATURE SENSOR (ETC)

ECT OVERVIEW 6. Safely position the ECT so that the sensor is
Mounted on the cylinder head, the engine temperature submerged in water from the threads down and the
sensor measures coolant temperature. The engine connector may be readily probed.
temperature sensor is a Negative Temperature
NOTICE
Coefficient (NTC) type sensor, as the temperature
increases, the resistance decreases. This signal is Use a wire or other type of prop to ensure the sensor is
processed by the ECU for determining the fuel and properly supported and the tip of the sensor is touching
ignition requirements during operation. The ECU also water only.
uses this signal to determine when to activate the fan.
7. Prepare a table similar to the one below, then heat
the water and document the resistance measured
ECT SENSOR TEST between pin 1 and pin 2 as the water and sensor
SYSTEM OPERATION TEST warm. If the sensor tests out of tolerance, the sensor
To quickly rule out other components and wiring related should be replaced.
to the ECT, disconnect the main wiring harness from the
ECT sensor and start the engine. After a few seconds, ECT SENSOR RESISTANCE READINGS
the fan should turn on and the “Check Engine” indicator
should display on the instrument cluster. This indicates TEMPERATURE °F (°C) RESISTANCE
all other components are working properly. 68 °F (20 °C) 2.5 k Ω ± 6%
86 °F (30 °C) 1.7 k Ω ± 6%
104 °F (40 °C) 1.2 k Ω ± 6%
122 °F (50 °C) 834 Ω ± 6%
140 °F (60 °C) 596 Ω ± 6%
158 °F (70 °C) 435 Ω ± 6%
176 °F (80 °C) 323 Ω ± 6%
194 °F (90 °C) 243 Ω ± 6%
212 °F (100 °C) 186 Ω ± 6%
RESISTANCE VERSUS TEMPERATURE

TEST
CAUTION
Contact with boiling water or steam may cause burns.
1. Disconnect the main wiring harness from the ECT

sensor on the engine.
2. Remove the ECT sensor.
3. Fill a pot of water half way.
4. Place the pot of water on a hot plate.
5. Place the sensor / tip of a thermometer in the water,
ensure the display is legible as you will reference the
thermometer throughout the test.

ENGINE ELECTRICAL
ECT SENSOR REPLACEMENT - 570

1. Lift the rear cargo box
2. Drain coolant to level below sensor.
3. Disconnect harness from the sensor q.
4. Using a wrench, remove and replace the sensor,

applying a light coating of thread sealant to aid
installation.
5. Torque the sensor to specification.
TORQUE
ETC Fasteners
7 ft-lbs (10 N·m)
6. Add the required amount of coolant and properly

bleed the cooling system (see Engine chapter).

ENGINE ELECTRICAL
NOTES

FUEL SYSTEM
CHAPTER 5
FUEL SYSTEM
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
EFI OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
PRINCIPAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
INITIAL PRIMING / STARTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
FUEL PRESSURE GAUGE KIT - PU-43506-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
FUEL PRESSURE GAUGE ADAPTER - PA-48838 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
DIGITAL WRENCH® - DIAGNOSTIC CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
DIGITAL WRENCH® DIAGNOSTIC SOFTWAREPU-47063-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
DIGITAL WRENCH® SMARTLINK MODULE KITPU-47471 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
DIGITAL WRENCH® - DOWNLOAD WEBSITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 5
EFI COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
EFI COMPONENT LOCATIONS - LEFT VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
EFI COMPONENT LOCATIONS - RIGHT VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
LINE / HOSE ROUTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.10
FUEL LINE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.10
VENT LINE TERMINATION FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
AIR BOX / INTAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.12
AIR BOX / AIR FILTER ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.12
AIR BOX REMOVAL / INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.14
FUEL TANK / PUMP / SENDING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.15
FUEL TANK ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.15
FUEL TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.15
FUEL TANK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.16
FUEL SENDER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.16
FUEL PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.17
FUEL PUMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.18
IGNITION COIL OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.22
IGNITION COIL / WIRE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.22
IGNITION COIL / WIRE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.22
FUEL INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.23
FUEL INJECTOR OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.23
FUEL INJECTOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.23
FUEL INJECTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.24
FUEL INJECTOR TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.25
EFI DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.26
SERVICE NOTES - FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.26
TROUBLE CODE DISPLAY (DTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.27
FUEL SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.34
FUEL STARVATION / LEAN MIXTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.34
RICH MIXTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.34

FUEL SYSTEM
POOR IDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.34

FUEL SYSTEM
GENERAL INFORMATION
EFI OPERATION OVERVIEW
The EFI system is designed to provide peak engine performance with optimum fuel efficiency and lowest possible
emissions. The ignition and injection functions are electronically controlled, monitored and continually corrected during
operation to maintain peak performance.
The central component of the system is the Bosch Electronic Control Unit (ECU) which manages system operation,
determining the best combination of fuel mixture and ignition timing for the current operating conditions.
An in-tank electric fuel pump is used to move fuel from the tank through the fuel line, to the fuel rail. The in-tank fuel
pressure regulator maintains a system operating pressure and returns any excess fuel back into the tank. At the
engine, fuel is fed through the fuel rail and into the injectors, which deliver fuel into the intake. The ECU controls the
amount of fuel by varying the PW (Pulse Width) of the injector signal. This determines how long the injector is open
and releasing fuel, which meters the amount of fuel delivered. This range can vary depending on fuel requirements.
The controlled injection of the fuel occurs every other crankshaft revolution, or once for each 4-stroke cycle. The total
amount of fuel needed for one firing of a cylinder is injected during each cycle. When the intake valve opens, the fuel/
air mixture is drawn into the combustion chamber, ignited and burned.
The ECU controls the amount of fuel being injected and the ignition timing by monitoring sensor inputs such as intake
air temperature, manifold absolute pressure and temperature, engine coolant temperature, engine speed (RPM), and
throttle position. These primary signals are compared to the programming in the ECU software, and the ECU adjusts
the fuel delivery and ignition timing outputs based on the inputs. 5
During operation, the ECU has the ability to re-adjust temporarily; providing compensation for changes in overall
engine condition and operating environment, so it will be able to maintain the ideal air/fuel ratio.
During certain operating periods such as cold starts, warm up, acceleration, etc., a richer air / fuel ratio is automatically
calculated by the ECU.

FUEL SYSTEM
PRINCIPAL COMPONENTS INITIAL PRIMING / STARTING

The Electronic Fuel Injection (EFI) system is a complete PROCEDURE
engine fuel and ignition management design. This
system includes the following principal components: NOTICE
The injection system must be purged of all air prior to
• Fuel Pump the initial start up, and / or any time the system has
• Fuel Rail been disassembled.
• Fuel Line If the EFI system is completely empty of fuel or has been
• Fuel Filter(s) disassembled and repaired:
• Fuel Injector 1. Cycle the key switch from “OFF” to “ON” 6 times,
waiting for approximately 3 seconds at each “ON”
• Pressure Regulator cycle to allow the fuel pump to cycle and shut down.
• Throttle Body / lntake Manifold 2. Once step 1 is completed, turn the key switch to
“START” until the engine starts or 5 seconds has
• Engine Control Unit (ECU)
passed.
• Ignition Coil
3. If the engine failed to start, repeat step 1 for 2 more
• Engine Coolant Temperature Sensor (ECT) cycles and attempt to start the engine.
• Throttle Position Sensor (TPS) If the engine fails to start, a problem may still exist,
and should be diagnosed.
• Pedal Position Sensor (PPS)
• Crankshaft Position Sensor (CPS) NOTICE
Accurate testing of EFI components is recommended
• Temperature and Manifold Absolute Pressure Sensor
utilizing the Digital Wrench® Diagnostic Software
(T-MAP)
(dealer only).
• Electronic Throttle Control (ETC)
• Wire Harness Assembly
• Check Engine Light

FUEL SYSTEM
SPECIAL TOOLS

FUEL SYSTEM
FUEL PRESSURE GAUGE KIT - PU- FUEL PRESSURE GAUGE ADAPTER -

43506-A PA-48838
NOTICE Used in conjunction with PA-48838 to check fuel
pressure.
The EFI fuel system remains under high pressure, even
when the engine is not running. Before attempting to
service any part of the fuel system, the pressure must
be relieved. The Fuel Pressure Gauge Kit has an
integrated pressure relief valve that can be used to
bleed off pressure.
WARNING
Gasoline is extremely flammable and explosive under
certain conditions.
Always stop the engine and refuel outdoors or in a well
ventilated area.
the area where refueling is performed or where
gasoline is stored.
Do not overfill the tank. Do not fill the tank neck.
If you get gasoline in your eyes or if you swallow DIGITAL WRENCH® - DIAGNOSTIC
induce vomiting. CONNECTOR
If you spill gasoline on your skin or clothing, The diagnostic connector q is located under the hood as
immediately wash it off with soap and water and shown.
change clothing.
burns may result.
Always wear safety goggles when working with high
pressure or flammable fluids. Failure to do so could
result in serious injury or complications.

FUEL SYSTEM
DIGITAL WRENCH® DIAGNOSTIC DIGITAL WRENCH® - DOWNLOAD

SOFTWARE WEBSITE
PU-47063-B Located at: www.polaris.diagsys.com
This dealer-only software installs on laptop computers
equipped with a CD drive and is designed to replace
multiple shop tools often used to test EFI components. It
also includes step-by-step diagnostic procedures to aid
technician repair and troubleshooting.
NOTICE
If the PC you are using is not equipped with a 9 pin
serial port, a USB to serial port adaptor will be
necessary. It is recommended to use the DSA USB to
serial port adaptor which can be purchased through
DSA at: www.diagsys.com
DIGITAL WRENCH® SMARTLINK

MODULE KIT Download Digital Wrench® Updates: 5
PU-47471
This module kit contains the necessary cables and
hardware to communicate between the vehicle ECU and
the Digital Wrench® diagnostic software. Polaris dealers
can also order the following separately: SmartLink
Module PU-47468, Vehicle Interface Cable PU-47469
and PC Interface Cable PU-47470.
NOTICE
For the most recent information on Digital Wrench®
software and update downloads please visit the
website: www.polaris.diagsys.com

FUEL SYSTEM
EFI COMPONENT LOCATIONS

EFI COMPONENT LOCATIONS - LEFT VIEW
EFI COMPONENT LOCATIONS – LEFT VIEW

REF. COMPONENT
1 Instrument Cluster
2 Ignition Switch
3 Battery
4 Starter Motor Solenoid
5 Regulator / Rectifier
6 Fuse / Relay Box
7 Starter Motor
8 ECU
9 Ignition Coil
10 Engine Temperature Sensor (ECT)

FUEL SYSTEM
EFI COMPONENT LOCATIONS - RIGHT VIEW
REF. COMPONENT
11 Fuel Pump / Sender
12 High Tension Wire / Spark Plug
13 Throttle Body (ETC)
14 Speed Sensor (Mounted to Transmission)
15 CPS
16 Stator (Magneto)

FUEL SYSTEM
LINE / HOSE ROUTING

FUEL LINE ROUTING
• The fuel supply line q is routed as shown below and retained by a clip w at the front engine mount.
• The fuel vent line e is routed as shown below and terminates at the fuel vent connector r that is inserted in the
frame.

FUEL SYSTEM
VENT LINE TERMINATION FITTING

This fitting should be inspected and tested using a Mity
Vac™ to ensure proper venting. Connect the Mity Vac to
the fitting and give it 5 pumps. The gauge should return
to 0 immediately or there is an obstruction.
5
NOTICE
If the vent line fitting is removed from the frame, it must
be replaced. The ears on the clip (arrows) will not hold
properly once it is removed.

FUEL SYSTEM
AIR BOX / INTAKE SYSTEM

AIR BOX / AIR FILTER ASSEMBLY VIEW

FUEL SYSTEM

q Cover, Airbox
w Seal, Cover
e Airbox
r Plug, Drain
t Air Filter
y Intake Boot
u Clamp, Gear
i Clamps, Gear Torque to 24 in-lbs (2.5 Nm)
o Pre-Filter
a Box, Intake
s Plug, Drain
d Screw Torque to 8 ft-lbs (11 Nm) 5

f Seal, Engine, Inlet
g Screw
h Nut Torque to 18 ft-lbs (27 Nm)
j Hose - Breather

FUEL SYSTEM
AIR BOX REMOVAL / INSTALLATION 4. Remove the screw e and nut securing the bottom of
The air box assembly can be removed from the vehicle the air box assembly to the transmission bracket.
through the maintenance access panel located in the
rear storage box.
Air Box Removal Procedure
1. Lift the rear cargo box to access the airbox.
5. Remove the air box assembly.
2. Loosen the gear clamps q and the spring clamp w.
Air Box Installation Procedure
1. Install the air box bottom assembly back into the

engine compartment.
2. Reinstall the screw and nut securing the air box to the
3. Unlatch the air box cover. Remove the cover from the transmission mount. Torque nut to specification.
air box.
TORQUE
Air Box Fastener:
18 ft-lbs (24 Nm)
3. Reinstall the air box cover. Verify the cover tabs

engage the air box. Lock the clamps to secure the
cover.
4. Reinstall the breather hose spring clamp. Reposition
the gear clamps to secure the intake hoses onto the
air box. Tighten gear clamps to specification.
TORQUE
Air Intake Hose Gear Clamps:
24 in-lbs (2.7 Nm)

FUEL SYSTEM
FUEL TANK / PUMP / SENDING UNIT

FUEL TANK ASSEMBLY VIEW FUEL TANK REMOVAL
TORQUE WARNING
1: 75 ft-lbs (92 Nm) Fuel is extremely flammable and may cause severe
burns, injury, or death.
Do not use any device that produces a flame or
electrical devices that may spark around fuel or fuel
vapors.
1. Lift the rear cargo box

2. Remove the seat from the vehicle.
3. Disconnect the negative (-), and then positive (+)
battery cables from the battery.
4. While holding a shop towel over the fuel line
connector, disconnect the quick connect fuel line from
the fuel pump q. Move the fuel line out of the way for
tank removal. 5
NOTICE
A small amount of fuel may come out of the fuel line or
tank. Properly drain fuel into a suitable container.
5. Disconnect the fuel pump electrical harness w.

6. Remove the fuel vent line from the tank vent fitting.
7. Remove the fuel cap, push rivets and screws
retaining the RH fender panel and remove panel from
the vehicle. See Floor / Rear Fenders page 11.9.

FUEL SYSTEM
8. Remove the four screws e securing the fuel tank to FUEL SENDER TEST
the frame support.
FUEL TANK INSTALLATION

WARNING
Fuel is extremely flammable and may cause severe
burns, injury, or death.
Do not use any device that produces a flame or
electrical devices that may spark around fuel or fuel
vapors.
Fuel Sender Resistance Specifications:
Full: 6 ± 1 Ω
1. Carefully reinstall the fuel tank assembly Empty: 90 ± 4.5 Ω
2. Reinstall the four fuel tank mounting screws and
torque to specification.
1. Hook up an ohm meter to the Fuel Pump Module
TORQUE connector terminal q and terminal w.
Fuel Tank Screw Torque:
17 Ft-Lbs (23 Nm)
3. Reinstall the RH fender panel, the fuel cap and all

previously removed fasteners.
4. Connect the fuel pump electrical harness, the fuel
line, and the vent line. Verify the fuel line is locked in
to place by lightly tugging on the connector at the fuel
pump.
5. Reconnect the negative battery cable. Test the fuel
pump by turning the ignition key on and listening for
the pump to activate. Check for leaks.
6. Reinstall the seat assembly.
• q Fuel Level Sender (+)

• w Fuel Level Sender (-)

FUEL SYSTEM
• e Fuel Pump Power (+) 1. Access the top of the fuel pump. Refer to “Fuel
Pump Replacement” page for more detail.
• r Fuel Pump Power Ground (-)
2. Cover the fuel line connection at the fuel tank with a
2. With the sender float in the empty position, the shop towel and disconnect the line from the fuel
meter should read 6 ohms. pump outlet.
3. With the float arm in the full position, the meter 3. Install the Fuel Pressure Gauge Adaptor (PV-48656)
should now read 90 ohms. in-line between the fuel pump outlet and fuel line.
4. If the readings are not between 6 ohms and 90 4. Connect the hose from the Fuel Pressure Gauge Kit
ohms, or if the reading is erratic or LCD display (PU-43506-A) to the test valve on the Fuel Pressure
“sticks”, check the following before replacing the tank Gauge Adaptor (PV-48656). Route the clear hose into
assembly. a portable gasoline container or the vehicle’s fuel
• Loose float tank.
• Float contact with tank

• Bent Float Rod
If the float/arm are not damaged or contacting the
tank restricting movement, and resistance is out of
specification, the sender assembly is faulty. The
sender is not serviceable separately, the Fuel Pump 5
Module must be replaced as an assembly.
FUEL PUMP TEST

If a fuel delivery problem is suspected, make certain the
fuel pump filters are not plugged, that the pump is being
activated through the ECU, all electrical connections are
properly secured, the fuses are good, and a minimum of
7.0 volts is being supplied. If during starting the battery
voltage drops below 7.0 volts, the ECU will fail to operate
the system.
WARNING
certain conditions.
ventilated area.
gasoline is stored.
If you get gasoline in your eyes or if you swallow
induce vomiting.
change clothing.
burns may result.
pressure or flammable fluids. Failure to do so could
result in serious injury or complications.

FUEL SYSTEM
5. Turn on the key switch to activate the pump and 8. If voltage at the plug was within the specified range,
check the system pressure on the gauge. If system and there was continuity across the pump terminals,
pressure of 58 ± 2 psi is observed, the ignition switch, reconnect the plug to the fuel pump, making sure you
ECU, fuel pump, and pressure regulator are working have a clean connection. Turn on the key switch and
properly. Turn the key switch off and depress the listen for the pump to activate.
valve button on the tester to relieve the system
pressure. NOTICE
If the pump starts, repeat steps 3, 4 and 5 to verify
Normal Fuel Pressure: correct pressure.
58 ± 2 psi (400 ± 14 kPa)
9. If the pump still does not operate, check for correct

NOTICE ECU operation by plugging in a known-good ECU of
If the fuel pressure is out of specification, replace the the same model.
fuel pump assembly. NOTICE
If the pump still does not operate, replace the fuel pump
6. If the pump did not activate (Step 5), disconnect the assembly.
harness connector from the fuel pump. Connect a DC
voltmeter across terminals “3” and “4” in the plug on
the vehicle fuel pump harness. Turn on the key switch
and observe voltage to ensure a minimum of 7 volts is
present. FUEL PUMP REPLACEMENT
WARNING
certain conditions.
ventilated area.
gasoline is stored.
induce vomiting.
change clothing.
burns may result.
NOTICE
If the voltage was below 7 VDC, test the battery, ignition pressure or flammable fluids. Failure to do so could
switch, relay(s), wiring harness and ECU. result in serious injury or complications.
7. If the reading is between 7 and 14 volts, turn key

switch off and connect an ohmmeter between
terminals “3” and “4”' at the white fuel pump
connector to check for continuity within the fuel pump.
NOTICE
If there was no continuity between the pump terminals,
replace the fuel pump assembly.

FUEL SYSTEM
6. Be sure the top of the fuel tank is clean. If it requires

CAUTION
cleaning, hand wash the top of the tank e to ensure
It is possible for pressurized fuel to be present when no debris will enter the fuel system when the fuel
disconnecting the fuel line. pump is removed.
It is recommended to allow the vehicle to sit for a period
of one hour after shutting off the engine before
servicing the fuel pump. This allows the exhaust to cool
and fuel pressure to drop.
1. Remove the seat to access the fuel pump.

2. Disconnect the battery (-) negative cable.
3. Ensure that static has been discharged from you by
touching a ground source such as the engine or
frame.
4. While holding a shop towel over the fuel line
connector, disconnect the quick connect fuel line q
from the fuel pump.
NOTICE
WARNING 5
A small amount of fuel may come out of the fuel line or
tank. Properly drain fuel into a suitable container. Failure to clean area around fuel pump may lead to
debris entering the fuel tank during service. Excessive
debris in fuel tank may cause premature wear of fuel
pump and/or clogging of internal fuel filters.
7. Place the Fuel Pump Service Tool (PU-50326) over

the fuel pump PFA nut. Using a 1/2” drive ratchet or
breaker bar, loosen and remove the PFA nut. Discard
the PFA nut.
NOTICE
Apply downward force on the fuel pump flange while
removing the fuel pump PFA nut.
5. Disconnect the fuel pump electrical harness w.

FUEL SYSTEM
8. Carefully lift the fuel pump out of the fuel tank. As the 12. Use cleaning wipes provided to clean fuel tank
fuel pump assembly is being removed, be aware of surface and threads. Remove all debris, grease and
float arm and pump pre-filter. Hold the float arm to the oil. Allow surfaces to dry completely.
pump body as you lift and tilt the pump to ensure that
13. Install new PFA gasket onto fuel pump assembly
the float arm is not bent when removed from the tank.
using care not to damage gasket or bend float arm.
14. Install fuel pump into fuel tank, hold float arm to the
pump body and tilt assembly to ensure float arm does
not get caught or bent during installation.
15. Gently push down on fuel pump flange ensuring
flange is centered.
16. Roughly align orientation mark on fuel pump between
the orientation marks on fuel tank to ensure float arm
does not get bent or snagged. The arrow on the fuel
pump should be between the two marks on the fuel
tank
WARNING
Failure to align the orientation marks may lead to
interferences with the fuel level float arm and cause
9. Transfer old fuel pump to a suitable container capable incorrect function.
of safely holding fuel. The fuel pump will retain some
fuel.
17. While maintaining downward pressure, thread new
10. Inspect the inside of the fuel tank for debris (may PFA nut onto fuel tank and hand tighten. Use care
require flashlight and mirror). If debris like mud or when starting PFA nut, ensuring threads are properly
sand is present, fuel tank should be flushed and aligned. Verify orientation marks are still aligned
cleaned out prior to installation of new fuel pump between fuel pump and fuel tank.
assembly.
18. Torque PFA nut to specification using the Fuel Pump
NOTICE Service Tool (PU-50326) and a calibrated torque
It is recommended to remove the fuel tank from the wrench.
vehicle and rinse it with a small amount of clean fuel. TORQUE
Do not use water or any other chemicals to remove
debris. Fuel Pump PFA Nut:
70 ± 5 ft-lbs (95 ± 7 Nm)
11. Remove new fuel pump assembly, gasket and PFA
nut from packaging. Use care not to bend float arm 19. Verify alignment of fuel pump and tank orientation
when unpacking. Do not lift or carry fuel pump marks.
assembly by the float arm.

FUEL SYSTEM
20. Connect the fuel line to the fuel pump outlet.

NOTICE
Be sure to engage the retainer on fuel line until it snaps
into place. Pull on fuel line lightly to confirm connection.
21. Connect the fuel pump electrical harness.

22. Connect battery.
23. Install the seat.
24. Test the fuel pump by turning on the key and listening
for the pump to activate. Cycle the key several times
to prime the system and check for leaks.

FUEL SYSTEM
IGNITION COIL OVERVIEW

IGNITION COIL / WIRE OVERVIEW SPARK PLUG WIRE CONNECTIONS
The ignition coil uses induction to convert high current,
low voltage in the primary ignition coil winding into low
current, high voltage in the secondary ignition coil
winding. The secondary side is the output that goes to
the ignition wire/cable, and then to the spark plug. The
circuit is completed to ground through the cylinder head
and then through engine ground back to the coil. When
the ignition key is on, DC voltage is present in primary
side of the ignition coil windings.
Spark is induced by the ECU opening the ground leg of
the coil circuit. This causes the magnetic field in the
primary to collapse, causing self induction and a great
voltage increase in both the primary and secondary. This
causes voltage to become high enough in the secondary
circuit that it can jump the spark plug gap.
IGNITION COIL / WIRE TEST

The ignition coil can be tested using an digital multimeter.
Use the following specification table and illustrations to
test the ignition coil.
TEST CONNECTION RESISTANCE
Primary Coil Coil Pack + and – 0.50Ω +/- 10%
Pins
Secondary Coil Coil Pack – and 6.6kΩ +/- 10%
Spark Plug Wire
Terminal
Spark Plug Wire Wire Connector 7.0kΩ +/- 10%
Terminal and
Spark Boot
Terminal
COIL PACK CONNECTIONS

FUEL SYSTEM
FUEL INJECTOR
FUEL INJECTOR OVERVIEW FUEL INJECTOR TEST
The fuel injector is mounted into the cylinder head, with The fuel injector is non-serviceable. If diagnosis indicates
the fuel rail retaining it from the top end. O-rings on both a problem with the injector, test the resistance of the fuel
ends of the injector prevent external fuel leaks and also injector solenoid windings by measuring between the two
insulate the injectors from heat and vibration. terminals e:
When the key switch is on, the fuel rail is pressurized,
and the EFI relay provides voltage to the injectors.
During engine operation, the ECU completes the ground
circuit, energizing the injectors. The valve needle in each
injector is opened electromagnetically, and the pressure
in the fuel rail forces fuel down through the inside. The
“director plate” at the tip of the injector contains a series
of calibrated openings which directs the fuel into the
intake port in a cone-shaped spray pattern.
The amount of fuel injected is controlled by the ECU and
determined by the length of time the valve needle is held
open, also referred to as the “injection duration” or “pulse
width”. It may vary in length depending on the speed and
load requirements of the engine. 5
Fuel Injector Resistance Specification:
11.4 - 12.6 Ω

FUEL SYSTEM
FUEL INJECTOR REPLACEMENT 6. Disconnect the harness from the fuel injector q.
WARNING
certain conditions.
ventilated area.
gasoline is stored.
induce vomiting.
change clothing. 7. Remove the two screws e that mount the fuel rail w
Never start the engine or let it run in an enclosed area. to the cylinder head.
loss of consciousness or death in a short time. 8. Carefully pull up on the fuel rail and injector to remove
Never drain the fuel when the engine is hot. Severe them from the engine as an assembly. If the injector
burns may result. stays in the cylinder head, grab the injector with your
Always wear safety goggles when working with high fingers and gently pull and twist the injector unit to
pressure or flammable fluids. Failure to do so could remove from cylinder head. Take care not to damage
result in serious injury or complications. the fuel injector ends during removal.
9. Gently pull and twist to free the injector from the fuel
rail.
CAUTION
10. Upon installation of the new fuel injector, lightly
It is possible for pressurized fuel to be present when lubricate the injector O-rings to aid installation.
disconnecting the fuel line.
11. Install the new injector into the fuel rail. Be sure to
It is recommended to allow the vehicle to sit for a period
align boss in the injector with the slot in the fuel rail.
of one hour after shutting off the engine before
servicing the fuel pump. This allows the exhaust to cool
and fuel pressure to drop.

2. Be sure the engine has cooled enough to work on.
3. Remove the seat and disconnect the negative battery
cable.
4. Thoroughly clean the fuel injector area if all dirt and
debris.
5. Hold a shop towel over the fuel line fittings and
remove the fuel supply line from the fuel rail.
12. Thoroughly clean the area around the fuel injector

port on the cylinder head.
13. Lightly lubricate the injector O-rings and reinstall the
fuel rail / injector assembly into the cylinder head.

FUEL SYSTEM
14. Install the fuel rail mounting screws and torque to FUEL INJECTOR TROUBLESHOOTING
specification Injector problems typically fall into three general
categories- electrical, dirty / clogged, or leakage. An
TORQUE
electrical problem usually causes injectors to stop
Fuel Rail Mounting Screws: functioning. Several methods may be used to check if the
7 ft-lbs (10 Nm) injectors are operating.
• With the engine running at idle, feel for operational

15. Reinstall the fuel line to the fuel rail. vibration, indicating that they are opening and closing.
16. Connect the harness lead to the fuel injector. • When temperatures prohibit touching, listen for a
buzzing or clicking sound with a screwdriver or
17. Reconnect the negative battery cable and reinstall
mechanic's stethoscope.
the driver’s seat.
• Disconnect the electrical connector from an injector
18. Cycle key ON several times to pressurize the fuel
and listen for a change in idle performance (only
system, and inspect the fuel rail and injector for fuel
running on one cylinder) or a change in injector noise
leaks.
or vibration.
NOTICE
Do not apply voltage directly to the fuel injector.
Excessive voltage will burn out the injector. Do not
ground the injector with the ignition on. The fuel injector
5
will open/turn on if relay is energized.
If an injector is not operating, it can indicate either a bad

injector, or a wiring/electrical connection problem. Check
as follows:
Injector leakage is very unlikely, but in rare instances it
can be internal (past the tip of the valve needle), or
external (weeping around the injector body). The loss of
system pressure from the leakage can cause hot restart
problems and longer cranking times.
Injector problems due to dirt or clogging are unlikely due
to the design of the injectors, the high fuel pressure, the
use of filters and the detergent additives in the gasoline.
Symptoms that could be caused by dirty/clogged
injectors include rough idle, hesitation/stumble during
acceleration, or triggering of fault codes related to fuel
delivery. Injector clogging is usually caused by a buildup
of deposits on the director plate, restricting the flow of
fuel, resulting in a poor spray pattern. Some contributing
factors to injector clogging include; dirty air filters, higher
than normal operating temperatures, short operating
intervals and dirty, incorrect, or poor quality fuel.
Cleaning of clogged injectors is not recommended; they
should be replaced. Additives and higher grades of fuel
can be used as a preventative measure if clogging has
been a problem.

FUEL SYSTEM
EFI DIAGNOSIS
SERVICE NOTES - FUEL SYSTEM 6. If the sensor and wiring passes inspection, and
For more convenient and accurate testing of EFI reconnecting the ECU does not resolve the issue,
components, it is recommended dealers utilize the Digital use a known-good ECU (from the exact model and
Wrench® Diagnostic Software (dealer only), or limited year) to test for problem resolution.
testing may be done manually using procedures
provided. • Never attempt to service any fuel system component
while engine is running or ignition switch "on".
80% of all EFI problems are caused by wiring harness
connections. Follow a common sense approach when • USE CARE when removing or installing the ECU
diagnosing a potential EFI issue: connector, as well as all other harness connections on
1. Disconnect harness at suspected sensor connector. the unit. Properly connect and disconnect the ECU
harness to minimize damage to the connector pins and
2. Inspect the connector ends for damage or locking mechanism.
contamination. If damaged, repair; if contaminated,
clean. Reconnect and check function. • Although every precaution has been taken to prevent
water intrusion failure, avoid direct water or spray
3. If problem persists, perform a sensor bench test (if contact with system components.
applicable) according to sensor requirements.
• Do not disconnect or reconnect the wiring harness
4. If the sensor bench tests pass, disconnect the connector to the ECU or any individual components
connector at the ECU and perform a continuity check with the ignition "on." This can send a damaging
between the sensor connector and the appropriate voltage spike through the ECU.
pin at the ECU connector (all connections for that
sensor). Wiring resistance should be less than one • Do not allow battery cables to touch opposite
(1) ohm. With the sensor and ECU still disconnected, terminals.
check each leg of the circuit for continuity to ground, • Never start the engine when the cables are loose or
you should have no continuity. poorly connected to the battery terminals.
5. If the resistance is high (or open), a wiring harness • Never disconnect battery while engine is running.
inspection is required (including a thorough
inspection of the ECU connector for contamination or • Always unplug ECU from the wire harness before
damage). performing any welding on the unit.

FUEL SYSTEM
TROUBLE CODE DISPLAY (DTC) 3. A set of three numbers will appear in the information
area.
NOTICE
• The first number (located far left) can range from 0 to
The diagnostic mode is accessible only when the check 9. This number represents the total number of trouble
engine MIL has been activated. code present (example: 2 means there are 3 codes
present).
Use the following procedure to display diagnostic trouble
codes that were activated during current ignition cycle • The second number (located top right) can be 2 to 6
causing the MIL to illuminate. Diagnostic trouble codes digits in length. This is the suspect parameter number
will remain stored in the gauge (even if MIL turns off) until (SPN).
the key is turned off. • The third number (located bottom right) can be 1 to 2
digits in length. This is the fault mode indicator (FMI).
NOTICE
1. If the trouble code (s) are not displayed, use the

MODE button to toggle until “CK ENG” displays on
the information display area.
5
4. If more than one code exists, press the MODE button

to advance to the next trouble code.
5. To exit the diagnostic mode, press and hold the
MODE button or turn the ignition key OFF once the
2. Press and hold the MODE button to enter the codes are recorded.
diagnostics code menu.

FUEL SYSTEM
DIAGNOSTIC TROUBLE CODE TABLE

COMPONENT CONDITION SPN FMI P-CODE
Not Plausible 2 P1225
Accelerator Position 2 Voltage Too High 29 3 P1228
Voltage Too Low 4 P1227
Valid But Above Normal 0 P1123
Valid But Below Normal 1 P1122
Data Erratic or Intermittent 2 P0121
Throttle Position Sensor 1 Voltage Too High 51 3 P0123
Abnormal Rate of Change 10 P0120
Out of Calibration 13 P1120
P0500
Valid But Above Normal 0 C1057
C1704
Data Erratic or Intermittent (or P0503
missing) 2
C1058
Voltage Above Normal 3 P1507
Voltage Below Normal 4 P1506
Vehicle Speed Signal 84
Abnormal Frequency or Pulse
8 P0501
Width
Abnormal Update Rate 9 P160A
Abnormal Rate of Change C1068
10
C1705
Bad Intelligent Device 12 P3503
Received Vehicle Speed Has Error P106B
19
C1069
Not Plausible 2 P0225
Accelerator Position 1 Voltage Too High 91 3 P0228
Voltage Above Normal 3
Fuel Level Signal 96
Voltage Below Normal 4
Data Erratic or intermittent 2 P0106
Voltage Too High 3 P0108
Manifold Absolute Pressure Voltage Too Low 4 P0107
Sensor (T-MAP) 102
Mechanical System Not
Responding 7 P1106
Valid But Above Normal 0
Intake Air Temperature (T-
Voltage Too Low 105 4 P0112
MAP)
Abnormal rate of Change 10 P0114
Valid But Above Normal
(least severe) 15 P0127
Engine Temperature Sensor
Engine Overheat Shutdown 110 0 P1217
(ECT)

FUEL SYSTEM

Temperature Too High 16 P0217
P0563
Voltage Too High 3
C1063
System Power
(Battery Potential / Power Voltage Too Low P0562
168 4
Input) C1064
Valid But Below Normal
5
P0219
Valid But Above Normal 0
C1059
Valid But Below Normal 1 C1060
Engine Speed (This is Data Erratic or Intermittent 2 C1061
applicable when the EPS Mechanical System Not
module gets the engine speed Responding 190 7 P1219
from the ECM)
Received Engine Speed Has Error 19 C1066
Error in Engine Speed
Computation 31 P121C
Error in Engine Speed
Engine Speed 400 31 P121D
Computation
Date Erratic or Intermittent 2 P0914
Voltage Above Normal 3 P0917
Gear Sensor Signal 523
P1602
EEPROM: Read/Write Failure 12
C1073
ECU Memory 628
P0601
Out of Calibration 13
C1601
Calibration Checksum/CRC Error 630 13 C1074
Plausibility Fault 2 P0335
Crankshaft Position Sensor
(CPS) Abnormal Frequency or Pulse 636
8 P0336
Width
Camshaft Phase Sensor Circuit Fault 637 8 P0340
Driver Circuit Short to B+ 3 P0262
Injector 1 (MAG) Driver Circuit Grounded 651 4 P1262
Driver Circuit Open 5 P0261
Injector 2 (PTO) Driver Circuit Grounded 652 4 P1265

FUEL SYSTEM

Rear Differential Output Driver Circuit Grounded 746 4 P1693
Fan Relay Driver Circuit Driver Circuit Grounded 1071 4 P1483
Ignition Coil Primary Driver 1
Driver Circuit Grounded 1268 4 P1361
(MAG)
Ignition Coil Primary Driver 2
(PTO)
Fuel Pump Driver Circuit Driver Circuit Grounded 1347 4 P0231
Driver Circuit Open / Grounded 5 P0230
Data Erratic, Intermittent or
2 P0130
Incorrect
Voltage Above Normal or Shorted
to High Source 3 P0132
Oxygen Sensor 1 3056
Voltage Below Normal or Shorted
4 P0131
to Low Source
Bad Intelligent Device 12 P113A
Valid But Above Normal 0 P16A3
Valid But Below Normal 1 P16A6
Voltage Too High 3 P16A2
Voltage Too Low 4 P16A1
ECU Output Supply Voltage 1 3597
(least severe) 16 P16A5
(least severe) 18 P16A7
Valid But Above Normal 0 P16AA
Valid But Below Normal 1 P16AC
Voltage Too High 3 P16A9
Voltage Too Low 4 P16A8
(least severe) 16 P16AB
(least severe) 18 P16AD
Valid But Above Normal 0 P17AC
Valid But Below Normal 1 P17AE
Voltage Too High 3 P17AA
Voltage Too Low 4 P17AB
(least severe) 16 P17AD
(least severe) 18 P17AF
Misfire Detected Cylinder Not Identified 65590 7 P0314

FUEL SYSTEM

Cylinder 1 65591 7 P0301
Cylinder 2 65592 7 P0302
ETC Accelerator Position
Sensor Outputs 1 & 2 Correlation Fault 65613 2 P1135
Correlation
Date Erratic or Intermittent 2 P0221
Throttle Position Sensor 2 Voltage Too High 520198 3 P0223
Out of Calibration 13 P1220
All Wheel Drive Control Circuit
(AWD)
Voltage Above Normal 3 P1614 5
Chassis Relay Voltage Below Normal 520208 4 P1613
Open Circuit 5 P1611
Voltage Above Normal or Shorted
to High Source 3 P0032
Oxygen Sensor Heater 1 Voltage Below Normal or Shorted 520209
4 P0031
to Low Source
Current below Normal or Open
5 P0030
Circuit
Steering Over Current Shut Current Above Normal or
520221 6 C1050
Down Grounded
Steering Excessive Current Current Above Normal or
520222 6 C1051
Error Grounded
Steering Torque Partial Failure Condition Exists 520223 31 C1052
Steering Torque Full Failure Condition Exists 520224 31 C1053
Greater than 120° C (248° F) 0 C1055
EPS Inverter Temperature 520225
Greater than 110° C (230° F) 16 C1054
EPS CAN Communications No RX Message for 2 Seconds 2 U0100
520226
Receive Error Condition Exists 31 C1067
EPS CAN Communications No TX Message for 2 Seconds 520227 2 U1100
Transmit Error
Root Cause Unknown 11 C1065
Position Encoder Error Bad Intelligent Device 520228 12
Condition Exists 31 C106B
Bad Intelligent Device 12 C1070
EPS Software Error 520229
Condition Exists 31 C106F
IC CAN Communication with EPS Off Line (EPS DM1 not seen) 520230 31 U0131
EPS
EPS: Key On, Engine Off, 5 Minute
EPS Power Save Condition 520231 31 C1071
Power Save/Timeout
Idle Air Control Valve (IAC)
M17; IAC Stepper Pin 3 Driver Circuit Short to B+ 520268 3 P1519

FUEL SYSTEM

Driver Circuit Grounded 4 P1518
Responding 7 P1559
Out Of Calibration 13 P1302
Idle Air Control Valve (IAC) Driver Circuit Open / Grounded 5 P1525
M17; IAC Stepper Pin 4 520269
Responding 7 P1579
Responding 7 P1589
Responding 7 P1549
Accelerator Position / Brake
Condition Exists 520275 31 P150A
Position Interaction
Position Sensor Correlation Fault 2 P150C
Throttle Position Sensor
(1 or 2 Indeterminable) Neither Position Sensor Passed 520276
12 P150B
Test
Not Plausible 2 P151A
Voltage Above Normal 3 P150D
Throttle Body Control - Power Voltage Below Normal 4 P150E
Stage 520277
Signal Error 8 P151B
Deactivated power stages due to
5V sensor supply error 31 P153F
Throttle Body Control - Return
Spring Check Failed Condition Exists 520278 31 P151C
Throttle Body Control -
Adaptation Aborted Condition Exists 520279 31 P151D
Throttle Body Control - Limp
Condition Exists 520280 31 P151E
Home Position Check Failed
Mechanical Stop Adaptation Condition Exists 520281 31 P152A
Failure
Repeated Adaptation Failed Condition Exists 520282 31 P152B
Outside of Pedal Range (Level 1) 2 P152F
Throttle Body Control Voltage Above Normal 520283 3 P152C
Voltage Below Normal 4 P152D

FUEL SYSTEM

Condition Exists 520284 31 P152E
Position Deviation Fault
Brake Switch (1 or 2
Indeterminable) Brake Switch Correlation Fault 520285 2 P153E
ECU Monitoring Error Condition Exists 520286 31 P1540
ECU Monitoring Error (Level
3) Condition Exists 520287 31 P1541
ECU Monitoring of Injection
Cut Off (Level 1) Condition Exists 520288 31 P1542
ECU Monitoring of Injection
Cut Off (Level 2) Condition Exists 520289 31 P1543
Controller Option Setting Not
Programmed Out of Calibration 520290 13 P1544
Requested Throttle Angle Not Condition Exists 520305 31 P1530
Plausible
ECU Analog to Digital
Converter Fault - No Load
Condition Exists 520306 31 P1531 5
ECU Analog to Digital
Converter Fault - Voltage Condition Exists 520307 31 P1532
Accelerator Sensor
Synchronicity Fault Sensor Condition Exists 520308 31 P1533
Difference Exceeds Limit
ECU Fault - ICO Condition Exists 520309 31 P1534
ECU Fault - Hardware
Disruption Condition Exists 520311 31 P1537
Adaptive Fuel Correction Bank Valid But Above Normal 15 P0170

520344
1 Valid But Below Normal 17 P1170

FUEL SYSTEM
FUEL SYSTEM TROUBLESHOOTING

The correct position of the throttle body stop screw is POOR IDLE
established and set at the factory. DO NOT remove the Symptom: Idle Too High (If greater than 1300 RPM when
tamper proof cap to adjust the throttle body stop screw engine is warm)
or alter its position in any manner. The stop screw
controls the air flow calibration of the throttle body. • Throttle stop screw tampering
• Throttle cable sticking, improperly adjusted, routed
incorrectly
FUEL STARVATION / LEAN MIXTURE
Symptoms: Hard start or no start, bog, backfire, popping • Failed sensor or disconnected wiring
through intake / exhaust, hesitation, detonation, low • IAC stuck or inoperative
power, spark plug erosion, engine runs hot, surging, high
idle, idle speed erratic. • Intake air leak
• No fuel in tank Symptom: Idle Too Low (if less than 1200 RPM when
engine is warm)
• Restricted tank vent, or routed improperly
• Fuel lines or fuel injectors restricted • Dirty throttle body (damaged or improper air filter)
• Fuel pump inoperative • Plugged air filter
• Air leak in system • Leaking injector (rich condition)
• Intake air leak (throttle shaft, intake boot, gasket or • Belt dragging
grommet) • Throttle stop screw tampering
• Failed sensor or disconnected wiring • Failed sensor or disconnected wiring
Symptom: Erratic Idle

RICH MIXTURE
• Throttle cable incorrectly adjusted
Symptoms: Fouls spark plugs, black, sooty exhaust
smoke, rough idle, poor fuel economy, engine runs • Air Leaks, dirty injector
rough/ misses, poor performance, bog, engine loads up,
• TPS damaged or mis-adjusted
backfire.
• Tight valves
• Air intake restricted (inspect intake duct)
• Belt dragging
• Air filter dirty/plugged
• Dirty air cleaner
• Poor fuel quality (old fuel)
• Engine worn
• Fouled spark plug
• Spark Plug fouled
• Injector failure
• Failed sensor or disconnected wiring
• Failed sensor or disconnected wiring

PVT SYSTEM
CHAPTER 6
PVT SYSTEM
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
PVT SYSTEM FASTENER TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
PVT SYSTEM OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
CLUTCHING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
GENERAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
DRIVE CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
DRIVEN CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
PVT BREAK-IN (DRIVE BELT / CLUTCHES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
MAINTENANCE / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
OVERHEATING / DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
PVT SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
PVT SEALING, GUARD, AND DUCT COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
PVT DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7 6
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
CLUTCH ALIGNMENT / OFFSET / CENTER DISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.12
DRIVE CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.13
DRIVE CLUTCH ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.13
CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.14
SHIFT WEIGHT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.15
SPIDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.16
ROLLER, PIN, AND THRUST WASHER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.16
BUTTON TO TOWER CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.17
BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.17
CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.17
BUSHING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.19
CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.22
DRIVEN CLUTCH SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.23
ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.23
CLUTCH DISASSEMBLY / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.24
CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.25
SECONDARY CLUTCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.25
PVT SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.26
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.26

PVT SYSTEM
GENERAL INFORMATION
SPECIAL TOOLS PVT SYSTEM FASTENER TORQUES
PART TOOL DESCRIPTION ITEM TORQUE VALUE
NUM-
BER Drive Clutch Retaining 45 ft-lbs (61 Nm)
Bolt
PU- Clutch Center to Center Distance Tool
50658-A Drive Clutch Spider 290 ft-lbs (393 Nm)
PA-48595 Clutch Puller Drive Clutch Cover Plate 8 ft-lbs (10 Nm)
9314177 Clutch Holding Wrench Driven Clutch Retaining 38 ft-lbs (51 Nm)
Bolt
2871358- Clutch Holding Fixture
A PVT Inner Cover Phillips- 50 in-lbs (5 Nm)
Head Screws
Drive Clutch Spider Removal and Install
2870341 PVT Inner Cover Hex-
Tool 12 ft-lbs (16 Nm)
Head Screws
2870913 Driven Clutch Puller
PVT Outer Cover Bolts 50 in-lbs (5 Nm)
2870910 Roller Pin Tool
Clutch Bushing
2871226 Replacement Tool Kit
2870386 Piston Pin Puller
PU- Universal Clutch Compressor Tool
50518
Clutch Bushing
2871025 Replacement Tool Kit
2870654 Standard Clutch Alignment Tool
PART SPECIAL SUPPLIES

NUM-
BER
N/A Loctite™ 680
8560054 RTV Silicone Sealer
Bosch Automotive Service Solutions: 1-800-345-2233

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

PVT SYSTEM
PVT SYSTEM OVERVIEW

CLUTCHING CHART GENERAL OPERATION
RANGER 500 WARNING
SHIFT DRIVE All PVT maintenance or repairs should be performed by
ALTITUDE
WEIGHT SPRING a certified Polaris Master Service Dealer (MSD)
0-1800 25–52G Black technician who has received the proper training and
(0-6000) (5632409) (7043594) understands the procedures outlined in this manual.
Meters Because of the critical nature and precision
(Feet) 1800-3700 25-48 Black balance incorporated into the PVT components, it is
(6000 - 12000) (5633217) (7043594) absolutely essential that no disassembly or repair
be made without factory authorized special tools
RANGER 570 and service procedures.
SHIFT DRIVE
ALTITUDE
WEIGHT SPRING The Polaris Variable Transmission (PVT) consists of
three major assemblies:
0-1800 25–52G Black
Meters (0-6000) (5632409) (7043594) 1) The Drive Clutch
(Feet) 1800-3700 25-48 Black 2) The Driven Clutch
(6000 - 12000) (5633217) (7043594) 3) The Drive Belt
RANGER CREW 570 The internal components of the drive clutch and driven
SHIFT DRIVE clutch control engagement (initial vehicle movement),
ALTITUDE
WEIGHT SPRING clutch upshift and backshift. During vehicle development,
0-1800 25-52G Black the PVT system is matched first to the engine power 6
Meters (0-6000) (5632409) (7043594) curve; then to average riding conditions and the vehicle’s
(Feet) intended usage. Therefore, modifications or variations of
1800-3700 25-48 Black components at random are never recommended. Proper
(6000 - 12000) (5633217) (7043594) clutch setup and careful inspection of existing
components must be the primary objective when
troubleshooting and tuning.

PVT SYSTEM
DRIVE CLUTCH OPERATION PVT BREAK-IN (DRIVE BELT /

Drive clutches primarily sense engine RPM. The two CLUTCHES)
major components which control its shifting function are A proper break-in of the clutches and drive belt will
the shift weights and the coil spring. Whenever engine ensure a longer life and better performance. Break in the
RPM is increased, centrifugal force is created, causing clutches and drive belt by operating at slower speeds
the shift weights to push against rollers on the moveable during the 10 hour break-in period as recommended (see
sheave, which is held open by coil spring preload. When Chapter 3 “Engine Break-In Period” for break-in
this force becomes higher than the preload in the spring, example). Pull only light loads. Avoid aggressive
the outer sheave moves inward and contacts the drive acceleration and high speed operation during the break-
belt. This motion pinches the drive belt between the in period.
spinning sheaves and causes it to rotate, which in turn
rotates the driven clutch.
At lower RPM, the drive belt rotates low in the drive MAINTENANCE / INSPECTION
clutch sheaves. As engine RPM increases, centrifugal Under normal use the PVT system will provide years of
force causes the drive belt to be forced upward on drive trouble free operation. Periodic inspection and
clutch sheaves. maintenance is required to keep the system operating at
peak performance. The following list of items should be
inspected and maintained to ensure maximum
DRIVEN CLUTCH OPERATION performance and service life of PVT components. Refer
to the troubleshooting checklist at the end of this chapter
Driven clutches primarily sense torque, opening and
for more information.
closing according to the forces applied to it from the drive
belt and the transmission input shaft. If the torque 1. Belt Tension, Drive to Driven Clutch Alignment/
resistance at the transmission input shaft is greater than Offset, and Belt Inspection.
the load from the drive belt, the drive belt is kept at the
outer diameter of the driven clutch sheaves. 2. Drive and Driven Clutch Buttons and Bushings,
Drive Clutch Shift Weights and Pins, Drive Clutch
As engine RPM and horsepower increase, the load from Spider Rollers and Roller Pins, Drive and Driven
the drive belt increases, resulting in the belt rotating up Clutch Springs.
toward the outer diameter of the drive clutch sheaves
and downward into the sheaves of the driven clutch. This 3. Sheave Faces. Clean and inspect for wear.
action, which increases the driven clutch speed, is called 4. PVT System Sealing. Refer to appropriate
upshifting. illustrations on the following pages. The PVT system
Should the throttle setting remain the same, and the is air cooled by fins on the drive clutch stationary
vehicle is subjected to a heavier load, the drive belt sheave. The fins create a low pressure area in the
rotates back up toward the outer diameter of the driven crankcase casting, drawing air into the system
clutch and downward into the sheaves of the drive clutch. through an intake duct. The opening for this intake
This action, which decreases the driven clutch speed, is duct is located at a high point on the vehicle (location
called backshifting. varies by model). The intake duct draws fresh air
through a vented cover. All connecting air ducts (as
In situations where loads vary (such as uphill and well as the inner and outer covers) must be properly
downhill), and throttle settings are constant, the drive and sealed to ensure clean air is being used for cooling
driven clutches are continually shifting to maintain the PVT system and also to prevent water and other
optimum engine RPM. At full throttle a perfectly matched contaminants from entering the PVT area. This is
PVT system should hold engine RPM at the peak of the especially critical on units subjected to frequent
power curve. This RPM should be maintained during water fording.
clutch upshift and backshift. In this respect, the PVT
system is similar to a power governor. Rather than vary
throttle position, as a conventional governor does, the
PVT system changes engine load requirements by either
upshifting or backshifting.

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

POSSIBLE CAUSES SOLUTIONS / WHAT TO DO
Loading the vehicle into a truck or tall trailer Shift transmission to Low during loading of the vehicle to prevent
when in high range. belt burning.
Starting out going up a steep incline from a
When starting out on an incline, shift the transmission to Low.
stopped position.
Drive at higher speed or use Low. The use of Low is highly
Driving at low RPM or low ground speed (at
recommended for cooler PVT operating temperatures and longer
approximately 3-7 MPH).
component life.
Warm engine at least 5 min., then with transmission in neutral,
Insufficient engine warm-up when exposed to advance throttle to approx. 1/8 throttle in short bursts, 5 to 7
low ambient temperatures. times. The belt will 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 speed. Use Low only. 6
Plowing snow, dirt, etc./utility use. Use Low only.
Shift the transmission to Low, carefully use fast, aggressive
Stuck in mud or snow. throttle application to engage clutch. WARNING: Excessive
throttle may cause loss of control and vehicle overturn.
Shift the transmission to Low, carefully use fast, aggressive, brief
Climbing over large objects from a stopped
throttle application to engage clutch. WARNING: Excessive
position.
throttle may cause loss of control and vehicle overturn.
Shift the transmission to neutral. Using the throttle, vary the
engine rpm from idle to full throttle. Repeat several times as
Belt slippage from water or snow ingestion into
required. During this procedure, the throttle should not be held at
the PVT system.
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
Clutch malfunction. dealer. Shift transmission to Low during loading of the vehicle to
prevent belt burning.
Fouled plugs, foreign material in gas tank, fuel lines, or
Poor engine performance.
carburetor. Contact you dealer for further service information.
Low: Heavy pulling, basic operational speeds less than 7 MPH,
riding through rough terrain (swamps, mountains, ect.), low
GENERAL RANGE OPERATION GUIDELINES: ground speeds.
High: High ground speeds, speeds above 7 MPH.
OPERATING IN LOW GEAR NOTICE

Low gear is the primary driving gear range. Low should
be used in ALL driving applications except for driving on Using High range for heavy loads, hilly terrain, or in wet,
hard packed level surfaces with light loads. In this cir- muddy conditions will increase the chance of drive belt
cumstance, High range may be used. burning.

PVT SYSTEM
PVT SYSTEM SERVICE

PVT SEALING, GUARD, AND DUCT COMPONENTS
REF DESCRIPTION NOTES

q Outer Clutch Cover
w Clutch Cover Seal
e Inner Clutch Cover
r PVT Intake Duct
t PVT Exhaust Duct
y Drain Plug
u Clamp Torque to 10 ft-lbs (14 Nm)
i Screw Torque to 60 in-lbs (7 Nm)
o Bolt Torque to 24 in-lbs (3 Nm)

PVT SYSTEM
PVT DISASSEMBLY 10. Remove the drive clutch retaining bolt and remove
1. Remove the seats. drive clutch using the Drive Clutch Puller.
2. Disconnect the (-) negative battery terminal.
3. Place transmission in neutral.
4. Raise and support the vehicle.
CAUTION
Serious injury may result if machine tips or falls. Be
sure machine is secure before beginning this service
procedure.
5. Remove the left rear wheel.

6. Remove the eight clutch cover screws and remove
the outer clutch cover from the vehicle.
Drive Clutch Puller PA-48595
Drive Clutch Holder 9314177
NOTICE
Be sure to use the correct Drive Clutch Puller to prevent
6
damage to crankshaft.
11. Loosen hose clamp attaching the PVT inlet duct to

the inner clutch cover. Disengage hose from the
inner clutch cover.
7. Mark the drive belt direction of rotation and remove 12. Remove the (8) bolts that retain the inner clutch
drive belt (see “DRIVE BELT - Belt Removal”). cover to the engine and transmission. Remove inner
clutch cover. Make note of cable and hose routings
8. Remove the driven clutch retaining bolt and driven for assembly.
clutch assembly.
9. Install the Drive Clutch Holder.

PVT SYSTEM
PVT ASSEMBLY 11. Install drive clutch onto the engine and torque
1. Inspect inner clutch cover. Replace if cracked or retaining bolt to specification.
damaged.
TORQUE
2. Inspect the seal on the transmission input shaft.
Replace if damaged. Drive Clutch Retaining Bolt:
45 ft-lbs (61 Nm)
3. Remove silicone sealant from the engine case and
inner PVT cover.
12. Install the drive belt noting direction of belt rotation
4. Apply RTV silicone sealant to the back side of the (see “DRIVE BELT - Belt Installation”). If a new belt is
inner clutch cover q to ensure a water tight fit installed, install so numbers can be easily read.
between the engine and inner clutch cover. Both
13. Install a new outer clutch cover seal with the colored
surfaces must be clean to ensure adhesion of the
stripe facing the inner clutch cover.
silicone sealant.
14. Reinstall outer clutch cover and secure with screws.
Torque screws to specification.
TORQUE
Outer Clutch Cover Retaining Screws:
50 in-lbs (5 Nm)
15. Install the clutch inlet and outlet ducts and tighten the
hose clamps.
TORQUE
Steel Wheel Nuts:
36 ft-lbs (49 Nm)

5. Install and properly align the inner clutch cover. Be 30 ft-lbs + 90º (41 Nm + 90º)
sure the cables and hose routings are correct.
6. Install the (4) inner clutch cover bolts and washers 16. Reconnect the battery negative (-) cable.
that retain the cover to the engine. Torque bolts to
specification. 17. Install engine service panel and both seats.
TORQUE
Inner Clutch Cover Bolts:
12 ft-lbs (16 Nm)
7. Clean the splines inside the driven clutch and on the

transmission input shaft.
8. Apply a light film of grease to the splines on the
shaft.
9. Install the inner clutch sheave, thrust washers (3)
and, noting clutch sheave orientation, outer clutch
sheave. Torque retaining bolt to specification.
TORQUE
Driven Clutch Retaining Bolt:
38 ft-lbs (51 Nm)
10. Clean the end of the taper on the crankshaft and the
tapered bore inside the drive clutch.

PVT SYSTEM
DRIVE BELT
BELT REMOVAL 6. Remove the belt from the vehicle.
NOTICE
Inspect the entire clutch outlet duct when replacing a
drive belt. Remove any debris found in the duct.
1. Remove the (8) screws that retain the outer clutch

cover.
2. Maneuver the outer clutch cover outward to access
the drive belt.
BELT INSPECTION
1. Inspect belt for hour glassing (extreme circular wear
in at least one spot and on both sides of the belt).
Hour glassing occurs when the drive train does not
move and the drive clutch engages the belt.
2. Inspect belt for loose cords, missing cogs, cracks,
6
abrasions, thin spots, or excessive wear. Compare
3. Mark the drive belt direction of rotation so that it can belt measurements with a new drive belt. Replace if
be installed in the same direction. necessary.
4. Remove the driven clutch mounting bolt. 3. Belts with thin spots, burn marks, etc., should be
replaced to eliminate noise, vibration, or erratic PVT
operation. See the Troubleshooting Chart at the end
of this chapter for possible causes.
5. Remove the outer sheave.

PVT SYSTEM
BELT INSTALLATION PVT BREAK-IN (DRIVE BELT /

NOTICE CLUTCHES)
Be sure to install belt in the same direction as it was A proper break-in of the clutches and drive belt will
removed. ensure a longer life and better performance. Break in the
clutches and drive belt by operating at slower speeds
during the 10 hour break-in period as recommended (see
1. Install the belt on the vehicle.
Chapter 3 “Engine Break-In Period” for break-in
example). Pull only light loads. Avoid aggressive
acceleration and high speed operation during the break-
in period.
2. Reinstall the outer sheave.

3. Reinstall the driven clutch mounting bolt. Torque to
specification.
TORQUE
Driven Clutch Mounting Bolt
38 ft-lbs (51.5 Nm)
4. Rotate / spin the driven clutch and belt approximately

5-7 times to properly seat the belt in the driven
clutch.
5. Install the outer clutch cover and (8) screws. Torque
screws to specification.
TORQUE
Outer Clutch Cover Retaining Screws:
50 in-lbs (5 Nm)

PVT SYSTEM
CLUTCH ALIGNMENT / OFFSET / CENTER DISTANCE

INSPECTION NOTICE
1. Remove the outer PVT cover, drive belt, drive clutch
and driven clutch as outlined in this chapter. Images for Reference only. The tool shown should only
be used to check center to center distance.
NOTICE The location the tool rests on the shafts may vary.
The inner PVT cover does not need to be removed to
check the clutch center to center distance.
PU-50658–A
2. Install the Clutch Center Distance Tool onto the
crankshaft and transmission input shaft. The pictures HOLE YEAR VEHICLE DESCRIPTION
below show a properly installed tool. 1 2012 RZR 570
2011-14 RZR 900
2 2014-15 RZR XP 1000
2013 RANGER 900
2014-16 ACE
2015-19 ACE 570
2015-16 RGR ETX
3
2013–19 RZR 570
2014–19 RANGER 500/570
2015-19 RANGER 570 Full-Size
2014-19 RANGER 900/1000
2015-19 RZR 900 6
4 2016-19 RZR 1000
2016–19 ACE 900
2016–19 GENERAL
5 2015-18 RANGER Diesel
Clutch Center Distance Tool

i.e. 2015 RZR 900 uses the holes marked with a
PU-50658 or PU-50658-A
4
3. If the tool fits as shown above, the clutch center to

center distance is correct.
4. If the tool does not fit as shown above, adjustment is
needed.

PVT SYSTEM
ADJUSTMENT 6. With the tool now properly installed, in sequence

1. Remove the Clutch Center Distance tool from the torque the eight engine to transmission coupler bolts
engine and transmission. to specification.
2. Remove the inner PVT Cover.
3. Loosen the eight engine to transmission coupler
bolts q.
TORQUE
Engine To Trans Coupler Bolts:
4. Loosen the two fasteners w securing the rear
transmission isolator to the vehicle frame.
7. Torque the two rear transmission isolator fasteners
e to specification
5. With the engine and transmission mounting

fasteners loose, install the Clutch Center Distance
Tool as shown in the inspection process. 8. Remove the Clutch Center Distance tool and
reassemble the PVT system as outlined in this
Clutch Center Distance Tool chapter.
PU-50658
TORQUE
Rear Trans. Isolator Bolts:
40 ft-lbs (54 Nm)

PVT SYSTEM
DRIVE CLUTCH SERVICE

DRIVE CLUTCH ASSEMBLY VIEW
REF DESCRIPTION REF DESCRIPTION

Clutch Bolt (Replace if removed)
q 47 ft-lbs (63.5 Nm) s Washers
w Lock Washer d One-Way Bearing (EBS)
e Flat Washer f Bolt

Cover Screws
r g Shift Weight
100 in-lbs (12 Nm)
Nut
t Spring h 25 in-lbs (2.8 Nm)
y Limiter Spacer j Button

Spider
u 210 ft-lbs (284 Nm) k Washer
i Sheave Bushing l Roller
o Bushing 1( Pin
a Spacer

PVT SYSTEM
CLUTCH DISASSEMBLY 5. Remove and inspect the clutch spring. See “Drive
1. Using a permanent marker, mark the cover, spider, Clutch Spring Specifications” for spring inspection.
and moveable and stationary sheaves for reference,
as the cast in X's may not have been in alignment
before disassembly.
6. Remove the limiter spacer w and inspect for wear.

Replace if excessive wear is evident.
7. Inspect area on shaft e where bushing rides for
2. Mark the stationary sheave and clutch shaft to verify
wear, galling, nicks, or scratches. Replace clutch
the shaft has not turned in the sheave after
assembly if worn or damaged.
tightening the spider during clutch assembly.
3. Remove the (6) cover bolts evenly in a cross pattern
and remove cover plate.
4. Inspect cover bushing q. The outer cover bushing is
manufactured with a Teflon coating. Wear is
determined by the amount of Teflon remaining on the
bushing.
CAUTION
DO NOT reassemble the drive clutch without the limiter
spacer w. Belt life will be greatly reduced.
Cover Bushing Inspection:

Replace the cover bushing if more brass than Teflon is
visible on the bushing. Refer to bushing replacement in
this chapter.

PVT SYSTEM
Drive Clutch Spring Inspection SHIFT WEIGHT INSPECTION

1. Remove shift weight bolts and weights. Inspect the
CAUTION contact surface of the weight q. The surface should
be smooth and free of dents or gall marks. Inspect
Never shim a drive clutch spring to increase its the weight pivot bore and bolts w for wear or galling.
compression rate. This may result in complete stacking If weights or bolts are worn or broken, replace in sets
of the coils and subsequent clutch cover failure. of three with new bolts and nuts.
The drive clutch spring is one of the most critical WARNING

components of the PVT system. It is also one of the The clutch assembly is a precisely balanced unit. Never
easiest to service. Due to the severe relaxation the replace parts with used parts from another clutch
spring is subject to during operation, it should always assembly!
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 spring coils are parallel to one another.
Distortion of the spring indicates stress fatigue,
requiring replacement.
DRIVE CLUTCH SPRING SPECIFICATIONS
COLOR FREE LENGTH

Red / Orange 2.54 (64.52 mm)
6
Black 2.8” (71.12 mm)
NOTICE
A damaged shift weight is usually caused by a
damaged or stuck roller in the spider assembly. See
“Roller, Pin and Thrust Washer Inspection”.

PVT SYSTEM
SPIDER REMOVAL Moveable Sheave Bushing Inspection

1. Install clutch in holding fixture q and loosen the 2. Inspect the Teflon™ coating on the moveable sheave
spider (counterclockwise) using Clutch Spider bushing.
Removal Tool w.
Moveable Sheave Bushing Inspection:

Clutch Holding Fixture:
Replace the cover bushing if more brass than Teflon is
PN 2871358-A visible on the bushing. Refer to bushing replacement in
this chapter.
Spider Removal Tool:
PN 2870341
NOTICE ROLLER, PIN, AND THRUST WASHER

It is important that the same number and thickness of INSPECTION
washers are reinstalled beneath the spider during 1. Inspect all rollers, bushings and roller pins by pulling
assembly. Be sure to note the number and thickness of a flat metal rod across the roller. Turn roller with your
these washers. finger. If you notice resistance, galling, or flat spots,
replace rollers, pins and thrust washers in sets of
three. Also inspect to see if roller and bushing are
separating. Bushing must fit tightly in roller. Use the
Roller Pin Tool to replace rollers and pins. Take care
not to damage roller bushing or bearing surface of
the new pin during installation.
Roller Pin Tool:

PN 2870910

PVT SYSTEM
2. Rubber backed buttons can be used in all RANGER BEARING INSPECTION

clutches if the hollow roller pin is changed to the solid 1. Rotate the clutch bearing in both clockwise and
roller pin. counter-clockwise directions.
NOTICE • The non-braking bearing should rotate both directions
on the shaft with only a slight amount of drag.
The rubber side of the button is positioned toward the
solid roller pin. 2. Verify there is no binding or rough spots. If problems
are noted continue with disassembly.
6
BUTTON TO TOWER CLEARANCE CLUTCH INSPECTION
INSPECTION NOTICE
1. Inspect for any clearance between spider button to
tower. If clearance exists, replace all buttons and Remove cover, spring, and spider following instructions
inspect surface of towers. See “Spider Removal” for drive clutch removal, then proceed as follows:
procedure.
1. Remove the moveable sheave spacer sleeve q.
Inspect for damage and wear.
Button to Tower Clearance:

.000-.010”
2. Inspect sheave surfaces. Replace the entire clutch if

worn, damaged or cracked.

PVT SYSTEM
2. Remove the moveable clutch sheave w. Inspect for 4. Inspect surface of shaft for pitting, grooves, or
damage and wear. damage. Measure the outside diameter and
compare to specifications. Replace the drive clutch
assembly if shaft is worn or damaged.
3. Lift bearing e and thrust washers r off shaft.

Replace as an assembly if worn, damaged, or if
problems were noted.
MEASUREMENT
Shaft Diameter:
Standard: 1.3745” - 1.375” (34.91 - 34.93 mm)
Service Limit: 1.3730” (34.87 mm)
5. Visually inspect PTFE thrust washers for damage.

Measure the thickness and compare to specification.
Replace if worn or damaged.
MEASUREMENT
PTFE Washer Thickness
Standard: .030” (.76 mm)
Service Limit: .025” (.64 mm)

PVT SYSTEM
BUSHING SERVICE NOTICE

NOTICE Bushings are installed at the factory using Loctite™
609. In order to remove bushings it will be necessary to
Special Tools Required
apply heat evenly to the area around each bushing.
Clean all residual Loctite™ from bushing bore prior to
installing new bushing.
ADDITIONAL SPECIAL TOOLS
QT- PAR-
PART DESCRIPTION CAUTION
Y. T#
Clutch components will be hot! In order to avoid serious
Clutch Bushing Replacement Tool Kit 2871- burns, wear insulated gloves during the removal
1
226 process.
2870-
1 Piston Pin Puller
386 Moveable Sheave - Bushing Removal
*Clutch Bushing Replacement Tool Kit (PN 2871226) 1. Remove clutch as outlined previously in this chapter.
2. Install handle end of the Piston Pin Puller securely
IT- QT- PAR-
PART DESCRIPTION into bench vise and lightly grease puller threads.
EM Y. T#
P-90 Drive/Driven Clutch Bushing 5020- Piston Pin Puller:
#2 1 PN 2870386
Install Tool 628
Drive Clutch Cover Bushing 3. Remove nut from puller rod and set aside.
Removal/Installation Tool (all 5020-
#3 1
clutches) 629
6
P-90 Driven Clutch Cover Bushing 5020-
#5 1
Removal Tool 631
Main Puller Adapter 5020-

#8 1
632
Adapter Reducer 5010-

#9 1
279
Number Two Puller Adapter 5020-

#10 1
633
4. Install puller adapter (Item 10 from kit).

Puller Adapter:
PN 2871226

PVT SYSTEM
5. Install main adapter (Item D) onto puller. 13. Thoroughly clean bushing bore
14. Apply Loctite™ 609 evenly to bushing bore inside
moveable sheave.
15. Set bushing in place on sheave.
16. Insert installation puller tool (Item A/B) with “A” side
down, into center of bushing.
17. With towers pointing upward, slide sheave, bushing
and tool onto puller rod.
18. Install nut on puller rod and hand tighten. Turn barrel
to apply additional tension if needed.
19. Turn sheave counterclockwise, making sure bushing
is drawn straight into bore. Continue until bushing is
seated.
20. Remove nut from puller rod and set aside.
21. Remove sheave from puller.
6. With towers pointing toward the vise, slide sheave
onto puller rod. 22. Remove installation tool.
7. Install removal tool (Item A, B) into center of sheave Cover Bushing Removal
with “A side" toward sheave. 23. Install main adapter (Item 8) on puller.
NOTICE
Use Bushing Tool PA-47336.
8. Install nut (C) onto end of puller rod and hand

tighten. Turn puller barrel to increase tension on
sheave if needed. Using a hand held propane torch,
apply heat around outside of bushing until tiny
smoke tailings appear.
9. Turn sheave counterclockwise on puller rod until it
comes free. Lift sheave off puller.
11. Pull bushing removal tool and adapter from puller
rod. Remove bushing from tool and discard.
Drive Clutch Bushing Installation
12. Place main adapter (Item 8) on puller.
24. Install adapter reducer (Item 9).
25. From outside of clutch cover, insert removal tool
(Item 3) into cover bushing.
26. With inside of cover toward vise, slide cover onto
puller.
27. Install nut onto puller rod and hand tighten. Turn
puller barrel to increase tension as needed.
28. Turn clutch cover counterclockwise on puller rod until
bushing is removed and cover comes free.
30. Remove bushing and bushing removal tool from
puller. Discard bushing.
Cover Bushing Installation
31. Apply Loctite™ 609 evenly to bushing bore in cover.

PVT SYSTEM
32. Working from inside of cover, insert new bushing and

bushing installation tool into center of clutch cover.
33. With main adapter on puller, insert cover onto puller
rod, placing outside of cover toward vise.
34. Install nut on rod and hand tighten. Turn puller barrel
to apply more tension if needed.
35. Turn clutch cover counterclockwise on puller rod until
bushing is seated.
36. Remove nut from puller rod. Take installation tool
and clutch cover off rod.

PVT SYSTEM
CLUTCH ASSEMBLY 3. Compress spider buttons for each tower and install
spider q, making sure that “X”, or the marks that
NOTICE were made earlier, on spider aligns with “X”, or the
The Teflon bushings are self-lubricating. marks that were made earlier, in moveable sheave.
4. Torque spider to specification using the holding
fixture and spider tool. Torque with smooth motion to
CAUTION avoid damage to the stationary sheave.
Do not apply oil or grease to the bushings.
TORQUE
Reassemble the drive clutch in the following sequence. Drive Clutch Spider:
Be sure the “X”, or the marks that were made earlier are 290 ft-lbs (393 Nm)
aligned during each phase of assembly.
5. Install shift weights using new lock nuts t on the
bolts.
1. Install the PTFE washers e and non braking bearing

r over the clutch shaft. There should be one fiber
washer on each side of the bearing. 6. Reinstall clutch spring.
2. Install the moveable sheave and spacer w onto the 7. Reinstall cover, aligning “X” mark with other marks.
clutch shaft. 8. Torque cover bolts evenly to specification.
NOTICE
TORQUE
To maintain proper clutch balance and belt-to-sheave
clearance. be sure to reinstall the original quantity and Drive Clutch Cover Screw:
thickness of washers / spacers beneath the spider 8 ft-lbs (10 Nm)
during assembly.

PVT SYSTEM
DRIVEN CLUTCH SERVICE

ASSEMBLY VIEW
q Subassembly, Stationary Boss u Cup, Spring Boss
w Roller, Clutch i Plate, Retainer

Screw
e Washer, Thrust o 9 ft-lbs (12 Nm)
r Ring, Retaining E-Ring External a Label, Clutch Boss
t Subassembly, Moveable Boss s Washer, Thrust
y Spring, Compression

PVT SYSTEM
CLUTCH DISASSEMBLY / INSPECTION 8. Remove the compressor tool from the clutch
assembly.
CAUTION
9. Remove the spring retainer (A), spring cup (B),
Hold outer sheave securely to relieve spring spring (C) and washer (D - early build only) from the
pressure while removing the retaining bolt. inner clutch sheave (E).
1. Mark the position of the clutch sheaves before clutch

removal or use the X’s on the sheaves for reference.
This aids in reassembly and maintains clutch
balance after reassembly.
10. Check the rollers in the stationary sheave for wear. If

rollers are worn, a new driven clutch assembly may
be needed.
11. Inspect the bearings inside the moveable sheave.
2. Remove the drive belt ().
12. Inspect driven clutch sheave faces for wear or
3. Remove the clutch retaining bolt and washer. damage.
4. Remove outer clutch sheave, thrust washers (3) and 13. Clean and inspect splines on helix and transmission
inner clutch sheave. input shaft.
5. Reassemble the clutch sheaves and place the driven 14. Lube splines with a light film of grease. Do not
clutch into a universal clutch compressor. Spin the lubricate the bearings!
tool down until it touches the spring cup.
6. Using a T30 Torx driver, remove the five screws that

secure the spring retainer to the inner clutch sheave.
7. Turn the compression tool handle counter-clockwise
to relieve spring pressure and allow the spring cup
and retaining ring to move out from the moveable
sheave.

PVT SYSTEM
CLUTCH ASSEMBLY SECONDARY CLUTCH ADJUSTMENT

1. Align the “X” marks on each of the sheaves during Vehicles that are equipped with a BOSS driven clutch
reassembly. may require the clutch to be shimmed for the following
concerns.
• Creeping
• Hard Shifting
• Belt tracking too close to one sheave
To correct any of these concerns proceed with the

following.
1. Check that the clutches are fully seated on the shafts

2. Disassemble the secondary clutch
• If belt is riding close to the primary clutch inside
fixed sheave
– Add 1 shim washer, 7556483 (0.059"
2. Assemble the clutch sheaves
thickness), in-between the secondary clutch
sheaves. This is in addition to the one factory-
installed shim washer 7556745 (0.120")
thickness, for a total of two washers inside the
clutch.
• If belt is riding close to the primary clutch outside 6
moveable sheave
– Remove the factory installed washer 7556745
(0.120") thickness and replace with the shim
washer, 7556483 (0.059" thickness)
3. If that still does not correct the issues, proceed with

loosening the transmission mounts for adjustment, or
install a known good primary clutch for trial.
3. Position the spring washer, spring, spring cup and

retaining ring into moveable sheave. Do not apply oil
or grease to the bearings.
4. Place the clutch into the universal clutch compressor.
Apply and hold downward pressure on the spring
cup. Torque the retaining ring bolts to specification.
TORQUE
Clutch Spring Retaining Ring Bolts:
12 ft-lbs (16 Nm)
5. Install driven clutch assembly and drive belt.

PVT SYSTEM
PVT SYSTEM TROUBLESHOOTING

TROUBLESHOOTING
-Wrong or broken drive clutch spring. -Replace with recommended spring.
Engine RPM
below specified -Drive clutch shift weight too heavy. -Install correct shift weight kit to match engine
operating range, application.
although engine -Driven clutch spring broken or installed in
is properly tuned. wrong helix location. -Replace spring; refer to proper installation
location.
-Drive clutch binding. A. Disassemble drive clutch; inspect shift
weights for wear and free operation.
B. Clean and polish stationary shaft hub;
reassemble clutch without spring to determine
Erratic engine problem area.
operating RPM
during -Belt worn unevenly - thin / burnt spots. Replace belt.
acceleration or
load variations. -Driven clutch malfunction. A. Replace ramp buttons.
B. Inspect movable sheave for excessive
bushing clearance.
-Sheave face grooved. -Replace the clutch.

-Incorrect drive clutch spring (too high spring -Install correct recommended spring.
rate).
-Drive clutch shift weights incorrect for -Install correct recommended shift weights.
application (too light).
-Drive clutch binding. -Disassemble and clean clutch, inspecting shift
weights and rollers. Reassemble without the
Engine RPM spring and move sheaves through entire range
above specified to further determine probable cause.
operating range.
-Driven clutch binding. -Disassemble, clean, and inspect driven clutch,
noting worn sheave bushing and ramp buttons
and helix spring location.
-Converter sheaves greasy; belt slippage. -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
belt. with shim washers beneath spider.
-Wrong belt for application. -Replace with correct belt.
Drive belt turns -Clutch alignment out of spec. -Adjust alignment offset.
over
-Engine mount broken or loose. -Inspect / adjust or replace.
-Abuse (continued throttle application when -Caution operator to operate machine within
vehicle is stationary, excess load) guidelines.
Belt burnt, thin -Dragging brake -Vehicle operated with park brake on. Inspect
spots brake system.
-Slow, easy clutch engagement
-Fast, effective use of throttle for efficient
engagement.

PVT SYSTEM
-Plugged air intake or outlet. -Clear obstruction
-Belt slippage due to water, oil, grease, etc., -Inspect system. Clean , repair or replace as
rubbing on cover.-Clutches or weight being necessary.
PVT cover applied to cover while in operation. Seal PVT system ducts.
overheating
(melting) -High vs. low range. -Remove weight. Inform operator.
-Instruct operator on guidelines for operation in

proper driving range for different terrain as
outlined in Owner’s Safety and Maintenance
Manual.
-Cover seals or ducts leaking -Find leak and repair as necessary.
Water ingestion -Operator error -Instruct operator on guidelines for operation in

wet terrain as outlined in Owner’s Safety and
Maintenance Manual.
-Belt worn out -Replace belt.
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 -Replace belt.
PVT noise belt-Broken or worn clutch components, -Inspect and repair as necessary. 6
cover hitting clutches
-Replace belt. Refer to belt burnt troubleshooting
Engagement -Thin spots on belt, worn belt
and instruct operator.
erratic or stabby -Drive clutch bushings stick
-Inspect and repair clutches.

PVT SYSTEM
NOTES

TRANSMISSION
CHAPTER 7
TRANSMISSION
SPECIAL TOOLS, TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
TRANSMISSION GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
TRANSMISSION MOUNTING AND TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
TRANSMISSION ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
SHIFT CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
SHIFT CABLE REMOVAL / INSTALL AND ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.10
TRANSMISSION SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.13 7
TRANSMISSION INTERNALS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.16
DIFFERENTIAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.16
TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.17
PLANETARY DIFFERENTIAL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.22
PLANETARY DIFFERENTIAL BUSHING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.23
PLANETARY DIFFERENTIAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.25
GEAR / SHAFT / BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.26
SNORKEL GEAR BACKLASH PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.27
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.35
TROUBLESHOOTING CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.35

TRANSMISSION
GENERAL INFORMATION
SPECIAL TOOLS, TRANSMISSION
PA-50231 Snorkel Tool
2871698 (Part of
Rear Output Seal Driver
2871702 Kit)
2871699 (Part of
2871702 Kit) Rear Driveshaft Seal Guide
2871282 Bearing Seal Driver (50 mm)

PU-50566 Transmission Nut Socket
PU-50658 Clutch Center Distance Tool
Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/

TRANSMISSION
SPECIAL TOOLS

TRANSMISSION
TRANSMISSION GEARS
Refer to the Polaris Electronic Parts Catalog for gear
tooth counts and part numbers.
To access the Polaris Electronic Parts Catalog, visit:
http://parts.polarisind.com/browse/browse.asp
LUBRICATION
FLUID CAPACITY
Recommended Transmission Lubricant:
AGL (PN 2878068) (Quart)
Capacity: 41 oz. (1200 ml)

TRANSMISSION
TRANSMISSION MOUNTING AND TORQUE VALUES
REF. DESCRIPTION NOTES 7

q Bolt Torque to 55 ft-lbs (75 Nm)
w Bolt Torque to 40 ft-lbs (54 Nm)
e Bolt Torque to 25 ft-lbs (34 Nm)

TRANSMISSION
ASSEMBLY VIEW
TRANSMISSION ASSEMBLY VIEW

TRANSMISSION
REF. DESCRIPTION REF. DESCRIPTION REF. DESCRIPTION

1. Plug, M18 34. Bearing, Ball 70. Gear, Low 67T
2. Magnetic Plug, M18 35. Bearing, Ball 71. Dog, Engagement
3. Plug, Cap Vent 5/16 36. Bearing, Needle 72. Gear, 53T
Screw, Hex Flange Head M8 x Bearing, Ball Gear, 46T
4. 37. 73.
1.25 x 30
Screw, Hex Flange Head M6 x 1 x Bearing, Ball Gear, 13T Snorkel
5. 38. 74.
20
6. Screw, Hex Flange Head M8 x 50 39. Spring, Compression 75. Shaft, Shift
Screw, Socket Head M6 x 1.0 x Spring, Compression Weldment, Rear Mount Bracket
7. 40. 76.
40
8. Screw, Socket Head 41. Spring, Torsion Return 77. Subassembly, Differential
9. Screw, Torx M6 x 1.0 x 18 42. Spring, Compression 78. Retainer, Fork
10. Nut, Lock Hex Flange M8 x 1.25 43. Spring, Compression 79. Bracket, Rear Mount
11. Washer, Cup 44. Spring, Wave 80. Cover, Bearing, Center Drive
12. Plate, Park 12–face 45. Tube, Snorkel 81. Spacer
13. Washer 46. Cover, Sector Gears 82. Chain, Silent .25P x .40W x 58L
14. Washer 47. Subassembly, LH Case 83. Diff Solenoid
15. Washer 48. Subassembly, RH Case 84. Switch, Rotary 2–pin
16. Pin, Dowel 6 x 20 49. Drum, Shift 85. O-ring
17. Pin, Spring, Slotted 6 x 12 50. Gear, Sector 16T 86. O-ring
18. Ring, Retaining 51. Gear, Sector 31T 87. O-ring
19. Ring, Retaining 56. Shaft, Reverse 25T 88. Seal, Triple Lip 25 x 80 x 10
7
20. Ring, Retaining 57. Shaft, Front Output 89. Seal, Dual Lip 25 x 47
21. Ring, Retaining 58. Shaft, Input 90. Seal, Triple Lip 40 x 70 x 7
22. Ring, Retaining 59. Subassembly, Pinion 92. Sensor, Speed
23. Ring, Retaining 60. Bellcrank 95. Bracket, Wire Harness
24. Ring, Retaining 61. Collar, Shift 96. Plug, Expansion 1 1/4
25. Ring, Retaining 62. Rail, Shift Shaft 97. Subassembly, 39T Side Gear
26. Ring, Retaining 63. Tube, Vent 98. Bearing, Plain 40 x 44 x 15
Washer, Thrust Fork, Pivot Shift Subassembly, 39T Side Gear

27. 64. 99.
Disconnect
28. Washer, Thrust 65. Dog, Engagement 100. Subassembly, Diff Cover
29. Shim, 1.180 OD x .995 ID 66. Shift Dog, Park 101. Subassembly, Planet Gear
30. Shim 2.040 OD x 1.63 ID 67. Gear, 48T 102. Subassembly, Gear 53T
31. Bearing, Needle 68. Subassembly, Shift Fork 104. Screw, Cap M8 - 1.25 x 25
32. Bearing, Ball 69. Sprocket, 48T 105. Bracket, Wire Harness
33. Bearing, Ball

TRANSMISSION
SHIFT LEVER
REMOVAL 5. Remove both bushings o from the shift lever and
1. Remove the shift knob cover q , retaining screw w service as needed.
and shift knob e from the shift lever r.
INSTALLATION
1. Perform the removal steps in reverse order to install
the gear shift lever (lever, cable, console, shift knob)
2. Remove the screws retaining the center console

using a T27 and T30 Torx driver. Remove the
console from the vehicle.
3. Remove the clip t and washer y retaining the shift
cable u to the shift lever and disconnect the cable
end from the lever.
4. Remove the retaining ring i and slide the shift lever

off the mounting bracket and out from the frame.

TRANSMISSION
SHIFT CABLE
INSPECTION 6. Tilt the box to access the cable where attached to the
Shift cable adjustment may be necessary if symptoms transmission linkage. Remove the clip and washer
include: attaching the cable to the linkage e.
• No gear position display on instrument cluster

• Inability to engage into or stay in a gear
• Excessive gear lash (noise)
Inspect shift cable, clevis pins, and pivot bushings and

replace if worn or damaged.
SHIFT CABLE REMOVAL / INSTALL AND

ROUTING
REMOVAL
1. Open hood to gain access to shift cable
2. Remove the clip and washer retaining the shift cable 7. Loosen the jam nut holding the cable to the Shift
to the shift lever q. Disconnect cable end from the Cable Bracket r.
lever.
8. Gently pull the cable towards the rear of the vehicle to
remove the cable from the vehicle.
IMPORTANT
Pay close attention to the shift cable routing while
removing so that cable can be routed correctly on
installation. 7
INSTALLATION
1. Feed the cable from the rear of the vehicle towards
the front of the vehicle.
2. Attach the Cable to the shift handle
3. Position the cable in the Shift Cable bracket and
tighten the jam nut.
3. Loosen the jam nut w, and remove the cable from the 4. Install the shift cable to the transmission linkage.
bracket.
5. Position the cable in the Shift Cable Bracket and
4. Remove the center floor cover, refer to Floor / Rear tighten the jam nut.
Fenders page 11.9.
6. Perform any cable adjustments needed at this time.
5. Remove the shift cable from the retainers. Refer toAdjustment page 7.10 for the cable
adjustment procedure.

TRANSMISSION
ROUTING 4. Adjust the shift cable so there is the same amount of

cable travel when shifting slightly past HIGH gear
and PARK.
5. Thread the upper or lower jam nut as required to
obtain proper cable adjustment.
NOTICE
This procedure may require a few attempts to obtain
the proper adjustment.
6. Once the proper adjustment is obtained, place the

shift cable and upper jam nut into the mount. Tighten
the lower jam nut against the mount.
7. Start engine and shift through all gears to ensure the
Image shown from right side of vehicle shift cable is properly adjusted. If transmission still
ratchets after cable adjustment, the transmission will
require service.
Image shown from top view
ADJUSTMENT
1. Locate the shift cable attached to the transmission
case in the right rear wheel well area.
2. Inspect shift cable, clevis pin, pivot bushings, and
dust boot. Replace if worn or damaged.
3. If adjustment is required, loosen the lower jam nut q
and pull the cable out of the mount to move the
upper jam nut w.

TRANSMISSION
TRANSMISSION SERVICE
TRANSMISSION REMOVAL 8. Remove the breather hose (Item 2), loosen the air
intake duct clamps (Item 3), remove the duct
WARNING mounting bolt (Item 4) and remove the intake duct
Serious injury may result if machine tips or falls. Be (Item 5).
sure machine is secure before beginning this
procedure. Always wear eye protection.
1. Remove the cargo box and seat (see Chapter 5).

2. Disconnect the (-) negative battery cable from the
battery.
3. Raise and support the vehicle.
4. Remove the propshaft from the transmission output
shaft (see Chapter 7).
9. Disconnect the main harness from the IAC and TPS

at the throttle body.
10. Loosen the air box to throttle body clamp (Item 6)
and move the air box assembly (Item 7) out of the
way towards the driver’s seat..
7
5. Remove rear wheels from the vehicle.
6. If internal transmission repair is required, drain the
transmission lubricant (see Chapter 2).
7. Remove the air box mounting bolt (Item 1).
11. Remove the outer clutch cover, drive belt, drive

clutch, driven clutch, inner clutch cover and clutch
outlet duct (see Chapter 6).
NOTICE
Be sure to use the correct Drive Clutch Puller (PA-
48595) to prevent damage to crankshaft.
12. Remove driveshaft from both sides (see Chapter 7).

TRANSMISSION
13. Place a spacer or support between the vehicle frame 17. Using a 15mm socket, remove the four bolts (Item
and engine to hold the engine up in position. 13) from the coupler securing the transmission to the
engine.
14. Remove vent hose from transmission.

18. Remove the two bolts (Item 14) attaching the rear
15. Remove the gear position switch connector (Item 8),
transmission mount bracket assembly to the frame.
speed sensor connector (Item 9), crankshaft position
Remove the bolt (Item 15) that attaches the rear
sensor connector, shift bracket bolts (Item 10) and
mount to the transmission. Remove the mount
shift bracket (Item 11), shift cable clevis pin and
assemblies from the vehicle.
washer (Item 12) from the transmission.
19. Using an overhead lift or an assistant, lift the
transmission up and out of the chassis.
16. Remove the wire ties retaining the main harness

harness to transmission and mounts.

TRANSMISSION
TRANSMISSION INSTALLATION 4. Install the Clutch Center Distance Tool (PU-50658)

1. With the help of an assistant, position the onto the crankshaft and transmission input shaft to
transmission into the vehicle frame through the top. properly position the clutch center distance. The
pictures below show the tool (PU-50658) properly
2. Install the rear transmission mount assemblies.
installed.
Torque all fasteners to specification.

q Fastener Bolt Torque: 40 ft-lbs
(54 Nm)
w Fastener Bolt Torque: 25 ft-lbs

(34 Nm)
TORQUE 7
Rear Transmission Mount Bracket Bolts:
17 ft-lbs (23 Nm)
3. By hand, install the coupler brackets and the eight

engine to transmission coupler bolts. Do not torque
fasteners at this time. 5. In sequence, torque the eight engine coupler bracket
TORQUE
Engine to Trans Coupler Fasteners

TRANSMISSION
6. Remove the clutch center distance tool. 14. Install new spring ring (Item 13) on rear drive shafts.
Apply an anti-seize compound to the splines (Item
7. Remove the spacer or support between the vehicle 14).
frame and engine.
15. Reinstall the driveshafts into the bearing carriers and

8. Install and properly route the gear position switch
fasten the bearing carriers to the control arms.
connector (Item 8), speed sensor connector (Item 9),
Torque fasteners to specification.
crankshaft position sensor connector, shift bracket
bolts (Item 10), shift bracket (Item 11), shift cable TORQUE
clevis pin and washer (Item 12) onto the
transmission. Bearing Carrier Fasteners:
40 ft-lbs (54 Nm)
16. Install rear wheels and wheel nuts. Torque to

specification.
TORQUE
Steel Wheel Nuts:
36 ft-lbs (49 Nm)

30 ft-lbs + 90º (41 Nm + 90º)
17. Properly lower the vehicle.

18. Install cone washers and castle nuts for the
9. Torque the (2) shift cable bracket bolts to driveshafts. Torque to specification.
specification. TORQUE
TORQUE Castle Nut110 ft-lbs (150 Nm)
Shift Cable Bracket Bolts:
37 ft-lbs (50 Nm) 19. Install a new cotter pin into each castle nut and
install the caps.
10. Install three wire ties to retain wire harness to 20. Install the throttle body, air box assembly and
transmission and mounts. ducting.
11. Install and properly route the vent hose. 21. Reconnect the TPS and IAC harnesses.
12. Lubricate the transmission splines and mid prop 22. Connect the (-) negative battery cable and reinstall
shaft joint splines with Polaris All Purpose Grease. the seat base.
Install the prop shaft onto the transmission output
shaft (see Chapter 7). 23. Reinstall the cargo box.
13. Install inner clutch cover, outlet duct, drive clutch,

driven clutch, belt and outer clutch cover (see
Chapter 6).

TRANSMISSION
24. If transmission lubricant was drained, fill the

transmission with the specified amount of Polaris
AGL (see Chapter 2 “Transmission Lubrication”).
FLUID CAPACITY
Recommended Transmission Lubricant:
AGL (PN 2878068) (Quart)
Capacity : 41 oz. (1200 ml)

TRANSMISSION
TRANSMISSION INTERNALS SERVICE

DIFFERENTIAL OPERATION When “Differential-Unlock” is selected, the rear
The transmission has two traction operational modes: differential becomes unlocked for tighter turns. An
Differential Lock and Differential Unlock. Locking the rear electrical solenoid mounted in the rear portion of the
differential is beneficial in low traction and rough terrain gearcase actuates the shift fork. The solenoid plunger
conditions. Unlocking the rear differential makes extends out to move the fork and slides the engagement
maneuvering easier and minimizes damage to terrain. dog away from the side gear that is part of the planetary
differential assembly. This unlocks the rear differential.
The rear drive shafts are now dependent on the
differential allowing for tighter turns.
When “Differential-Lock” is selected, power is removed

from the electrical solenoid allowing the solenoid plunger
to retract. Spring tension moves the shift fork back into
place and mates the engagement dog to the side gear
that is part of the planetary differential assembly. This
locks the rear differential as a solid rear axle, increasing
traction.

TRANSMISSION
TRANSMISSION DISASSEMBLY 6. Remove the compression spring (H).

NOTICE
Refer to the exploded view at the end of this chapter as
a reference.
1. Place transmission in High gear before disassembly.

2. Drain and properly dispose of the transmission
lubricant (see Chapter 2).
3. Remove the bell crank nut (A) and bell crank (B).
7. Remove the detent star (I). Note how the detent star
fits onto the splined shaft with the raised edge facing
outward for reassembly.
8. Remove the spacer (J).
9. Remove the shift shaft (K), detent pawl (L) and the
shift sector gears (M and N).
NOTICE
Note the timing marks on the shift gears (M and N) for
reassembly purposes.
7
4. Remove E-clip (C) that retains spring washer (D), flat
washer (D) and gear switch (E). Remove the switch. 10. Remove the O-rings (P) from each shaft and discard.
Use new O-rings upon assembly.
5. Remove the sector cover bolts (F) and remove the
sector cover (G).
NOTICE
Removal can be aided by using your thumbs to press in
on the shafts while pulling out the cover with your
fingers.

TRANSMISSION
11. Remove all transmission case bolts. Using suitable 13. Remove the shift shaft rail (Q) and shift forks from
pry bars, remove the cover using the designated pry the transmission housing as an assembly.
points (indicated by black arrows in illustration
below).
14. Remove the rear output shaft assembly (S) by lifting

underneath the gear or by tapping the shaft from the
opposite side. If use of a pry bar is necessary, take
care not to pry on sealing surfaces of case.
CAUTION
Do not pry on case sealing surfaces. Use only the
designated pry points on the transmission.
12. Lift up on the shift shaft rail (Q) and move the rail
assembly rearward to allow the shift fork pins to be
removed from the shift drum (R). Remove the shift
drum (R) from the transmission housing.

TRANSMISSION
15. Remove the idler gear shaft assembly (T) and gear 19. Using a 5 mm Allen wrench, remove the screws that
cluster assembly (U) from the transmission housing secure the pinion shaft assembly (V). Lift the pinion
by pulling both assemblies straight up. shaft assembly straight up to remove it from the
housing. Note the longer screw (W) that locks the
snorkel tube.
16. Place the idler gear shaft assembly (T) and gear
cluster assembly (U) on a clean surface for
inspection. If disassembly is required, refer to “Gear 20. Remove all seals from the gearcase halves and
Cluster Disassembly”. clean the cases in preparation for assembly.
17. Slide engagement dog (X) off of shift fork guides. Gear Cluster Disassembly
21. Remove the bearing from the reverse shaft using a
18. Remove two screws and retaining plates, then lift bearing puller. Remove the retaining ring and slide
shift fork (Y) and torsion spring out of transmission the washers, 53T gear and needle bearing off the
housing. reverse shaft (see Figure 8-1).
7
22. Remove the retaining ring and engagement dog from

the reverse shaft (see Figure 8-1).

TRANSMISSION
23. Remove the retaining ring, washer, needle bearing, Snorkel Shaft Removal / Disassembly
and sprocket from the reverse shaft (see Figure 8-1).
24. Tilt the two shafts towards each other and remove CAUTION
the silent chain from the two shafts. The pinion shaft must be removed prior to removing the
25. If necessary, disassemble the other end of the snorkel shaft assembly. Failure to remove pinion shaft,
reverse shaft. Remove the bearing, engagement will result in damage to the snorkel shaft.
dog, retaining ring, washer, gear and needle bearing
from the reverse shaft (see Figure 8-2). 27. Extract the seal from the snorkel shaft to access the
snorkel tube for removal.
28. Using the Snorkel Tool (PA-50231), fully loosen the

snorkel tube.
26. To disassemble the shift shaft rail remove the snap
ring (X) from the end of the shift rail on either side.
CAUTION
Use caution when disassembling the shift rail. The
compressed springs on the shift rail may pop off
causing eye or face injury.

TRANSMISSION
29. Remove the snorkel tube and shaft assembly from 33. Lightly tap on the bearing from the opposite side to
the transmission case. remove it from the snorkel tube.
30. Remove the snap ring (Y) and shim (Z) from the 34. Remove the retaining ring to remove the remaining
snorkel shaft. washer, bearing and gear from the snorkel shaft.
31. Use an arbor press to remove the snorkel tube from

the snorkel shaft.
32. Remove the snap ring (A) and shim (B) retaining the
bearing in the snorkel tube.

TRANSMISSION
PLANETARY DIFFERENTIAL 3. Remove the (6) planet gears and each side gear
DISASSEMBLY assembly from the ring gear.
NOTICE
If the gearcase is completely assembled, perform the
“Gearcase Disassembly and Inspection” procedure.
1. Use a scribe to mark the differential cover and ring

gear prior to disassembly.
4. Inspect the female side gear (A), male side gear (B),
planet gears (C) and ring gear (D). Replace
components or bushings as needed. Bushing
replacement can be performed on all necessary
differential components. If bushing replacement is
required, proceed to Planetary Differential Bushing
Replacement”.
2. Remove the (6) screws retaining the differential
cover and remove the cover.

TRANSMISSION
PLANETARY DIFFERENTIAL BUSHING 4. Install the bushing to the specified depth as shown.
REPLACEMENT
NOTICE
If the differential is completely assembled, perform the
“Planetary Differential Disassembly” procedure.
Ring Gear Bushing Replacement

1. Press the old bushing out of the ring gear.
2. Thoroughly clean the bore of the ring gear and check
for any unwanted burs.
3. Press the new bushing into the ring gear housing.
Planet Gear Bushing Replacement 7

5. Press the old bushing out of the planet gear.
6. Thoroughly clean the bore of the planet gear and
check for any unwanted burs.
7. Press the new bushing into the planet gear until it is
flush on each end. Repeat this procedure for the
remaining planet gears.
Differential Cover Bushing Replacement

8. Press the old bushing out of the differential cover.
9. Thoroughly clean the bore of the differential cover
and check for any unwanted burs.

TRANSMISSION
10. Press the new bushing into the differential cover. 12. Locate the bushing split. Using a small chisel or flat
blade screwdriver, peel back and remove the old
bushing from the side gear, being careful not to
damage the side gear.
13. Thoroughly clean the bore of the side gear and

check for any unwanted burs.
14. Press the new bushing into the side gear until it
11. Install the bushing to the specified depth as shown. bottoms out.
Female Side Gear Bushing Replacement

TRANSMISSION
PLANETARY DIFFERENTIAL ASSEMBLY

1. Thoroughly clean the differential components.
2. Assemble the side gears and place them onto the
ring gear along with the (6) planet gears.
3. Align and install the differential cover using the

previously made scribe marks.
4. Apply Loctite® 2760™ to cover screws.
5. Install screws hand tight. Place assembly in soft jaw
vise and torque to specification.
TORQUE
Differential Cover Screws:
22 ft-lbs (30 Nm)

TRANSMISSION
GEAR / SHAFT / BEARING INSPECTION

TRANSMISSION
SNORKEL GEAR BACKLASH 4. Apply a small amount of white lithium grease or Anti-
PROCEDURE Seize on the threads of the snorkel tube.
1. Reassemble the snorkel tube and snorkel shaft
assembly by reversing the disassembly procedure
(see “Snorkel Shaft Removal / Disassembly”).
5. Install the snorkel shaft into the gearcase. Using the

Snorkel Tool (PA-50231), tighten the snorkel tube
until it is lightly seated in the transmission housing.
2. After the 13T gear and bearing are pressed onto the
snorkel shaft (flush to the shoulder), install the
7
washer and new retaining ring.
3. Press the gear back towards the retaining ring. Avoid
excessive force so the retaining ring is not damaged
or pre-stressed significantly.
NOTICE
Failure to press the gear back against the washer and
retaining ring will lead to a gear backlash change after
vehicle is placed into service.

TRANSMISSION
6. Inspect the pinion shaft assembly. Replace bearings 9. Using a 5 mm Allen wrench, install only the (3)
if needed. Inspect each gear for damage, chips or screws that secure the pinion shaft assembly as
abnormally worn teeth. shown below. Leave the longer locking screw (A) out
at this point.
NOTICE
NOTICE DO NOT install the longer screw (A). Installing the
If pinion shaft was disassembled, the bearing cover longer screw will lock the snorkel tube and not allow for
must be installed on the shaft before installing the 46T backlash setting adjustment.
gear.
10. Torque the bearing cover retaining screws to
7. Install the pinion shaft assembly. Be sure to properly specification.
mesh the snorkel shaft bevel gear with the pinion
shaft bevel gear. TORQUE
8. Apply Loctite® 242™ to the threads of the bearing Snorkel Bearing Cover Retaining Screws:
cover retaining screws. 8 ft-lbs (11 Nm)
11. Rotate the snorkel tube counterclockwise using the

snorkel tool (PA-50231) until the snorkel gear and
pinion gear have ‘zero’ backlash.
NOTICE
DO NOT overtighten the snorkel tube when backing it
out. At the 'zero' backlash position, you should still be
able to turn the snorkel shaft using your fingers, but it
will feel rough and may have some tight spots.
12. Look down into the transmission housing to see the

snorkel locking screw hole opening to reference your
starting point.
NOTICE
If you have a hard time seeing into the hole, insert a
small Allen wrench, punch or screwdriver into the hole
to feel when the notch is aligned with the hole.

TRANSMISSION
13. Slowly rotate the snorkel tube clockwise while 16. Torque the locking screw to specification.
counting the number of notches passing through the
hole opening as you rotate the tube. Rotate the
snorkel tube to the 3rd notch from the ‘zero’
backlash position obtained in step 11.
TORQUE
Snorkel Locking Screw:
8 ft-lbs (11 Nm)
14. Check the pinion shaft gear backlash again by feel. If
the pinion shaft gear lash appears to be too tight,
rotate the snorkel shaft clockwise to the next notch Transmission Assembly
(4th notch).
NOTICE
15. Once the backlash is set, apply Loctite® 242™ to the
threads and install the locking screw to secure the The snorkel shaft and pinion shaft must be installed
snorkel tube. prior to transmission assembly. The snorkel shaft
cannot be installed after assembling the transmission. 7
17. Clean both transmission case halves thoroughly.
Inspect case half mating surfaces for damage.
18. Install shift fork (S) and torsion spring into
transmission housing as an assembly. Load spring
as shown in image below

TRANSMISSION
19. Apply Loctite® 242™ to two screws (T) and install 21. Assemble the reverse shaft assembly and input shaft
with retaining plates over shift fork. Torque to assembly if previously disassembled (see
specification. illustrations).
TORQUE
Shift Fork Screws:
10 ft-lbs (14 Nm)
20. Slide engagement dog (U) onto retaining pins of shift

fork.

TRANSMISSION
22. Install the idler gear shaft assembly (A) and gear 24. Assemble shift shaft rail if previously disassembled.
cluster assembly (B) into the transmission housing,
all at the same time.
NOTICE
23. Install the rear output shaft assembly (C). Rotate Both shift forks need to be orientated the same way, so
output shaft assembly to align slots with engagement that the shift fork pins are both offset to the same side
dog. Ensure bearing is fully seated upon assembly. of the rail.
25. Install the shift shaft rail (D) and shift forks into the
transmission housing as an assembly. Be sure the
shift forks are engaged into the engagement dogs.
NOTICE
Shift fork pins should be offset towards the input shaft
as shown above.

TRANSMISSION
26. Inspect the shift drum for any damage or wear. 29. Install the transmission case cover and retaining
Inspect the splines of the shift drum. bolts. Torque bolts to specification.
27. Install the shift drum (E) into the transmission

housing. Lift up on the shift shaft rail (D) and move
the rail assembly towards the shift drum to allow the
shift fork ends to be installed into the shift drum (E).
TORQUE
Transmission Case Bolts:
18 ft-lbs (24 Nm)
30. Install new seals into the transmission case halves.

• The snorkel shaft seal (F), should be pressed in until it
seats against the housing counter-bore.
• The input shaft seal (G), should be pressed in until it
seats flush with the housing.
• The rear output shaft seals (H) and pinion shaft seal
(J) can be installed using a standard bushing
installation tool. Seals should be installed just past the
case lead-in chamfer (.070" or 1.8 mm from outer face
of bore).
28. Apply a continuous bead of Crankcase 3 Bond
Sealant (PN 2871557) to the left hand transmission
mating surface.

TRANSMISSION
31. Thoroughly clean the shift shaft housing. Be sure 34. Install the detent star onto the shift drum shaft. Be
the transmission is in High gear prior to sure to install the detent star with the raised edge
reassembly. facing outward and skip-tooth aligned.
35. Install the detent pawl onto the shift shaft and
carefully install the compression spring.
32. Install the sector gear (16T) onto the shift drum shaft.
Install the shift shaft assembly and sector gear (11T)
into the bushing pocket on the left side. Align the
timing marks on the gears as shown. 36. Install a new O-ring on each shift shaft. Apply a small
amount of white lithium grease on the O-rings, shift
shafts and component contact surfaces prior to
installing the sector cover.
33. Install the spacer onto the shift drum shaft.
37. Clean the transmission and gear sector cover mating

surfaces thoroughly.
38. Apply Crankcase Sealant (3-Bond) (PN 2871557)
onto the cover and transmission case mating
surface.
39. Install the sector cover and align the transmission
case dowel with the alignment hole. Install and
torque the bolts to specification.
TORQUE
Sector Cover Bolts:
11 ft-lbs (15 Nm)

TRANSMISSION
40. Install the transmission drain plug and torque to

specification.
TORQUE
Transmission Fill / Drain Plug:
14 ft-lbs (19 Nm)
41. Install the bellcrank onto the shift shaft. Note the key
splined on the bellcrank and shift shaft. Install the nut
and torque to specification.
TORQUE
Bell Crank Nut:
15 ft-lbs (20 Nm)
42. Refer to “Transmission Installation” to complete the

repair.

TRANSMISSION
TROUBLESHOOTING
TROUBLESHOOTING CHECKLIST
Check the following items when shifting difficulty is
encountered.
• Shift cable adjustment/condition

• PVT alignment (clutch center distance)
• Idle speed (throttle cable routing)
• Transmission lubricant type/quality
• Loose fasteners on sector gear cover
• Worn rod ends, clevis pins, or pivot arm bushings
• Shift selector rail travel
• Worn, broken or damaged internal transmission
components
NOTICE
To determine if shifting difficulty or problem is caused
by an internal transmission problem, isolate the
transmission by disconnecting the shift cable end from
the transmission bellcrank. Manually select each gear
range at the transmission bellcrank, and test ride
vehicle. If it functions properly, the problem is outside
the transmission.
If transmission problem remains, disassemble

transmission and inspect all gear dogs for wear 7
(rounding) or damage. Inspect all bearings, circlips,
thrust washers and shafts for wear.

TRANSMISSION
NOTES

FINAL DRIVE
CHAPTER 8
FINAL DRIVE
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
FRONT HUB / BEARING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
HUB REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
HUBSTRUT BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
HUB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
FRONT HUB/WHEEL EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
FRONT DRIVE SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
FRONT DRIVE SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
FRONT GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.10
GEARCASE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.10
GEARCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.10
FRONT GEARCASE (NON-ADC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.12
FRONT GEARCASE ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.12
ALL WHEEL DRIVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.13
AWD DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.14
FRONT GEARCASE DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.15
FRONT GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.18
FRONT GEARCASE (ADC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.21
EXPLODED VIEW, FRONT GEARCASE (4WDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.21
OPERATION, FRONT GEARCASE (4WDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.23 8
DISASSEMBLY / INSPECTION, FRONT GEARCASE (ADC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.24
REASSEMBLY, FRONT GEARCASE (ADC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.28
TROUBLESHOOTING, FRONT GEARCASE (ADC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.31
REAR BEARING CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.35
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.35
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.35
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.36
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.37
REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.38
REAR DRIVE SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.38
REAR DRIVE SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.38
DRIVE SHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.39
DRIVE SHAFT / CV JOINT HANDLING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.39
OUTER CV JOINT / BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.39
INNER PLUNGING JOINT / BOOT REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.42
DRIVE SHAFT ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.44
PROPSHAFT U-JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.45
REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.45

FINAL DRIVE
FRONT PROP SHAFT COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.45

REMOVAL / INSTALLATION (CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.45
SUPPORT BEARING REPLACEMENT (CREW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.46
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.47
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.48

FINAL DRIVE
GENERAL INFORMATION
SPECIAL TOOLS
PART TOOL DESCRIPTION
NUMBER
2872608 Roll Pin Removal Tool
PU-48951 CV Boot Clamp Tool
or 8700226


FINAL DRIVE
FRONT HUB / BEARING

HUB REMOVAL / INSPECTION 6. Rotate each bearing r by hand and check for
1. Elevate and safely support front end of the machine smooth rotation. Visually inspect bearing for
under the footrest / frame area. moisture, dirt, or corrosion. Replace bearing if
moisture, dirt, corrosion, or roughness is evident.
CAUTION
procedure. Wear eye protection when removing
bearings and seals.
2. Check bearings for side play by grasping the tire /

wheel firmly and checking for movement. Grasp the
top and bottom of the tire. The tire should rotate
smoothly without binding or rough spots.
HUBSTRUT BEARING REPLACEMENT

Bearing Removal
1. Remove outer snap ring q.
3. Remove wheel nuts, washers, and wheel.

4. Remove the two brake caliper mounting bolts.
CAUTION
Do not hang the caliper q by the brake line. Use wire to
hang the caliper to prevent possible damage to the
brake line.
2. From the back side, tap on the outer bearing race

with a drift punch in the reliefs as shown in Step 3.
5. Remove hub cap, cotter pin e, front spindle nut w,

and washer.

FINAL DRIVE
3. Drive bearing out evenly by tapping on outer race 7. Wipe the housing clean of any excess compound
only. Once bearing is at bottom of casting, support and install the retaining ring.
casting on outer edges so bearing can be removed.
HUB INSTALLATION
1. Inspect the hubstrut bearing surface for wear or
damage.
2. Apply anti-seize to drive axle spindle.
3. Install spindle through the backside of the hubstrut.
Install the hub onto the spindle.
NOTICE
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. 4. Install cone washer with domed side out.
4. Inspect bearing hubstrut housing for scratches, wear

or damage. Replace hubstrut housing if damaged.
Bearing Installation
5. Thoroughly clean the hubstrut housing and the outer
race on the new bearing. Be sure that all oil residue
has been removed from each surface. 8
6. Apply Loctite RC™ 680 to the outer circumference
of the new bearing race w and carefully install the
new bearing into the strut housing.
5. Install flat washer and spindle nut and tighten to

specification.
TORQUE
Front Hub Nut Torque:
90 ft-lbs (122 Nm)
6. Install a new cotter pin. Tighten nut slightly if

necessary to align cotter pin holes.
7. Rotate wheel and check for smooth operation. Bend
both ends of cotter pin around end of spindle in
NOTICE different directions.
Use care to not allow any of the Loctite compound to 8. Install hub cap.
get in the bearing.

FINAL DRIVE
9. Rotate hub. It should rotate smoothly without binding

or rough spots or side play.
10. Install brake caliper using new bolts q. Tighten bolts
to specified torque.
TORQUE
Brake Caliper Bolt Torque:
46 ft-lbs (62 Nm)
CAUTION
New brake disc bolts have a pre-applied locking agent
which is destroyed upon removal. Always use new
brake disc mounting bolts upon assembly if removed.
11. Install wheel, washers, wheel nuts, and tighten

evenly in a cross pattern to specified torque.
Refer to “Torque Specifications”.

FINAL DRIVE
FRONT HUB/WHEEL EXPLODED VIEW

q Cotter Pin
w Castle Nut 90 ft-lbs (122 Nm)
e Washer 8
r Wheel Nut Steel Wheel Nuts:
36 ft-lbs (49 Nm)
30 ft-lbs + 90º (41 Nm + 90º)
t Washer
y Tire
u Rim
i Front Hub
o Stud
a Brake Disc
s Bolt

FINAL DRIVE
FRONT DRIVE SHAFT

FRONT DRIVE SHAFT REMOVAL 6. Remove the front wheel hub.
1. Elevate front of vehicle and safely support machine
under the frame area.
CAUTION
bearings and seals.
2. Check bearings for side play by grasping tire / wheel

firmly and checking for movement. It should rotate
smoothly without binding or rough spots.
7. Remove cotter pin w and castle nut e from A-arm

ball joint.
3. Remove the four wheel nuts and remove the front

wheel.
4. Remove the brake caliper mounting bolts q.
8. Remove lower A-arm from ball joint using a tie rod

fork.
CAUTION
Do not hang the caliper by the brake line. Use wire to
hang the caliper to prevent possible damage to the
brake line.
5. Remove and discard the cotter pin, then remove the

front hub castle nut.

FINAL DRIVE
9. Pull strut assembly out while pivoting front drive shaft 3. Install the lower A-arm onto the lower ball joint,
downward until it clears strut assembly. torque nut q to specification and install new cotter
pin w.
10. With short sharp jerks, remove drive shaft from front
gearcase. 4. Install hub and tighten spindle nut to specification.
Install a new cotter pin
5. Install the brake caliper. Torque fasteners to
specification.
TORQUE
Ball Joint Nut Torque:
30 ft-lbs (41 Nm)
Front Hub Nut Torque:

90 ft-lbs (122 Nm)
Brake Caliper Bolt Torque:

46 ft-lbs (62 Nm)
8
FRONT DRIVE SHAFT INSTALLATION
1. Install new spring ring on drive shaft. Apply an anti-
seize compound to splines. Align splines of drive
shaft with front gearcase and install by lightly tapping
on drive shaft with rubber faced hammer.
2. Install drive shaft into strut housing.

FINAL DRIVE
FRONT GEARCASE
GEARCASE REMOVAL 7. Remove the gearcase from the front LH wheel well
1. Stop engine and place gear selector in Park. area and slide it between the upper and lower A-arm.
2. Refer to “FRONT DRIVE SHAFT - Drive Shaft
Removal” and remove both front drive shafts from
the front gearcase.
3. Remove the propshaft from the front gearcase. (see
“PROPSHAFT SERVICE”).
4. Disconnect the wire harness above the front
gearcase (Item 1) and remove the harness (Item 3)
from the retaining dart.
GEARCASE INSTALLATION
1. Install the gearcase back into the vehicle through the
left-hand wheel well area, between the upper and
lower A-arms.
5. Remove the vent line (Item 4) from the front

gearcase.
6. Remove the (4) bolts (Item 2) securing the front
gearcase to frame.
2. Install the propshaft onto the front gearcase input

shaft. Use a NEW spring pin in the front propshaft.
3. Install the (4) bolts that secure the front gearcase to
the frame and torque to specification.

FINAL DRIVE
4. Install the vent line (Item 3) and attach wire harness 6. Refer to “FRONT DRIVE SHAFT - Drive Shaft
(Item 2) to the retaining dart. Installation” and install both front drive shafts into the
gearcase.
7. Add the proper lubricant to the front gearcase. Refer
to Chapter 2 for fluid fill and change information.
Polaris Demand Drive
(PN 2877922)
Front Housing Capacity
6.7–7.6 fl. oz. (200–225 ml)
TORQUE
Front Gearcase Mounting Bolts:
33 ft-lbs (56 Nm)
5. Connect the AWD wire harness (Item 4).

FINAL DRIVE
FRONT GEARCASE (NON-ADC)

FRONT GEARCASE ASSEMBLY VIEW
q Seal s Ring Gear

w Cover Plate d Spring
e AWD Coil f Output Hub
r Backlash Spacer g Bearing
t Nylon Spacer h Gearcase Housing
j Drain Plug
y Armature Plate 10 ft-lbs (14 N·m)
u Roller Cage k Fill / Check Plug

10 ft-lbs (14 N·m)
i Roller l Pinion Gear
o Spring Retainer 1( Snap Ring
a O-ring 2) Cover Plate Screws

FINAL DRIVE
ALL WHEEL DRIVE OPERATION Torsion Spring Operation: The torsion spring t acts
The AWD switch may be turned on or off while the as a return mechanism to help disengage the coupling of
vehicle is moving, however, AWD will not enable until the the output hubs and ring gear by creating an “over-
engine RPM drops below 3100. Once the AWD is running” condition for the rollers upon disengagement.
enabled, it remains enabled until the switch is turned off.
Engage the AWD switch before getting into conditions
where the front wheel drive may be needed. If the rear
wheels are spinning, release the throttle before switching
to AWD.
CAUTION
Switching to AWD while the rear wheels are spinning
may cause severe drive shaft and gearcase damage.
Always switch to AWD while the rear wheels have
traction or are at rest.
With the AWD switch off, the vehicle drives through the
rear wheels only (2 wheel drive). When the AWD is
enabled, the front drive acts as an on-demand AWD
system. This means, the front drive will engage once the
rear wheels have lost traction, and will remain engaged
until the torque requirement goes away (i.e. rear wheels
regain traction).
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 q that is keyed to the roll cage w. When the ring
gear e and roll cage are spinning (vehicle is moving),
the energized coil and armature plate will apply drag to
the roll cage that indexes the rollers inside the ring gear
to an engagement position. While in the engagement
position, the front drive will be in an “over-running”
condition (not engaged), until the rear wheels lose
traction. Once the rear wheels begin to lose traction, the
8
front drive will engage by coupling the output hubs r 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).
AWD Disengagement: Once the rear wheels regain
traction, the front wheels will return to the “over-running”
condition. The vehicle is now back to rear wheel drive
until the next loss of rear wheel traction occurs.

FINAL DRIVE
AWD DIAGNOSIS 5. Check to make sure the coil t is seated in the U-

Symptom: AWD Will Not Engage shaped y insert that is pressed into the gearcase
cover u. The top of the coil should be seated below
1. Check the gearcase coil resistance. To test the coil
the U-shaped insert. The U-shaped insert controls
resistance, measure between the power wire q (GY)
the pole gap. If the top of the coil is above the
and ground wire w (BN/WH). Measurement should
surface of the U-shaped insert it raises the armature
be within specification.
plate, thereby increasing pole gap. If the pole gap
increases the coil will not be strong enough to
engage the AWD system. If this is found, replace the
cover plate assembly.
Front Gearcase Coil Resistance:

22 - 24 Ω
2. Turn on ignition and AWD switches and place gear 6. Inspect the roller surface on the inside of the ring
selector in High or Low. Check for minimum battery gear for gouging/rough spots.
voltage at Gray and Brown/White chassis wires that
power the coil. Should have a minimum of 11 Vdc.
3. If electrical tests are within specification, remove
gearcase (see Chapter 7 – Front Gearcase Removal
page ) and inspect components.
4. Inspect armature plate e for a consistent wear
pattern. There should be two distinct wear bands r.
If only one band of wear is present (or if there is wear
between the two bands), inspect the coil area as
indicated in Step 5. A wear band with an interrupted
wear mark may indicate a warped plate, which may
cause intermittent operation.
7. Inspect the roll cage o assembly for cracks or

excessive wear. If damaged, replace the roll cage
assembly.
8. Inspect the rollersa for nicks and scratches. The
rollers must slide up, down, in and out freely within
the roll cage sliding surfaces and H-springs.

FINAL DRIVE
FRONT GEARCASE DISASSEMBLY / 3. Remove the LH output hub assembly e from the
INSPECTION clutch housing or outer cover plate assembly.
1. Drain and properly dispose of gearcase fluid.
Remove any metal particles from the drain plug
magnet.
2. Remove the seven cover screws q and remove the
cover plate w assembly.
NOTICE
Nylon spacer is non-serviceable and should not be
removed.
4. Remove and inspect the armature plate r. Refer to

AWD Diagnosis page 8.14 for detailed inspection
process.

FINAL DRIVE
5. Remove the torsion spring retainer t and torsion 7. Remove the RH output hub assembly i from the
spring y from the top of the ring gear. gearcase housing.
8. Remove pinion seal o, internal retaining ring a, and

pinion gear assembly s from the gearcase housing.
Inspect and clean the gearcase housing and replace
all oil seals and O-rings.
6. Remove the clutch housing / ring gear and roll cage

assembly u from the gearcase housing.
9. Inspect the pinion gear s for chipped, broken or

missing teeth. Inspect the pinion bearing for signs of
wear and the pinion shaft seal surface for pitting.

FINAL DRIVE
10. Inspect the AWD coil d located in the outer cover 14. Inspect the roll cage assembly j sliding surfaces
plate assembly. Refer to AWD Diagnosis page 8.14 and H-springs l. The sliding surfaces must be clean
for detailed inspection process. Replace the cover and free of nicks, burrs or scratches. If damaged,
plate seal f and O-ring g. replace the roll cage assembly.
11. Remove the roll cage assembly and rollers from the 15. Inspect both output hub assemblies. Inspect the
clutch housing. Use a shop towel to cover the bearings and replace if needed.
housing in order to retain all the rollers.
NOTICE
Rollers are spring loaded. Take care not to allow them
to fall out or lose them upon removal of the roll cage.
12. Thoroughly clean all parts and inspect the rollers h

for nicks and scratches. The rollers must slide up
and down and in and out freely within the roll cage j
sliding surfaces and H-springs.
1( Bearing 2! Roller Surface

2) Spacer 2@ Thrust Bearing
16. Clean and inspect all remaining front gearcase

components. Check each for excessive wear or
damage.
NOTICE
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 k for a consistent

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

FINAL DRIVE
FRONT GEARCASE ASSEMBLY 5. Carefully install the rollers e into the roll cage
1. As mentioned during gearcase disassembly section, assembly while installing the assembly into the
replace all O-rings, seals and worn components. clutch housing.
2. Install pinion shaft assembly and install internal snap
ring.
NOTICE
If bearing replacement was required, press new bearing
onto the pinion shaft and install a new external snap
ring.
3. Install a new pinion shaft seal q into the pinion gear

housing. Using a universal seal installer, press the
new seal into the housing until the seal is just below
the housing chamfer.
NOTICE
Install roll cage so that the ring gear grooves line up
with the roll cage windows (see below). Be sure role
cage top groove is facing upward.
6. Install the torsion spring r by wrapping each leg of

the spring around the dowel pin on the ring gear.
4. Install the RH output hub w into the gearcase

housing.

FINAL DRIVE
7. Align spring retainer dowel pin t with ring gear 9. Install armature plate u. Be sure all of the armature
dowel pin y and install the retainer on top of the plate tabs are fully engaged into the roll cage
torsion spring. assembly and that it is resting properly on the torsion
spring retainer.
8. Check the action of the torsion spring by rotating in

both directions to ensure the spring and retainer are
installed properly. NOTICE
Verify armature plate tabs are in the roll cage slots and
that it rests properly on the spring retainer.
10. Carefully install the ring gear and roll cage assembly
i into the gearcase housing.
11. Install a new O-ring on the cover plate assembly.

NOTICE
Be sure the square O-ring is placed flat on the cover
surface. If the O-ring is twisted fluid leakage may occur.

FINAL DRIVE
12. Carefully install the LH output hub assembly o into

the cover plate. Take care not to damage the new
cover plate seal while installing the output hub.
13. Install the output cover assembly a onto the

gearcase housing. Install the seven cover plate
screws s and torque to specification.
TORQUE
Cover Plate Screws:
9 ft-lbs (12 N·m)

FINAL DRIVE
FRONT GEARCASE (ADC)

EXPLODED VIEW, FRONT GEARCASE (4WDC)

FINAL DRIVE
REF. PART DESCRIPTION NOTES

q ASM., GEARCASE, RH, ADC, 4WDC [INCL.
ALL]
w ASM., COVER, OUTPUT
e ASM., OUTPUT HUB
r KIT, FASTENERS 8 ft-lbs (11 Nm)
t KIT, SEAL REPAIR
y PLATE, ARMATURE
u PLATE, ARMATURE, BD
i BEARING
o KIT, ROLLER [SET OF 20]
a ASM., ROLL CAGE [INCL. CAGE, 20 CLIPS]
s ASM., GEARCASE
d ASM., PLUG, DRAIN 11 ft-lbs (15 Nm)
f PLUG, OIL FILL 8-10 ft-lbs (11-14 Nm)
g RING, RETAINING, INTERNAL
h KIT, SPRING
j RING, RETAINING, EXTERNAL
k ASM., GEAR HOUSING AND PINION GEAR

FINAL DRIVE
OPERATION, FRONT GEARCASE (4WDC)

The active descent control front gearcase is designed to allow the vehicle to operate in 2x4, 4x4, or utilize the vehicles
EBS to allow 4x4 ADC (active descent control) in the forward and reverse direction.
IMPORTANT
All-wheel drive ADC MUST be selected on the all-wheel drive / ADC switch to activate the ADC system.
When the vehicle is in 2x4, all coils within the gearcase are off. This allows the pinion and ring gear to spin without
engaging the front gearcase output hubs.
When the vehicle is in 4x4, the 4 wheel drive coil is turned on but the ADC coil remains off. Turning on the 4 wheel
drive coil applies drag to the outer armature plate. The outer armature plate is connected to the roller cage, which
engages the rollers in the cage with the forward / reverse ramp in the bi-directional clutch. In the event that the vehicle
wheels roll down a hill faster than it is being driven, ADC will not slow the vehicle.
When the vehicle is in 4x4 ADC, the AWD coil is turned on and the ADC coil remains off until necessary. When
descending a hill, the EBS slows the driveline and rear wheels. The ADC coil detects the speed difference and locks
the front wheels to the driveline. The front wheels can now assist in controlling the descent. Turning on the ADC Coil
applies drag to 2 inner armature plates. One armature plate is connected to an output hub and the other is connected
to the roller cage. The frictional drag between the two armature plates causes the output hub to rotate the roller cage,
which engages the rollers in the cage with the forward / reverse ramp in the bi-directional clutch. Because the hubs
rotate faster than the driveline in an engine breaking situation this combination of events slows the vehicle when the
clutch engine brake system is active allowing true four wheel engine braking in forward / reverse gears.
During engine braking the front drive can also speed differentiate across the axle when turning. Also, if the outer wheel
slips or loses traction the inner wheel will then begin to slow the vehicle as well.

FINAL DRIVE
DISASSEMBLY / INSPECTION, FRONT 3. Remove the outer cover plate assembly.

GEARCASE (ADC)
NOTICE
1. Drain and properly dispose of used oil. Remove any Press on the output hub assembly e while lifting up on
metal particles from the drain plug magnet q. the outer cover plate(4) to prevent removing more than
the cover plate.
2. Remove bolts w retaining the outer cover plate

assembly.
4. Remove the output hub assembly e.
5. Inspect the bearing and contact surfaces of the output

hub for signs of wear or damage. Replace component
if found to be worn or damaged.

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

FINAL DRIVE
12. Thoroughly clean all parts. Inspect the bearing 15. Inspect the armature plate for a consistent wear
surfaces of the output hub. Inspect the rollers a for pattern. Uneven wear of the armature plate indicates
nicks, scratches and flat spots. Inspect the roll cage a warped plate, which may cause intermittent
o for damage or cracks. The rollers must slide up operation.
and down freely within the roller cage surfaces.
NOTICE
See “FRONT GEARCASE DIAGNOSIS” later in this
chapter for more details.
13. Inspect the ring gear i for inconsistent wear patterns

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

FINAL DRIVE
17. Remove the snap ring retaining the input shaft

assembly.
18. Remove the input shaft assembly. Inspect the pinion

gear g for chipped, broken, or missing teeth. Inspect
the input shaft bearing h for signs of wear. Replace
the input shaft cover O-ring prior to reassembly.
19. Inspect the input shaft bushing j for wear.
20. Thoroughly clean the gearcase components before

beginning reassembly.

FINAL DRIVE
REASSEMBLY, FRONT GEARCASE (ADC) 6. Install the LH output hub s into the gearcase
housing. The output hub should spin freely.
1. Clean the gearcase housing of debris.
2. Replace all O-rings, seals, and worn components.
3. Inspect bearings on output and pinion shafts. To
replace, press new bearing onto shaft.
NOTICE
down movement and minimal movement side to side.
4. Install input shaft, bearing, and snap ring.

7. Install the torsion spring by wrapping each leg of the
spring around the dowel pin on the ring gear.
8. Install the rollers and roll cage into the ring gear.
Insert the rollers as the roll cage is installed.
5. Press the pinion shaft seal into the gearcase, until the
seal is flush.
9. Install the pins a, roll cage o, and ring gear

assembly i into the gearcase housing.

FINAL DRIVE
10. Align the spring retainer dowel pin with the ring gear 13. Install the RH output hub e into the gearcase
dowel pin and install the retainer y on top of the housing. The output hub should spin freely.
torsion spring.
14. Install the cover plate assembly with a new o-ring

11. Check the action of the torsion spring by rotating in onto the gearcase.
both directions to ensure the spring and retainer are
installed properly. NOTICE
12. Install the armature plates t. Be sure the armature Verify the square O-ring is placed flat on the cover
plate tabs are fully engaged into the roll cage surface. If the O-ring is twisted, fluid leaks may occur.
assembly.
15. Torque the cover plate bolts w to specification.
NOTICE
Verify armature plate tabs are in the slots on the roll TORQUE
cage and are resting in the ring gear grooves.
AWD Cover Screws:
8 ft-lbs (11 Nm)
16. Fill the gearcase with fluid.

FLUID CAPACITY
Polaris Demand Drive Fluid
8.97 oz. (265 ml)

FINAL DRIVE
17. Install the drain plug. Torque to specification.

TORQUE
Fill Plug:
8-10 ft-lbs (11-14 Nm)
Drain Plug:
11 ft-lbs (15 Nm)

FINAL DRIVE
TROUBLESHOOTING, FRONT GEARCASE (ADC)

Customer Complaint: ADC not functioning
Verification of complaint: Drive vehicle with ADC switched on and off down a grade if possible to determine if ADC
(Auto-lock is working correctly). May need to be in low range to tell in high traction areas. Make sure switch on handle
bar is on ADC mode. Make sure ADC light is lit on gage pod. Vehicle must be in hi, low, or reverse. Also, vehicle
throttle lever must be off. If complaint is warranted, move onto component check list. If no, move onto other vehicle
components (suspension, driveline, engine, etc.) Vehicle may also be tested in air. All 4 wheels need to be off ground,
put into ADC mode and roll back wheels if possible. Rotate cover side front wheel forward and back, should feel roll
cage in front drive index and lock the front wheel to the drive line. This can only be done on the cover side wheel. It is
also best to make sure 4x4 is not engaged any more. This way is possible to test but best way is to ride vehicle down
steep hill as stated above.
DIAGNOSIS PROBLEM DIAGNOSIS REPAIR PROCEDURE REPAIR VERIFICATION

POTENTIAL PROBLEM
PROCEDURE
Check to see if ADC light No ADC light on gage Problem might not be front N/A
is lit on gage pod. pod. differential related. Check
electrical system in
vehicle.
Check wires to see if there Cut wire. Replace output cover (Unit Drive vehicle with ADC
are any visible cuts or will need to be removed mode on to determine if
Unplugged / damaged nicks. from vehicle to do repair.) problem has been fixed. If
wire connector. not, continue onto
additional problems listed.
Check to see if front Unplugged Plug wire harness into Drive vehicle with ADC
differential is plugged into front drive connector. mode on to determine if
wire harness. problem has been fixed. If
not, continue onto
Differential installed in vehicle

No power from vehicle to Unhook wire connector to No power to front Problem might not be front N/A
front differential (blown front differential. Using differential wire harness. differential related. Check
fuse) multimeter determine if electrical system in
vehicle wire connector is vehicle.
getting power to the front
drive on two outer most
pins.
ADC Coil Short Check resistance of coil Coil to be +/- 4 ohms to
nominal
Replace output cover (Unit Drive vehicle with ADC
will need to be removed mode on to determine if 8
from vehicle to do repair.) problem has been fixed. If
not, continue onto
Check continuity to both Continuity should be Replace output cover (Unit Drive vehicle with ADC
leads present between leads. will need to be removed mode on to determine if
not, continue onto
Check continuity to case No continuity between Replace output cover (Unit Drive vehicle with ADC
Check continuity to case either lead and the case. will need to be removed mode on to determine if
not, continue onto
4x4 Not turning off Lift Vehicle off ground. Power to 4x4 is not Problem might not be front N/A
Rotate cover side wheel in turning off when ADC is differential related. Check
both the forward and turning on. electrical system in
reverse direction. If it locks vehicle.
to the drive train in only
one direction, ADC is not
indexing cage in both
directions

FINAL DRIVE
DIAGNOSIS PROBLEM DIAGNOSIS REPAIR PROCEDURE REPAIR VERIFICATION

POTENTIAL PROBLEM
PROCEDURE
Hub Plate Hub Plate will be attached Plate should be flat. Plate Replace hub plate or hub Drive vehicle with ADC
to output hub. Initially look should have even wear assembly with hub plate. mode on to determine if
at plate and see if any on both sides and no May need to replace Hub problem has been fixed. If
excessive wear is present. significant gauging plate and Armature plate not, continue onto
Look and see if plate is should be present. at the same time. additional problems listed.
bent or warped. Look to
see if any debris is on
plate or debris is causing
uneven wear. To do further
evaluation plate would
need to be removed from
hub, by removing bearing.
Plate then can be placed
on a flat surface to
determine if plate is flat.
ADC Armature Plate Place Plate on flat surfacePlate should not have Replace Armature plate. Drive vehicle with ADC
with tangs up to check for significant rock when May need to replace both mode on to determine if
flatness. Also look for pushing on one side of Armature plate and hub problem has been fixed. If
even wear on surface the plate. Plate should plate at the same time. not, continue onto
Differential removed from vehicle
towards Hub plate also have even consistent additional problems listed.
wear on the surface.
Roll Cage Check to see if cage is Roll cage should have no Replace roll cage Drive vehicle with ADC
broken or cracked. Look to cracks or breaks. Springs assembly (cage and mode on to determine if
see if any springs are should have no cracks spring). Always replace problem has been fixed. If
broken or stuck in place. and fully intact. Clutch both. (do not take springs not, continue onto
Look to see if cage can should be able to off old cage and put onto additional problems listed.
index properly in both advance down the new cage).
directions engagement ramp
smoothly.
Torsion Spring Make sure Spring is Plastic retainer should If torsion spring is not Drive vehicle with ADC
installed properly. Make index with some force installed correctly, install mode on to determine if
sure Spring is able to from spring. Retainer correctly and retest. If problem has been fixed. If
index properly in both should also index far other issue with retainer or not, continue onto
directions enough to allow clutch to spring, replace one or both additional problems listed.
engage. and retest.
Cover Side Hub Check to see if Hub plate If Hub plate can not slide Replace with new hub Drive vehicle with ADC
can slide on hub spline. it may not engage coil assembly and Hub Plate. mode on to determine if
correctly. problem has been fixed. If
not, continue onto
ADC Coil/Coil Pocket Check Pole Faces for Pole faces should be Clean off pole faces if no Drive vehicle with ADC
(Output Cover) debris smooth and even wear significant wear is noticed. mode on to determine if
should be present. If pole faces are severely problem has been fixed. If
worn and damaged, not, continue onto
replace output cover. additional problems listed.
Check for Coil raised Coil should be well below Replace output cover. Drive vehicle with ADC
above pole faces the pole faces. If coil is mode on to determine if
outside pole faces it problem has been fixed. If
would cause the plates not, continue onto
not to touch the pole additional problems listed.
faces.
Check Wear on Pole faces Pole faces should be Clean off pole faces if no Drive vehicle with ADC
smooth and even wear significant wear is noticed. mode on to determine if
should be present. If pole faces are severely problem has been fixed. If
worn and damaged, not, continue onto
replace output cover. additional problems listed.

FINAL DRIVE
Symptom: AWD Will Not Engage

1. Check the gearcase coil resistance. To test the gearcase coil resistance, use the coil harness (Grey & Brown/
White).
NOTICE
To test the gearcase coil resistance, use the coil harness. The gearcase coil should measure between 22.8 ohms and
25.2 ohms.
ADC Front Gearcase Coil Resistance

B-C (4X4): 23 Ω ±4Ω
A–D (4X4 ADC): 12.49 Ω ±4Ω
2. Check the minimum battery voltage at the Grey & Brown/White wires that feed the hub coil wires.
AWD Coil Applied Battery Voltage:
11.80-12.0 Vdc
3. Inspect the armature plate e for a consistent wear pattern. There should be two distinct wear bands r (one band
inside the other). If only one band of wear is present (or if there is wear between the two bands, inspect the coil
8
area as indicated in Step 4. A band with an interrupted wear mark may indicate a warped plate, which may cause
intermittent operation.

FINAL DRIVE
4. Check to make sure the coil t is seated in the U-shaped y insert that is pressed into the gearcase cover u. 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 insert it raises the armature plate, thereby increasing pole gap. If the
pole gap increases the coil will not be strong enough to engage the AWD system. If this is found, replace the cover
plate assembly.
5. Inspect the rollers for nicks, scratches, and flat spots. Also inspect the roll cage o for cracks and ensure the rollers
a are able to slide up and down and in and out freely within the roll cage sliding surfaces.

FINAL DRIVE
REAR BEARING CARRIER

INSPECTION 4. Remove the two brake caliper mounting bolts r and
1. Support the machine securely with rear wheels remove the caliper from the bearing carrier.
elevated.
CAUTION
bearings and seals.
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.
CAUTION
REMOVAL Do not hang the caliper by the brake line. Use
1. Elevate the rear end of the vehicle and safely mechanics wire to hang the caliper to prevent possible
support the vehicle under the main frame area. damage to the brake line.
2. Remove wheel nuts, washers and wheel.
5. Slide the wheel hub out from the bearing carrier and
3. Remove the cotter pin q, castle nut w and washers drive shaft.
e.
6. Remove the upper and lower A-arm fasteners from
the bearing carrier t.
7. Remove the bearing carrier. Inspect the bearing

again for smoothness and side to side movement,
replace as needed.

FINAL DRIVE
DISASSEMBLY ASSEMBLY
1. Remove the retaining ring from the bearing carrier 1. Thoroughly clean the bearing carrier housing e and
q. prepare the bearing w and retaining ring q for
assembly.
2. From the back side, tap on the outer bearing race

with a drift punch in the reliefs as shown. 2. Support the bottom of the bearing carrier housing.
Start the bearing r in the bearing carrier housing t.
NOTICE Use an arbor press to install the bearing.
Drive bearing out evenly by tapping on outer race only.
Once bearing is at bottom of casting, support casting on
outer edges so bearing can be removed.
3. Inspect the bearing.

NOTICE
down movement and minimal movement sideways
between inner and outer race.
4. Inspect bearing housing for scratches, wear or

damage. Replace housing if damaged.
5. Replace the bearing carrier bushings if worn or
damaged.

FINAL DRIVE
3. Press the bearing into place until the outer bearing 4. Torque the upper and lower bearing carrier fasteners
race bottoms in housing. to specification.
CAUTION TORQUE
Use an arbor and press only on the outer race, as Bearing Carrier Fasteners:
bearing damage may occur. 40 ft-lbs (54 Nm)
5. Install the wheel hub assembly onto the rear drive

shaft.
6. Install the washers (domed side out) e and the
wheel hub castle nut w.
4. Install a new retaining ring into the bearing carrier

groove.
INSTALLATION 7. Install the wheel, washers t and wheel nuts r.

1. Place the bearing carrier over the drive shaft. Torque wheel nuts to specification.
2. Align the bottom of the bearing carrier with the lower
A-arm. If previously removed, install new lower A- TORQUE
arm bushings. Install the lower bearing carrier Steel Wheel Nuts:
fastener. 36 ft-lbs (49 Nm)
3. With the drive shaft placed in the bearing carrier, Aluminum Wheel Nuts:
30 ft-lbs + 90º (41 Nm + 90º)
8
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. 8. Carefully lower the vehicle. Torque the rear hub
castle nut to specification. Install a new cotter pin q.
TORQUE
Rear Hub Castle Nut:
110 ft-lbs (150 Nm)
NOTICE
The lower shock bolt may need to be removed to allow
the upper A-arm to move freely.

FINAL DRIVE
REAR DRIVE SHAFT

REAR DRIVE SHAFT REMOVAL 5. Remove the rear drive shaft using short, sharp jerks
1. Perform the “REAR BEARING CARRIER - Removal” to free the circlip from the transmission.
procedure, steps 1-5.
2. Remove the lower shock fastener q to free the
upper A-arm.
6. Refer to the “DRIVE SHAFT SERVICE” section if

repairing the drive shaft.
3. Remove the upper bearing carrier fastener and REAR DRIVE SHAFT INSTALLATION
separate the bearing carrier from the upper A-arm. 1. Install a new circlip q on the end of the drive shaft
and apply an anti-seize compound to the splines.
4. Carefully slide the drive shaft out by pulling the

bearing carrier outward and tipping it down to 2. Align the splines of the drive shaft with the
remove the shaft. transmission and reinstall the drive shaft. Use a
rubber mallet to tap on the outboard end of the drive
shaft if necessary.
3. Install the drive shaft into the rear bearing carrier.
4. Perform the “REAR BEARING CARRIER -
Installation” procedure to properly reassemble the
vehicle.

FINAL DRIVE
DRIVE SHAFT SERVICE

DRIVE SHAFT / CV JOINT HANDLING 2. Remove the large end of the boot from the CV joint
TIPS and slide the boot down the shaft.
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.
• Make sure surface-ground areas and splines of shaft
are protected during handling to avoid damage.
• Do not allow boots to come into contact with sharp 3. Clean the grease from the face of the joint.
edges or hot engine and exhaust components. 4. Place the drive shaft in a soft-jawed vise.
• The drive shaft is not to be used as a lever arm to 5. Using a soft-faced hammer, or brass drift, strike the
position other suspension components. inner race of the joint to drive the joint off the drive
• Never use a hammer or sharp tools to remove or to shaft. Be sure to tap evenly around the joint to avoid
install boot clamps. binding.
• 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.
8
OUTER CV JOINT / BOOT
REPLACEMENT
1. Using side cutters, cut away and discard the boot
clamps.
NOTICE
Tap on inner race only!

FINAL DRIVE
6. Make sure the circlip is on the shaft and not left in the 9. Visually inspect the joint by tilting the inner race to
joint. one side to expose each ball. Severe pitting, galling,
play between the ball and its cage window, any
cracking or damage to the cage, pitting or galling or
chips in raceways call for joint replacement.
NOTICE
Shiny areas in ball tracks and on the cage spheres are
normal. Do not replace CV joints because parts have
polished surfaces. Replace CV joint only if components
are cracked, broken, worn or otherwise unserviceable.
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.
7. Remove the CV boot from the shaft.
13. Grease the joint with the special CV joint grease
CAUTION provided in the boot replacement kit. Fill the cavity
behind the balls and the splined hole in the joint’s
Complete disassembly of the CV joint is NOT inner race. Pack the ball tracks and outer face flush
recommended. The internal components are a with grease. Place any remaining grease into the
precision fit and develop their own characteristic wear boot.
patterns. Intermixing the internal components could
result in looseness, binding, and/or premature failure of CAUTION
the joint.
The grease provided in the replacement kit is specially
formulated for wear resistance and durability. DO NOT
NOTICE use substitutes or mix with other lubricants.
If the grease in the joint is obviously contaminated with
water and/or dirt, the joint should be replaced. NOTICE
The amount of grease that’s provided is pre-measured,
so use all the grease.
Boot Replacement Grease Requirements:

Grease Only Service Kits
PN 1350059 - 20g
PN 1350046 - 30g
PN 1350047 - 50g
Outer CV Joint Capacity:

Front - 74g / Rear - 90g
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.

FINAL DRIVE
14. Slide the joint onto the drive shaft splines and align 20. While pulling out on the CV shaft, fully extend the CV
the circlip with the lead-in chamfer on the inner race joint and slide a straight O-ring pick or a small slotted
of the joint. screw driver between the small end of the boot and
the shaft. This will allow the air pressure to equalize
in the CV boot in the position that the joint will spend
most of its life. Before you remove your instrument,
be sure the small end of the boot is in its correct
location on the shaft.
21. Install and tighten the small clamp on the boot using
the Axle Boot Clamp Tool (PU-48951 or 8700226).
15. Use a soft-faced hammer to tap the joint onto the

drive shaft until it locks into place.
16. Pull on the joint to make sure it is securely locked in
place.
17. Remove excess grease from the CV joint's external
surfaces and place the excess grease in the boot.
Axle Boot Clamp Tool
18. Pull the boot over the joint and position the boot lips PU-48951 or 8700226
into the grooves on the joint housing and shaft. Make
sure the boot is not dimpled or collapsed.
19. Install and tighten the large clamp using the Axle
Boot Clamp Tool (PU-48951 or 8700226).

PU-48951 or 8700226

FINAL DRIVE
INNER PLUNGING JOINT / BOOT 5. Using a soft-faced hammer, or brass drift, strike the
REPLACEMENT inner race of the joint to drive the joint off the drive
1. Using a side cutters, cut away and discard the boot shaft. Be sure to tap evenly around the joint to avoid
clamps. binding.
NOTICE
Tap on inner race only!
2. Remove the large end of the boot from the plunging

joint and slide the boot down the shaft.
6. Make sure the circlip q is still on the shaft and not

left in the joint.
3. Clean the grease from the face of the joint.

4. Place the drive shaft in a soft-jawed vise.

FINAL DRIVE
7. Remove the boot from the shaft. 13. Grease the joint with the special CV joint grease
provided in the boot replacement kit. Fill the cavity
CAUTION behind the balls and the splined hole in the joint’s
Complete disassembly of the plunging joint is NOT inner race. Pack the ball tracks and outer face flush
recommended. The internal components are a with grease. Place any remaining grease into the
precision fit and develop their own characteristic wear boot.
patterns. Intermixing the internal components could
result in looseness, binding, and/or premature failure of CAUTION
the joint. The grease provided in the replacement kit is specially
formulated for wear resistance and durability. DO NOT
use substitutes or mix with other lubricants.
NOTICE
If the grease in the joint is obviously contaminated with Boot Replacement Grease Requirements:
water and/or dirt, the joint should be replaced.
Grease Only Service Kits
PN 1350059 - 20g
PN 1350046 - 30g
PN 1350047 - 50g
Inner Plunging Joint Capacity:

Front - 60g / Rear - 100g
14. Fully compress the joint and push the drive shaft
firmly into the inner race.
15. Align the circlip with the lead-in chamfer.
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.
8
9. Visually inspect the joint for damage. Replace if
needed.
10. Clean the splines on the end of the shaft and apply a
light coat of grease prior to reassembly.
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. 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.

FINAL DRIVE
20. Install and tighten the small clamp using the Axle DRIVE SHAFT ASSEMBLY VIEW
Boot Clamp Tool (PU-48951 or 8700226).

PU-48951 or 8700226
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.

PU-48951 or 8700226

FINAL DRIVE
PROPSHAFT U-JOINT SERVICE

REMOVAL / INSTALLATION REMOVAL / INSTALLATION (CREW)
1. Remove the PVT cover. 1. Elevate and safely support vehicle under the frame.
The use of a vehicle hoist is recommended for this
2. Remove the Drive Clutch and belt.
procedure.
3. Access the front prop shaft roll pin through the hood
opening. CAUTION
CAUTION sure machine is secure before beginning this service
Be sure machine is secure before beginning this procedure. Wear eye protection when removing
service procedure. Wear eye protection when removing bearings and seals.
pins, bearings or seals.
NOTICE
4. Use the Roll Pin Removal Tool to drive out the roll pin
from the prop shaft. Prop shaft roll pin removal is only required if removing
the front portion of the prop shaft.
Roll Pin Removal Tool (PN 2872608)
2. Access the front prop shaft roll pin through skid plate
5. Slide the prop shaft back and away from front hole.
gearcase, then pull the shaft sharply forward to
remove it from the transmission shaft. 3. Use the Roll Pin Removal Tool (PN 2872608), to
drive out the roll pin from prop shaft.
6. Using care, pull the prop shaft towards the right side
of the frame and slide it out the right rear side of the Roll Pin Removal Tool (PN 2872608)
vehicle.
7. Reverse this procedure to reinstall the front prop 4. Remove the front seat base and large storage
shaft. container to access the support bearing (Item 1).
8. Use a NEW roll pin upon installation.
FRONT PROP SHAFT COMPONENTS
REF DESCRIPTION
q Grease Zerk
w Rear Yoke
e U-Joint
r Front Yoke

FINAL DRIVE
5. Remove the two nuts and bolts retaining the bearing SUPPORT BEARING REPLACEMENT
support. (CREW)
1. Follow steps 4-6 of the “Removal / Installation
(CREW)” procedure.
2. Remove the bearing support (upper and lower half)
and the retaining ring. Loosen the two set screws
retaining the bearing to the shaft.
6. Slide the rear portion of the shaft back on the

transmission shaft and move both shafts toward the
left side of the vehicle to separate them.
3. Slide the bearing off the end of the shaft.

NOTICE
If bearing is seized on the shaft, remove the rear portion
of the shaft from the vehicle. Refer to “Removal /
Installation (CREW)”.
4. Clean the surface of the shaft and install the new

bearing.
5. Install a new retaining ring and slide the bearing tight
against the retaining ring.
7. If removing the front portion of the prop shaft, slide it
back and away from front gearcase to remove it.
8. If removing the rear portion, remove the bearing
support (upper & lower half).
9. Using care, pull the rear portion of the prop shaft
towards the right side of the frame and slide it out the
right rear side of the vehicle.
10. Reverse this procedure to reinstall and assemble the
front prop shaft.
11. Torque bearing support fasteners to specification.
TORQUE
Prop Shaft Bearing Support Fasteners:
36 ft-lbs (49 Nm)
12. If front prop shaft was removed, use a NEW roll pin
upon installation.

FINAL DRIVE
6. Apply Loctite™ 242® to the set screw threads and DISASSEMBLY

torque the two bearing set screws to specification.
CAUTION
Always wear eye protection.
1. Remove internal snap ring q from all four bearing

caps.
TORQUE
Prop Shaft Bearing Set Screws:
35 in-lbs (4 Nm)
NOTICE
7. Align the front and rear portions of the prop shaft as
shown below and slide them together. 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 suitable press.
8. Install the upper and lower halves of the bearing

support along with the two fasteners. Torque the
support bearing fasteners to specification.
TORQUE
Prop Shaft Support Bearing Fasteners:
36 ft-lbs (49 Nm)
9. Grease the prop shaft yoke(s).

10. Reinstall the large storage container and front seat
base.

FINAL DRIVE
3. Support U-joint and press inner yoke down to

remove remaining bearing caps.
4. Force U-joint cross to one side and lift out of inner

yoke.
ASSEMBLY
1. Install new bearing caps in yoke by hand. Carefully
install U-joint cross. Tighten vise or use a press to
force bearing caps in.
2. Using a suitable arbor, fully seat bearing cap in one
side. Continually check for free movement of bearing
cross as bearing caps are assembled.
3. Install snap ring to contain bearing cap just installed.
Repeat procedure for other side.
4. Install outer yoke, aligning marks made before
disassembly.
5. Repeat Steps 1-3 to install bearing caps on outer
yoke.
6. Seat all bearing caps against snap rings.
7. 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.

CHAPTER 9
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
SHOCK ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
STEERING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
STEERING ASSEMBLY VIEW (NON-EPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
STEERING ASSEMBLY VIEW (EPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
STEERING WHEEL REMOVAL (NON-EPS MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
STEERING SHAFT BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
STEERING SHAFT / STEERING RACK REMOVAL (NON-EPS MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
STEERING WHEEL / UPPER STEERING SHAFT REMOVAL (EPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.10
POWER STEERING UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
POWER STEERING UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
STEERING RACK REMOVAL / INSTALLATION (EPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.13
FRONT STRUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.15
ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.15
FRONT STRUT CARTRIDGE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.16
BALL JOINT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.16
REAR A-ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.18
REMOVAL / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.18
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.19
ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.20
REAR STABALIZER BAR / LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.21
REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.21
ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.21
SHOCKS / SPRINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.22 9
ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.22
SHOCK REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.22
SHOCK REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.22

GENERAL INFORMATION
SPECIAL TOOLS
2870872 Shock Spanner Wrench
2870623 Shock Spring Compressor Tool

2876389 Multi-Function Pliers
2870871 Strut and Ball Joint Tool Set
2871573 Strut Spring Compressor (LH)
2871574 Strut Spring Compressor (RH)

or http://polaris.service-solutions.com/
Included in this machine’s tool kit, the multi-function

pliers is designed to remove the plastic push rivets used
to fasten body components.

SHOCK ANALYSIS

STEERING ASSEMBLY
STEERING ASSEMBLY VIEW (NON-EPS)

REF PART DESCRIPTION NOTES

q ASM, TILT STEERING
w WHEEL, STEERING
e SHAFT, STEERING, UPPER / LOWER
r ASM, GEAR BOX, STEERING
t CAP, STEERING WHEEL
y ASM, SHOCK, OIL LOCKING
u BOLT
i BOLT 40 ft-lbs (54 Nm)
o SCREW
a BOLT
s NUT
d NUT 16 ft-lbs (22 Nm)
f NUT 40 ft-lbs (54 Nm)
g NUT 36 ft-lbs (49 Nm)
h NUT 65 ft-lbs (88 Nm)
j BUSHING, STEERING
k PIN, COTTER
l LOCTITE® 271

STEERING ASSEMBLY VIEW (EPS)

REF PART DESCRIPTION NOTES

q MOUNT, EPAS
w WHEEL, STEERING
e SHAFT, STEERING, LOWER
r SHAFT, STEERING, UPPER
t ASM, GEAR BOX, STEERING
y ASM, TILT STEERING
u ASM, POWER STEERING
i CAP, STEERING WHEEL
o ASM, SHOCK, OIL LOCKING
a BOLT
s BOLT
d BOLT 30 ft-lbs (41 Nm)
f SCREW
g BOLT
h SCREW
j BOLT
k NUT
l NUT 15 ft-lbs (21 Nm)
1( NUT 40 ft-lbs (54 Nm)
2) NUT 49 ft-lbs (66 Nm)
2! NUT 65 ft-lbs (88 Nm)
2@ BUSHING, STEERING
2# PIN, COTTER
9
2$ LOCTITE 271

STEERING WHEEL REMOVAL (NON-EPS 5. Drive the bearings out of the pivot tube using a drift
MODELS) punch.
6. Inspect the pivot tube bearing surfaces for signs of
CAUTION excessive wear or damage.
This procedure should NOT be used on EPS models. 7. Apply Loctite® 271 (Red) to the outer circumference
Using this procedure on an EPS model can of the new lower bearing race. Slide the new lower
permanently damage the EPS unit and cause a Power bearing onto the steering shaft and install the
Steering Fault. steering shaft through the pivot tube.
1. Remove the steering wheel cap. NOTICE
2. Loosen the nut and back it half way off the steering Use care not to allow any of the Loctite® to get in the
shaft. bearing.
NOTICE Be sure the lower spacers are still on the steering shaft.
If reinstalling the same steering wheel, use a white
paint marker to help align upon installation.
3. With a glove on your hand, place it under the

steering wheel. Lift upward on the inner portion of the
steering wheel while using a hammer to strike the
steering shaft nut.
4. Once the steering wheel pops loose, completely
remove the nut and lift the steering wheel off the
shaft.
5. To install:
Ensure flat washer is installed on the steering shaft and
the two wave washers above it.
6. Center the wheels and install the steering wheel so it
is properly centered on the steering shaft.
7. Install the steering wheel nut. Torque nut to REF DESCRIPTION
specification.
q CAP
TORQUE w NUT
Steering Wheel Nut: e STEERING WHEEL
65 ft-lbs (88 Nm) r HUB INSERT
t BUSHING
y SHAFT, UPPER
STEERING SHAFT BEARING u TILT ASSEMBLY
REPLACEMENT
8. Apply Loctite® 271 (Red) to the outer circumference
NOTICE of the new upper bearing race. Slide the new upper
Replacement pivot tube assembly comes with new bearing onto the steering shaft and press it into the
upper and lower bearings installed. Use this procedure pivot tube by hand.
if replacing just the bearings only. NOTICE
1. Perform the “Steering Shaft Removal” procedure. Use care not to allow any of the Loctite® to get in the
bearing.
2. Remove the steering wheel cap and retaining nut. Bearings will be seated in the pivot housing upon
3. Press steering shaft out of the steering wheel and tightening the steering wheel nut in step 14.
pivot tube.
9. Install the steering wheel and hand tighten the nut.
4. Note the order and location of the spacers between
the pivot tube and steering shaft.

10. Reinstall the steering shaft assembly in the vehicle. 4. Remove the steering shaft, pivot tube and steering
Install the lower portion of the steering shaft onto the wheel from the vehicle as an assembly.
steering gear box assembly. Torque the lower pinch
bolt to specification.
TORQUE
Steering Gear Box Pinch Bolt:
35 lb-ft (47 Nm)
11. Install the fastener retaining the steering wheel tilt

assembly to the frame. Torque fastener to
specification.
TORQUE
Steering Wheel Tilt Assembly Fasteners:
40 lb-ft (54 Nm)
12. Be sure the front wheels are facing straight forward. 5. Remove the cotter pin t and then remove the
Remove the steering wheel and align as needed. fasteners y retaining the both tie rod ends to the
Torque the steering wheel nut to specification. steering knuckle.
TORQUE
Steering Wheel Nut:
65 lb-ft (88 Nm)
13. Wipe the pivot tube clean of any excess Loctite®.

14. Install steering wheel cap and field test steering
operation.
STEERING SHAFT / STEERING RACK

REMOVAL (NON-EPS MODELS)
1. Remove the pinch bolt w retaining the lower portion
of the steering shaft e to the steering rack assembly
q. 6. Remove the five fasteners u retaining the steering
rack to the frame.
9
2. Remove upper and lower dash panels.

3. Remove the steering wheel tilt assembly fasteners.

7. Reverse procedure for installation. Torque fasteners 3. Remove the steering tilt assembly fasteners.
to specification.
TORQUE
Steering Rack Mounting Bolts:
16 ft-lbs (22 Nm)
Floor Access Panel Screws

8 ft-lbs (11 Nm)
Steering Pivot Assembly to Frame Fasteners:

40 ft-lbs
Steering Wheel Nut:

65 ft-lbs (88 Nm)
4. Remove the fastener retaining the upper steering
shaft to the power steering unit.
Steering Shaft to Steering Rack Fasteners:
46–51 ft-lbs (62-69 Nm) 5. Remove the steering wheel, upper steering shaft and
pivot out as an assembly.
6. Remove the steering wheel cap.
STEERING WHEEL / UPPER STEERING
SHAFT REMOVAL (EPS)
1. Remove upper and lower dash panels (See Body /
Frame chapter).
CAUTION
Striking the steering wheel or steering shaft while
installed in the vehicle can permanently damage the
EPS unit and cause a Power Steering Fault.
2. Remove the pinch bolt retaining the upper steering

shaft to the power steering unit.
7. Loosen the nut and back it half way off the steering
shaft.
8. Place the assembly in a vise.
9. Using a large bronze drift and hammer, strike
steering shaft nut to pop the steering wheel off the
tapered shaft.
10. Once the steering wheel pops loose, completely
remove the nut and lift the steering wheel off the
shaft.

POWER STEERING UNIT REMOVAL POWER STEERING UNIT INSTALLATION

1. Remove upper steering shaft and steering wheel 1. Install the power steering unit onto the mount bracket
(See Steering Wheel / Upper Steering Shaft and torque power steering mounting bolts to
Removal (EPS) page 9.10). specification.
2. Using a 15 mm socket, remove the fastener TORQUE
qretaining the lower steering shaft to the power EPS Unit Mount Bolts:
steering unit.
30 lb-ft (41 Nm)
2. Align the skip-tooth spline on the power steering

output shaft with the opening in the lower power
steering shaft.
3. Install power steering to mount assembly and torque
TORQUE
EPS Unit Frame Bolts:
14 lb-ft (19 Nm)
4. Install the pinch bolt retaining the lower power

steering shaft to the power steering unit. Torque to
specification.
3. Remove the four fasteners w retaining the power
steering mount to the power steering unit. TORQUE
EPS Unit Pinch Bolts:
15 lb-ft (20 Nm)
5. Position the steering wheel, pivot tube and upper

steering shaft assembly to the proper mounting
location.
6. Be sure the front wheels are pointing straight ahead
and that the steering wheel is straight. Align the skip-
tooth spline q on the power steering input shaft with
the opening w in the upper steering shaft and install
the upper shaft onto the power steering input shaft.
9
WARNING
Electronic Power Steering (EPS) units are not
interchangeable between ATV and RANGER product
lines.

7. Loosely install the steering tilt assembly bolts and

nuts.
CAUTION
Striking the steering wheel or steering shaft can
permanently damage the EPS unit and cause a Power
Steering Fault.
8. Install the upper steering shaft pinch bolt and torque

to specification.
TORQUE
EPS Unit Pinch Bolts:
15 lb-ft (20 Nm)
9. Install the fastener retaining the steering wheel tilt

assembly to the frame. Torque fastener to
specification.
TORQUE
Steering Wheel Tilt Assembly Fasteners:
40 lb-ft (54 Nm)
10. Reconnect both electrical harnesses onto the power

steering unit. Be sure the connectors snap into place
and the wires are routed correctly.
11. Reinstall the upper and lower dash panels making
sure to reconnect the instrument cluster, both 12V
outlets and all the switches.
12. Turn the key switch on and test EPS operation.

STEERING RACK REMOVAL / 5. Remove the fasteners u, washers, and nuts

INSTALLATION (EPS) attaching the steering rack to the chassis.
REMOVAL
1. Remove the skid plate and open the hood to access
steering rack fasteners.
NOTICE
Lifting the vehicle and removing the front wheels will
assist in removal and installation, but does not require
removal to perform the procedure.
2. Remove the pinch bolt q retaining the steering shaft

w to the steering rack assembly e.
6. Gently pry between the steering shaft and steering

rack while lowering the steering rack and remove
from the vehicle.
3. Remove the cotter pin from both tie rod ends.

4. Remove the fasteners r, washers t, and nuts y
retaining the both tie rod ends to the steering knuckle.
INSTALLATION
1. Lay the old and new steering racks next to each other 9
on a clean surface. Measure the old steering rack
length from tie rod end to tie rod end. Turn the tie rod
ends in or out to adjust the new steering rack to this
measurement.
IMPORTANT
Pay close attention to the location of the washers to
ensure they are installed in the correct location during
assembly.

2. Install the steering rack in the vehicle. Align the 4. Install the pinch bolt r retaining the steering shaft q
splines of the steering shaft q to the steering rack w. to the steering rack assembly w. Torque to
specification.
3. Install the fasteners e, washers, and nuts attaching

the steering rack to the chassis. Torque to TORQUE
specification.
Steering Shaft Pinch Bolt:
46 ft-lbs (62 N·m)
5. Install the fasteners t, washers y, and nuts u

retaining the both tie rod ends to the steering knuckle.
Torque to specification.
TORQUE
Steering Rack Mounting Fasteners:
16 ft-lbs (22 N·m)
TORQUE
Tie Rod End Fastener:
40 ft-lbs (54 N·m)
6. Install cotter pins in both tie rod end fasteners.

7. Verify that steering alignment is within specifications.
If not, perform steering alignment.

FRONT STRUT
ASSEMBLY VIEW

Nut
q 13–17 ft-lbs (18–23 Nm) d Washers
w Washer f Ball Joint
e Rubber Spacer g Screws
r Upper Pivot Ball h Ball Joint Bracket

Spacer
Retaining Ring
9
t 15 ft-lbs ( 20 Nm) j
y Lower Pivot Ball k Wheel Bearing
u Spring Retainer l Hubstrut
i Spring 1( Cam Adjuster
o Bumper 2) Washer
a Spacer 2! Front Strut

Nut
s Bolts 2@ 20 ft-lbs (27 Nm)

FRONT STRUT CARTRIDGE 4. Remove cotter pin q from ball joint castle nut.
REPLACEMENT
1. Hold strut rod and remove top nut.
2. Compress spring using strut spring compressor
tools.
Strut Spring Compressor Tools
(PN 2871573) and (PN 2871574)
3. Remove upper strut pivot assembly.

4. Remove coil spring and collapse strut cartridge.
5. Remove two pinch bolts from strut casting.
6. Remove strut cartridge.
7. Install cartridge until bottomed in strut casting.
5. Remove castle nut w and separate A-arm from ball
8. Install pinch bolts with wire clamp (s) and torque to joint stud e.
specification.
6. Remove screws and ball joint retaining plate r.
TORQUE
7. Using ball joint removal/installation tool kit (PN
Strut Pinch Bolt: 2870871), remove ball joint from strut housing.
26 ft-lbs. (35 Nm)
• Install puller guide t with extension cap y.
9. Reassemble spring and top pivot assembly. Be sure • Apply grease to extension cap and threads of puller
all parts are installed properly and seated fully. bolt to ease removal.
10. Torque strut rod nut to specification. Do not over • Thread bolt u with nut i onto ball joint stud as shown.
torque nut.
• Apply heat to ease removal.
TORQUE
• Hold bolt and turn nut clockwise until ball joint is
Strut Mounting Nut (top): removed from strut housing.
15 ft-lbs (21 Nm)
BALL JOINT REPLACEMENT

1. Loosen front wheel nuts slightly.
2. Elevate and safely support machine under footrest/
frame area.
CAUTION
procedure.
3. Remove wheel nuts and wheels.

8. To install new ball joint:

• Remove extension cap and attach puller guide using
short bolts provided in the kit.
• Insert new ball joint o into driver a.
• Slide ball joint / driver assembly into guide.

• Apply heat to ease installation.
• Drive new joint into strut housing until fully seated.
9. Apply Loctite™ 242 (PN 2871949) to threads of

retaining plate screws or install new screws with pre-
applied locking agent. Torque screws to
specification.
TORQUE
Ball Joint Retaining Plate Screws:
8 ft-lbs (11 Nm)
10. Install A-arm on ball joint and torque castle nut to

specification. 9
TORQUE
Ball Joint Nut:
30 ft-lbs (41 Nm)
11. Install new cotter pin with open ends toward rear of
machine.

REAR A-ARMS
REMOVAL / REPLACEMENT 4. Remove the fasteners attaching the upper A-arm to
The following procedure details upper and lower A-arm the frame and remove the upper A-arm from the
removal and replacement on one side of the vehicle. vehicle.
Repeat the following steps to remove the A-arm(s) from
the opposite side.
NOTICE
Use the exploded view in this section as a reference
during the procedure.
1. Elevate and safely support the rear of vehicle off the

ground and remove the rear wheel.
Upper A-arm Removal
2. Remove the fastener q retaining the lower portion of
the shock and stabilizer linkage to the upper A-arm.
5. Examine A-arm and bearing carrier bushings and

pivot tubes (see “Exploded View”). Replace if worn.
Discard hardware.
WARNING
The locking agent on the existing bolts was destroyed
during removal. DO NOT reuse old hardware. Serious
injury or death could result if fasteners come loose
during operation.
6. If not replacing the A-arm, thoroughly clean the a-

arm and pivot tubes.
3. Remove the fastener w attaching the upper A-arm to 7. Insert new A-arm bushings and pivot tubes into the
the bearing carrier. new A-arm.
Lower A-arm Removal
8. Remove the fastener e attaching the lower A-arm to
the bearing carrier.

9. Remove the fasteners attaching the lower A-arm to 3. Route the brake line over the top of the lower A-arm
the frame and remove the lower A-arm from the and secure it in the retainer q.
vehicle.
4. Install upper A-arm assembly onto vehicle frame.

10. Examine A-arm and bearing carrier bushings and Torque new fasteners to specification.
pivot tubes (see “Exploded View”). Replace if worn.
Discard hardware. TORQUE
Control Arm Fasteners:
WARNING 40 ft-lbs (54 Nm)
The locking agent on the existing bolts was destroyed
during removal. DO NOT reuse old hardware. Serious 5. Attach upper A-arm to bearing carrier. Torque new
injury or death could result if fasteners come loose fastener to specification.
during operation.
TORQUE
11. If not replacing the A-arm, thoroughly clean the a- Bearing Carrier Fastener:
arm and pivot tubes. 40 ft-lbs (54 Nm)
12. Insert new A-arm bushings and pivot tubes into the
new A-arm. 6. Reinstall the lower portion of the shock and stabilizer
linkage to the upper A-arm. Torque shock / linkage
fastener to specification.
INSTALLATION
1. Install lower A-arm assembly onto vehicle frame. TORQUE
Torque NEW fasteners to specification. Shock / Linkage Fastener:
TORQUE 40 ft-lbs (54 Nm) 9
Control Arm Fasteners: 7. Install wheel and torque wheel nuts to specification.
40 ft-lbs (54 Nm)
TORQUE
2. Attach lower A-arm to bearing carrier. Torque NEW Steel Wheel Lug Nuts:
fastener to specification. 36 ft-lbs (49 Nm)
TORQUE Aluminum Wheel Lug Nuts:
30 ft-lbs + 90º (41 Nm + 90º)
Bearing Carrier Fasteners:
40 ft-lbs (54 Nm)
WARNING
Upon A-arm installation completion, test vehicle at low
speeds before putting into service.

ASSEMBLY VIEW

q Lower A-Arm y Bushing
w Upper A-Arm u Pin

e Bearing Carrier i Grease Zerk
Nuts
r Wheel Bearing o 40 ft-lbs (54 Nm)
t Snap Ring

REAR STABALIZER BAR / LINKAGE

REMOVAL / INSTALLATION REF. DESCRIPTION NOTES
1. Elevate and safely support vehicle with weight
removed from the rear wheel(s). q Lower A-Arm
2. Remove the retaining nut q from the upper portion w Stabilizer Bar
of the stabilizer bar linkage bushing on each side of Linkage
the vehicle.
e Stabilizer Bar
r Stabilizer Bar
Bushing / Shield
t Nut Torque to 17 ft-lbs

(23 Nm)
3. Remove the two fasteners w that secure the

stabilizer bar to the main frame on each side.
4. Remove the stabilizer bar from the frame and inspect
the stabilizer bar for straightness.
5. Inspect the stabilizer bar bushings and replace if
needed.
6. Inspect the rubber bushings on the stabilizer linkage
rod and replace if needed. If replacing the stabilizer
linkage, remove the lower shock bolt from the upper
A-arm.
7. Reverse this procedure for installation.
8. Torque the stabilizer retaining bolts and upper rubber
bushing nuts to specification.
9. If the stabilizer linkage was removed, torque the
9
lower shock retaining bolt to specification.
ASSEMBLY VIEW

SHOCKS / SPRINGS
ASSEMBLY VIEW SHOCK REPLACEMENT
1. Using a spring compressor, compress the shock
spring far enough to remove the spring retainer.

2. Remove the spring and adjusting cam from the
q Spring Adjuster existing shock and install components onto the new
shock.
w Spring Retainer
3. Compress the shock spring and install the spring
e Nuts Torque to 40 ft-lbs retainer.
(54 Nm)
4. Reinstall the shock onto the vehicle and torque new
TORQUE
SHOCK REMOVAL / INSTALLATION
1. Elevate the vehicle off the ground to relieve the Shock Bolt Torque:
suspension load. 40 ft-lbs (54 Nm)
2. Remove the upper and lower fasteners retaining the
shock and remove the shock from the vehicle.
3. Reverse the procedure to reinstall the shock. Torque

NEW fasteners to specification.
TORQUE
Shock Fasteners:
40 ft-lbs (54 Nm)

BRAKE SYSTEM
CHAPTER 10
BRAKE SYSTEM
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3
BRAKE SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3
BRAKE SYSTEM NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.4
BRAKE SYSTEM SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.4
BRAKE NOISE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.4
HYDRAULIC BRAKE SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.5
BRAKE SYSTEM ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.6
RANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.6
RANGER CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.7
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.8
BRAKE PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.8
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.9
PEDAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.9
PEDAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.9
BRAKE SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
BRAKE BLEEDING / FLUID CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
2 SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
PAD REMOVAL / DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
PAD ASSEMBLY / INSTALLATION- RANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
PAD ADJUSTMENT- RANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
PAD REMOVAL - CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15 10
PAD ASSEMBLY / INSTALLATION- CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
FRONT CALIPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
2 SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
FRONT CALIPER ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
FRONT CALIPER REMOVAL- RANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
FRONT CALIPER DISASSEMBLY - RANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
FRONT CALIPER INSPECTION- RANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
FRONT CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
FRONT CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
FRONT CALIPER ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
FRONT CALIPER REMOVAL- CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21

BRAKE SYSTEM
FRONT CALIPER DISASSEMBLY - CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21

FRONT CALIPER INSPECTION - CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
FRONT CALIPER ASSEMBLY - CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
FRONT CALIPER INSTALLATION - CREW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
FRONT BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
DISC REMOVAL / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27
REAR PAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
REAR CALIPERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
CALIPER ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
REAR CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
REAR CALIPER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
REAR CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
REAR CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
REAR BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
DISC RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
BRAKE DISC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
DISC REMOVAL / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
BRAKES SQUEAL / POOR BRAKE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
PEDAL VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
CALIPER OVERHEATS (BRAKES DRAG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
BRAKES LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
BRAKE WARNING SYSTEM (INTL MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
BRAKE WARNING SYSTEM INSPECTION (INTL MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36
BRAKE PEDAL SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36

BRAKE SYSTEM
GENERAL INFORMATION
BRAKE SERVICE SPECIFICATIONS
FRONT BRAKE
ITEM STANDARD SERVICE LIMIT
Front Brake Pad Thickness 0.298 ± .007" / 7.56 ± .178 mm 0.030" (.76 mm)
Front Brake Disc Thickness 0.158" (4.01 mm) 0.140" (3.56mm)
Front Brake Disc Runout - 0.010" (.254mm)
REAR BRAKE
ITEM STANDARD SERVICE LIMIT
Rear Brake Pad Thickness 0.298 ± .007"/ 7.56 ± .178 mm 0.030" (.76 mm)
Rear Brake Disc Thickness 0.188" (4.78 mm) 0.170" (4.32 mm)
Rear Brake Disc Runout - 0.010" (.254 mm)
SPECIAL TOOLS
Mity Vac™ Pressure Test
2870975
Tool

10

BRAKE SYSTEM
BRAKE SYSTEM NOTES

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.

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 is commercially available,
and can be applied to the back of the pads. Follow directions on the package. This will keep pads in contact with
caliper piston(s) to reduce the chance of squeaks caused by dirt or dust.

POSSIBLE CAUSE REMEDY
Spray disc and pads with CRC Brakleen™ or an
equivalent non-flammable aerosol brake cleaner.
Dirt, dust, or imbedded material on pads or disc
Remove pads and/or disc hub to clean imbedded
material from disc or pads.
Pad(s) dragging on disc (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
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

BRAKE SYSTEM
HYDRAULIC BRAKE SYSTEM OPERATION

The 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.
10

BRAKE SYSTEM
BRAKE SYSTEM ASSEMBLY VIEWS

RANGER

q Master Cylinder
w Banjo Bolt Torque to 15 ft-lbs (20 Nm)
e Caliper Mounting Bolts Torque to 46 ft-lbs (62 Nm)
r Pad Adjuster Screw Torque to 48 ft-lbs (5.5 Nm)
t Brake Line Fastener Bolt Torque to 15 ft-lbs (20 Nm)
y Screw Torque to 12–15 ft-lbs (16–20 Nm)

BRAKE SYSTEM
RANGER CREW

q Master Cylinder
w Banjo Bolt Torque to 15 ft-lbs (20 Nm)
e Caliper Mounting Bolts Torque to 46 ft-lbs (62 Nm)
r Pad Adjuster Screw Torque to 48 ft-lbs (5.5 Nm)
t Brake Line Fastener Bolt Torque to 15 ft-lbs (20 Nm)
y Screw Torque to 12–15 ft-lbs (16–20 Nm)
10

BRAKE SYSTEM
MASTER CYLINDER 5. Loosen the brake line banjo bolts r and allow the
fluid to drain.
REMOVAL
1. Remove the retaining clip q from the clevis pin w NOTICE
that attaches the master cylinder to the brake pedal Make note of front and rear brake line orientation on the
lever. master cylinder.
2. Remove LH wheel well panel to access master
cylinder. 6. Dispose of brake fluid properly and do not re-use.
INSTALLATION
Reverse Steps 1-5 for master cylinder installation. Refer
to the torque specifications in the illustration.
BRAKE PRESSURE SWITCH

The brake pressure switch q is located on the front
brake line outlet on the master cylinder.
3. Remove the two mounting bolts e that secure the

master cylinder to the frame.
4. Remove master cylinder and place a fluid catch
container under the master cylinder brake line banjo
bolt r.
TORQUE
Brake Pressure Switch / Banjo Bolt:
15 ft-lbs (20 Nm)
NOTICE
Always replace banjo washers if fastener is loosened or
removed.

e Mounting Bolts Torque to 15 ft-lbs
(20 Nm)
r Banjo Bolts Torque to 15 ft-lbs

(20 Nm)
CAUTION
Brake fluid will damage finished surfaces.
Do not allow brake fluid to come in contact with finished

surfaces.

BRAKE SYSTEM
BRAKE PEDAL
PEDAL REMOVAL
1. Remove the retaining clip q and clevis pin w from
the master cylinder e to free it from the brake pedal
r.
2. Remove the brake pedal pivot fastener and bushings

t off the mount bracket.
PEDAL INSTALLATION
1. Reverse steps for foot brake installation.
2. Tighten pivot bolt sufficiently. Refer to the general
torque specifications in Chapter 1.
10

BRAKE SYSTEM
BRAKE SERVICE PROCEDURES 6. Install a box-end wrench on caliper bleeder screw w.
BRAKE BLEEDING / FLUID CHANGE

NOTICE
When bleeding the brakes or replacing the fluid always
start with the furthest caliper from the master cylinder.
CAUTION
Always wear safety glasses.
CAUTION
Brake fluid will damage finished surfaces. Do not allow
brake fluid to come in contact with finished surfaces.
7. Attach a tight-fitting, clear hose to the bleeder fitting.
1. Locate master cylinder reservoir under the hood. 8. Place a small amount of fresh brake fluid into a
Clean reservoir cover thoroughly. small, clear container and place the other end of
2. Remove cover from reservoir. bleeder hose into the container.
3. If changing fluid, remove old fluid from reservoir with 9. Have an assistant slowly pump the brake pedal until
a Mity Vac™ pump or similar tool. pressure builds and then hold.
10. Quickly open and close the bleed screw while
Mity Vac™ (PN 2870975) holding pressure on the brake pedal.
4. Add brake fluid to the indicated MAX level q of NOTICE
reservoir. Do not release brake pedal before bleeder screw is
tight or air may be drawn into master cylinder.
11. Release brake pedal pressure. Check level of fluid in

reservoir and add if necessary (Figure 1-6).
12. Repeat Steps 9, 10, and 11 until brake pedal is firm
and no air can be seen moving through the clear
hose. Add fluid as necessary to maintain level in
reservoir.
Master Cylinder Fluid Level
Between the MIN and MAX line
CAUTION
Maintain at least 1/2"(1.27 cm) of brake fluid in the
Polaris DOT 4 Brake Fluid reservoir to prevent air from entering the master
(P/N 2872189) cylinder.
5. Begin bleeding procedure with caliper furthest from 13. Tighten bleeder screw and remove bleeder hose.
master cylinder. Torque bleeder screw to specification.
TORQUE
Bleeder Screw:
47 in-lbs (5.3 Nm)
14. Repeat Steps 9 - 13 for the remaining brake calipers.

15. Install master cylinder reservoir cover.

BRAKE SYSTEM
16. Field test machine at low speed before putting into

service. Check for proper braking action and pedal
reserve. With pedal firmly applied, pedal reserve
should be no less than 1/2"(1.3 cm).
17. Check brake system for fluid leaks.
BRAKE BURNISHING PROCEDURE

It is required that a burnishing procedure be performed
after installation of new brake pads to extend service life
and reduce noise.
Test drive machine and slowly increase speed to above
20 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 to maximize pad
service life.
10

BRAKE SYSTEM
FRONT BRAKE PADS 5. Push upper pad retainer pin e inward and slip outer
brake pad past edge. Remove the pad.
2 SEAT
PAD REMOVAL / DISASSEMBLY
1. Elevate and support front of machine.
WARNING
Use care when supporting vehicle so that it does not tip
or fall. Severe injury may occur if machine tips or falls.
2. Remove the front wheel. Loosen pad adjuster screw

q 2-3 turns.
BRAKE PAD INSPECTION

looseness.
2. Inspect the brake pad wear surface for excessive
wear.
3. Remove the two caliper bolts w and caliper from

mounting bracket.
4. Push caliper piston into caliper bore slowly using a
C-clamp or locking pliers with pads installed.
MEASUREMENT
Brake Pad
.030″ (0.762 mm)
pads should be replaced.
NOTICE
Brake fluid will be forced through compensating port
into master cylinder fluid reservoir when piston is
pushed back into caliper. Remove excess fluid from
reservoir as required.

BRAKE SYSTEM
PAD ASSEMBLY / INSTALLATION- RANGER PAD ADJUSTMENT- RANGER

1. Lubricate mounting bracket pins (Item 1) with a light 1. Install the adjuster screw (Item 1) and turn clockwise
film of disc brake caliper lube, and install rubber dust until stationary pad contacts disc, then back off 1/2
boots (Item 2). turn (counterclockwise).
2. Compress mounting bracket and make sure dust 2. Be sure fluid level in reservoir is up to MAX line
boots are fully seated. Install pads with friction inside reservoir and install reservoir cap.
material facing each other. Be sure pads and disc
are free of dirt or grease. Master Cylinder Fluid
Up to MAX line inside reservoir
3. Install caliper on hub strut, and torque mounting bolts
(Item 3) to specification.
3. Install wheels and torque wheel nuts.
4. It is recommended 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. Repeat procedure 10
times.
TORQUE
Steel Wheel Lug Nuts:
36 ft-lbs (49 Nm)
30 ft-lbs + 90º (41 Nm + 90º)
TORQUE
Front Caliper Mounting Bolts: 10
46 ft-lbs (62 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.

BRAKE SYSTEM
CREW 4. Push caliper piston into caliper bore slowly using a

C-clamp or locking pliers with pads installed.
PAD REMOVAL - CREW
1. Elevate and support front of vehicle.
WARNING
or fall.
Severe injury may occur if machine tips or falls.
2. Remove the wheel nuts, washers and front wheel.

Loosen pad adjuster screw (Item 1) 2-3 turns.
NOTICE
Brake fluid will be forced through compensating port
into master cylinder fluid reservoir when piston is
5. Push mounting bracket inward and slip outer brake

3. Remove the upper and lower caliper mounting bolts pad past edge. Then remove inner pad.
and remove the caliper from the front hub.
NOTICE
When removing caliper, use care not to damage brake
line. Support caliper so to avoid kinking or bending
brake line.

BRAKE SYSTEM
PAD INSPECTION 3. Install caliper onto front hub and torque mounting
1. Measure overall thickness of brake pad with insulator bolts.
plate. Replace pads if worn beyond the service limit.
TORQUE
MEASUREMENT Front Caliper Mount Bolt:
46 ft-lbs (62 Nm)
Front Brake Pad Thickness:
New: .298 ± .007” (7.56 ± .178 mm)
Service Limit: .180” (4.6 mm)
built up. Maintain at least 1/2, (12.7 mm) of brake
brake system.
PAD ASSEMBLY / INSTALLATION- CREW 5. Install the pad adjuster set screw (Item 1) and turn
1. Lubricate mounting bracket pins with a light film of clockwise until stationary pad contacts disc, then
disc brake caliper lube, and install rubber dust boots. back off 1/2 turn (counterclockwise).
10
2. Compress mounting bracket and make sure dust 6. Verify fluid level in reservoir is up to MAX line inside
boots are fully seated. Install pads with friction reservoir and install reservoir cap.
material facing each other. Master Cylinder Fluid
Up to MAX line inside reservoir
WARNING
If brake pads are contaminated with grease, oil, or 7. Install wheel and torque wheel nuts to specification
liquid soaked do not use the pads. (see “Chapter 2 - Maintenance”).
Use only new, clean pads.

BRAKE SYSTEM
FRONT CALIPER
2 SEAT
FRONT CALIPER ASSEMBLY VIEW

q Adjuster Screw Finger Tighten
w Bleeder Screw 30–60 in-lbs (3.4–6.8 Nm)
e Caliper Body
r Square O-Rings Apply Polaris Dot 4 Brake Fluid
t Piston Apply Polaris Dot 4 Brake Fluid
y Dust Boots
u Caliper Bracket
i Caliper Pins Apply Brake Disc Caliper Lube
o Pads

BRAKE SYSTEM
FRONT CALIPER REMOVAL- RANGER FRONT CALIPER DISASSEMBLY - RANGER

1. Elevate and support front of machine. 1. Remove brake pad adjuster screw (Item 1).
2. Push upper pad retainer pin inward and slip brake
WARNING pads past edge, if pads are still installed.
3. Remove mounting bracket (Item 2) and dust boot
(Item 3)
2. Remove the front wheel.
3. Remove brake line from the caliper. Place a
container under caliper to catch fluid draining from
brake line.
4. Remove piston (Item 4) and square O-rings (Item 5)

from the caliper body (Item 6).
4. Remove brake caliper mounting bolts and caliper.
5. Clean the caliper body, piston, and retaining bracket

with brake cleaner or alcohol.
NOTICE
10
Be sure to clean seal grooves in caliper body.

BRAKE SYSTEM
FRONT CALIPER INSPECTION- RANGER FRONT CALIPER ASSEMBLY

1. Inspect caliper body for nicks, scratches or wear. 1. Install new square O-rings q in the caliper body. Be
Measure bore size and compare to specifications. sure that the grooves are clean and free of residue or
Replace if damage is evident or if worn beyond brakes may drag.
service limit.
2. Coat the piston with clean Polaris DOT 4 Brake Fluid

MEASUREMENT (P/N 2872189). Install piston w with a twisting
motion while pushing inward. Piston should slide in
Front Caliper Piston Bore I.D.: and out of bore smoothly, with light resistance.
Std. 1.5050-1.5040” (32.27-30.202 mm)
3. Lubricate the mounting bracket pins with disc brake
Service Limit 1.5060” (38.252 mm)
caliper lube, and install the rubber dust seal boots.
2. Inspect piston for nicks, scratches, wear or damage. CAUTION
Measure diameter and replace if damaged or worn
beyond service limit. Do not allow grease to come into contact with the piston
and seals.
Damage may occur to the components.
MEASUREMENT
Front Caliper Piston O.D.:
Std. 1.4985-1.5000” (38.062 - 38.10 mm) 4. Compress the mounting bracket and make sure the
Service Limit 1.4980” (38.049 mm) dust seals are fully seated. Install the brake pads.
Clean the disc and pads with brake parts cleaner or
3. Inspect the brake disc and pads as outlined for brake denatured alcohol to remove any dirt, oil or grease.
pad replacement in this chapter.

BRAKE SYSTEM
FRONT CALIPER INSTALLATION 4. Follow brake bleeding procedure outlined earlier in

1. Install caliper on hub strut, and torque mounting bolts this chapter.
q. 5. Install wheels and torque wheel nuts to specification.
TORQUE
36 ft-lbs (49 Nm)
6. Burnish brake pads as outlined in this chapter
TORQUE
Front Caliper Mounting Bolt:
46 ft-lbs (62 Nm)
2. Install brake line and tighten securely with a flare nut

wrench.
3. Install the adjuster screw w and turn until stationary
pad contacts disc, then back off 1/2 turn.
10

BRAKE SYSTEM
CREW
FRONT CALIPER ASSEMBLY VIEW

q Bleeder Screw 47 in-lbs (5.3 Nm)
w Socket Set Screw
e Caliper Assembly
r Dust Boots
t Square O-Rings Apply Polaris DOT 4 Brake Fluid
y Piston
u Caliper Mount
i Caliper Pins Apply Disc Brake Caliper Lube
o Brake Pads

BRAKE SYSTEM
FRONT CALIPER REMOVAL- CREW 6. Remove the two caliper mounting bolts and remove
1. Elevate and safely support the front of the vehicle. the caliper assembly from the front strut.
WARNING
or fall. Severe injury may occur.
2. Remove the four wheel nuts and the front wheel.

3. Clean caliper area before removal.
4. Place a container below the caliper to catch brake
fluid when removing the line. Remove brake line
(Item 1) from caliper.
FRONT CALIPER DISASSEMBLY - CREW

1. Push brake pad retainer pin inward and slip brake
pads past the edge.
5. Loosen brake pad adjustment set screw (Item 2) 2-3

turns to allow brake pad removal after the caliper is
removed.
2. Remove both brake pads from the caliper.
10

BRAKE SYSTEM
3. Remove mounting bracket, pin assembly and dust 7. Clean the caliper body, piston, and retaining bracket
boot. with brake cleaner or alcohol.
4. Thoroughly clean the brake caliper before

disassembly and prepare a clean work area to
disassemble the caliper. NOTICE
5. While holding the caliper and covering the pistons
with a shop towel, carefully apply compressed air to
the brake line inlet to force the pistons out from the
caliper.
FRONT CALIPER INSPECTION - CREW
CAUTION 1. Inspect caliper body for nicks, scratches, pitting or
wear. Measure bore size and compare to
Use caution and always wear safety glasses when specifications. Replace if damaged or worn beyond
working with compressed air. service limit.
NOTICE
Do not remove the caliper pistons with a pliers. The
piston sealing surfaces will become damaged if a pliers
is used.
6. 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.
MEASUREMENT
Caliper Piston Bore I.D.:
Std: 1.373” (34.87 mm)

BRAKE SYSTEM
2. Inspect piston for nicks, scratches, pitting or wear. 3. Lubricate the mounting bracket pins with disc brake
Measure piston diameter and replace if damaged or caliper lube, and install the rubber dust seal boots.
worn beyond service limit.
4. Compress the mounting bracket and make sure the

dust seal boots are fully seated. Install the brake
MEASUREMENT pads. Clean the disc and pads with brake parts
Caliper Piston O.D.: cleaner or denatured alcohol to remove any dirt, oil
Std: 1.370” (34.80 mm) or grease.
3. Inspect the brake disc and pads as outlined in this FRONT CALIPER INSTALLATION - CREW
chapter. 1. Install caliper and torque mounting bolts to
specification.
FRONT CALIPER ASSEMBLY - CREW

1. Install new O-rings (Item 1) in the caliper body. Be
sure the grooves (Item 2) are clean and free of
residue or brakes may drag upon assembly.
TORQUE
10
Front Caliper Mount Bolt:
46 ft-lbs (62 Nm)
2. Coat pistons with clean Polaris DOT 4 Brake Fluid.

Install pistons with a twisting motion while pushing
inward. Piston should slide in and out of bore
smoothly, with light resistance.

BRAKE SYSTEM
2. Install brake line and torque the banjo bolt (Item 1) to

the proper torque specification.
3. Install the pad adjustment screw (Item 2) and turn

until stationary pad contacts disc, then back off 1/2
turn.
4. Perform brake bleeding procedure as outlined earlier

in this chapter.
5. Install wheel and torque wheel nuts to specification
(see Chapter 2).
NOTICE
If new brake pads are installed, brake burnishing is
required. SeeBrake Burnishing Procedure page 10.11.

BRAKE SYSTEM
FRONT BRAKE DISC 3. Mount dial indicator as shown to measure disc

runout. Slowly rotate the disc and read total runout
DISC INSPECTION on the dial indicator. Replace the disc if runout
1. Visually inspect the brake disc for nicks, scratches, exceeds specifications.
or damage.
2. Measure the disc thickness at 8 different points
around the pad contact surface using a 0-1"
micrometer. Replace disc if worn beyond service
limit.
MEASUREMENT
Brake Disc Runout:
Service Limit .010” (.254 mm)
MEASUREMENT
Brake Disc Thickness:
New .150-.165” (3.81 - 4.19 mm)
Service Limit .140”/3.56 mm
MEASUREMENT
Brake Disc Thickness Variance:
Service Limit .002” (.051 mm)
difference between measurements
10

BRAKE SYSTEM
DISC REMOVAL / REPLACEMENT REAR BRAKE PADS

1. Remove bolts q and disc w.
PAD REMOVAL
1. Elevate and support rear of machine.
WARNING
2. Remove the rear wheel. Loosen pad adjuster screw

q 2-3 turns.
2. Clean mating surface of disc and hub e.

3. Install disc on hub.
4. Apply Loctite® 272 to new bolts, install and tighten to
specification.
TORQUE
Front Brake Disc Mounting Bolts:
18 ft-lbs (25 Nm)
3. Clean caliper area before removal.
4. Remove caliper mounting bolts w and lift caliper off
of disc.
CAUTION
When removing caliper, be careful not to damage brake
line. Support caliper so as not to kink or bend brake
line.

BRAKE SYSTEM
5. Push caliper piston into caliper bore slowly with pads BRAKE PAD INSPECTION
installed.
NOTICE looseness.
Brake fluid will be forced through compensating port 2. Inspect the brake pad wear surface for excessive
into master cylinder fluid reservoir when piston is wear.
6. Remove the brake pads.
MEASUREMENT
Brake Pad
.030″ (0.762 mm)
pads should be replaced.
10

BRAKE SYSTEM
REAR PAD INSTALLATION

1. Install new pads in caliper body.
2. Install caliper and torque mounting bolts.
TORQUE
Rear Brake Caliper Mounting Bolts:
46 ft-lbs (62 Nm)
3. Turn adjuster screw back in finger tight using a hex

wrench. Then back off 1/2 turn.
built up. Maintain at least 1/2"(12.7 mm) of brake
master cylinder.
5. Fill master cylinder to Max level.
6. Burnish brakes as outlined in this chapter.

BRAKE SYSTEM
REAR CALIPERS
CALIPER ASSEMBLY VIEW

q Socket Set Screw
w Bleeder Screw 47 in-lbs (5.3 Nm)
e Caliper Assembly
r Dust Boots
t Square O-Rings Apply Polaris DOT 4 Brake Fluid
y Piston Apply Polaris DOT 4 Brake Fluid
u Caliper Pins Apply Disc Brake Caliper Lube

10
i Caliper Mount
o Brake Pads

BRAKE SYSTEM
CALIPER REMOVAL REAR CALIPER DISASSEMBLY

1. Safely support the rear of the machine. 1. Remove brake pad adjuster screw q.
2. Push upper pad retainer pin inward and slip brake
WARNING pads u past edge, if pads are still installed.
3. Remove mounting bracket w and dust boot e.
2. Use a wrench to remove the brake line. Place a

container to catch brake fluid draining from brake
lines.
4. Remove piston r and square O-rings t from the

caliper body y.
3. After the fluid has drained into the container, remove

the two caliper mounting bolts and remove caliper.
5. Clean the caliper body, piston, and retaining bracket

with brake cleaner or alcohol.
NOTICE
4. Clean disc, caliper body, and pistons with brake
cleaner or alcohol.

BRAKE SYSTEM
REAR CALIPER INSPECTION REAR CALIPER ASSEMBLY

1. Inspect caliper body for nicks, scratches or wear. 1. Install new square O-rings q in the caliper body. Be
Measure bore size and compare to specifications. sure that the grooves are clean and free of residue or
Replace if damage is evident or if worn beyond brakes may drag.
service limit.
2. Coat the piston with clean DOT 4 Brake Fluid (PN

MEASUREMENT 2872189). Install piston w with a twisting motion
while pushing inward. Piston should slide in and out
Caliper Piston Bore I.D.: of bore smoothly, with light resistance.
Std: 1.505” (38.23 mm)
3. Lubricate the mounting bracket pins with disc brake
caliper lube, and install the rubber dust seal boots.
2. Inspect piston for nicks, scratches, wear or damage.
Measure diameter and replace if damaged or worn
beyond service limit.
4. Compress the mounting bracket and make sure the

dust seals are fully seated. Install the brake pads.
Clean the disc and pads with brake parts cleaner or 10
denatured alcohol to remove any dirt, oil or grease.
MEASUREMENT
Caliper Piston O.D.:
Std: 1.500” (38.10 mm)
3. Inspect the brake disc and pads as outlined for brake

pad replacement in this chapter.

BRAKE SYSTEM
REAR CALIPER INSTALLATION

1. Install the rear caliper onto the mounting bolts.
Torque mounting bolts to specification.
TORQUE
Rear Caliper Mounting Bolts:
46 ft-lbs (62 Nm).
2. Install brake line banjo bolt. Torque banjo bolt to

specification.
TORQUE
Banjo Bolt:
15 ft-lbs (20 Nm)
3. Install the rear wheel and wheel nuts. Carefully lower

the vehicle.
4. Field test unit for proper braking action before putting
into service. Inspect for fluid leaks and firm brakes.
Make sure the brake is not dragging when pedal is
released. If the brake drags, re-check assembly and
installation.
NOTICE
If new brake pads are installed, brake burnishing is
recommended (see “REAR BRAKE PADS - Brake
Burnishing Procedure”).

BRAKE SYSTEM
REAR BRAKE DISC BRAKE DISC INSPECTION

DISC RUNOUT 1. Check the surface condition of the brake discs.
1. Mount a dial indicator and measure disc runout. 2. Measure the thickness of the front and rear brake
Slowly rotate the disc and read total runout on the discs.
dial indicator. Replace the disc if runout exceeds
specification. 3. The disc(s) should be replaced if thickness is less
than the specified service limit
MEASUREMENT
Brake Disc Runout REF PART SERVICE LIMIT
Service Limit .010” (.254 mm) q Front Disc See the specifications
at the beginning of
w Rear Disc the Brake System
chapter.
WARNING
Do not apply WD-40 or any petroleum product to brake
discs. These types of products are flammable and may
also reduce the friction between the brake pad and
caliper.
10

BRAKE SYSTEM
DISC REMOVAL / REPLACEMENT

1. Remove brake caliper (see “Brake Caliper Service”).
2. Remove cotter pin q, castle nut w and washers e.
3. Remove the wheel hub assembly from the vehicle
and remove the four bolts r retaining the disc to the
hub.
4. Clean the wheel hub mating surface and install new

disc on wheel hub.
5. Apply Loctite® 272 to new bolts, install and torque to
specification.
6. Install wheel hub assembly, washers, and castle nut.
Torque castle nut to specification and install a new
cotter pin.
TORQUE
Rear Brake Disc Mount Bolts:
27 ft-lbs (36 Nm)
Rear Hub Castle Nut:

110 ft-lbs (150 Nm)
Front Hub Castle Nut:

90 ft-lbs (122 Nm)
7. Install rear brake caliper (see “BRAKE CALIPER

SERVICE”). Follow the bleeding procedure outlined
earlier in this chapter.
8. Field test unit for proper braking action before putting
into service. Inspect for fluid leaks and firm brakes.
Make sure the brake is not dragging when pedal is
released. If the brake drags, re-check assembly and
installation.

BRAKE SYSTEM
TROUBLESHOOTING BRAKE WARNING SYSTEM (INTL

BRAKES SQUEAL / POOR BRAKE MODELS)
PERFORMANCE • This vehicle uses a brake monitoring system with full
plausibility check. This system uses a brake pedal
• Air in system switch mounted to the pedal, and either one or two
• Water in system (brake fluid contaminated) brake pressure switches mounted on the master
cylinder.
• Caliper/disc misaligned
• For this system to operate correctly. The Brake
• Caliper dirty or damaged Pressure Switch and Brake pedal switch need to close
within an acceptable amount of time.
• Brake line damaged or lining ruptured
• When the pressure switch or pedal switch changes
• Worn disc and/or friction pads
their status, the ECU waits 3 seconds to receive the
• Incorrectly adjusted stationary pad second signal.
– Example : When the brake pedal is depressed, the
• Worn or damaged master cylinder or components
Brake Pedal Switch changes status from closed to
• Damaged break pad noise insulator open. The ECU then waits 3 seconds for the
pressure switch signal. If not received the Brake
Warning Light will be switched ON. Reverse
plausibility is monitored as well (system works in
PEDAL VIBRATION opposite as well). If pressure switch changes status
• Disc damaged first, the ECU waits 3 seconds for the status
change of the Brake Pedal Switch. If the signal is
• Disc worn (runout or thickness variance exceeds not received, the Brake Warning Light will be
service limit) turned ON.
• If the Brake warning light is active, refer to Brake
Warning System Inspection (INTL Models) page 10.36
CALIPER OVERHEATS (BRAKES DRAG) for testing procedures.
• 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
10
• Alignment of caliper to disc
• Caliper pistons sticking
• Improper assembly of brake system components

BRAKE SYSTEM
BRAKE WARNING SYSTEM BRAKE PEDAL SWITCH INSPECTION

INSPECTION (INTL MODELS) The Brake Pedal Switch is mounted near the Brake
Pedal Assembly. When the brake pedal is depressed this
1. Inspect the brake hydraulic system for any concerns. switch will turn from active to inactive. This can be
If any leaks or mechanical failures are found with the monitored using Digital Wrench ®. If the status does not
hydraulic system, concerns need to be repaired switch when depressed, proceed with further testing.
before proceeding.
2. Connect the vehicle to Digital Wrench® and select 1. Disconnect electrical connector from sensor.
the Data Item Menu. 2. Inspect sensor and connector for moisture or
3. Add the Brake Switch and Foot Brake Switch inputs corrosion. If moisture or corrosion is found, clean first
to the main table. and re check.
4. Slowly depress the brake pedal, and observe the 3. With connector disconnected, check resistance
switching point of the Brake Pressure Switch and the across pins on the sensor. When switch is closed
Brake Pedal Switch. (brake pedal not depressed) resistance should be
less than 0.5 ohms. With switch open (brake pedal
5. When the brake pedal is depressed the brake depressed) resistance should show an open (OL).
pressure switch and brake pedal switch should
become active very close to each other. 4. If the sensor test fails, resistance is not within
specification; the sensor should be replaced.
6. If one / both switches are not changing status, check
the brake pedal (pay close attention to were the lever 5. If the sensor test passes, resistance is within
triggers brake pedal switch), inspect the pedal mount specification, inspect the circuit for correct operation.
for mechanical damage, and check for free play. If there is a concern found with the circuit repair and
recheck operation.
NOTICE
6. If the concern is still present, it is possible that there
A sticking brake pedal may also cause false brake may be a concern with the ECU.
warning alarms.
7. The Brake Warning message could also be caused

by a failed sensor. If one / both do not switch when
monitoring on Digital Wrench®. Refer toBrake Light
Switch page for Brake Pressure Switch testing.
Refer toBrake Pedal Switch Inspection page 10.36 for
Brake Pedal Switch testing.
8. If one / both sensors fail the testing, check the
electrical circuit for the sensor that has failed. It is
possible that there could be a concern with the circuit.
If a circuit concern is found, repair or replace as
necessary.
9. If the concern is still present after previous testing has
passed, suspect there is a fault within the ECU.

BODY / FRAME
CHAPTER 11
BODY / FRAME
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
CHASSIS / BODY ASSEMBLY VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
FRAME ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
CREW FRAME ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4
2017–2020 CAB FRAME EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
2017 CREW CAB FRAME ASSEMBLY VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.6
DASH INSTRUMENTS / CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7
HOOD / DASH / FRONT FASCIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8
FLOOR / REAR FENDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9
SEAT MOUNTING / SEAT BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.10
CREW FLOOR / REAR FENDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.11
CREW SEAT MOUNTING / SEAT BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.12
REAR CARGO BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.13
CARGO BOX - TAILGATE / BOX SUPPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.13
BOX REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.15
BOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.15
BODY COMPONENT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.16
LOWER SEAT BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.16
FRONT BUMPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.16
FENDERS / FOOT PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.16
HOOD / DASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.17
FLOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.18
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.19
DECAL REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.19
11

BODY / FRAME
GENERAL INFORMATION
TORQUE SPECIFICATIONS SPECIAL TOOLS
ITEM TORQUE VALUE PART
TOOL DESCRIPTION
NUMBER
Body T-40 Screws 8 ft-lbs (11 Nm)
2870872 Shock Spanner Wrench
Bearing Carrier Fasteners 40 ft-lbs (54 Nm)
2870623 Shock Spring Compressor Tool
Ball Joint Fastener 30 ft-lbs (41 Nm)
2876389 Multi-Function Pliers
Control Arm Fasteners 40 ft-lbs (54 Nm)
2870871 Strut and Ball Joint Tool Set
Hub Castle Nut (front) 90 ft-lbs (122 Nm)
2871573 Strut Spring Compressor (LH)
Hub Castle Nut (rear) 110 ft-lbs (150 Nm)
2871574 Strut Spring Compressor (RH)
Seat Belt Mounting 40 ft-lbs (54 Nm)
Fasteners Bosch Automotive Service Solutions: 1-800-345-2233
or http://polaris.service-solutions.com/
Shock Mounting Bolts
40 ft-lbs (54 Nm)
(rear) Included in this machine’s tool kit, the multi-function
pliers is designed to remove the plastic push rivets used
Steering Rack Mounting 16 ft-lbs (22 Nm) to fasten body components.
Bolts
Steering Shaft to EPS 20 ft-lbs (27 Nm)
Steering Shaft to Steering 46–51 ft-lbs (62-69 Nm)
Rack
Steering Wheel Nut 65 ft-lbs (88 Nm)
Strut Casting Pinch Bolt 26 ft-lbs (35 Nm)
Strut Rod Retaining Nut
15 ft-lbs (21 Nm)
(Top)
Tie Rod End Jamb Nut 14 ft-lbs (19 Nm)
Tie Rod End Mounting 40 ft-lbs (54 Nm)
Nut
Wheel Lug Nuts 36 ft-lbs (49 Nm)
NOTICE
Refer to exploded views throughout this chapter for
more torque specifications, component identification,
and location of components.

BODY / FRAME
CHASSIS / BODY ASSEMBLY VIEWS

FRAME ASSEMBLY VIEW

q Main Frame
w Front Bumper
e Seat Base Frame
r Dash Support
t Left Floor Support
y Right Floor Support
u Skid Plate
i Bumper Screen
11
o Screws Torque to 22 ft-lbs (30 Nm)
a Screws Torque to 8 ft-lbs (11 Nm)

BODY / FRAME
CREW FRAME ASSEMBLY VIEW

q Rear Main Frame
w Front Main Frame
e Front Bumper
r Dash Support
t Left Floor Support
y Right Floor Support
u Front Skid Plate
i Rear Skid Plate
o Seat Base Frame
a Bumper Screen
s Screws Torque to 22 ft-lbs
d Screws Torque to 8 ft-lbs
f Screws Torque to 40 ft-lbs

BODY / FRAME
2017–2020 CAB FRAME EXPLODED VIEW
NUMBER PART DESCRIPTION TORQUE (IF APPLICABLE)

q Cab Frame, LH -
w Cab Frame, RH -
e Cab Frame, Lower / Rear -
r Cab Support, Rear -
t Windshield Mount, Upper -
y Grab Handle -
u Screw - M8 x 1.25 x 20 (QTY.8) 18 ft-lb (24 Nm)

i Screw - M10 x 1.5 x 20 (QTY.6) 36 ft-lb (49 Nm)
o Bolt - M8 x 1.25 x 20 (QTY.2) 10 ft-lbs (14 Nm)
a Screw - M10 x 1.25 x 30 (QTY.4) 36 ft-lb (49 Nm)
s Screw - M6 x 1.0 x 25 (QTY.2) 8 ft-lb (11 Nm)
d Screw - M8 x 1.25 x 30 (QTY.4) 14 ft-lbs (19 Nm)
f Screw - M10 x 1.5 x 75 (QTY.4) 36 ft-lb (49 Nm)
g Screw - M10 x 1.5 x 30 (QTY.4) 36 ft-lb (49 Nm)
h Nut - M10 1.5 (QTY.10) -
j Nut - M8 x 1.25 (QTY.8)

Nut - M10 x 1.25 (QTY.4)
-
-
11
k
Nut Used with part f on 2017–2018 cab frames
Net Rod Mounts (Not Shown) -
Screw (Used to fasten Net Rod Mounts) Torque to 8 ft-lbs (11 Nm)

BODY / FRAME
2017 CREW CAB FRAME ASSEMBLY VIEW
NOTICE
Image for reference only. 2016 cab frame shown. Refer to E-cat for an image of the 2017 cab frame.

q Front Cab Frame
w Middle Cab Frame
e Rear Cab Frame
r Cab Frame Brace
t Screws Torque to 36 ft-lbs (48 Nm)
y Screws Torque to 36 ft-lbs (48 Nm)
u Screws Torque to 36 ft-lbs (48 Nm)
Nut Used with part u on 2017 cab frames
i Nets - Door
Net Rod Mounts (Not Shown)
Screw (Used to fasten Net Rod Mounts) Torque to 8 ft-lbs (11 Nm)

BODY / FRAME
DASH INSTRUMENTS / CONTROLS

q Instrument Cluster
w Bezel
e Key Switch
r 12V Accessory Plug
t Turf Switch
y Dash Panel
11

BODY / FRAME
HOOD / DASH / FRONT FASCIA

q Hood
w Front Fascia
e Dash Panel
r Glove Box Lid
t Hood Strap
y Hood Hinge Pins
u Push Rivet
i Hood Latch

BODY / FRAME
FLOOR / REAR FENDERS

q Front Floor
w Main Floor
e Floor Cover
r Cup Holder
11
t Push Rivet
y Screws Torque to 5 ft-lbs (7 Nm)

BODY / FRAME
SEAT MOUNTING / SEAT BELTS

q Seat Back
w Seat Base
e LH Seat Belt Assm
r RH Seat Belt Assm
t Seat Base Frame
y Screw 24 in-lbs (3 Nm)
u Bolt 40 ft-lbs (54 Nm)

BODY / FRAME
CREW FLOOR / REAR FENDERS

q Front Floor
w Main Floor
e Front Seat Panel
r Rear Main Floor
11
t Storage Box
y Front Inner Fender
u Cup Holder
i Floor Cover
o Push Rivet

BODY / FRAME
CREW SEAT MOUNTING / SEAT BELTS

q Front Seat Base Frame
w Rear Seat Base Frame
e Seat Base
r Seat Back
t Screw 24 in-lbs (3 Nm)
y Bolt 40 ft-lbs (54 Nm)

BODY / FRAME
REAR CARGO BOX

CARGO BOX - TAILGATE / BOX
SUPPORT
11

BODY / FRAME

q Cargo Box
w Box Frame
e Tailgate Inner Panel
r Tailgate Outer Panel
t Box Tilt Shock
y Box Tilt Latch
u Heat Shield
i Tailgate Tube
o Tailgate Mount Bracket
a Bushing
s Tailgate Latch
d Screw Torque to 8 ft-lbs (11 Nm)
f Screw Torque to 5 ft-lbs (7 Nm)

BODY / FRAME
BOX REMOVAL BOX INSTALLATION

1. Remove the screw q that secures the hinge pin to 1. If the shock was replaced, install the lower portion of
the frame on both sides. the shock to the frame and secure it with the pin and
clip.
2. Place the cargo box onto the frame. Align the hinges
of the box with the bracket on the frame.
3. Install the box hinges on both sides.
4. Secure the box hinges with the hinge screws on both
sides.
5. With the hinges installed, attach the shock to the
cargo box by inserting the pin and clip.
6. Lower the box and secure the latch.
2. Lift the cargo box into the dump position.

3. Disconnect the rear wire harness attached to the tail
lights.
4. Remove the upper clip w and pin e attaching the
shock to the cargo box.
CAUTION
Safely support the box during the remainder of the
removal process. The box is not as stable with the
shock removed.
5. Remove the hinge pin from both sides.

6. With both hinge pins removed, remove the box from
the frame. Two people may be needed to remove the
11
box from the frame.
CAUTION
Use caution when removing the box. It is recommended
to have two people carefully remove the box from the
frame.

BODY / FRAME
BODY COMPONENT REMOVAL

LOWER SEAT BASE FENDERS / FOOT PADS
1. Lift up on the seat base to disengage the seat from 1. FRONT - Remove the lower T27 Torx-head screws
the rubber grommets q. retaining the foot pads.
2. Pull the seat base forward to disengage the rear tabs 2. Remove the two push rivets retaining the front fender
and remove the seat base from the vehicle. and remove the fender from the vehicle.
3. Repeat this procedure to remove the other front
FRONT BUMPER fender.
1. Unlatch the hood and disconnect the head lamp 4. REAR - Remove the lower T27 Torx-head screws
harnesses. Remove the two pivot screws retaining retaining the foot pads.
the hood and remove the hood from the bumper.
5. Remove the three T27 Torx-head screws retaining
2. Remove the three bolts from the lower portion of the the rear panel.
bumper.
6. Repeat this procedure to remove the other rear
fender.
3. Remove the two fasteners from each side of the

upper portion of the bumper.
4. Carefully remove the bumper from the vehicle.

BODY / FRAME
HOOD / DASH
1. Hood Removal - Unlatch the hood and disconnect
the head lamp harnesses. Remove the two clips and
pivot pins retaining the hood and remove the hood
from the bumper.
2. Dash Removal - Remove the three Torx-head
screws retaining the front of the dash to the frame.
3. Open the glove box and remove the Torx-head screw
from the dash.
4. Remove the Torx-head screw retaining the left

portion of the dash.
5. Remove the eight fasteners from each side of the
dash where it attaches to the front and rear fenders.
6. Remove the rubber boot from around shift lever.
7. Remove the five push rivets from under the dash
panel. Unhook all electrical components to allow the
panel to be completely removed.
8. Carefully remove the dash assembly from the
vehicle.
11

BODY / FRAME
FLOORS 5. Remove the Torx-head screws retaining the main

1. Remove the Foot pads. floor and remove the main floor from the vehicle.
2. Remove the rear fender push rivets. 6. Continue with ‘Hood / Dash Removal’ procedure.
3. Remove the seven Torx-head screws retaining the 7. Remove the accelerator and brake pedals for
center floor. adequate clearance to remove the front floor section.
4. Remove the Torx-head screws retaining the front
floor cover.

BODY / FRAME
DECALS
DECAL REPLACEMENT
WARNING
The following procedure involves the use of an open
flame. Perform this procedure in a well ventilated area,
away from gasoline or other flammable materials. Be
sure the area to be flame treated is clean and free of
gasoline or flammable residue.
WARNING
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.
To flame treat the decal area:
1. Pass the flame of a propane torch back and forth
quickly over the area where the decal is to be applied
until the surface appears slightly glossy. This should
occur after just a few seconds of flame treating. Do
not hold the torch too close to the surface (2-3 inches
from the flame tip is recommended). Keep the torch
moving to prevent damage.
2. Apply the decal on one edge first. Slowly lay down
remainder of the decal while rubbing lightly over the
decal surface to eliminate any air bubbles during the
application.
11

BODY / FRAME
NOTES

ELECTRICAL
CHAPTER 12
ELECTRICAL
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.3
ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.3
BATTERY CONDUCTANCE ANALYZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.3
COMPONENTS UNDER HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.4
SWITCHES / CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.5
IGNITION / HEADLIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.5
AWD / 2WD / TURF SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.5
DIFFERENTIAL SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.6
BRAKE PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.6
ALL WHEEL DRIVE (AWD) COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.7
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.7
DIAGNOSING SYSTEM FAILURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.7
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.8
SPEED SENSOR LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.8
SPEED SENSOR TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.8
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.9
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.9
RIDER INFORMATION DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.10
INFORMATION DISPLAY AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.11
DIAGNOSTIC MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.13
INSTRUMENT CLUSTER PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.14
INSTRUMENT CLUSTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.14
INSTRUMENT CLUSTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.14
HEADLIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.15
HEADLIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.15
HEADLIGHT BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.16
HEADLIGHT HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.16
HEADLIGHT HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.16
TAIL LIGHT / BRAKE LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.17
LED LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.17
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.18
FAN CONTROL CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.18
FAN CONTROL CIRCUIT BYPASS TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.18
IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.19
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.19 12
IGNITION COIL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.19
IGNITION COIL AND HT LEAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.20
RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.21
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.21

ELECTRICAL
FUSES / CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.23

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.23
OPERATION (INTL.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.24
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.25
CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.25
CHARGING SYSTEM “BREAK EVEN” TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.25
CHARGING SYSTEM ALTERNATOR TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.26
CHARGING SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.28
BATTERY SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.29
BATTERY TERMINALS / BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.29
BATTERY TERMINAL BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.29
BATTERY ACTIVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.29
BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.30
BATTERY REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.31
CONVENTIONAL BATTERY TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.31
OCV - OPEN CIRCUIT VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.31
VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.31
SPECIFIC GRAVITY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.31
LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.32
CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.32
OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.32
STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.33
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.33
STARTER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.33
STARTER SOLENOID BENCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.34
STARTER SOLENOID OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.34
STARTING SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.35

ELECTRICAL
GENERAL INFORMATION
SPECIAL TOOLS BATTERY CONDUCTANCE ANALYZER
PART Conductance describes the ability of a battery to conduct
TOOL DESCRIPTION current. A conductance tester functions by sending a low
NUMBER
PV-43568 Fluke™ 77 Digital Multimeter frequency AC signal through the battery and a portion of
the current response is captured, from this output a
PV-43526 Connector Test Kit conductance measurement is calculated. Conductance
2870630 Timing Light testing is more accurate than voltage, specific gravity, or
2870836 Battery Hydrometer load testing.
2460761 Hall Sensor Probe Harness Authorized Polaris dealers/distributors are required to
2871745 Static Timing Light Harness use the conductance analyzer when testing 12V Polaris
PU-47063 Digital Wrench™ Diagnostic Software batteries.
PU-47471 Digital Wrench™ SmartLink Module Kit
PU-50296 Battery Conductance Analyzer

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 Polaris MDX-610P
sure leads are in the proper jack for the test being
Bosch PN: PU-50296
performed (i.e. 10A jack for current readings). Refer to
the Owner’s Manual included with your meter for more
information.
• Voltage, amperage, and resistance values included in
this manual are obtained with a Fluke™ 77 Digital
Multimeter. This meter is used when diagnosing
electrical problems. Readings obtained with other
meters may differ.
Fluke™ 77 Digital Multimeter:
PV-43568
• 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.
12

ELECTRICAL
COMPONENTS UNDER HOOD

The following components can be accessed under the
hood.
• Voltage Regulator
• Terminal Block
• Digital Wrench Diagnostic Connector
• AWD/2WD/TURF Switch
• 12 VDC Accessory Power Point
• Ignition Switch
• Instrument Cluster
• Cooling Fan
• TRS Connector
• Brake Switch
• Headlights

ELECTRICAL
SWITCHES / CONTROLS
IGNITION / HEADLIGHT SWITCH AWD / 2WD / TURF SWITCH
1. Open the hood (see Chapter 5). 1. Remove the dash panel from the dash (see Chapter
5).
2. Disconnect the ignition switch harness, by
depressing the connector lock and pulling on the 2. Disconnect the switch harness (Gray, Orange/White,
connector. Do not pull on the wiring. Brown, White/Green), by depressing the connector
lock and pulling on the connector. Do not pull on the
3. Inspect the switch connections and test the switch wiring.
for continuity.
3. Inspect the switch connections and test the switch
• Turn the ignition key to ON LIGHTS. There should be for continuity.
continuity between switch pins C and D; A, E and F.
• When the switch is in position #1 (AWD), there should
• Turn the ignition key to ON. There should be continuity
be continuity between terminals 2 (Orange/White) and
between switch pins C and D; E and F.
3 (Gray).
• Turn the ignition key to START. There should be
• When the switch is in position #3 (TURF), there should
continuity between switch pins A and B; C and D; E
be continuity between terminals 1 (White/Green) and 2
and F.
(Orange/White).
12

ELECTRICAL
DIFFERENTIAL SOLENOID • Check the solenoid and relay connectors. Look for
The differential solenoid q is located on the right side of loose wires or bad connections.
the transmission. The solenoid actuates an engagement • Check for power from the relay connector, to ensure
dog, which locks and unlocks the rear differential. Refer the solenoid has power to be activated. Check for
to Chapter 8 for more information on the rear differential power at the ECU and Rear Differential Solenoid
mechanical operation. Relay.
• Check the switch wires for loose connections.
• Remove solenoid from rear differential and ensure the
solenoid plunger is actuating.
CAUTION
Do not power the solenoid with 12 Volts for more than 1
second, or damage may occur to solenoid.
BRAKE PRESSURE SWITCH

The brake pressure switch q is located on the rear brake
line outlet on the master cylinder.
REAR DIFFERENTIAL SOLENOID
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,
key-on accessory battery voltage is sent from the AWD /
2WD / TURF Switch to the ECU.
Depending on engine speed and gear position criteria,
the ECU energizes the Rear Diff Solenoid Relay allowing
it to enable the differential solenoid.
TORQUE
Master Cylinder Brake Pressure Switch / Banjo Bolt:
180 in-lbs +/- 10 in-lbs
NOTICE
Always replace brake system seals if fastener is
1. Disconnect the wire harness from the brake switch.

2. Connect an ohmmeter across switch contacts.
Reading should be infinite (OL).
If the rear differential fails to switch from operational
modes: 3. Apply foot brake and check for continuity between
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.

ELECTRICAL
ALL WHEEL DRIVE (AWD) COIL

OPERATION OVERVIEW
• When the AWD switch is “ON”, 12 VDC power is
present at the hub coil on the Red/Green wire.
• If the criteria is met, the ECU provides a ground path
on the Brown/White wire.
• 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 on the
Gray wire.
• Verify the AWD hub coil is functional. Test the AWD
hub coil using an ohm meter. See specifications below:
AWD Hub Coil Resistance:

24 Ohms ± 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.
12

ELECTRICAL
VEHICLE SPEED SENSOR

SPEED SENSOR LOCATION 4. Be sure connections are good and 9V battery is in
The speed sensor q is located on the right side of the good condition. If the light flashes, the sensor is
transmission case and can be accessed from behind the good.
right rear wheel.
SPEED SENSOR TESTING

Special Tools Required:
Static Timing Light Harness (PN 2871745)
Hall Sensor Probe Harness (PN 2460761)
1. Disconnect the 3 wire harness from the speed
sensor and remove the sensor from the
transmission.
2. Connect the wires from the Static Timing Light
Harness to the sensor 3 pin connector using the Hall
Sensor Probe Harness (PN 2460761).
3. Pass a screwdriver back and forth in front of the
sensor tip.

ELECTRICAL
INSTRUMENT CLUSTER
OVERVIEW
The instrument cluster displays critical vehicle information to the user. Reference the following page for display
functions and descriptions.
NOTICE
Some features are not applicable to all models.
The use of a high pressure washer may damage the instrument cluster. Wash the vehicle by hand or with a garden
hose using mild soap. Certain products, including insect repellents and chemicals, will damage the instrument cluster
lens. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately
12
clean off any gasoline that splashes on the instrument cluster.

ELECTRICAL
RIDER INFORMATION DISPLAY 13. Gear Position Indicator - Displays gear selector
The rider information display is located in the instrument position.
cluster. All segments will light up for 1 second at start-up. H = High
NOTICE L = Low
If the instrument cluster fails to illuminate, a battery N = Neutral
over-voltage may have occurred and the instrument
cluster may have shut off to protect the electronic R = Reverse
speedometer. P = Park
1. Vehicle Speed Display - Analog display of vehicle – = Gear Signal Error (shifter stuck between gears)
speed in MPH or km/h. 14. Power Steering System MIL - LED icon illuminates
when a fault has occurred with the power steering
2. Information Display Area - Odometer / Trip Meter system. This indicator illuminates when the key is
/ Tachometer / Engine Temperature / Engine turned to the ON position and goes off when the
Hours / Service Info / Clock - LCD display of the engine is started (EPS Option Only).
service hour interval, total vehicle miles or km., total
engine hours, a trip meter, engine RPM and engine 15. Turn Signal / Hazard Lamp Indicator - LED icon
temperature. illuminates whenever the LH, RH or hazard lamps
are activated (INT’L Models Only).
3. MPH / KM/H Display - MPH is displayed when the
instrument cluster is in the Standard mode. KM/H is 16. Helmet / Seat Belt Indicator - LED icon illuminates
displayed when the instrument cluster is in the Metric for several seconds when the key is turned to the ON
mode. position. The lamp is a reminder to the operator to
ensure all riders are wearing helmets and seat belts
4. High Beam Indicator LED icon illuminates before operating the vehicle.
whenever the Headlamp switch is in the high beam
position.
5. Fuel Level Indicator - LCD bar graph indicating
current fuel level. All segments will flash when the
last segment is cleared indicating a low fuel warning.
6. Clock - Displays current time in either 12-hour or 24-
hour formats.
7. Engine Temperature Indicator - LED icon
illuminates when the ECM determines the engine is
overheating. The indicators will initially flash to
indicate the engine is overheating. The indicators will
stay lit and not flash if a severe overheating condition
exists.
8. Service Interval Indicator - Preset at the factory
and adjustable by the user, a flashing wrench symbol
alerts the operator that the preset service interval
has been reached and maintenance should be
performed. The wrench icon will flash for 10 seconds
upon start-up once it reaches 0.
9. Check Engine MIL - Illuminated when the ECM has
detected a Diagnostic Trouble Code in the engine
management system.
10. AWD Indicator - Illuminated when the AWD / TURF
switch is in the AWD position.
11. TURF Indicator - Illuminated when the AWD / TURF
switch is in the TURF position.
12. Neutral Gear Indicator - LED icon illuminates when
gear selector is in the neutral (N) position.

ELECTRICAL
INFORMATION DISPLAY AREA 2. To reset to 0, push and hold the MODE button until
The LCD portion of the instrument cluster is the the distance display changes to 0.
information display area. Information displayed in this Tachometer (RPM)
area includes: odometer, trip meter, engine RPM, engine
hours, service interval, clock, engine Diagnostic Trouble
Codes (DTCs) and power steering DTCs.
Odometer
Engine RPM can be displayed digitally.

Engine Temperature
The odometer records and displays the total distance

traveled by the vehicle. The odometer can not be reset.
Trip Meter
Engine temperature can be displayed in Â ° F or Â °

C. Refer to “Units of Measurement” to change the
format.
Engine Hours
The trip meter records the miles traveled by the vehicle
on each trip. To reset the trip meter:
1. Toggle the MODE button to TRIP 1.
12
Engine hours are logged anytime the engine is
running. Total hours can not be reset.

ELECTRICAL
Programmed Service Interval 9. With the segment flashing, tap the MODE button to
advance to the desired setting.
10. Press and hold the MODE button until the next
segment flashes. Release the button.
11. Repeat steps 3-4 twice to set the 10 minute and 1
minute segments. After completing the 1-minute
segment, step 4 will save the new settings and exit
the clock mode.
Units of Measurement
STANDARD METRIC
DISPLAY DISPLAY
Kilometers (KM/
Distance Miles (MPH)
H)
The initial factory service interval setting is 50 hours.
Each time the engine is started, the engine hours are Time 12-Hour Clock 24-Hour Clock
subtracted from the service interval hours. When the Tempera-
service interval reaches 0, the LCD wrench icon will Fahrenheit Celsius
ture
flash for approximately 10 seconds each time the
engine is started. To change between Standard and Metric units of
To change the hour setting or reset the function, measurement, follow these steps:
follow these steps: 12. Turn the key to the OFF position.
3. Toggle the MODE button until the wrench icon is 13. Press and hold the MODE button while turning the
displayed in the information area. key to the ON position.
4. Press and hold the MODE button until the 14. When the display flashes the distance setting, tap
information display area begins to flash. the MODE button to advance to the desired setting.
5. Toggle the MODE button to increase the service
interval hours in 5 hour increments to a maximum of
100 hours.
6. To turn off the service interval function, toggle the
MODE button until “OFF” is displayed.
Clock
The clock displays the time in a 12-hour or 24-hour

format. Refer to “Units of Measurement” to change
the format (Standard 12-hour / Metric-24 hour). To
set the clock, follow these steps:
7. Toggle the MODE button until the odometer is
displayed.
8. Press and hold the MODE button until the hour
segment flashes. Release the button.

ELECTRICAL
15. Press and hold the MODE button to save the setting Use the following procedure to display diagnostic trouble
and advance to the next display option. codes that were activated during current ignition cycle
causing the MIL to illuminate. Diagnostic trouble codes
16. Repeat the procedure to change remaining display
will remain stored in the gauge (even if MIL turns off) until
settings.
the key is turned off.
Under / Over Voltage
1. If the trouble code (s) are not displayed, use the
This warning usually indicates that the vehicle is MODE button to toggle until “CK ENG” displays on
operating at an RPM too low to keep the battery the information display area.
charged. It may also occur when the engine is at idle
and a high electrical load is applied (lights, cooling
fan or other accessories).
If battery voltage drops below 11 volts, a warning
screen will display “Lo” and provide the present
battery voltage. If voltage drops below 8.5 volts, LCD
backlighting and icons will turn off.
2. Press and hold the MODE button to enter the

diagnostics code menu.
3. A set of three numbers will appear in the information
area.
• The first number (located far left) can range from 0 to
9. This number represents the total number of trouble
codes present (example: 2 means there are 3 codes
If battery voltage rises above 15 volts, a warning present).
screen will display “OV” and provide the present
• The second number (located top right) can be 2 to 6
battery voltage. If voltage rises above 16.5 volts,
digits in length. This number equates to the suspected
LCD backlighting and icons will turn off.
area of fault (SPN).
• The third number (located bottom right) can be 1 to 2
digits in length. This number equates to the fault mode
(FMI).
DIAGNOSTIC MODE
The diagnostic mode is accessible only when the check
engine MIL has been activated. 12
4. Use the trouble code reference table in the EFI

Chapter for a description of each code.

ELECTRICAL
5. If more than one code exists, press the MODE button 3. Push the instrument cluster out from the back side of
to advance to the next trouble code. the dash panel, while securely holding the panel and
rubber mount.
6. To exit the diagnostic mode, press and hold the
MODE button or turn the ignition key OFF once the
codes are recorded.
NOTICE
INSTRUMENT CLUSTER PINOUTS
NOTICE
Do not remove the rubber mount from the dash panel.
Only remove the rubber mount if necessary.
INSTRUMENT CLUSTER INSTALLATION

1. Spray a soap and water mixture onto the outer
FUNCTION PIN surface area of the instrument cluster. This will help
the instrument cluster slide into the rubber mount
CAN High 1 more easily.
CAN Low 2
Switched Power (Vdc) 3
Constant Power (Vdc) 4
Ground 5
High Beam 8
Fuel Level Sensor 11
INSTRUMENT CLUSTER REMOVAL

NOTICE
2. Be sure the rubber mount inside the dash panel is
Do not allow alcohol or petroleum products to come in fully installed and that the indexing key on the rubber
contact with the instrument cluster lens. mount is lined up with the keyway in the dash panel.
1. Remove seat, disconnect battery and open hood to 3. Hold the dash panel securely and insert the
gain access to back of instrument cluster. instrument cluster into the dash panel. Twist the
instrument cluster gently in a clockwise motion to
2. Disconnect the wire connectors from the back side of properly seat the instrument cluster. Apply pressure
the instrument cluster. on the bezel while pressing down on the instrument
cluster.

ELECTRICAL
HEADLIGHTS
HEADLIGHT ADJUSTMENT 6. Once the beam is set to the position, tighten the
The headlights are adjustable. adjustment screw. Repeat the procedure to adjust
the other headlight.
1. Place the vehicle on a level surface with the
headlight approximately 25 ft. (7.6 m) (Item 1) from a
wall. WARNING
Due to the nature of light utility vehicles and where they
are operated, headlight lenses become dirty. Frequent
washing is necessary to maintain lighting quality. Riding
with poor lighting can result in severe injury or death.
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 Park and wheels chocked, 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) (item 2) below the mark
placed on the wall in Step 2.
NOTICE
Rider weight must be included in the seat while
performing this procedure.
5. Locate the T25 Torx-head adjustment screw through

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.
12

ELECTRICAL
HEADLIGHT BULB REPLACEMENT HEADLIGHT HOUSING REMOVAL

1. Open the hood. 1. Open the hood.
2. Locate the bulb on the back side of headlight q. 2. Remove the bulb from the headlight housing (see
“Headlight Bulb Replacement”).
3. Turn the bulb counterclockwise to remove it.
3. Remove the O-rings q from each side of the
headlight housing. Remove the adjustment screw w
and pull the headlight from the brackets.
4. Unplug the headlight bulb from the wiring harness.

Be sure to pull on the connector, not on the wiring.
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 q. Install the adjustment screw w.
NOTICE
Be sure to twist the O-rings upon installation.
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.
NOTICE
Make sure the tab on the bulb locates properly in the
housing.
3. Reinstall the bulb into the housing and rotate it

clockwise 90° to lock it in place.
4. Close the hood and adjust headlights using the
“Headlight Adjustment” procedure.

ELECTRICAL
TAIL LIGHT / BRAKE LIGHT

LED LAMP REPLACEMENT
1. From the rear of the LED lamp, remove the (2) T20
Torx-head screws q retaining the lamp assembly.
2. Remove the lamp from the cargo box and disconnect

the tail light / brake light wire harness.
NOTICE
Before replacing the LED lamp assembly, use a digital
multi-meter to test the harness to ensure the lamp is
receiving 12-14 DC volts and that a ground path is
present. Lamps can be bench tested by applying 12-14
volts directly, as the LED tail/brake lamp units are
internally regulated.
3. If the LED lamp does not function with power and

ground applied to the lamp directly, replace the lamp
assembly. Apply dielectric grease (PN 2871329) to
the new lamp connector terminals.
4. Reinstall the assembly by reversing this procedure.
5. Test after installation to verify proper function of tail,
brake, and turn signal lamps.
12

ELECTRICAL
COOLING SYSTEM
FAN CONTROL CIRCUIT OPERATION
Power is supplied to the fan via the Orange/Black wire
when the relay is energized. The brown wire provides a
ground path for the fan motor. Refer to “RELAYS” later in
this chapter for more information on fan functions.
CAUTION
Keep hands away from fan blades during operation.
Serious personal injury could result.
NOTICE
The fan may not function or operation may be delayed if
coolant level is low or if air is trapped in the cooling
system. Be sure cooling system is full and purged of air.
Refer to Chapter 2 “Maintenance” for cooling system
information.
FAN CONTROL CIRCUIT BYPASS TEST

1. Disconnect harness from the engine coolant
temperature sensor located in the cylinder head of
the engine.
2. With the vehicle in park, turn the key on. After a few
seconds, you should hear the cooling fan turn on and
remain running.
3. If the fan does not run or runs slowly, check the fan
motor wiring, wire connections, ground path, 12V
power input, and fan motor condition. Repair or
replace as necessary. If the fan runs while the engine
is running with the sensor harness disconnected, but
will not turn on when the engine is hot, verify the
coolant level is correct and check the coolant
temperature sensor and connector terminals.

ELECTRICAL
IGNITION COIL
OPERATION OVERVIEW PRIMARY TEST
The ignition coil q is used to provide high voltage to fire
the spark plug. When the ignition key is on, DC voltage is
present in primary side of the ignition coil windings.
During engine rotation, an AC pulse is created within the
crankshaft position sensor for each passing tooth on the
flywheel. The two-tooth gap creates an “interrupt” input
signal, corresponding to specific crankshaft position. This
signal serves as a reference for the control of ignition
timing. The ECU then calculates the time interval
between the consecutive pulses, and determines when
to trigger the voltage spike that induces the voltage from
the primary to the secondary coil windings to fire the
spark plug.
SECONDARY TESTS
IGNITION COIL TESTS

The ignition coil can be tested by using an Ohm meter.
Use the following specification table and illustrations to
test the ignition coil.
IGNITION COIL RESISTANCE READINGS
TEST PIN CONNECTION RESISTANCE

Between Battery (+) &
Primary 0.5 Ω ± 10%
Coil (-)
Between Coil (-) and
Primary
(+) at the Coil 0.5 Ω
Test
Connection
Secondary Between High Tension
Lead Caps 7.0 k Ω ± 5%
Test
12

ELECTRICAL
IGNITION COIL AND HT LEAD

REPLACEMENT
1. Remove the drivers seat and disconnect the (-)
negative battery cable.
2. Disconnect harness connection to the ignition coil.
3. Remove high tension lead cap q from the spark
plug.
4. Remove fasteners w retaining the ignition coil and

remove coil assembly from the vehicle.
5. Install new ignition coil assembly and tighten

NOTICE
Be sure to reinstall the coil mounting spacers upon
assembly (if equipped).
TORQUE
Ignition Coil Retaining Bolt:
75 in-lbs (8.5 Nm)
6. Connect harness connection to the ignition coil.

7. Reconnect battery cable and install the drivers seat.

ELECTRICAL
RELAYS
OPERATION • EFI Relay, controlled by the ECM, supplies power to
The relays assist with fan, ignition coil, fuel pump, brake EFI components and sensors.
light, EFI, headlight, EPS, and rear differential operation.
EFI RELAY
• Fan Relay, controlled by the ECM and engine coolant
temperature sensor, operates the fan motor. FUSE
BOX WIRE
PIN COLOR OPERATION
FAN RELAY
17 Red Relay coil 12v from
FUSE Unswitched Fused EFI
BOX WIRE Splice
PIN COLOR OPERATION 18 Red High side 12v from
9 Red / Dark Relay coil 12v from EFI Unswitched Fused EFI
Blue Splice Splice
10 Orange / High side 12v from 15A 21 Red / Dark 12v output to EFI Splice #1
Black circuit breaker Blue
13 Orange / 12v output to fan motor 22 Dark Green ECU controlled ground
Black / Yellow
14 Orange / ECU controlled ground
Black • Headlight Relay, controlled by the ignition switch,
supplies power to the headlights.
• Fuel Pump Relay, controlled by the ECM and key
switch, powers the fuel pump. HEADLIGHT RELAY
FUEL PUMP RELAY FUSE

BOX WIRE
FUSE PIN COLOR OPERATION
BOX WIRE 1 Red / Relay coil 12v from Lights
PIN COLOR OPERATION Yellow splice
25 Red / Dark Relay coil 12v from EFI 2 Red / High side 12v from Lights
Blue Splice Yellow splice
26 Orange High side 12v from Fuel 5 Dark Green 12v output to Headlight Low
Pump fuse Beam splice
29 Red / Blue Ground, Chassis Rear #1 6 White / Red Ignition switch controlled
30 Dark Green ECU controlled ground ground
/ Yellow
• Chassis Relay, controlled by the key switch, supplies

B+ to the chassis circuits.
CHASSIS RELAY
FUSE
BOX WIRE
PIN COLOR OPERATION
33 Red / Blue Relay coil 12v from EFI
Splice
34 Red High side 12v from Start
Solenoid
37 Red 12v output to Splice, Chassis 12
38 Gray ECU controlled ground

ELECTRICAL
• EPS Relay (if equipped), controlled by the ignition

switch, provides power to the EPS unit.
EPS RELAY
FUSE
BOX WIRE
PIN COLOR OPERATION
3 Orange Relay coil 12v from R/S B+
Splice #2
4 Red High side 12v from EPS fuse
7 Orange 12v output to EPS unit
8 Brown Chassis ground #2
• Rear Differential Solenoid Relay, controlled by the

AWD/2WD/TURF switch and ECM, operates the
differential solenoid to unlock the rear end.

ELECTRICAL
FUSES / CIRCUIT BREAKER

OPERATION
The fuses, located in the relay/fuse box under driver’s seat base, provide current protection for components such as
the EFI system, main harness, lights and accessories.
FUSE SIZE FEATURE SUPPORTED

5A Brake Light
10 A Drive System, Fuel Pump
20 A EFI, Power Steering (if equipped), Lights, Accessories
20 A Circuit Breaker Fan
12

ELECTRICAL
OPERATION (INTL.)
The fuses, located in the relay/fuse box under driver’s seat base, provide current protection for components such as
the EFI system, main harness, lights and accessories.
FUSE SIZE FEATURE SUPPORTED

10 A Brake Light, Drive System, Fuel Pump
20 A EFI, Power Steering (if equipped), Lights, Accessories
20 A Circuit Breaker Fan

ELECTRICAL
CHARGING SYSTEM
CURRENT DRAW - KEY OFF 6. Momentarily key the ignition switch on, then off.
Parasitic draw is when there is excessive current flow
IMPORTANT
with the key off.
Ensure all electrical components are switched off, or
While the most common causes of draws are improperly damage to your jumper and/or meter will occur.
installed accessories (tapping into un-switched B+
instead of switched) there can be electronic component
failures that can cause this as well. 7. Wait 10 minutes before checking the value. Vehicles
will vary, but electronic components will take time to
IMPORTANT fully go to sleep after switched power is removed.
Do not connect or disconnect the battery cable, or 8. Maximum allowable is 10 milliamps. If your meter is
ammeter with the engine running. Damage will occur to ranged to the 10 Amp scale, this will appear as 0.010
electrical components. Amps.
Current Draw - Key Off:
IMPORTANT
Maximum of .01 DCA (10 mA)
Charging system damage will occur if incompatible
components are installed. Always reference the Polaris
Electronic Parts Catalog for the proper part numbers. 9. If over 10 milliamps, go to the fuse block and start
systematically removing one fuse at a time until the
value drops, indicating the circuit that requires
NOTICE attention.
Wait ten minutes with the key off for the ECU to power
down. This will avoid a faulty readout while testing
amperage draw. CHARGING SYSTEM “BREAK EVEN”
TEST
TESTING PROCEDURE
CAUTION
1. Remove the negative cable from the battery. Do not allow the battery cables to become
2. Connect a jumper from the negative battery cable disconnected with the engine running. Follow the steps
terminal to the negative battery post. below as outlined to reduce the chance of damage to
electrical components.
3. Ensure your meter leads and selector dial are set to
measure amperage.
The “break even” point of the charging system is the
4. Connect your red lead to the battery negative cable point at which the alternator overcomes all system loads
terminal. (lights, etc.) and begins to charge the battery. Depending
on battery condition and system load, the break even
point may vary slightly. The battery should be fully
charged before performing this test.
WARNING
Never start the engine with an ammeter connected in
series. Damage to the meter or meter fuse will result.
Do not run test for extended period of time.
Do not run test with high amperage accessories.
1. Turn key on and push the Mode button until the

instrument cluster is displaying RPM.
2. Using an inductive amperage metering device, (set
to DC amps) connect to the negative battery cable. 12
5. Connect your black lead to the battery negative post. 3. With engine off and the key switch “ON/Lights”
position, the ammeter should read negative amps
(battery discharge). Reverse meter lead if a positive
reading is indicated.

ELECTRICAL
4. Shift transmission into park and start the engine. CHARGING SYSTEM ALTERNATOR
With the engine running at idle, observe meter TESTS
readings. Three tests can be performed using a multimeter to
5. Increase engine RPM while observing ammeter and determine the condition of the stator (alternator).
tachometer.
6. Note RPM at which the battery starts to charge
(ammeter indication is positive).
7. With lights and other electrical loads off, the “break
even” point should occur at approximately 1500 RPM
or lower.
8. With the engine running, turn the lights on and apply
the brake to keep brake light on.
9. Repeat test, observing ammeter and tachometer.
With lights on, charging should occur at or below
2000 RPM.
TEST 1: Resistance Value of Each Stator Leg

1. Measure the resistance value of each of the three
stator legs: Y1 to Y2, Y1 to Y3, and Y2 to Y3.
2. Each test should measure: 0.15 Ω ± 20%
CONNECT
OHMS
TEST METER
READING
LEADS TO:
Battery Charge
Y1 to Y2 Less than 1 Ω
Coil
Battery Charge
Coil
Battery Charge
Coil
NOTICE
If there are any significant variations in ohm readings
between the three legs it is an indication that one of the
three stator legs maybe weak or failed.
TEST 2: Resistance Value of Each Stator Leg to

Ground
3. Measure the resistance value of each of the stator
legs to ground: Y1 to Ground, Y2 to Ground, Y3 to
Ground.

ELECTRICAL
4. Each test should measure: Open Line (OL) 8. Refer to the following table for approximate AC
Voltage readings according to RPM. Test each leg at
CONNECT the specified RPM in the table.
OHMS
TEST METER
READING
LEADS TO:
9. Example: The alternator voltage output reading
Battery Charge Y1, Y2, or Y3 Open Line should be approximately 18 VAC at 1300 RPM
Coil to Ground (Infinity) between each ‘leg’.
NOTICE
NOTICE
If one or more of the stator leg output AC voltage varies
Any measurement other than Infinity (open) will indicate significantly from the specified value, the stator may
a failed or shorted stator leg. need to be replaced.
TEST 3: Measure AC Voltage Output of Each

Stator Leg at Charging RPM AC VOLTAGE (VAC)
RPM READING
READING
5. Set the selector dial to measure AC Voltage.
1300 21 VAC ± 25 %
6. Start the engine and let it idle.
3000 49 VAC ± 25 %
7. While holding the engine at a specified RPM,
separately measure the voltage across each ‘leg’ of 5000 80 VAC ± 25 %
the stator by connecting the meter leads to the wires
leading from the alternator (Y1 to Y2, Y1 to Y3, Y2 to
Y3).
12

ELECTRICAL
CHARGING SYSTEM TESTING FLOW

CHART
Whenever charging system problems are suspected, proceed with the following system check after verifying that all
wires are in good condition, connected and not exposed or pinched.

ELECTRICAL
BATTERY SERVICE
BATTERY TERMINALS / BOLTS BATTERY ACTIVATION
Use Polaris corrosion resistant Nyogel™ grease (PN
2871329) on battery terminal bolts. WARNING
Battery electrolyte is poisonous. It contains sulfuric
acid. Serious burns can result from contact with skin,
eyes or clothing. Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow
with milk of magnesia, beaten egg, or vegetable oil. Call
physician immediately.
Eyes: Flush with water for 15 minutes and get prompt
medical attention.
Batteries produce explosive gases. Keep sparks, flame,
cigarettes etc. away.
Ventilate when charging or using in an enclosed space.
Always shield eyes when working near batteries.
KEEP OUT OF REACH OF CHILDREN.
WARNING
BATTERY TERMINAL BLOCK The gases given off by a battery are explosive. Any
The terminal block q is located under the hood next to spark or open flame near a battery can cause an
the battery and fuse box. The terminal block provides explosion which will spray battery acid on anyone close
easy hookup for accessories. to it. Should there be contact with battery acid, wash the
affected area with large quantities of cool water and
seek immediate medical attention.
To ensure maximum service life and performance from a

new battery, perform the following steps.
NOTICE
Do not service the battery unless it will be put into
regular service within 30 days. After initial service, add
only distilled water to the battery. Never add electrolyte
after a battery has been in service.
NOTICE
New Battery: Battery must be fully charged before use
or battery life will be significantly reduced 10-30% of the
battery’s full potential.
TORQUE
Terminal Block Nuts:
To activate a new battery:
20-25 in-lbs (2.3-2.8 Nm)
1. Remove all the filling plugs.
2. Remove the sealing tube (red cap) from vent fitting.
WARNING
3. Place battery on a level surface. Fill battery with
CALIFORNIA PROPOSITION 65 WARNING: electrolyte to upper level marks on the battery case.
Batteries, battery posts, terminals and related
accessories contain lead and lead compounds, and
other chemicals known to the State of California to
NOTICE 12
Never activate a battery on the vehicle. Electrolyte
cause cancer and birth defects or other reproductive spillage can cause damage.
harm. WASH HANDS AFTER HANDLING.
4. Set battery aside to allow for acid absorption and
stabilization for 30 minutes.

ELECTRICAL
5. Add electrolyte to bring the level back to the upper 2. Make sure the battery top is clean and dry. A dirty
level mark on the battery case. battery actually discharges across the grime on top
of the case. Use a soft brush and a baking soda
6. Charge battery for 3 - 5 hours at 1/10 of its amp/hour solution. Make sure plugs are finger tight so cleaning
rating. Examples: 1/10 of 9 amp battery = .9 amp; 1/ solution doesn’t get into the cells and neutralize the
10 of 14 amp battery = 1.4 amp; 1/10 of 18 amp acid.
battery = 1.8 amp (recommended charging rates).
7. Check during initial charging to see if electrolyte level
has fallen, and if so, fill with acid to the upper level.
After adding, charge for another hour at the same
rate.
NOTICE
This is the last time that electrolyte should be added. If
the level becomes low after this point, add only distilled
water.
8. When charging is complete, install the filling plugs

firmly.
NOTICE
Do not apply excessive pressure. Finger tighten only.
Do not over-tighten.
3. Inspect the battery terminals, screws and cables for
9. Wash off spilled acid with water and baking soda breakage, corrosion or loose connections. Clean the
solution, paying particular attention that any acid is terminals and cable ends with a wire brush and coat
washed off the terminals. Dry the battery case. terminals with Nyogel™.
4. Check the electrolyte level and add distilled water if
necessary.
BATTERY INSPECTION
The battery is located under the seat on the drivers side.
1. Inspect the battery case for obvious damage such as

cracks or leaks. Look for discoloration, warping or
raised top, which may indicate the battery has NOTICE
overheated or been overcharged.
Don’t add acid, use distilled water only!
5. Check the vent tube. Make sure it’s not kinked,

pinched or otherwise obstructed.

ELECTRICAL
BATTERY REMOVAL / INSTALLATION VOLTAGE DROP TEST

See Chapter 2 “Maintenance” for battery service The Voltage Drop Test is used to test for bad
procedures. connections. When performing the test, you are testing
the amount of voltage drop through the connection. A
poor or corroded connection will appear as a high
CONVENTIONAL BATTERY TESTING voltage reading. Voltage shown on the meter when
testing connections should not exceed .1 VDC per
Whenever a service complaint is related to either the
connection or component.
starting or charging systems, the battery should be
checked first. To perform the test, place the meter on DC volts and
place the meter leads across the connection to be tested.
Perform the battery tests to determine its condition.
Voltage should not exceed
0.1 DC volts per connection
OCV - OPEN CIRCUIT VOLTAGE TEST
Battery voltage should be checked with a digital
multimeter. Readings of 12.6 volts or less require further
battery testing and charging. See the following chart. SPECIFIC GRAVITY TEST
A tool such as a Battery Hydrometer (PN 2870836) can
be used to measure electrolyte strength or specific
gravity. As the battery goes through the charge/
discharge cycle, the electrolyte goes from a heavy (more
acidic) state at full charge to a light (more water) state
when discharged. The hydrometer can measure state of
charge and differences between cells in a multi-cell
battery. Readings of 1.270 or greater should be observed
in a fully charged battery. Differences of more than .025
between the lowest and highest cell readings indicate a
need to replace the battery.
NOTICE
Lead-acid batteries should be kept at or near a full
charge as possible. Electrolyte level should be kept
between the low and full marks. 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 SPECIFIC GRAVITY
12.70 V
State of Charge* YuMicron™ Type
75% Charged 12.50 V
100% Charged 1.275
50% Charged 12.20 V
25% Charged 12.0 V
75% Charged 1.225 12
50% Charged 1.175
0% Charged 11.9 V or less
25% Charged 1.135

ELECTRICAL
SPECIFIC GRAVITY 6. Install clear battery vent tube from vehicle to battery
vent.
0% Charged 1.115 or less
WARNING
* At 80° F. NOTE: Subtract .01 from the specific gravity
reading at 40° F. 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
LOAD TEST with electrolyte. Avoid skin contact with electrolyte, as
A battery may indicate a full charge condition in the OCV severe burns could result. If electrolyte contacts the
test and the specific gravity test, but still may not have vehicle frame, corrosion will occur.
the storage capacity necessary to properly function in the
electrical system. For this reason, a battery capacity or 7. Route cables so they are tucked away in front and
load test should be conducted whenever poor battery behind battery.
performance is encountered.
This is the best test of battery condition under starting OFF SEASON STORAGE
load. Use a load testing device that has an adjustable
See Chapter 2 “Maintenance” for battery service
load. Apply a load of three times the ampere-hour rating.
procedures.
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.
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 at
0.1Ah for max of 15 hours. The battery is faulty if it
does not achieve a specific gravity of 1.270 after 15
hours.
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
To avoid the possibility of explosion, connect positive
(+) cable first and negative (-) cable last.
5. After connecting the battery cables, install the cover

on the battery and attach the hold down strap.

ELECTRICAL
STARTER SYSTEM
TROUBLESHOOTING If the garter spring is damaged, the overrun clutch may
STARTER MOTOR DOES NOT RUN fail to return properly. The replacement spring is (PN
7042039). Use either of the following methods to remove
• Battery discharged - Low specific gravity and install a new garter spring.
• Brake not applied
• faulty switch or switch wiring
• 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 1. Screw the overrun clutch out to the engaged position
on the pinion shaft assembly. Use a small piece of
• Faulty flywheel gear or loose flywheel wire with the end bent in a hook and pick the old
spring out of its channel. Slide it off the end of the
shaft. Slide the new spring over the overrun clutch
and into the spring groove. Make sure that the spring
STARTER DRIVE is positioned between the shoe alignment pins and
Pinion Gear - Anti Kick-out Shoe, Garter Spring the back flange of the anti kick-out shoes.
Replacement
2. Remove the lock ring, end washer, spring retainers
and clutch return spring. Screw the overrun clutch off
the end of the pinion shaft. Remove the old spring
and install a new one. Lightly grease the pinion shaft
and reinstall the clutch, spring, retainers, end washer
and lock ring in the reverse order. Make sure the end
washer is positioned properly so that it will hold the
lock ring in its groove.
Polaris Premium Starter Drive Grease 12
PN 2871460

ELECTRICAL
STARTER SOLENOID BENCH TEST STARTER SOLENOID OPERATION

Test the start solenoid by powering the solenoid using To energize the starter solenoid the following must occur:
battery voltage for a maximum of 5 seconds. With the
solenoid energized, there should be continuity between • The brake must be applied to provide a ground path
terminals (A) and (B). If there is no continuity or high via the Brown / Yellow wire.
resistance, replace the starter solenoid.
• The key switch must be turned to the “start” position to
provide 12V power via the White / Red wire.
• Once the pull-in coil is energized, the solenoid
provides a current path for 12V power to reach the
starter motor.

ELECTRICAL
STARTING SYSTEM TESTING FLOW CHART
12

ELECTRICAL
NOTES

INDEX
A Vehicle.................................................................. 2.4
Breather
Air Box / Air Filter
Assembly View ......................................................5.12
Hose ...................................................................2.13 IX
Valve Inspection.....................................................2.13
Removal / Installation ..............................................5.14
Air Filter
Service ................................................................2.22
Air Intake Inspection C
Engine .................................................................2.23 Caliper
PVT.....................................................................2.23 Front (CREW)...................................................... 10.20
Assembly View Camshaft
Dash ................................................................... 11.8 Bore Inspection.............................................. 3.49, 3.95
Front Fenders........................................................ 11.8 Chain and Guide Service ................................. 3.50, 3.96
Hood ................................................................... 11.8 Decompression Mechanism ............................. 3.50, 3.95
AWD Inspection..................................................... 3.49, 3.95
Diagnosis .............................................................8.14 Installation / Timing ........................................3.65, 3.116
Operation .............................................................8.13 Removal....................................................... 3.48, 3.93
AWD/2WD/TURF Switch.............................................12.5 Sprocket Inspection ........................................ 3.49, 3.94
Timing - Quick Reference................................3.67, 3.119
Cargo Box
B Installation .......................................................... 11.15
Removal............................................................. 11.15
Balance Shaft Installation...................................3.83, 3.135 Charging System Flow Chart ..................................... 12.28
Balance Shaft Removal / Inspection .....................3.76, 3.128 Circuit Breaker............................................... 12.23-12.24
Balance Shaft Timing ........................................3.83, 3.135 Clutch Chart ....................................................... 1.19, 6.3
Ball Joint Clutch Weights .........................................................6.15
Replacement.........................................................9.16 Clutch, Starter One Way ....................................3.85, 3.136
Battery Clutching
Charging ..............................................................2.38 Torque Specifications ............................................... 6.2
Fluid Level ............................................................2.37 Cold Weather Operation .............................................. 2.3
Installation ............................................................2.38 Compression Test .....................................................2.12
Removal...............................................................2.37 Coolant
Removal/Installation ............................................. 12.31 Level Inspection .....................................................2.16
Storage ................................................................2.38 Strength and Type ..................................................2.19
Battery Maintenance ..................................................2.37 Coolant Drain / Radiator Removal .................................3.22
Boot Cooling System
Inspection (CV) ......................................................2.27 Bleeding...............................................................3.24
Brake Drain ...................................................................2.20
Brake Warning System .......................................... 10.35 Hoses ..................................................................2.19
Brake Burnishing..................................................... 10.11 Overview ..............................................................2.16
Brake Pedal Pressure Cap Test ..................................................3.21
Replacement.........................................................10.9 Pressure Test ........................................................3.21
Brake Switch .................................................... 10.8, 12.6 Radiator ...............................................................2.20
Brake System Troubleshooting ............................................. 1.69, 3.32
Assembly View ......................................................10.6 Cooling System Diagram ............................................3.20
Assembly View (CREW) ..........................................10.7 Cooling System Specifications .....................................3.21
Bleeding............................................................. 10.10 CPS Replacement ...................................................... 4.9
Operation .............................................................10.5 Crankcase
Brake, Assembly ....................................................3.81, 3.133
Brake Pedal Switch Inspection ................................ 10.36 Identification........................................................ 3.109
Brake Warning System Inspection............................ 10.36 Sealant Path .........................................................3.37
Brakes Separation ...................................................3.75, 3.127
Brake Vibration ......................................................1.96 Crankcase Bearings .........................................3.78, 3.130
Brakes Lock ..........................................................1.97 Crankcase Breather Service ...............................3.75, 3.127
Disc Inspection .............................................2.36, 10.33 Crankcase, Disassembly ...................................3.69, 3.121
Fluid Inspection .....................................................2.35 Crankcase, Inspection .......................................3.80, 3.132
Hose / Fitting Inspection ..........................................2.35 Crankshaft
Overheating ..........................................................1.97 Inspection....................................................3.77, 3.129
Pad Inspection.................................... 2.35, 10.12, 10.27 Removal......................................................3.77, 3.129
Performance Issues ................................................1.97 Crankshaft Position Sensor (CPS)
System Break-In ..................................................... 2.4 Overview ............................................................... 4.7
Troubleshooting Brake Noise ....................................1.96 Test ...................................................................... 4.7
Break Even Test...................................................... 12.25 CV Shaft Boot
Break-In Inspection.............................................................2.27
Brake System ......................................................... 2.4 Cylinder
Engine and Drivetrain............................................... 2.4 Misfire..................................................................1.87
PVT...................................................................... 2.4 Cylinder Head

© Copyright Polaris Inc. IX.1
INDEX
Combustion Chamber Cleaning......................... 3.54, 3.99 ETC Learn Procedure .............................................. 4.4
Disassembly ................................................. 3.51, 3.97 Overview ............................................................... 4.2
Identification........................................................ 3.108 Replacement.......................................................... 4.3
Inspection..................................................... 3.52, 3.98 Service ................................................................. 4.2
Removal....................................................... 3.51, 3.96 EFI Component Locations
Warp ........................................................... 3.52, 3.98 Left View ............................................................... 5.8
Right View ............................................................. 5.9
EFI System
D Initial Priming / Starting Procedure .............................. 5.4
Operation Overview ................................................. 5.3
Dash .................................................................... 11.17 Electrical
Dash Instruments and Controls .................................... 11.7 Break Even Test................................................... 12.25
Decal Replacement ................................................. 11.19 Charging System Tests.......................................... 12.26
Decompression.........................................................3.95 Connector Probing Guidelines................................. 1.103
Diagnostic ...............................................................1.59 Continuity / Resistance .......................................... 1.104
Engine Cranks but does Not Start ..............................1.62 Current Draw - Key Off ................................. 1.107, 12.25
No Crank No Start or Slow Crank...............................1.64 Digital Multi-Meter (DMM) ...................................... 1.102
Over Heating .........................................................1.65 Open Circuit Voltage Test....................................... 12.31
Warning Lights.......................................................1.66 Service Notes ...................................................... 1.102
Diagnostic Codes, Instrument Cluster .......................... 12.13 Static and Dynamic Testing .................................... 1.102
Diagnostic Trouble Codes (ETC) ..................................5.27 Testing Current Flow (Amperage) ............................ 1.106
Differential Assembly .................................................7.25 Testing For A Short To Ground ................................ 1.104
Differential Disassembly .............................................7.22 Testing For A Short To Voltage ................................ 1.105
Differential Solenoid...................................................12.6 Testing for Intermittent Conditions ............................ 1.106
Digital Wrench® Testing Voltage Drop ............................................. 1.107
Communication Errors.............................................1.72 Voltage Drop Test ................................................. 12.31
ECU Reprogramming ..............................................1.74 Electronic Power Steering (EPS)
Feature Map..........................................................1.73 Troubleshooting - EPS Non-Functional MIL Off .............1.99
Guided Diagnostics ................................................1.70 Troubleshooting - EPS Non-Functional MIL On .............1.98
Polaris Mobile Digital Wrench® (PMDW) .....................1.74 Troubleshooting - Using Digital Wrench® .................. 1.100
Serial Number Location ...........................................1.72 Electronic Throttle Body
Software Installation and Updates ..............................1.71 Learn Procedure ..................................................... 4.4
Software Overview .................................................1.70 Electronic Throttle Control (ETC)
Special Tools .........................................................1.70 Test ...................................................................... 4.4
Disassembly, Engine Lower End..........................3.69, 3.121 Engine
Drive Belt.................................................................. 6.9 Break-In Period......................................................3.16
Drive Clutch Cam Chain and Guide Service .......................... 3.50, 3.96
Assembly .............................................................6.22 Cam Shaft Removal........................................ 3.48, 3.93
Assembly View ......................................................6.13 Camshaft Bore Inspection ................................ 3.49, 3.95
Bushing Service .....................................................6.19 Camshaft Inspection ....................................... 3.49, 3.95
Button to Tower Clearance .......................................6.17 Camshaft Installation / Timing ..........................3.65, 3.116
Disassembly .........................................................6.14 Camshaft Sprocket Inspection........................... 3.49, 3.94
Spider Removal .....................................................6.16 Camshaft Timing - Quick Reference ..................3.67, 3.119
Drive Clutch, Operation ............................................... 6.4 Combustion Chamber Cleaning......................... 3.54, 3.99
Drive Shaft Cylinder Head Inspection ................................. 3.52, 3.98
Assembly View ......................................................8.44 Cylinder Head Installation ........................................3.61
Installation (front) .................................................... 8.9 Cylinder Head Installation - Black Bolts ..................... 3.110
Installation (rear) ....................................................8.38 Cylinder Head Installation - Silver Bolts ..................... 3.111
Removal (front) ....................................................... 8.8 Cylinder Head Removal ............................ 3.51, 3.96-3.97
Removal (rear).......................................................8.38 Cylinder Head Warp........................................ 3.52, 3.98
Driven Clutch Cylinder Inspection ........................................3.56, 3.102
Assembly .............................................................6.25 Cylinder Installation .......................................3.60, 3.108
Assembly View ......................................................6.23 Cylinder Removal ..........................................3.55, 3.102
Disassembly .........................................................6.24 Decompression Mechanism ............................. 3.50, 3.95
Driven Clutch, Operation.............................................. 6.4 Exploded Views ............................... 3.38-3.39, 3.43, 3.45
Driveshaft (Half Shaft) Installation ............................................................3.13
Diagnostics ...........................................................1.95 Installed Gap Measurement, Piston ...................3.58, 3.105
DTC .......................................................................5.27 Intake Valve Lash - Tappet Selection Matrix .................3.64
Dynamic Limiting / Misfire .....................................................1.87
Testing ............................................................... 1.102 Lubrication Specifications ......................................... 3.5
Oil and Filter Change ..............................................2.12
Oil Level ...............................................................2.12
E Oil Pressure Test..................................................... 3.6
Piston / Connecting Rod Assembly....................3.60, 3.107
ECT Sensor ............................................................. 4.11 Piston / Rod Inspection ...................................3.57, 3.104
ECU Piston Removal.............................................3.56, 3.103
Diagnostic Trouble Codes Overview ...........................1.75 Piston Ring Installation ...................................3.59, 3.106

IX.2 © Copyright Polaris Inc.
INDEX
Piston Ring Installed Gap ................................3.58, 3.105 Lines ...................................................................2.22

Piston-to-Cylinder Clearance .................................. 3.103 Fuel Injector
Removal...............................................................3.10 Overview ..............................................................5.23 IX
Special Tools .......................................................... 3.5 Test .....................................................................5.23
Specifications .................................................. 3.8, 3.33 Troubleshooting .....................................................5.25
Torque Sequences .................................................3.35 Fuel Injector Replacement...........................................5.24
Troubleshooting ............................................. 1.67, 3.31 Fuel Line
Valve Clearance Check / Adjustment .................3.62, 3.112 Routing ................................................................5.10
Valve Cover Installation ..................................3.68, 3.120 Fuel Pump ...............................................................5.18
Valve Cover Removal ...................................... 3.48, 3.93 Test .....................................................................5.17
Valve Inspection............................................. 3.52, 3.98 Fuel Sender Test .......................................................5.16
Valve Lash - Tappet Selection ................................. 3.115 Fuel System
Valve Sealing Test .........................................3.62, 3.112 Troubleshooting .....................................................1.89
Valve Seat Reconditioning...............................3.54, 3.100 Fuel System Troubleshooting.......................................5.34
Valve Spring.................................................. 3.51, 3.97 Fuel Tank
Valve Spring Removal ..................................... 3.51, 3.97 Assembly View ......................................................5.15
Engine Air Intake Inspection ........................................2.23 Installation ............................................................5.16
Engine Antifreeze Removal...............................................................5.15
50/50 Extended-Life................................................2.18 Fuses .......................................................... 12.23-12.24
Engine Coolant Temperature (ECT) Sensor
Overview ..............................................................4.10
Test .....................................................................4.10 G
Engine Fastener Torque Specifications
570 .....................................................................3.88 Gears
Engine Lubrication...................................................... 3.5 Transmission.......................................................... 7.4
Engine Oil Flow Chart ................................................. 3.7 General Information
Engine Serial Number Location ..................................... 1.4 Publication Part Numbers.......................................... 1.6
ETC Ground
Learn Procedure ..................................................... 4.4 Engine .................................................................2.40
Overview ............................................................... 4.4
Replacement.......................................................... 4.4
H
F Headlight Switch .......................................................12.5
Hood .................................................................... 11.17
Fan Control Circuit
,Bypass Test ....................................................... 12.18
Operation ........................................................... 12.18
Floor.............................................................. 11.9, 11.18
I
Floor (Crew) ........................................................... 11.11 Ignition Coil ............................................................ 12.19
Fluid Inspection Ignition Coil / Wire
Fluid Condition ......................................................1.88 Overview ..............................................................5.22
Fluid Leak.............................................................1.88 Test .....................................................................5.22
Flywheel Installation .........................................3.85, 3.137 Ignition Coil Tests .................................................... 12.19
Flywheel, Removal ...........................................3.69, 3.121 Ignition Switch ..........................................................12.5
Frame Inner Plunging Joint / Boot Replacement ........................8.42
Assembly View ...................................................... 11.3 Inspection
Assembly View (Crew) ............................................ 11.4 Brake Hose and Fitting ............................................2.35
Front Bumper ......................................................... 11.16 Instrument Cluster, Installation ................................... 12.14
Front Fascia ............................................................. 11.8 Instrument Cluster, Removal...................................... 12.14
Front Fenders......................................................... 11.16
Front Gearcase
Assembly .............................................................8.18
Assembly View ......................................................8.12
K
Disassembly / Inspection .........................................8.15 Keys
Disassembly / Inspection (ADC) ................................8.24 Replacement.......................................................... 1.5
Exploded View (4WDC) ...........................................8.21
Installation ............................................................8.10
Operation (4WDC)..................................................8.23
Reassembly (ADC) .................................................8.28
L
Removal...............................................................8.10 Leakdown Test .........................................................2.12
Front Gearcase Lubrication .........................................2.25 Lower Seat Base..................................................... 11.16
Front Strut Lubrication
Assembly View ......................................................9.15 Front Gearcase......................................................2.25
Cartridge Replacement............................................9.16 Grease Points......................................................... 2.8
Fuel Stabilizer Bar Pivot .................................................2.32
Filter....................................................................2.22 Suspension...........................................................2.33

INDEX
Transmission................................................... 2.24, 7.4 Periodic Maintenance Chart Key.................................... 2.5

Power Steering Unit (EPS)
Installation ............................................................ 9.11
M Removal............................................................... 9.11
PPS ........................................................................ 4.6
MAG Side Crankcase Bearing Service ..................3.79, 3.131 Replacement.......................................................... 4.6
Maintenance Pre-Ride / Daily Inspection ........................................... 2.3
Battery .................................................................2.37 Pressure Cap Test .....................................................3.21
Engine Oil.............................................................2.12 Propshaft
Engine Oil and Filter Change ....................................2.12 Removal...............................................................8.45
Periodic Maintenance Chart....................................... 2.5 Removal (CREW)...................................................8.45
Periodic Maintenance Chart Key................................. 2.5 PVT
PVT/Clutch ............................................................ 6.4 Break-In ................................................................ 2.4
Quick Reference Chart ............................................. 2.9 PVT Air Intake Inspection ............................................2.23
Service Products and Lubricants ............................... 2.11 PVT System
Storage Tips..........................................................2.10 Assembly .............................................................. 6.8
Master Cylinder Disassembly .......................................................... 6.7
Installation ............................................................10.8 Drive Clutch Disassembly ........................................6.14
Removal...............................................................10.8 Overheating / Diagnosis...........................................1.93
Master Torque Table ..................................................1.17 Troubleshooting ............................................. 1.91, 6.26
Misc. Specifications / Charts
Conversion Table ...................................................1.52
Decimal Equivalents ...............................................1.55 R
Tap / Drill Sizes (Metric) ...........................................1.54
Tap / Drill Sizes (SAE) .............................................1.53 Radiator .......................................................... 2.20, 3.22
Model Number Designation .......................................... 1.4 Removal...............................................................2.20
Model Specifications Rear A-Arm
2017-2018 Assembly View ......................................................9.20
RANGER 500 .....................................................1.20 Replacement.........................................................9.18
RANGER 570 4x4 ................................ 1.22, 1.24, 1.26 Rear Fenders ........................................................... 11.9
RANGER 570 CREW ...........................................1.28 Rear Fenders (Crew) ............................................... 11.11
2019 Relays .................................................................. 12.21
RANGER 500 .....................................................1.30 Replacement...................................................... 4.5, 5.18
RANGER 570 4x4 ................................ 1.32, 1.34, 1.36 ETC ..................................................................... 4.4
RANGER 570 CREW ...........................................1.38 RPM Limit................................................................. 4.2
2020
RANGER 500 .....................................................1.40
RANGER 570 4x4 ...............................................1.42 S
RANGER 570 CREW ...........................................1.44
2021 Seat Assembly........................................................ 11.10
RANGER 500 .....................................................1.46 Seat Assembly (Crew).............................................. 11.12
RANGER 570 4x4 ...............................................1.48 Seat Belts .............................................................. 11.10
RANGER 570 CREW ...........................................1.50 Seat Belts (Crew) .................................................... 11.12
Sensor ..................................................................... 4.5
Sequence
O Torque .................................................................3.90
Service
Oil Flow Chart............................................................ 3.7 Air Filter ...............................................................2.22
Oil Pickup Assembly Inspection ...........................3.80, 3.132 Service Notes
Oil Pressure Regulator (Bypass) Valve Inspection ...3.80, 3.132 Fuel System ..........................................................5.26
Oil Pressure Test........................................................ 3.6 Setting TDC .............................................................3.18
Oil Pump Shift Cable
Assembly ....................................................3.74, 3.126 Adjustment ...........................................................2.24
Oil Pump, Removal...........................................3.72, 3.124 Inspection....................................................... 2.24, 7.9
Open Circuit Voltage Test .......................................... 12.31 Inspection and Adjustment .......................................7.10
Outer CV Joint / Boot Replacement ...............................8.39 Shift Cable Removal / Install and Routing ..................... 7.9
Overview Shift Lever
ETC ..................................................................... 4.4 Replacement.......................................................... 7.8
Shift Weights ............................................................6.15
Shock
P Analysis ................................................ 1.101, 2.34, 9.3
Snorkel Gear Backlash ...............................................7.27
Pad Solenoid.
Inspection (Brakes).............................. 2.35, 10.12, 10.27 Rear Differential .....................................................12.6
Pedal Position Sensor ................................................. 4.6 Spark Plug
Test ...................................................................... 4.6 Service - 570 .................................................. 2.38-2.39
Periodic Maintenance Chart.......................................... 2.5 Special Tools .................................................. 1.8, 5.5, 7.3

INDEX
Body/Steering/Suspension ................................. 9.2, 11.2 Headlight..............................................................12.5

Brakes .................................................................10.3 Ignition.................................................................12.5
Digital Wrench®.....................................................1.70 IX
Electrical ..............................................................12.3
Engine .................................................................. 3.5 T
Final Drive ............................................................. 8.3
Master Special Tools Table ........................................ 1.9 T-MAP ..................................................................... 4.5
PVT/Clutching ........................................................ 6.2 Overview ............................................................... 4.5
Transmission.......................................................... 7.2 Sensor Test............................................................ 4.5
Specification TDC .......................................................................3.18
Compression.........................................................2.12 Terminal Block ........................................................ 12.29
Toe......................................................................2.30 Thermostat Replacement ............................................3.23
Specifications Throttle Pedal
Brake Service ........................................................10.3 Inspection.............................................................2.22
Cooling System......................................................3.21 Tie Rod End Inspection...............................................2.29
Cylinder Head Warp........................................ 3.52, 3.98 Timing
Engine .................................................................. 3.8 Crankcase ............................................................3.92
Engine Lubrication............................................ 3.5, 3.16 Sealing Path ......................................................3.92
Engine Oil and Filter ...............................................2.12 Timing...............................................................3.92
Engine Oil Pressure ................................................. 3.6 Timing, Balance Shaft .......................................3.83, 3.135
Engine, 500cc .......................................................3.33 Tire
Valve Seat Contact Width................................3.54, 3.100 Inspection.............................................................2.28
Valve Spring.................................................. 3.51, 3.97 Toe Adjustment .........................................................2.30
Valve Stem Diameter ...................................... 3.52, 3.98 Torque
Valve Stem Guide I.D. ..................................... 3.52, 3.98 Master Torque Table ...............................................1.17
Spring Sequence .............................................................3.90
Adjustment ...........................................................2.32 Torque Specification
Stabilizer Bar Pivot Lubrication .....................................2.32 Wheel and Hub ......................................................2.27
Starter Drive........................................................... 12.33 Torque Specifications
Starter Drive, Removal ......................................3.69, 3.121 Body/Steering/Suspension ....................................... 11.2
Starter Solenoid Clutching ............................................................... 6.2
Operation ........................................................... 12.34 Engine Mounting ....................................................3.17
Test ................................................................... 12.34 Transmission Mounting............................................. 7.5
Starter System Transmission
Testing Flow Chart................................................ 12.35 Assembly View ....................................................... 7.6
Static Differential Assembly ..............................................7.25
Testing ............................................................... 1.102 Differential Disassembly ..........................................7.22
Stator Disassembly .........................................................7.17
Tests ................................................................. 12.26 Gears ................................................................... 7.4
Stator Housing Removal ....................................3.69, 3.121 Installation ............................................................7.13
Stator Installation .............................................3.87, 3.138 Output Shaft Backlash.............................................7.27
Stator Removal ................................................3.71, 3.123 Removal............................................................... 7.11
Steering Transmission Diagnostics
Inspection.............................................................2.29 Hard Shifting .........................................................1.94
Shaft, Removal (Non-EPS)........................................ 9.9 Transmission Isolation.............................................1.94
Steering Rack Removal (EPS) ..................................9.13 Transmission Lubrication ...................................... 2.24, 7.4
Wheel Removal (Non-EPS) ....................................... 9.8 Trouble Code List
Steering Assembly (ORV Master) ........................................................1.76
Assembly View ..................................................9.4, 9.6 Trouble Codes
Power Steering Unit Installation ................................. 9.11 Instrument Cluster (DTC) .........................................5.27
Power Steering Unit Removal ................................... 9.11 Trouble Tree
Steering Shaft Bearing Replacement ........................... 9.8 Guided Symptom Diagnostic.....................................1.57
Steering Shaft Removal (EPS) ..................................9.10 Troubleshooting
Steering Wheel Removal (EPS).................................9.10 Brake Noise .................................................. 1.96, 10.4
Steering Shaft Clutching ..............................................................6.26
Bearing Replacement............................................... 9.8 Cooling System.............................................. 1.69, 3.32
Removal (EPS) ......................................................9.10 Engine ......................................................... 1.67, 3.31
Steering Wheel EPS Non-Functional MIL Off .....................................1.99
Removal (EPS) ......................................................9.10 EPS Non-Functional MIL On .....................................1.98
Suspension EPS Using Digital Wrench®.................................... 1.100
Inspection.............................................................2.32 Front Gearcase (ADC).............................................8.31
Pivot Lubrication ....................................................2.33 Fuel Injector ..........................................................5.25
Shock Analysis ....................................... 1.101, 2.34, 9.3 Fuel System ..........................................................1.89
Spring Adjustment ..................................................2.32 Misfire Detection ....................................................1.87
Switch PVT System ..........................................................1.91
AWD/2WD/TURF ...................................................12.5
Brake........................................................... 10.8, 12.6

INDEX
V
Valve Clearance
Adjustment .................................................. 3.62, 3.112
Adjustment - DOHC ................................................2.14
Adjustment SOHC ..................................................2.14
Intake Valve Lash - Tappet Selection Matrix .................3.64
Valve Lash - Tappet Selection ................................. 3.115
Valve Cover
Installation ...................................................3.68, 3.120
Removal....................................................... 3.48, 3.93
Valve Sealing Test ................................................... 3.112
Valve Seat
Inspection.............................................................3.54
Valve Spring
Removal....................................................... 3.51, 3.97
Vehicle Identification
Model Number Designation ....................................... 1.4
Vehicle Identification Number........................................ 1.4
Vent Line
Termination Fitting .................................................. 5.11
Vent Lines ...............................................................2.22
VIN ......................................................................... 1.4
VIN Location ............................................................. 1.4
Voltage Drop Test .................................................... 12.31
W
Water Pump
Mechanical Seal / Oil Seal........................................3.25
Removal / Installation ..............................................3.25
Wheel
Installation ............................................................2.28
Removal...............................................................2.27
Wheel Alignment .......................................................2.30


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2017-2021 RANGER 500 / 570

Publication Printed January 2021 (PN 9850043 R01)

CHAPTER 1 : GENERAL INFORMATION

9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual

WARNING LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.66

9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual

TESTING FOR A SHORT TO GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.104

9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual

VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION (2015+)

VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS

VIN / ENGINE NUMBER LOCATION

9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual

SERIES# PART NUMBER

9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual

PUBLICATION PART NUMBERS

2017 RANGER 570 (Intl.) R17RMA57F1

2017 RANGER 570 Tractor (Intl.) R17RMT57C1

2018 RANGER 570 (Intl.) R18RMA57F1

9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual

MODEL MODEL NUMBER OWNER’S MANUAL

2019 RANGER 570 (Intl.) R19RMA57F1

2021 RANGER 570 (Intl.) R21MAA57F1

9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual

9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual

MASTER SPECIAL TOOLS TABLE

9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual

ENGINE / COOLING SYSTEM

9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual

9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual

Laptop or Desktop Computer USB/

9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual

9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual

Rear Output Seal Driver Snorkel Tool Transmission Nut Socket

Roller Pin Removal Tool

9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual

9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual

Relay Bypass Connector Test Kit

9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual

MASTER TORQUE TABLE ITEM TORQUE

9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual

ITEM TORQUE ITEM TORQUE

9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual

9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual

9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual

MODEL SPECIFICATIONS DRIVETRAIN

9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual

2017-2018 RANGER 570 4X4

9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual

MODEL SPECIFICATIONS DRIVETRAIN

9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual

2017-2018 RANGER 570 4X4 (INTL.)

9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual

MODEL SPECIFICATIONS DRIVETRAIN

0.005-0.007″ (0.125–0.175 Rear Suspension Independent (IRS)

9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual

2017-2018 RANGER 570 4X4 TRACTOR

9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual

MODEL SPECIFICATIONS DRIVETRAIN