Polaris RANGER XP 700 4X4, 2008 ranger 700 xp Service Manual

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POLARIS

RANGER

XP 700 4X4

RANGER 6X6

SERVICE

MANUAL

GENERAL INFORMATION

MAINTENANCE

ENGINE

FUEL INJECTION

BODY / STEERING / SUSPENSION

CLUTCHING

FINAL DRIVE

TRANSMISSION

BRAKES

ELECTRICAL

POLARIS

RANGER

XP 700 4X4

RANGER 6X6

SERVICE

MANUAL

GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

UNIT SERIAL NUMBER (VIN) LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

TRANSMISSION I.D. NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

VEHICLE DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

VEHICLE DIMENSIONS RANGER 4X4, 6X6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

MODEL: RANGER XP 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

MODEL: RANGER XP 6X6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

MODEL: RANGER XP 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7

MODEL: RANGER XP 6X6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8

VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9

PUBLICATION NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9

PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9

REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9

MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11

SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12

METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12

DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12

GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13

1.1

GENERAL INFORMATION

MODEL INFORMATION

Model Identification

The machine model number must be used with any correspondence regarding warranty or service.

Machine Model Number Identification

R 0 7 R H 6 8 A G

Model Year Designation

Engine Designation Number

EH068OLE043PLE............................................................Twin, Liquid Cooled, OHV 4 Stroke, Electric Start

VIN Identification

World

Mfg. ID

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A R H 6 8 A * 7 P 0 0 0 0 0 0

Vehicle Description

}

Basic Chassis

Designation

}

Emissions & Model Option

Engine Designation

Vehicle Identifier



Body Style

Engine

Emissions

Powertrain

Engine Serial Number Location

Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This information can be found on the sticker applied to the cylinder head on the side of engine.

Engine Serial Number

Model

Year

Check Digit

Plant No.

Individual Serial No.

* This could be either

a number or a letter

1.2

GENERAL INFORMATION

Unit Serial Number (VIN) Location

The machine model number and serial number are important for vehicle identification. The machine serial number (A) is stamped on the lower LH frame rail close to the front drive wheel. The model and serial number are also located on a sticker under the hood (B).

Transmission I.D. Number Location

The transmission I.D. number is located on the right side when installed in the machine.

1.3

GENERAL INFORMATION

VEHICLE DIMENSIONS

RANGER 4X4, 6X6

75 in.

190.50 cm

10 in.

25.4 cm

RANGER 4x4

1.4

58 in.

147 cm

V ehicle Dimensions RANGER 4X4, 6X6

GENERAL INFORMATION

120 in. 305 cm

90 in.

229 cm

58 in. 147 cm

27 in.

69 cm

113 in. 287 cm

76 in. 193 cm

58 in. 147 cm

1.5

GENERAL INFORMATION

GENERAL SPECIFICATIONS

MODEL: RANGER XP 4X4

MODEL NUMBER: R07RH68AD,AG,AH,AK,AL,AW ENGINE MODEL: EH068OLE

Category Dimension / Capacity

Length 113 in. / 287 cm Width 60 in. / 152.4 cm Height 75 in. / 190.5 cm Wheel Base 76 in. / 193 cm Ground Clearance 11.5 in. / (29 cm) Turning Radius 132 in. / 335 cm Dry Weight 1185 lbs. / 537 kg Gross Vehicle Weight 2750 lbs. / 1247 kg Cargo Box Capacity 1000 lbs. / 454 kg

Cargo Box Dimensions

Vehicle Payload

passengers - 500 lbs. / 227kg) Hitch Towing Capacity 1500 lbs. / 681 kg Hitch Tongue Capacity 150 lbs. / 68 kg

58 x 42 x 10 in.

(147 x 106.7 x 25.4 cm)

1500 lbs. / 681 kg

(Includes driver and two

MODEL: RANGER XP 6X6

MODEL NUMBER: R07RF68AF ENGINE MODEL: EH068OLE

Category Dimension / Capacity

Length 120 in. / 305 cm Width 60 in. / 152.4 cm Height 75 in. / 190.5 cm Wheel Base 90 in. / 229 cm Ground Clearance 7.2 in. / (18.25 cm) Turning Radius 180 in. / 457 cm Dry Weight 1410 lbs. / 640 kg Gross Vehicle Weight 2900 lbs. / 1315 kg Cargo Box Capacity 1250 lbs. / 567 kg

Cargo Box Dimensions

Vehicle Payload

passengers - 500 lbs. / 227kg) Hitch Towing Capacity 1750 lbs. / 794 kg Hitch Tongue Capacity 150 lbs. / 68 kg

58 x 48 x 10 in.

(147 x 122 x 25.4 cm)

1750 lbs. / 794 kg

(Includes driver and two

1.6

GENERAL INFORMATION

MODEL: RANGER XP 4X4

MODEL NUMBER: R07RH68AD,AG,AH,AK,AL,AW ENGINE MODEL: EH068OLE

Engine

Platform

Engine Model Number EH068OLE044

Engine Displacement 683cc Number of Cylinders 2

Bore & Stroke (mm) 80 x 68 mm

Compression Ratio 9.40:1

Compression Pressure 150-170 psi

Engine Idle Speed 1150 ± 100 RPM

Lubrication Pressurized Wet Sump

Oil Requirements 0W-40

Oil Capacity 2 qts. / 1.9 L

Coolant Capacity 3.25 qts. / 3.1 L

Overheat Warning Instrument Cluster Indicator

Exhaust System 2 to 1 Canister Style

Fuel System Type Bosch Electronic Fuel Injection

Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 39 psi

Fuel Filters See Chapter 4

Fuel Capacity / Requirement

Alternator Max Output 500 watts @ 3000 RPM

Lights: Main Headlights 2 - Dual Beam 35 watts / quartz

Tail 5 watts x 2

Brake 5 watts x 2

Indicator Panel Lights 1 watt (ea.)

Starting System Electric Start Ignition System Bosch EFI (ECU Controlled) Ignition Timing 7° BTDC @ 1200 RPM

Spark plug / Gap

Battery / Model / Amp Hr

Instrument Type Multifunction Speedometer

DC Outlet Standard

Circuit Breakers

Polaris Domestic Twin Cylinder,

Liquid Cooled, 4-Stroke

Fuel System

9 gal. (34 l)

87 Octane (minimum)

Electrical

Champion RC7YC3 /

.035 in. (0.9 mm)

Yuasa YB30L-B /

30 Amp Hr. / 12 Volt

Fan: 20 Amp

Dash Harness: 20 Amp

Accessory Terminal: 20 Amp

Power Relay: 15 Amp

ECU Battery Supply: 6 Amp

Drivetrain

Transmission Type Polaris Automatic PVT

Gear Ratio: Front / Rear

High

Low

Rev Drive Ratio - Front 3.818:1 Drive Ratio - Final 3.70:1

Shift Type In Line Shift - H / L / N / R

Trans. Oil Requirements Polaris AGL Gearcase Lube

Belt 3211106

Drive Belt Deflection 1.125” / 28.57 mm

Center Distance 10” / 254.5 mm

Clutch Offset 0.365” / 9.27 mm

Steering / Suspension

Front Suspension MacPherson Strut

Front Travel 8 in. / 20 cm

Rear Suspension Independent Rear Suspension

Rear Travel 9 in. / 23 cm

Ground Clearance 11.5 in. / 29 cm

Shock Preload Adjustment

Front / Rear

Turning Radius 132 in. / 335 cm

Toe Out 1/8-1/4 in. / 3-6.35 mm

Wheels / Brakes

Front Wheel Size

Rear Wheel Size

Front Tire

Make / Model / Size

Rear Tire

Make / Model / Size

F/R Tire Air Pressure 8-12 psi Front / 8-12 psi Rear

Brake - Front / Rear

Parking Brake Foot Actuated (Mechanica l)

Brake Fluid DOT 3 or DOT 4

L.E. Model AW - Kenda / Radial

3.34:1 / 2.89:1

8.67:1 / 7.49:1

5.92:1 / 5.11:1

Cam Adjustment 2-2” Twin Tubes

12 x 6 / 10 gauge

L.E. Model AW - 14 x 7

12 x 8 / 10 gauge

L.E. Model AW - 14 x 8

Carlisle / PXT / 26 x 8 R12

Bounty Hunter / 26 x 10 R14

Carlisle / PXT / 26 x 11 R12

Bounty Hunter / 26 x 12 R14

Foot Actuated - 4 Wheel

Hydraulic Disc

CLUTCH CHART

Altitude Shift Weight Drive Spring

Meters

(Feet)

0-1500

(0-5000)

1500-3700

(5000 - 12000)

20-60

(5631698)

20-56

(5631215)

Blu/Gray

(7042202)

Blu/Gray

(7042202)

Driven Spring

Blk/Almd

(7043167)

Blk/Almd

(7043167)

1.7

GENERAL INFORMATION

MODEL: RANGER XP 6X6

MODEL NUMBER: R07RF68AF ENGINE MODEL: EH068OLE

Engine

Platform

Engine Model Number EH068OLE044

Engine Displacement 683cc Number of Cylinders 2

Bore & Stroke (mm) 80 x 68 mm

Compression Ratio 9.40:1

Compression Pressure 150-170 psi

Engine Idle Speed 1150 ± 100 RPM

Lubrication Pressurized Wet Sump

Oil Requirements 0W-40

Oil Capacity 2 qts. / 1.9 L

Coolant Capacity 3.25 qts. / 3.1 L

Overheat Warning Instrument Cluster Indicator

Exhaust System 2 to 1 Canister Style

Fuel System Type Bosch Electronic Fuel Injection

Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 39 psi

Fuel Filters See Chapter 4

Fuel Capacity / Requirement

Alternator Max Output 500 watts @ 3000 RPM

Lights: Main Headlights 2 - Dual Beam 35 watts / quartz

Tail 5 watts x 2

Brake 5 watts x 2

Indicator Panel Lights 1 watt (ea.)

Starting System Electric Start Ignition System Bosch EFI (ECU Controlled) Ignition Timing 7° BTDC @ 1200 RPM

Spark plug / Gap

Battery / Model / Amp Hr

Instrument Panel Type Multifunction Speedometer

DC Outlet Standard

Circuit Breakers

Polaris Domestic Twin Cylinder,

Liquid Cooled, 4-Stroke

Fuel System

9 gal. (34 l)

87 Octane (minimum)

Electrical

Champion RC7YC3 /

.035 in. (0.9 mm)

Yuasa YB30L-B /

30 Amp Hr. / 12 Volt

Fan: 20 Amp

Dash Harness: 20 Amp

Accessory Terminal: 20 Amp

Power Relay: 15 Amp

ECU Battery Supply: 6 Amp

Drivetrain

Transmission Type Polaris Automatic PVT

Gear Ratio: Front / Rear

High Low

Rev

Drive Ratio - Front 3.818:1

Drive Ratio - Mid 3.70:1

Drive Ratio - Final 3.70:1

Shift Type In Line Shift - H / L / N / R

Trans. Oil Requirements Polaris AGL Gearcase Lube

Belt 3211106

Drive Belt Deflection 1.125” / 28.57 mm

Center Distance 10” / 254.5 mm

Clutch Offset 0.365” / 9.27 mm

Steering / Suspension

Front Suspension MacPherson Strut

Front Travel 8 in. / 20 cm

Center Suspension Progressive Rate / Independent

Center Travel 5.25 in. / 13 cm

Rear Suspension Swing Arm w/Dual Shocks

Rear Travel 6.25 in. / 16 cm

Ground Clearance 7.2 in. / 18.25 cm

Shock Preload Adjustment

Front / Rear

Turning Radius 180 in. / 457 cm

Toe Out 1/8-1/4 in. / 3-6.35 mm

Wheels / Brakes

Front Wheel Size 12 x 6 / 10 gauge

Middle / Rear Wheel Size 12 x 8 / 10 gauge

Front Tire

Make / Model / Size

Middle / Rear Tire

Make / Model / Size

F/M/R Tire Air Pressure 8-12 psi Front / 8-12 psi Rear

Brake - Front / Rear

Parking Brake Foot Actuated (Mechanical)

Brake Fluid DOT 3 or DOT 4

3.89:1 / 3.36:1

10.08:1 / 8.71:1

6.87:1 / 5.94:1

Cam Adjustment 2-2” Twin Tubes

Titan / AT489 / 25 x 10 R12

Titan / AT489 / 25 x 11 R12

Foot Actuated - 4 Wheel

Hydraulic Disc

CLUTCH CHART

Altitude Shift Weight Drive Spring

Meters

(Feet)

0-1500

(0-5000)

1500-3700

(5000 - 12000)

20-60

(5631698)

20-56

(5631215)

Blu/Gray

(7042202)

Blu/Gray

(7042202)

Driven Spring

Blk/Almd

(7043167)

Blk/Almd

(7043167)

1.8

20 20

NOTE: NOTE:

www.purepolaris.com.

Paint Codes

RANGER XP 4x4 - Plastic - Hood / Dash Black Metallic P-177 RANGER XP 6x6 - Plastic - Hood / Dash Dark Green P-195

GENERAL INFORMATION

Painted Part Color Description Polaris Number

Frame / Cab Medium Gloss Black P-067

RANGER XP 4x4 - Plastic - Hood / Dash Turbo Silver P-402 RANGER XP 4x4 - Plastic - Hood / Dash RANGER XP 4x4 - Plastic - Hood / Dash Delta Green P-492

RANGER XP 4x4 - Plastic - Hood / Dash Sunset Red Metallic P-520

Mossy Oak

™

P-455

Replacement Keys

Replacement keys can be made from the original key. To identify which series the key is, take the first two digit s on th e original key and refer to the chart to the right for the proper part number.

KEY COVER P/N 5533534

Key Series Number

Series# Part Number

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

SPECIAL TOOLS

Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, 1-800-328-6657.

1.9

GENERAL INFORMATION

MISC. SPECIFICATIONS AND CHARTS

Conversion Table

1.10

°C to °F: 9 (°C + 40) ÷ 5 - 40 = °F °F to °C: (°F + 40) ÷ 9 - 40 = °C

Standard Torque Specifications

GENERAL INFORMATION

The following torque specifications are to be used only as a general guideline. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque.

1.11

GENERAL INFORMATION

SAE Tap / Drill Sizes

Decimal Equivalents

Metric Tap / Drill Sizes

1.12

GENERAL INFORMATION

Glossary of Terms

ABDC: After bottom dead center. ACV: Alternating current voltage. Alternator: Electrical generator producing voltage alternating current. ATDC: After top dead center. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches. Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch. Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face. Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to

close and grip the drive belt. Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase. Measure at various points especially at PTO.

DCV: Direct current voltage CVT: Centrifugal Variable Transmission (Drive Clutch System) DCV: Direct current voltage. Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the

cylinder bore.

Electrical Open: Open circuit. An electrical circuit which isn't complete. Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire

touching the chassis).

End Seals: Rubber seals at each end of the crankshaft. Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt. ft.: Foot/feet. Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction. g: Gram. Unit of weight in the metric system. gal.: Gallon. ID: Inside diameter. in.: Inch/inches. Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb. kg/cm²: Kilograms per square centimeter. kg-m: Kilogram meters. Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction. l or ltr: Liter. lbs/in²: Pounds per square inch. Left or Right Side: Always referred to based on normal operating position of the driver. m: Meter/meters. Mag: Magneto. Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings.

Mechanical energy is converted to electrical energy in the stator.

mi.: Mile/miles. mm: Millimeter. Unit of length in the metric system. 1 mm = approximately .040". Nm: Newton meters. OD: Outside diameter. Ohm: The unit of electrical resistance opposing current flow. oz.: Ounce/ounces. Piston Clearance: Total distance between piston and cylinder wall. psi.: Pounds per square inch. PTO: Power take off. PVT: Polaris Variable Transmission (Drive Clutch system) qt.: Quart/quarts. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases. Reservoir Tank: The fill tank in the liquid cooling system. Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat. RPM: Revolutions per minute. Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings. Stator Plate: The plate mounted under the flywheel supporting the battery charging coils. TDC: Top dead center. Piston's most outward travel from crankshaft. Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit. Watt: Unit of electrical power. Watts = amperes x volts. WOT: Wide open throttle.

1.13

GENERAL INFORMATION

CHAPTER 2

GENERAL INFORMATION

PERIODIC MAINTENANCE CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

PERIODIC MAINTENANCE OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

PRE-RIDE - 25 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

50 - 100 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

100 - 300 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

GENERAL COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7

RH SIDE AND DASH VIEW (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7

LH SIDE AND REAR VIEW (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

LH SIDE AND RH SIDE VIEWS (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9

SERVICE PRODUCTS AND LUBES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10

POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS . . . . . . . . . . . 2.10

MAINTENANCE REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

MAINTENANCE REFERENCES, CONTINUED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 2.13

PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13

FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13

SHIFT LINKAGE INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13

FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14

FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14

FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14

FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14

VENT LINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14

THROTTLE PEDAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14

THROTTLE FREEPLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15

AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15

AIR INTAKE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17

COMPRESSION AND LEAKDOWN TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17

BREATHER HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17

ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17

ENGINE OIL AND FILTER CHANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18

EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19

TRANSMISSION AND GEARCASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20

TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20

FRONT GEARCASE LUBRICATION (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21

MIDDLE GEARCASE LUBRICATION (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22

REAR GEARCASE LUBRICATION (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

REAR GEARCASE LUBRICATION (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24

COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

LIQUID COOLING SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

RADIATOR COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26

COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26

COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26

COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26

RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27

COOLANT DRAIN / RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27

2.1

GENERAL INFORMATION

FINAL DRIVE / WHEEL AND TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27

WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27

CV SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

WHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

TIRE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

BATTERY FLUID LEVEL (CONVENTIONAL BATTERY) . . . . . . . . . . . . . . . . . . . . . . . 2.29

BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

BATTERY STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

BATTERY CHARGING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

ENGINE TO FRAME GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

STEERING AND SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

TIE ROD END / STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

CAMBER AND CASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

WHEEL TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32

TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32

FRONT SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

REAR SUSPENSION ADJUSTMENT (4X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

REAR SPRING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34

BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34

BRAKE SYSTEM INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34

BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34

PARKING BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35

BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35

2.2

GENERAL INFORMATION

PERIODIC MAINTENANCE CHART

Periodic Maintenance Overview

Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer.

NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

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

Maintenance Chart Key

The following symbols denote potential items to be aware of during maintenance :

= CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an

authorized Polaris dealer.

= SEVERE USE ITEM --If vehicle is subjected to severe use, decrease interval by 50%

(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 exte nde d idle. More pre ven tati ve maint enance is r equire d under these conditions. Fluid changes, cable, chain and chassis lu bricat i on are re quired more fre quently. For engine oil, short trip cold weather riding also constitutes se vere use. Pay specia l attention to oil lev el. 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.)

E= Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.

WARNING

Improperly performing the procedures marked with a could

result in component failure and lead to serious injury or death.

Have an authorized Polaris dealer perform these services.

2.3

GENERAL INFORMATION

Pre-Ride - 25 Hour Maintenance Interval

Maintenance Interval

Item

Hours Calendar

 Steering - Pre-Ride -

Front Suspension - Pre-Ride -



Rear Suspension - Pre-Ride -



Tires - Pre-Ride -

Brake Fluid Level - Pre-Ride -



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



Air Box Sediment Tube - Daily - Drain deposits when visible

Coolant Level - Daily -

Head Lamp / Tail Lamp - Daily -

Air Filter,



Main Element

Brake Pad Wear / Inspect



Parking Brake Pads



Battery 20 H Monthly - Check terminals; clean; test Front Gearcase Oil



(if equipped)

Middle Gearcase Oil



(if equipped)

Rear Gearcase Oil



(if equipped)

Transmission Oil 25 H Monthly - Inspect level; change yearly



Engine Breather



Filter (if equipped)

Engine Oil Change



(Break-In Period)

10 H Monthly - Inspect periodically

25 H Monthly - Inspect level; change yearly

25 H Monthly - Inspect; replace if necessary

25 H 1 M - Perform a break-in oil change at one month

(whichever comes first)

Miles

(KM)

Make adjustments as needed. See Pre-Ride Checklist on Page 2.13.

Check level daily, change coolant every 2 years

Check operation; apply dielectric grease if replacing

- Weekly - Inspect; replace as needed

Remarks

Perform these procedures more often for vehicles subjected to severe use.

E Emission Control System Service (California)

 Have an authorized Polaris dealer perform these services.

2.4

GENERAL INFORMATION

50 - 100 Hour Maintenance Interval

Maintenance Interval

Item

General Lubrication 50 H 3 M -



Shift Linkage 50 H 6 M - Inspect, lubricate, adjust

 Steering 50 H 6 M - Lubricate

Front Suspension 50 H 6 M - Lubricate



Rear Suspension 50 H 6 M - Lubricate



EThrottle Cable / Throttle

Pedal Throttle Body Air Intake

Ducts / Flange Drive Belt 50 H 6 M - Inspect; adjust; replace as needed

Cooling System 50 H 6 M -



Engine Oil Change 100 H 6 M -



Oil Filter Change 100 H 6 M - Replace with oil change

(whichever comes first)

Hours Calendar

50 H 6 M -

50 H 6 M - Inspect ducts for proper sealing/air leaks

Miles

(KM)

Lubricate all grease fittings, pivots, cables, etc.

Inspect; adjust; lubricate; replace if necessary

Inspect coolant strength seasonally; pressure test system yearly

Perform a break-in oil change at 25 hours/ one month

Remarks



Perform these procedures more often for vehicles subjected to severe use.

E Emission Control System Service (California)

 Have an authorized Polaris dealer perform these services.

2.5

GENERAL INFORMATION

100 - 300 Hour Maintenance Interval

Maintenance Interval

Item

Hours Calendar



Fuel System 100 H 12M -



Fuel Filter 100 H 12M - Replace yearly

Radiator 100 H 12M - Inspect; clean external surfaces



Cooling Hoses 100 H 12M - Inspect for leaks



Engine Mounts 100 H 12M - Inspect



Exhaust Muffler / Pipe 100 H 12M - Inspect



Spark Plug 100 H 12M - Inspect; replace as needed

Wiring 100 H 12M -



 Clutches (Drive and Driven) 100 H 12M - Inspect;clean; replace worn parts  Front Wheel Bearings 100 H 12M - Inspect; replace as needed

 Toe Adjustment 100 H

 Brake Fluid 200 H 24M - Change every two years (DOT 3 or DOT 4)

Spark Arrestor 300 H 36M - Clean out



Auxiliary Brake - Inspect daily; adjust as needed



Headlight Aim - Adjust as needed

(whichever comes first)

Miles

(Km)

Remarks

Check for leaks at tank cap, fuel lines, fuel pump, and fuel rail. Replace lines every two years.

Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.

Inspect periodically; adjust when parts are replaced



Perform these procedures more often for vehicles subjected to severe use.

E Emission Control System Service (California)

 Have an authorized Polaris dealer perform these services.

2.6

GENERAL COMPONENT LOCATIONS

RH Side (4X4) and Dash View

Gas Tank

Rear Gearcase

GENERAL INFORMATION

Front Gearcase

(Behind Radiator)

Cup

Holder

Storage

Box

Engine (under seat)

Dash Components

Instrument

Cluster

Ignition

Switch

Storage

Tray

Light

Switch

Mode

Button

AWD / Differential Switch

(if equipped)

12V

Accessory

Outlet

Storage

Compartment

(with lid)

Cup

Holder

2.7

GENERAL INFORMATION

LH Side and Rear View (4X4)

Battery

Front Prop Shaft

Tail Gate Latch

Air Cleaner

Storage

Compartment

Rear Prop Shaft

Transmission

2.8

2" Hitch

Muffler

Drive Shafts

LH Side and RH Side Views (6X6)

GENERAL INFORMATION

Front Gearcase

(behind radiator)

Rear Gearcase

Battery

Engine (under seat)

Transmission

Mid Gearcase

Front Prop Shaft

Drive Shafts

Rear Prop Shaft

2.9

GENERAL INFORMATION

SERVICE PRODUCTS AND LUBES

Polaris Lubricants, Maintenance and Service Products

Part No. Description

Engine Lubricant

2870791 Fogging Oil (12 oz. Aerosol)

2871098

2871281

2871844

2871567

2873602

2873603

2871653

2872276

2870465 Oil Pump for 1 Gallon Jug

2871654

2872277

2871322

2871423

2871460 Starter Drive Grease (12 Count) 2871515 Premium U-Joint Lube (3 oz.) (24 Count) 2871551 Premium U-Joint Lube (14 oz.) (10 Count) 2871312 Grease Gun Kit 2871329 Dielectric Grease (Nyogel™)

2871323 60/40 Coolant (Gallon) (6 Count) 2871534 60/40 Coolant (Quart) (12 Count)

Premium 2 Cycle Engine Oil (Quart) (12 Count)

Engine Oil (Quart) Premium 4 Synthetic 0W-40 (4-Cycle) (12 Count)

Engine Oil (Gallon) Premium 4 Synthetic 0W-40 (4-Cycle) (4 Count)

Engine Oil (16 Gallon) Premium 4 Synthetic 0W-40 (4-Cycle)

Gearcase / Transmission Lubricants

Premium Synthetic AGL Gearcase Lube (12 oz. bottle) (12 Count)

Premium Synthetic AGL Gearcase Lube (1 Gal.) (4 Count)

Premium ATV Angle Drive Fluid (8 oz.) (12 Count)

Premium ATV Angle Drive Fluid (2.5 Gal) (2 Count)

Premium Demand Drive Hub Fluid (8 oz.) (12 Count)

Premium Demand Drive Hub Fluid (2.5 gal.) (2 Count)

Grease / Specialized Lubricants

Premium All Season Grease (3 oz. cartridge) (24 Count)

Premium All Season Grease (14 oz. cartridge) (10 Count)

Coolant

NOTE: Each item can be purchased separately at your local Polaris dealer.

Part No. Description

Additives / Sealants / Thread Locking Ag ents / Misc.

2870585 Loctite™ Primer N, Aerosol, 25 g

2871956

2871949

2871950

2871951

2871952

2871953

2871954

2870584

2870587

2871326

2870652 Fuel Stabilizer (16 oz.) (12 Count)

2871957

2871958

2870990 DOT 3 Brake Fluid (12 Count) 2871557 Crankcase Sealant, 3-Bond 1215 (5oz.) 2872893 Engine Degreaser (12oz.) (12 Count)

NOTE: The number count indicated by each part number in the table above indicates the number of units that are shipped with each order.

Loctite™ Thread Sealant 565 (50 ml.) (6 Count)

Loctite™ Threadlock 242 (50 ml.) (10 Count)

Loctite™ Threadlock 242 (6 ml.) (12 Count)

Loctite™ Threadlock 262 (50 ml.) (10 Count)

Loctite™ Threadlock 262 (6 ml.) (12 Count)

Loctite™ Threadlock 271 (6 ml.) (12 Count)

Loctite™ Threadlock 271 (36 ml.) (6 Count)

Loctite™ 680-Retaining Compound (10 ml.)

Loctite™ 518 Gasket Eliminator / Flange Sealant (50 ml.) (10 Count)

Premium Carbon Clean (12 oz.) (12 Count)

Black RTV Silicone Sealer (3 oz. tube) (12 Count)

Black RTV Silicone Sealer (11 oz. cartridge) (12 Count)

2.10

GENERAL INFORMATION

MAINTENANCE REFERENCES

Item Lube Rec. Method Frequency*

Change after 1st month (25 hrs), 6 months

1. Engine Oil

2. Brake Fluid DOT 3 (PN 2870990) or Dot 4

3. Transmission

4. Front Gearcase

5. Middle Gearcase

Polaris 0W-40 Synthetic (PN 2871281)

Polaris AGL Gearcase Lubricant (PN 2873602)

Polaris Demand Drive Hub Fluid (PN 2871654)

ATV Angle Drive Fluid (PN 2871653)

Add oil to proper level.

Fill reservoir between MAX and Min lines.

Add lube to bottom of fill plug threads.

Drain completely. Add lube to specified quantity.

or 100 hours thereafter; Change more often in extremely dirty conditions, or short trip cold weather operation.

As required. Change fluid every 2 years. Change annually. Change more often if

used in severe conditions. Change annually***

Semi-annually**

1. Engine

Dipstick / Fill Tube

4. Front Gearcase

2. Brake Master Cylinder

3. Transmission

5. Middle Gearcase (6x6)

Drain Plug

Fill Plug

Drain Plug

2.11

GENERAL INFORMATION

Maintenance References, Continued.....

Item Lube Rec. Method Frequency*

Locate grease fitting on the

6. Hubstrut Assembly (Both Sides)

7. Swing Arm Pivot

8. Rear Prop Shaft Yoke

9. Front Prop Shaft Yoke

10. Rear Gearcase

* More often under severe use, such as operated in water or under severe loads. **Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information) ***Annually or 100 hours of operation (refer to Maintenance Schedule for additional information) Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or Mobilegrease Special

Polaris All Season Grease (PN

2871423)

Polaris All Season Grease (PN

2871423) Polaris Premium U-Joint Lube

(PN 2871551) Polaris Premium U-Joint Lube

(PN 2871551) ATV Angle Drive Fluid

(PN 2871653)

underside of the hubstrut assembly and grease with grease gun.

Locate grease fitting on inside of the swing arm pivot.

Locate fittings and grease with grease gun.

Drain completely. Add lube to specified quantity.

Semi-annually**

Change annually***

6. Hubstrut Assembly

Swing Arm Pivot

7. Swing Arm (6x6)

9. Front Prop Shaft

10. Rear Gearcase (6x6)

8. Rear Prop Shaft (6x6)

10. Rear Gearcase

Fill Plug

Yoke

(4x4)

2.12

GENERAL INFORMATION

GENERAL VEHICLE INSPECTION AND MAINTENANCE

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 - fi ll both tanks to their proper level; Do not overfill oil tank

• All brakes - check operation and adjustment (includ es auxiliary brake)

• Throttle - check for free operation and closing

• Headlight/Taillight/Brakelight - check operation of all indicator lights and switches

• Engine stop 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

Shift Linkage Inspection / Adjustment

Linkage rod adjustment is necessary when symptoms include:

• No All Wheel Drive light

• Noise on deceleration

• Inability to engage a gear

• Excessive gear clash (noise)

• Shift selectors moving out of desired range

NOTE: Remove necessary components to gain access to shift linkage cable ends (i.e. exhaust heat shield, exhaust pipe, etc.)

• 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 fo r 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.

Frame, Nuts, Bolts, and Fasteners

Periodically inspect the torque of all fasteners in accordance with the maintenance schedule. Check that all cotter pins are in place. Refer to specific fastener torques listed in each chapter.

1. Inspect shift linkage cable, clevis pins, and pivot bushings and replace if worn or damaged.

2. Be sure idle speed is adjusted properly.

3. Place gear selector in neutral. Make sure the transmission bell crank is engaged in the neutral position detents.

4. With two wrenches loosen the outside jam nut counterclockwise. Turn the outside jam nut 1 1/2 turns. Perform this procedure on the shift lever end, also.

Inside Jam Nut

Shift Cable Adjustment

5. After turning the outside jam nut 1 1/2 turns. Hold the outside jam nut with a wrench and tighten the inside jam nut clockwise, until it is tight against the bracket.

6. Repeat Step 4 and Step 5 until the proper adjustment is made for the transmission cable.

Outside Jam Nut

2.13

GENERAL INFORMATION

7. Use this procedure to loosen or tighten the shift linkage cable as needed.

Clockwise

Counterclockwise

Inside Jam Nut

Outside Jam Nut

FUEL SYSTEM AND AIR INTAKE

Fuel System

WARNING

Gasoline is extremely flammable and explosive

under certain conditions.

Always stop the engine and refuel outdoors or in

a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or

where gasoline is stored. Do not overfill the tank. Do not fill the tank neck. If you get gasoline in your eyes or if you swallow

gasoline, seek medical attention immediately.

If you spill gasoline on your skin or clothing, immediately wash it off with soap and water

and change clothing. Never start the engine or let it run in an enclosed area. Engine exhaust fumes are poisonous and

can result loss of consciousness or death

in a short time.

Never drain the fuel when the engine is hot.

Severe burns may result.

Fuel Filter

The RANGER XP 4x4 and 6x6 EFI engines use a nonserviceable, high-volume, high-pressure, 60-micron internal fuel pump filter and an internal 10-micron filter located before the pump regulator. Neither filter is servicable.

Fuel filter in tank is not serviceable

NOTE: For all other information related to the EFI fuel system refer to Chapter 4.

Vent Lines

1. Check fuel tank and transmission vent lines for signs of wear, deterioration, damage or leakage. Replace every two years.

2. Be sure vent lines are routed properly and secured with cable ties. CAUTION: Make sure lines are not kinked or pinched

Throttle Pedal Inspection

Throttle Pedal

Fuel Lines

1. Check fuel lines for signs of wear, deterioration, da mage or leakage. Replace if necessary.

2. Be sure fuel lines are routed properly and secured with cable ties. CAUTION: Make sure lines are not kinked or pinched.

3. Replace all fuel lines every two years.

2.14

If the throttle pedal has excessive play due to cable stretch or cable misadjustment, it will cause a delay in throttle speed. Also, the throttle may not open fully. If the throttle pedal has no play , the throttle may be hard to control, and the idle speed may be erratic.

Check the throttle pedal play periodically in accordance with the Periodic Maintenance Chart and adjust the play if necessary.

GENERAL INFORMATION

Throttle Freeplay Adjustment

Inspection

1. Apply the parking brake.

2. Put the gear shift lever in the N (Neutral) position.

3. Start the engine, and warm it up thoroughly.

4. Measure the distance the throttle pedal moves before the engine begins to pick up speed. Free play should be 1/16”

- 1/8” (1.5 - 3 mm).

Adjustment

1. Remove the seat.

2. Locate the throttle cable adjuster.

3. Squeeze the end of the rubber boot and slide it far enough to expose the end of the inline cable adjuster.

Boot

Lock Nut

4. Loosen the adjuster lock nut.

5. Rotate the boot to turn the adjuster until 1/16" to 1/8" (1.5 - 3 mm) of freeplay is achieved at the throttle pedal.

Adjuster

Air Filter Service

It is recommended that the air filter be replaced annually. When riding in extremely dusty conditions replacement will be required more often.

The filter should be inspected periodically before each ride, using the following procedure.

1. Lift the box to access the filter box cover.

Air Box Location

2. Remove clips (2) from air box cover and remove cover. Inspect the gasket. It should adhere tightly to the cover and seal all the way around.

3. Remove air filter assembly. Do not clean the main filter, the filter should be replaced.

4. Inspect main element and replace if necessary. If the filter has been soaked with fuel or oil it must be replaced.

Breather Filter

NOTE: While adjusting, lightly flip the throttle pedal up and down.

6. Tighten the lock nut.

7. Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position.

Cover Seal

Filter

Cover

Installation

1. Reinstall the filter into the air box container. Be sure the filter fits tightly in the air box.

NOTE: Apply a small amount of general purpose grease to the sealing edges of the filter before installing.

2.15

GENERAL INFORMATION

2. Check air box. If oil or water deposits are found, drain them into a suitable container.

NOTE: Service more frequently if vehicle is operated in wet conditions or at high throttle openings for extended periods.

3. Install air box cover and secure with clips.

Air Intake Inspection

1. Lift the hood.

2. Inspect the foam inserts in the air baffle boxes. If the foam inserts are dirty, clean the foam with a high flash point solvent, followed by hot soapy water.

3. Rinse and dry the foam thoroughly.

4. Inspect the foam for tears or damage. Replace if necessary.

Foam

5. Reinstall the foam inserts into the air baffle boxes.

Air Baffing

Box

Air Box

Engine Intake Duct

PVT Intake Duct

2.16

GENERAL INFORMATION

ENGINE

Compression and Leakdown Test

NOTE: This engine does NOT have decompression components. Compression readings will vary in proportion to cranking speed during the test. Average compression (measured) is about 150-200 psi during a compression test.

A 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 carbon deposits in the combustion chamber or worn, damaged exhaust cam lobes. Inspect camshaft and combustion chamber if compression is abnormally high.

A cylinder leakdown test is the best indication of engine condition. Follow manufacturer's instructions to perform a cylinder leakage test. (Never use high pressure leakage testers, as crankshaft seals may dislodge and leak).

Cylinder Compression Standard: 150-200 PSI

Cylinder Leakdown

Service Limit 15%

Engine Oil Level

The twin cylinder engine is a wet-sump engine, meaning the oil is contained in the bottom of the crankcase. To check the oil level follow the procedure listed below.

Dipstick

1. Set machine on a level surface and set the parking brake.

2. Be sure the machine has sat for awhile before removing the dipstick.

IMPORTANT: Do not run the machine and then check the dipstick.

3. Stop engine and unlock the lever lock. Remove dipstick and wipe dry with a clean cloth.

(Inspect for cause if test exceeds 15%)

Breather Hose Inspection

The engine is equipped with a breather hose (A). Inspect the breather hose for possible kinks or wear. The hose is form fitted for a proper fit. Follow the breather hose from the side of the airbox to the engine valve cover.

NOTE: Make sure lines are not kinked or pinched.

Lever Lock

Dipstick

2.17

GENERAL INFORMATION

4. Reinstall dipstick and push it into place. Do not lock the dipstick.

NOTE: Make certain the dipstick is inserted all the way into the filler tube to keep the an gle and dep th of dipstick consistent. When reinstalling the dipstick, make certain to seat the lever lock.

5. Remove dipstick and check to see that the oil level is in the normal range. Add oil as indicated by the level on the dipstick. Do not overfill. (See NOTE below!)

NOTE: Due to the dipstick entry angle into the crankcase, the oil level will read higher on the bottom side of the dipstick. Proper level indication is determined on the upper surface of the dipstick as it is being removed, regardless of the level marks being on top or on bottom. (See the next illustration)

Dipstick

Always read top side of dipstick to

properly check oil level in crankcase

Engine Oil and Filter Change

WARNING

Personal injury can occur when handling used

oil. Hot oil can cause burns or skin damage.

Recommended Engine Oil:

Polaris Premium Synthetic OW-40

(PN 2871281) (Quart)

Ambient Temperature Range

-40° F to 120° F

1. Place vehicle on a level surface.

2. To ease access to the oil filter, try to access the oil filter from the front engine cover or remove the storage container located under the driver side seat (refer to Chapter 5 for front engine cover and storage removal).

3. Run engine two to three minutes until warm. Stop engine.

4. Clean area around drain plug at bottom of oil engine. Drain plug is accessible through the skid plate.

NOTE: A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the full mark, change the oil immediately.

CAUTION

Oil may be hot. Do not allow hot oil to come into

contact with skin, as serious burns may result.

5. Place a drain pan beneath crankcase and remove drain plug.

Drain Plug

6. Allow oil to drain completely.

7. Replace the sealing washer on drain plug.

NOTE: The sealing surface on the drain plug should be clean and free of burrs, nicks or scratches.

2.18

8. Reinstall drain plug and torque to 192 ± 24 in. lbs. (21.7 ±

2.7 Nm).

GENERAL INFORMATION

9. Place shop towels beneath oil filter. Using Oil Filter Wrench (PV-43527), turn filter counterclockwise to remove.

Oil Filter

10. Using a clean dry cloth, clean filter sealing surface on crankcase.

11. Lubricate O-ring on new filter with a film of fresh engine oil. Check to make sure the O-ring is in good condition.

12. Install new filter and turn by hand until filter gasket contacts the sealing surface, then turn an additional 1/2 turn.

13. Remove dipstick and fill sump with 2 quarts (1.9 l) of Polaris Premium 4 Synthetic Oil (PN2871281)

Crankcase Drain Plug Torque:

192 ± 24 in. lbs. (21.7 ± 2.7 Nm)

Exhaust Pipe

WARNING

Do not perform clean out immediately after the engine

has been run, as the exhaust system becomes very hot.

Serious burns could result from contact with exhaust

components.

To reduce fire hazard, make sure that there are no

combustible materials in the area when purging the

spark arrestor.

Wear eye protection.

Do not stand behind or in front of the vehicle while

purging the carbon from the spark arrestor.

Never run the engine in an enclosed area. Exhaust

contains poisonous carbon monoxide gas.

Do not go under the machine while it is inclined. Set the

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

personal injury or death.

The exhaust pipe must be periodically purged of accumulated carbon as follows:

1. Remove the clean out plugs located on the bottom of the muffler as shown below.

Oil Filter Torque:

Turn by hand until filter gasket contacts

sealing surface, then turn an

additional 1/2 turn

Oil Filter Wrench:

(PV-43527)

14. Place gear selector in neutral and set parking brake.

15. Start the engine and let it idle for one to two minutes. Stop the engine and inspect for leaks.

16. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick.

17. Dispose of used oil and oil filter properly.

Clean Out Plug

2. Place the transmission in Park and start the engine. Purge accumulated carbon from the system by momentarily revving the engine several times.

3. If some carbon is expelled, cover the exhaust outlet and lightly tap on the pipe around the clean out plugs with a rubber mallet while revving the engine several more times.

2.19

GENERAL INFORMATION

4. If particles are still suspected to be in the muffler, back the

machine onto an incline so the rear of the machine is one

foot higher than the front. Set the hand brake and block the wheels. Make sure the machine is in Park and repeat Steps 2 and 3. SEE WARNING

5. If particles are still suspected to be in the muffler, drive the

machine onto the incline so the front of the machine is one foot higher than the rear. Set the hand brake and block the wheels. Make sure the machine is in Park and repeat Steps 2 and 3. SEE WARNING

1 ft.

6. Repeat steps 2 through 5 until no more particles are expelled when the engine is revved.

7. Stop the engine and allow the arrestor to cool.

8. Reinstall the clean out plugs.

The transmission lubricant level should be checked and changed in accordance with the maintenance schedule.

• Be sure vehicle is level with the parking brake on before proceeding.

• Check vent hose to be sure it is routed properly and unobstructed.

To check the level:

1. Remove the fill plug on the backside of the transmission.

Fill Plug

2. The fluid should be at the bottom of the fill plug hole threads.

Figure 7-26

TRANSMISSION AND GEARCASES

Transmission Lubrication

NOTE: It is very important to follow a regular transmission fluid check/change schedule. The service manual of the RANGER recommends the level be checked every twenty-five (25) hours of operation, and changed once (1) a year.

TRANSMISSION SPECIFICATIONS

Specified Lubricant:

AGL Synthetic Gearcase Lubricant

(PN 2873602) (32 oz.)

Approximate Capacity at Change:

15.2 oz. (450 ml.)

Drain Plug / Fill Plug Torque:

14 ft. lbs. (19 Nm)

Fill Plug Threads

Proper Fluid Level

2.20

GENERAL INFORMATION

To change lubricant:

1. Remove skid plate (if necessary).

2. Place a drain pan beneath the transmission oil drain plug area.

3. Remove the drain plug and wipe the magnetic end clean to remove accumulated metallic filings.

TRANSMISSION

Drain Plug 14 ft. lbs. (19 Nm)

4. After the oil has drained completely, install the drain plug. Torque to 14 ft. lbs. (19 Nm).

5. Add the proper lubricant through the fill plug hole until the oil level is at the bottom of the fill plug threads (see figure 7-26). Do not overfill.

• The correct front gearcase lubricant to use is Polaris Premium Demand Hub Fluid.

Front Gearcase Specifications

Specified Lubricant:

Premium Demand Drive Hub Fluid

(PN 2871654)

Capacity: 5.0 oz. (150 ml.)

Fill Plug Torque: 8-30 ft. lbs. (11-41 Nm)

Drain Plug Torque: 10 ft. lbs. (14 Nm)

FRONT GEARCASE

Make sure vent is unobstructed

Fill Plug

8-30 ft. lbs.

(11-41 Nm)

6. Torque fill plug to 14 ft. lbs. (19 Nm)

7. Check for leaks.

Front Gearcase Lubrication

The gearcase lubricant level should be checked and changed in accordance with the maintenance schedule.

• Be sure vehicle is level with parki ng brake on before proceeding.

• Check vent hose to be sure it is routed properly and unobstructed.

Drain Plug: 10 ft. lbs. (14 Nm)

To check the lubricant level:

The front gearcase lubricant level cannot be checked with a dipstick. The gearcase must be drained and re-filled with the proper amount of lubricant or be filled to the bottom of the fill plug hole threads. Refer to procedures.

2.21

GENERAL INFORMATION

To change gearcase lubricant:

10 ft. lbs (14 Nm)

1. Remove gearcase drain plug (B) (11 mm) located on the bottom of the gearcase and drain oil. (The drain plug is accessible through the skid plate.) Catch and discard used oil properly.

2. Clean and reinstall drain plug (B) using a new sealing washer (A). Toque to 10 ft. lbs. (14 Nm).

3. The fill plug can be accessed through the top hood area by removing the storage box or by removing the left side panel in the left wheel well.

4. Remove fill plug (8 mm hex) and check the O-ring.

Fill Plug

5. Fill with the recommended fluid amount (5 oz.) or to the bottom of the fill plug hole threads.

Front Gearcase

Plug Threads

Fill with 5 oz.

Top View of Hood Area

LH Side Panel

6. Install fill plug and check for leaks.

Middle Gearcase Lubrication (6x6)

Middle Gearcase Specifications

Specified Lubricant:

ATV Angle Drive Fluid (PN 2871653)

Capacity: 6.75 oz. (200 ml.)

Drain Plug / Fill Plug Torque:

14 ft. lbs. (19.4 Nm)

The gearcase lubricant level should be checked and changed in accordance with the maintenance schedule.

• Be sure vehicle is level with parking brak e on befo re

proceeding.

2.22

• Check vent hose to be sure it is routed properly and

unobstructed.

• The correct middle gearcase lubricant to use is ATV

Angle Drive Fluid

GENERAL INFORMATION

To check the lubricant level:

The gearcase must be drained and re-filled with the proper amount of lubricant. Refer to the procedure below.

To change middle gearcase lubricant:

1. With the RANGER on a level surface, remove the fill plug and check the lubricant level. Lubricant should be kept at the specified level, according to the proper gearcase specifications listed.

2. Support the vehicle securely with a jack stand and remove the front tire on the driver’s side.

3. Remove gearcase drain plug located on the bottom of the gearcase and drain oil. (The drain plug is accessible through the skid plate.) Catch and discard used oil properly.

4. Clean and reinstall drain plug using a new sealing washer.

5. Remove fill plug.

6. Fill with the recommended fluid amount or fill to the bottom of the threads of the fill plug hole.

7. Install fill plug. Check for leaks.

MIDDLE GEARCASE (6X6)

Make sure vent is unobstructed

Rear Gearcase Lubrication (4x4)

REAR GEARCASE SPECIFICATIONS

Specified Lubricant:

ATV Angle Drive Fluid (PN 2871653)

Capacity: 18 oz. (532 ml)

Fill Plug Torque: 40 ft. lbs. (54 Nm)

Drain Plug Torque: 30-45 in. lbs. (3-5 Nm)

To check the level:

1. With machine on level ground and with the parking brake on, remove fill plug from rear gearcase.

2. The fluid level should be 0.75 in. (1.9 cm) from the bottom of the fill plug hole threads. Use a light colored and nonabsorbent measuring instrument (white zip tie) to measure the depth of the fluid in the rear gearcase. If level is low, add ATV Angle Drive Fluid (PN 2871653).

Side View

Fill to bottom of fill plug hole threads: 6.75 oz.

Fill Plug

14 ft. lbs. (19 Nm)

Bottom View

0.75 in. (1.9 cm)

Measuring Instrument

0.75 in. (1.9 cm)

Fluid Level

3. Reinstall fill plug. Tighten to 40 ft. lbs. (54 Nm).

4. Check for leaks.

Drain Plug

14 ft. lbs. (19 Nm)

2.23

GENERAL INFORMATION

To change the lubricant:

1. Remove gearcase drain plug located on the bottom and drain the oil. Catch and discard used oil properly.

Under Side View

Drain Plug

30-45 in. lbs. (3-5 Nm)

2. Clean and reinstall the drain plug with a new sealing washer and tighten to 30-45 in. lbs. (3-5 Nm).

3. Remove fill plug.

Rear Gearcase Lubrication (6x6)

Rear Gearcase Specifications

Specified Lubricant:

ATV Angle Drive Fluid (PN 2871653)

Capacity: 10 Oz. (300 ml.)

Drain Plug / Fill Plug Torque:

14 ft. lbs. (19.4 Nm)

The gearcase lubricant level should be checked and changed in accordance with the maintenance schedule.

• Be sure vehicle is level before proceeding with parking brake on.

• Check vent hose to be sure it is routed properly and unobstructed.

• The correct rear gearcase lubricant to use is Polaris ATV Angle Drive Fluid

To check the lubricant level:

Fill Plug

40 ft. lbs. (54 Nm)

4. Add 18 oz. (532 ml.) of ATV Angle Drive Fluid (PN 2871653).

5. Reinstall fill plug. Tighten to 40 ft. lbs (54 Nm).

40 ft. lbs (54 Nm)

6. Check for leaks.

The gearcase must be drained and re-filled with the proper amount of lubricant. Refer to the procedure below.

To change rear gearcase lubricant:

1. With the vehicle on a level surface, remove the fill plug and check the lubricant level. Lubricant should be kept at the specified level, according to the proper gearcase specifications listed.

2. Support the vehicle securely with a jack stand and remove the front tire on the driver’s side.

3. Remove gearcase drain plug located on the bottom of the gearcase and drain oil. (The drain plug is accessible through the skid plate.) Catch and discard used oil properly.

4. Clean and reinstall drain plug using a new sealing washer.

REAR GEARCASE - 6X6

Make sure vent is unobstructed

Fill Plug

2.24

Drain Plug

GENERAL INFORMATION

5. Remove fill plug (A).

6. Fill with 10 oz. (300 ml.) or fill to the bottom of the threads of the fill plug hole.

7. Install fill plug and torque to 14 ft. lbs (19 Nm). Check for leaks.

COOLING SYSTEM

Liquid Cooling System Overview

The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose.

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 tank past the pressure cap and into the radiator.

Coolant Level Inspection

The recovery bottle, located on the left side of the machine, must be maintained between the minimum and maximum levels indicated on the recovery bottle.

Surge Tank Cap

With the engine at operating temperature, the coolant level should be between the upper and lower marks on the coolant reservoir. If not:

1. Remove reservoir cap. Inner splash cap vent hole must be clear and open.

2. Fill reservoir to upper mark with Polaris Premium 60/40 Anti Freeze / Coolant or 50/50 or 60/40 mixture of antifreeze and distilled water as required for freeze protection in your area.

3. Reinstall cap.

NOTE: Some coolant level drop on new machines is normal as the system is purging itself of trapped air. Observe coolant levels often during the break-in period.

Overheating of engine could occur if air is not fully purged from system.

Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water.

Surge Tank

NOTE: If overheating is evident, allow system to cool completely and check coolant level in the radiator and inspect for signs of trapped air in system.

2.25

GENERAL INFORMATION

Radiator Coolant Level Inspection

NOTE: This procedure is only required if the cooling system has been drained for maintenance and/or repair. However, if the recovery bottle has run dry, or if overheating is evident, the level in the radiator should be inspected and coolant added if necessary.

Radiator Cap

WARNING

• Straight water or antifreeze may cause the system to freeze, corrode, or overheat.

Polaris 60/40 Anti-Freeze / Coolant

(PN 2871323)

Cooling System Pressure Test

Refer to Chapter 3 for cooling system pressure test procedure.

Cooling System Hoses

1. Inspect all hoses for cracks, deterioration, abrasion or leaks. Replace if necessary.

Coolant Lines

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.

NOTE: Use of a non-standard pressure cap will not allow the recovery system to function properly.

To access the radiator pressure cap raise the front hood. The radiator cap is located on the drivers side.

Coolant Strength / Type

T est the strength of the coolan t using an antifreeze hydrometer.

Antifreeze Hydrometer

• A 50/50 or 60/40 mixture of antifreeze and distilled water will provide the optimum cooling, corrosion protection, and antifreeze protection.

• Do not use tap water, straight antifreeze, or straight water in the system. Tap water contains minerals and impurities which build up in the system.

Radiator

2. Check tightness of all hose clamps.

CAUTION

Do not over-tighten hose clamps at radiator, or radiator fitting may distort, causing a restriction

to coolant flow. Radiator hose clamp torque is

36 in. lbs. (4 Nm).

2.26

GENERAL INFORMATION

Radiator

1. Check radiator (A) air passages for restrictions or damage.

2. Carefully straighten any bent radiator fins.

3. Remove any obstructions with compressed air or low pressure water.

Coolant Drain / Radiator Removal

1. Remove the front bumper. Remove three bolts that secure the bumper to the bottom of the frame. Remove six screws (both sides) that secure the wheel well panel to the frame. Remove two bolts that secure the top bumper to the frame. Remove the darts that attach the plastic to the bumper.

4. Remove the outlet radiator hose, inlet radiator hose, surge tank hose, and overflow hose from the radiator.

5. Remove the radiator.

Inlet Radiator Hose

Outlet Radiator Hose

Surge Tank Hose

Plug

FINAL DRIVE / WHEEL AND TIRE

Wheel, Hub, and Spindle Torque Table

Item Nut Type Specification

Bolts

Wheel Well

Bolts

2. Remove two mounting screws that secure the top of the radiator to the frame. Remove the radiator cap. Pull the radiator out of the frame at an angle.

NOTE: If you have trouble reaching the top radiator bolts, remove four screws from the top front of the hood liner. Prop the front of the hood up 1.5 inches (38.10 mm) to help remove the top bolts that secure the radiator to the frame.

3. Remove the drain plug and drain the coolant from the radiator. Drain the coolant into a suitable container and properly dispose of the coolant.

Aluminum Wheels (Cast)

Steel Wheels (Black / Camo)

Front Spindle Nut - 70 Ft. Lbs. (95 Nm) Rear & Center Hub

Retaining Nut

Aluminum Wheel

(LE Models)

90 ft. lbs. (122 Nm)

Lug Nut (1) 90 ft. lbs. (122 Nm)

Flange Nut (2) 35 ft. lbs. (47 Nm)

- 110 Ft. Lbs. (150 Nm)

Steel Wheel

(Standard Models)

35 ft. lbs. (47 Nm)

2.27

GENERAL INFORMATION

CV Shaft Boot Inspection

Inspect the CV shaft boots in the front and rear of the RANGER for damage, tears, wear, or leaking grease. If the rubber boot exhibits any of these symptoms, replace the boot. Refer to Chapter 7 for CV boot replacement, or have you Polaris dealer replace the boot.

Inspect Boots

Wheel Removal

Front & Rear Wheel Nuts (4)

4. Securely tighten the wheel nuts to the proper torque li sted in the torque table at the beginning of this section.

CAUTION

If wheels are improperly installed it could affect vehicle handling and tire wear. On vehicles with tapered rear wheel nuts, make sure tapered end

of nut goes into taper on wheel.

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.

Tire Tread Depth

Always replace tires when tread depth is worn to 1/8" (3 mm) or less.

Tread Depth 1/8" (3 mm)

Front Hub Nut 70 ft. lbs. (95 Nm)

Rear Hub Nut 110 ft. lbs. (150 Nm)

1. Stop the engine, place the transmission in gear and lock the parking brake.

2. Loosen the wheel nuts slightly.

3. Elevate the side of the vehicle by placing a suitable stand under the footrest frame.

4. Remove the wheel nuts and washers and remove the wheel.

Wheel Installation

1. With the transmission in gear and the parking brake locked, place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation.

2. Attach the washers (if applicable) and wheel nuts and finger tighten them.

3. Lower the vehicle to the ground.

WARNING

Operating a RANGER with worn tires will

increase the possibility of the vehicle skidding

easily with possible loss of control.

Worn tires can cause an accident.

Always replace tires when the tread depth

measures 1/8", (.3 cm) or less.

2.28

GENERAL INFORMATION

Tire Pressure

CAUTION

Maintain proper tire pressure.

Refer to the warning tire pressure decal

applied to the vehicle.

Tire Pressure Inspection (PSI - Cold)

Front Rear

8-12 8-12

ELECTRICAL AND IGNITION SYSTEM

Battery Maintenance

Keep battery terminals and connections free of corrosion. If cleaning is necessary, remove th e corrosion with a stiff wire brush. W ash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly.

NOTE: Batteries must be fully charged before use or battery life will be reduced by 10-30% of full potential. Charge battery for 3-5 hours at a current equivalent of 1/10 of the battery’s rated amp/hour capacity. Do not use the alternator to charge a new battery. (Refer to Battery Activation and Maintenance video PN 9917987)

Battery Fluid Level (Conventional Battery)

A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. Maintain the fluid level between the upper and lower level marks.

Upper Level

Lower Level

Be careful not to allow cleaning solution or tap water into the battery

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.

Add only distilled water. Tap water contains minerals that are harmful to a battery.

Battery Removal

1. Open the Hood.

2. Remove the battery vent tube from the battery.

3. Disconnect the black (negative) battery cable.

4. Disconnect the red (positive) battery cable.

2.29

GENERAL INFORMATION

5. Lift the battery out of the vehicle, being careful not to tip it sideways and spill any electrolyte.

CAUTION

To reduce the chance of sparks: Whenever

removing the battery, disconnect the negative

(black) cable first. When reinstalling the battery,

install the negative cable last.

Battery Installation

Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging procedure before installing the battery.

1. Ensure that the battery is fully charged.

2. Place the battery in the battery holder.

3. Install the battery vent tube.

NOTE: The vent tube must be free of obstructions and securely installed. Rout e t he tu b e aw ay fro m th e frame and vehicle body to prevent contact with electrolyte.

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.

Spark Plug Service

1. Remove both spark plug high tension leads (A). Clean plug area so no dirt and debris can fall into engine when plug is removed.

2. Remove spark plugs (B).

3. Inspect electrodes for wear and carbon buildup. Look for a sharp outer edge with no rounding or erosion of the electrodes.

Inspect electrode for wear and buildup

Battery Storage

Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge.

NOTE: Battery charge can be maintained by using a Polaris battery tender charger or by charging about once a month to make up for normal self-discharge. Battery tenders can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point.

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 greater.

3. Reinstall the battery.

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.

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

Gap - .035" (0.90 mm)

6. If necessary, replace spark plug with proper type. CAUTION: Severe engine damage may occur if the incorrect spark plug is used.

7. Apply a small amount of anti-seize compound to the spark plug threads.

2.30

8. Install spark plug and torque to specification

GENERAL INFORMATION

Recommended Spark Plug:

Champion RC7YC3

Spark Plug Torque:

18 Ft. Lbs. (24 Nm)

Engine To Frame Ground

Inspect engine ground cable connection. Be sure it is clean and tight. The ground cable runs from the engine to the terminal block located under the front hood next to the battery.

Black Ground

Terminal Block

(under hood)

WARNING

Due to the critical nature of the procedures

outlined in this chapter, Polaris recommends

steering component repair and adjustment be

performed by an authorized Polaris MSD-

certified technician when replacing worn or

damaged steering parts.

Use only genuine Polaris replacement parts.

One of two methods can be used to measure toe alignment. The string method and the chalk method. If adjustment is required, refer to following pages for procedure.

Tie Rod End / Steering Inspection

• To check for play in the tie rod end, grasp the steering tie rod, pull in all directions feeling for movement.

• Repeat inspection for inner tie rod end (on steering post).

• Replace any worn steering components. Steering should move freely through entire range of travel without binding.

STEERING AND SUSPENSION

Steering

The steering components should be checked periodically for loose fasteners, worn tie rod ends, and damage. Also check to make sure all cotter pins are in place. If cotter pins are removed, they must not be re-used. Always use new cotter pins.

Replace any worn or damaged steering components. Steering should move freely through entire range of travel without binding. Check routing of all cables, hoses, and wiring t o be sure the steering mechanism is not restricted or limited.

NOTE: Whenever steering components are replaced, check front end alignment. Use only genuine Polaris parts.

• Elevate front end of m achin e so front wheels are off the ground. Check for any looseness in front hub / wheel assembly by grasping the tire firmly at top and bottom first, and then at front and rear. Try to move the wheel and hub by pushing inward and pulling outward.

• If abnorm al movement is detected, inspect the hub and wheel assembly to determine the cause (loose wheel nuts or loose front hub nut).

• Refer to the Body/Steering or Final Drive chapter for more information.

Camber and Caster

The camber and caster are non-adjustable.

2.31

GENERAL INFORMATION

Wheel Toe Alignment Inspection

1. Place machine on a smooth level surface.

2. Set steering wheel in a straight ahead position and secure the steering wheel in this position.

3. Place a chalk mark on the center line of the front tires approximately 10” (25.4 cm) from the floor or as close to the hub/axle center line as possible.

Chalk Mark

Measurement “A”

NOTE: It is important that the height of both marks be equally positioned in order to get an accurate measurement.

4. Measure the distance between the marks and record the measurement. Call this measurement “A”.

5. Rotate the tires 180 backward. Position chalk marks facing rearward, even with the hub/axle centerline.

6. Again measure the distance between the marks and record. Call this measurement “B”. Subtract measurement “B” from measurement “A”. The 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).

 by moving vehicle forward or

Measurement “B”

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.

NOTE: Be sure steering wheel is straight ahead before determining which tie rod(s) need adjustment.

CAUTION

During tie rod adjustment, it is very important that

the following precautions be taken when

tightening tie rod end jam nuts.

If the rod end is positioned incorrectly it will not

pivot, and may break.

To adjust toe alignment:

• Hold tie rod end to keep it from rotating.

• Loosen jam nu ts at both end of the ti e rod.

• 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 premature wear. Damage may not be immediately apparent if done incorrectly.

Hold Rod End

Correctly Tightened Jam Nut

Incorrectly Tightened Jam Nut

2.32

= In. / mm.

Wheel Toe-Out:

(A) - (B) = 1/8 - 1/4" (.3 to .6 cm)

• After alignmen t is compl ete, torq ue jam nuts to 12-14 ft. lbs. (16-19 Nm).

= T

Tie Rod Jam Nut Torque:

12-14 ft. lbs. (16-19 Nm)

GENERAL INFORMATION

Front Suspension

• Compress and release front suspension. Damping should be smooth throughout the range of travel.

• Check all front suspension components and fasteners for wear or damage.

• Inspect front strut cartridges for leakage.

Bolt Torque

15 ft. lbs. (20 Nm)

Inspect for leaks

Rear Suspension

RANGER 4X4

Independent Rear Suspension

RANGER 6X6

Rear Swingarm Suspension

• Compress and release rear suspension. Damping should be smooth throughout the range of travel.

• Check all rear suspension components for wear or damage.

• Inspect shock for leakage.

2.33

GENERAL INFORMATION

Rear Suspension Adjustment (4x4)

The rear suspension may be adjusted to provide a stiffer suspension if necessary.

1. Remove the top shock mounting bolts from the inside mounting holes.

2. Reposition the shocks to the outside mounting holes.

3. Reinstall the shock mounting bolts. Torque to 30 ft. lbs. (40 Nm).

Outside Mounting Holes

Inside Mounting Holes

BRAKE SYSTEM

Brake System Inspection

The following checks are recommended to keep the brake system in good operating condition. Service life of brake system components depends on operating conditions. Inspect brakes in accordance with the maintenance schedule and before each ride.

• Keep fluid level in the m aster cylinder reservoir to the indicated level inside reservoir.

• Use Polaris DOT 3 or DOT 4 Brake Fluid.

Rear Spring Adjustment

The rear shock absorber springs are adjusted by rotating the adjustment cam either clockwise or counterclockwise to increase or decrease spring tension.

To adjust the suspension, use the adjustment cam located near the bottom of the rear shock. This will allow you to increase or decrease the amount of spring preload.

Rear Spring

Adjustment Cam

• Check brake system for fluid leaks.

• Check brake for excessive travel or spongy feel.

• Check friction pads fo r wear, damage or looseness.

• Check surface condition of the disc.

Brake Pad Inspection

Pads should be changed when the friction material is worn to .180" (4.6 mm). When the pad are new the thickness is .298 ± .007" (7.56 ± .178 mm).

Brake Pad

Measure Thickness

Service Limit - .180" (4.6 mm)

2.34

Shock Spanner Wrench

(PN 2870872)

Parking Brake Pad Inspection

Measure the thickness of the rear caliper parking brake pads. Replace assembly as needed. See illustration below for proper readings.

Inboard Pad Thickness New .304” (7.72 mm) Limit: 0.24” (6.1 mm)

GENERAL INFORMATION

Inboard Pad

Outboard Pad

Outboard Pad Thickness

New 0.360” (9.14 mm) Limit: 0.31” (7.87 mm)

Installed Disc to Park Brake

0.375” (0.953 cm)

New Rotor Disc Thickness

0.150” - 0.164”

(3.81 - 4.16 mm)

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.

2.35

ENGINE

CHAPTER 3

ENGINE

ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2

CRANKCASE EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2

ENGINE FASTENER TORQUE PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9

TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10

700 EFI ENGINE SERVICE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13

GENERAL ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13

ACCESSIBLE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13

PISTON IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13

COOLING SYSTEM SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13

COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14

COOLING SYSTEM EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15

COOLING SYSTEM BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15

VALVE COVER REMOVAL - 6X6 MODELS (ENGINE INSTALLED) . . . . . . . . . . . . . . 3.17

ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18

ENGINE INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19

CYLINDER HONE SELECTION AND HONING PROCEDURE. . . . . . . . . . . . . . . . . . . 3.20

HONING TO DEGLAZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20

CLEANING THE CYLINDER AFTER HONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21

ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21

OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21

OIL FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22

ENGINE DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23

CYLINDER HEAD ASSEMBLY EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23

ROCKER ARMS / PUSH RODS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24

CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24

CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25

CYLINDER HEAD WARP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25

VALVE SEAL / SPRING SERVICE (ON ENGINE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25

CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26

VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27

COMBUSTION CHAMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28

VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28

CYLINDER HEAD REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30

VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31

CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31

VALVE LIFTER REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31

PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32

CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33

PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34

PISTON / ROD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34

PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35

STARTER DRIVE BENDIX REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 3.35

FLYWHEEL / STATOR REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36

ENGINE CRANKCASE DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 3.36

CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44

ENGINE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45

CRANKCASE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45

FLYWHEEL / STATOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.54

CYLINDER HEAD REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.54

OIL PUMP PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.57

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.58

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.58

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59

3.1

ENGINE

ENGINE SPECIFICATIONS

Crankcase Exploded Views

A. Jo ur n a l B ea rin gs B. Camshaft C. Thrust Plate D. Balance Shaft E. Woodruff Key F. Flange Seal G. Crankshaft H. Oil Pickup I. Journal Bearings J. Baffle K. Oil Plug L. Washer M. O-ring N. Crankcase O. Crankcase Bolts

115  12 in. lbs. (13  1.35 Nm)

60  6 in. lbs. (6.8  .68 Nm)

NOTE: If needed, heat

the oil baffle bolts with a heat gun to remove.

192  24 in. lbs

(21.7  2.7 Nm

3.2

22  2 ft. lbs. (30  3 Nm)

Apply Loctite 242 to bolt threads.

Apply White Lithium Grease

Apply Moly Lube Grease.

Oil Pump / Water Pump / Engine Cover Exploded View

22  2 ft. lbs. (30  3 Nm)

84  8 in. lbs. (9.5  .90 Nm)

A. Split Gear B. Washer C. Bolt D. Oil Rotor E. Oil Pump F . Mag Gasket Cover G. Impeller H. Washer I. Nut J. Counterbalance Gear K. Washer L. Bolt M. Oil Pump Bolts N. Engine Cover

O. Wire Hold down P . Stator Housing Bolts

ENGINE

Oil Pump Bolt Tighten Sequence

No Grease on this Portion of the Gasket!

Apply corrosion resistant grease to stator grommet area.

96  3 in.lbs.

(10.85  0.35 Nm)

Mag Cover Bolt Tighten Sequence

Apply Polaris OW-40 oil to component

108 12 in.lbs. (6.8  .68 Nm)

Apply White Lithium Grease

3.3

ENGINE

Stator Cover / Starter / Water Pump Exploded View

Apply Polaris Starter Grease

Apply Polaris 0W-40 oil to seal

Loctite Pipe Sealant

(PN 2871956)

84  8 ft.lbs. (9.5 0.9 Nm)

Tighten Top Bolt First

1st

2nd

108  12 ft.lbs. (12  1.35 Nm)

Water Pump Cover Bolt Tighten Sequence

No Grease or Oil

65  7 ft. lbs. (88  9.5 Nm)

96  12 in. lbs. (10.85  1.35 Nm)

A. Bolts B. Starter C. Washer D. Nut E. Positive Cable F. Negative Cable G. Gasket H. Clamp I. Bolts J. Gasket K. Wa te r Pu m p C o ve r L. Bolts M. C ra nk N ut / Was h er N. Flywheel

96  12 in. lbs. (10.85  1.35 Nm)

Stator Cover Bolt Tighten Sequence

3.4

Oil Filter / Pressure Relief / Dipstick Assembly Exploded View

A. Clamp B. Oil Fill Tube C. Dipstick D. O-ring E. Hex Plug F. Oil Filter Nipple G. Oil Filter H. Dowel I. Ga l l ey P l u g As m . J. Screw K. Relief Spring

ENGINE

22  2 ft. lbs. (30  3 Nm)

50  5 in. lbs.

(5.65 0.56 Nm)

18  2 ft. lbs.

(24.4  2.71 Nm)

35  4 ft. lbs.

(47.5  5.4 Nm)

50  5 in. lbs.

(5.65  0.56 Nm)

3.5

ENGINE

Cylinder / Cylinder Head / Piston Exploded View

 Lubricate threads & between

washers and underside of bolt heads with engine oil. Torque in sequence pro vided .

Apply Moly Lube grease to

valve tips.

Gasket free of oil. V erify tabs are

visible.

Apply thin film of 0W- 40 to

25-55 mm of cylinder bore.

 Apply 0W-40 to piston pin or pin

bore.

Apply 0W- 40 to lifters.

Do Not install expansion plug more than 1.5 mm inward.

1.5 mm

(Apply each Bolt Threads)

22 ± 2 ft. lbs. (30 ± 3 Nm)

Initial:

 4 ft. lbs (47.5  5.5 Nm)

35 in sequence. Finalize sequence

by tightening an additional 90 (1/4 turn)

  

  

Head Bolt Tighten Sequence

Side View

A. Head Bolts B. Rocker Arms C. He ad A ss em bl y D. Gasket E. Pushrods F . Bushing G. Expansion Plug H. Cylinder I. Piston Assembly J. Circlip K. Gasket L. Hydraulic Lifter

Apply Polaris 0W-40 Oil

Apply Moly Lube Grease

Circlip UP

for Install

3.6

Engine Sensors / Valve Cover / General Component Exploded View





ENGINE





A. Screws B. Rocker Cover C. Breather D. O-ring Seal E. Breather Bolts F. Spark Plugs G. Intake Boot H. Bolts I. Boot Clamp J. Throttle Body K. Crank Position Sensor L. Thermistor M. O-ring N. Thermostat O. Bolts P. Gasket Q. Exhaust Manifold R. Bolts S. Thermostat Housing





20  5 in. lbs. (2.5  0.55 Nm)

18  2 ft. lbs. (24.5  2.7 Nm)

20  5 in. lbs. (2.5  0.55 Nm)

Apply Corrosion Resistant Grease

84  8 in. lbs. (9.5  0.9 Nm)

18  2 ft. lbs. (24.5  2.7 Nm)

(Apply Dielectric Grease to threads of Spark Plug)

84  4 in. lbs. (9.5  0.9 Nm)

18  2 ft. lbs. (24.5  2.7 Nm)

17  2 ft. lbs.

(23  3 Nm)

84  8 in. lbs. (9.5  0.9 Nm)

3.7

ENGINE

EFI Harness / Fuel Injection Exploded View

A. Fuel Injector B. Fuel Rail C. EFI Harness

18  2 ft. lbs.

(24.5  2.7 Nm)

3.8

NOTE: See Chapter 4 for more information on the EFI system.

Engine Fastener Torque Patterns

Crankcase Bolt Tighten Sequence

ENGINE

22  2 ft. lbs. (30  3 Nm)

Cylinder Head Bolt Tighten Sequence

Lubricate threads and between washer and underside of bolt with engine oil. Torque in sequence to spec provided, allow the gasket to set for 1 minute, th en

tighten in sequence 90

35  4 ft. lbs. (47.5  5.5 Nm)

 (1/4 turn).

+ 90

 (1/4 turn)

3.9

ENGINE

Torque Specifications

Engine Torque Specifications

Fastener Size in. lbs. (Nm) ft. lbs. (Nm)

Camshaft Gear 8 mm 22 ± 2 (30 ± 3) Camshaft Thrust Plate 6 mm 115 ± 12 (13 ± 1.35) 9.5 ± 1 (13 ± 1.35) Throttle Body Adaptor Bolts 8 mm 216 ± 24 (24.5-± 2.7) 18 ± 2 (24.5 ± 2.7) Counterbalance Gear 8 mm 22 ± 2 (30 ± 3) Crankcase Bolts 8 mm * 22 ± 2 (30 ± 3) Crankcase Breather 5 mm 20 ± 5 (2.5 ± 0.55) Cylinder Head Bolts 11 mm * 35 ± 4 (47.5 ± 5.5) Exhaust Manifold 8 mm 216 ± 24 (24.5 ± 2.70) 18 ± 2 (24.5 ± 2.7) Flywheel 14 mm 65 ± 7 (88 ± 9.50) Injector Rail 8 mm 216 ± 24 (24.5 ± 2.70) 18 ± 2 (24.5 ± 2.7) Magneto Cover 6 mm * 96 ± 3 (10.8 5 ± 0.35) Oil Baffle Weldment 5 mm 60 ± 6 (6.8 ± 0.68) Oil Drain Bolt (Crankcase) 12 mm 192 ± 24 (21.7 ± 2.7) 16 ± (21.7) Oil Fill Tube Bolt 5 mm 50 ± 5 (5.64 ± 0.56) Oil Filter Pipe Fitting 20 mm 35 ± 4 (47.5 ± 5.4) Oil Pick Up 5 mm 60 ± 6 (6.8 ± 0.68) Oil Pressure Relief Plug 10 mm 22 ± 2 (30 ± 3) Oil Pump Housing Screw 6 mm * 84 ± 8 (9.50 ± 0.90) Rocker Arm 8 mm * 22 ± 2 (30 ± 3) Rocker Cover 6 mm * 84 ± 8 (9.5 ± 0.9) Spark Plug 14 mm 216 ± 24 (24.5 ± 2.7) 18 ± 2 (24.5 ± 2.7) Starter Motor 6 mm * 84 ± 8 (9.5 ± 0.9) Stator Assembly 6 mm 96 ± 3 (10.85 ± 0.35) Stator Housing 6 mm * 96 ± 3 (10.8 5 ± 0.35) Temperature Switch 3/8 NPT 17 ± 2 (23 ± 3) Thermostat Housing 6 mm 84 ± 8 (9.5 ± 0.9) Timing Plug 3/4-16 7 - 9 (10 - 12) Trigger Coil/Stator Wire Holddown 5 mm * 96 ± 3 (10.85 ± 0.35) Water Pump Housing Cover 6 mm * 96 ± 3 (10.85 ± 0.35) Water Pu mp Impeller Nut 8 mm 108 ± 3 (12 ± 0.35) -

NOTE: * See exploded views for notes or torque sequences.

3.10

700 EFI Engine Service Specifications

Cylinder Head - Engine Specifications

Main Component: Cylinder Head EH068OLE

Cam Lobe Height - Intake / Exhaust 1.3334" (33.8674 mm) Camshaft Journal Outer Diameter - Mag 1.654"  0.00039" (42  0.010 mm) Camshaft Journal Outer Diameter - Center 1.634" 0.00039" (41.50  0.010 mm)

ENGINE

Camshaft Journal Outer Diameter - PTO 1.614"  0.00039" (41  0.010 mm)

Camshaft

Counter Balance Counter Balance End Play 0.0 05" (0.127 mm)

Cylinder Head

Valve Seat

Valve Guide

Camshaft Journal Bore Inner Diameter - Mag 1.656"  0.00039" (42.07  0.010 mm) Camshaft Journal Bore Inner Diameter - Center 1.637"  0.00039" (41.58  0.010 mm) Camshaft Journal Bore Inner Diameter - PTO 1.617"  0.0003 9" (41 .0 7  0.010 mm) Camshaft Oil Clearance 0.00276"  0.00079" (0.07  0.02 mm) Camshaft End Play 0.0167"  0.0098" (0.425  0.25 mm)

Cylinder Head - Surface warp limit 0.00394" (0.1 mm) Cylinder Head - Standard height 3.478" (88.3 5 mm )

Valve Seat - Contacting Width - Intake

Valve Seat - Contacting Width - Exhaust

Valve Seat Angle 45.5  0.255 Valve Guide Inner diameter 0.2367"  0.00029" (6.012  0.007 mm) Valve Guide Protrusion Above Head 0.807"  0.0039" (20.50  0.01 mm)

0.0472"  0.00787" - 0.0039" (1.20  0.20 - 0.10mm)

0.0591"  0.00787" - 0.0039" (1.50  0.20 - 0.10 mm)

Valve

Valve Spring

Valve Margin Thickness - Intake

Valve Margin Thickness - Exhaust

Valve Stem Diameter - Intake 0.2356"  0.00039" (5.985  0.01 mm) Valve Stem Diameter - Exhaust 0.2351"  0.00039" (5.972  0.01 mm) Valve Stem Oil Clearance - Intake 0.0022 8"  0.00098" (0.058  0.025 mm) Valve Stem Oil Clearance - Exhaust 0.00275"  0.00098" (0.0870  0.025mm) Valve Stem Overall Length - Intake 4.51"  0.01476" (114.5550  0.375 mm) Valve Stem Overall Length - Exhaust 4.5453"  .01496" (115.45  0.38 mm) Valve Spring Overall Length - Free Length 1.735" (46.069 mm )

Valve Spring Overall Length - Installed Height

Standard: 0.79" (20.06 mm) Max- 0.98" (24.89 mm) Min.- 0.59" (14.98 mm)

Standard: 0.80" (20.32 mm) Max- 1.0" (25.4 mm) Min.- 0.60" (15.24 mm)

Intake - 1.4638" (37.18 mm) Exhaust - 1.4736" (37.43 mm)

3.11

ENGINE

Cylinder / Piston - Engine Specifications

Main Components: Cylinder / Piston / Connecting Rod EH068OLE

Cylinder

Lifter

Piston

Piston Pin

Cylinder - Surface warp limit (mating with cylinder head)

Cylinder Bore - Standard 3.1495" (80 mm) Cylinder Taper Limit 0.00031" (0.008 mm) Cylinder Out of Round Limit 0.00030" (0.0075 mm) Cylinder to Piston Clearance .0015"  .00059" (.040  .015mm)

Lifter Outer Diameter Standard 0.84245"  0.00025" (21.39 8  0.00635 mm) Lifter Block Bore 0.8438"  0.00062" (21.4322  0.0157 mm) Piston - Standard 3.1477"  .000121" (79.954  .003mm) Piston Standard Inner Diameter of

Piston Pin Bore Piston Pin Outer Diameter 0.7874" - 0.7872" (20 - 19.995 mm) Piston Pin - Standard Clearance - Piston Pin to

Pin Bore Piston Pin - Degree of Fit Piston pin must be a push fit (by hand) at 68 F (20 C)

0.004" (0.10 mm)

0.78789"  .00009" (20.0125  0.003 mm)

0.00059"  0.0002" (0.015  0.005 mm)

Piston / Connecting Rod / Crankshaft - Engine Specifications

Main Components: Piston / Connecting Rod EH068OLE

T op Ring - Standard 0.0059 0.138" (0.15 0.35mm) Top Ring - Limit > 15% Leakdown

Installed

Gap

Piston Ring

Ring to Groove

Clearance

Connecting Rod

Crankshaft Crankshaft Runout Limit 0.00236" (0.060mm)

Second Ring - Standard 0.0098  0.197" (0.25 0.50mm) Second Ring - Limit > 15% Leakdown Oil Ring - Standard 0.0196 0.00984" (0.50 0.25mm) Oil Ring - Limit > 15% Leakdo wn T op Ring - Standard 0.0024"  0.0008" (0.060  0.020 mm) Top Ring - Limit > 15% Leakdown Second Ring - Standard 0.0028"  0.0008" (0.070  0.020 mm) Second Ring - Limit > 15% Leakdown

Connecting Rod Small End I.D. 0.789" 0.78841" (20.030  20.015 mm)

Connecting Rod Small End

Radial Clearance

Connecting Rod Big End

Side Clearance

Connecting Rod Big End

Radial Clearance

0.0098" 0.00039" (0.025  0.010mm)

0.01181" 0.005 91" (0.030  0.015mm)

0.0015" 0.00006" (0.0038  0.0015mm)

3.12

Special Tools

ENGINE

Part Number Tool Description

PV-43527 OIL FILTER WRENCH

2200634 VALVE SEAT RECONDITIONING KIT

PU-45257 VALVE SPRING COMPRESSOR

PU-45652 VALVE PRESSURE HOSE

2871043 FLYWHEEL PULLER

2870390 PISTON SUPPORT BLOCK

PU-45497-1 CAM GEAR SPRING INSTALLATION KIT

PU-45497-2 CAM GEAR TOOTH ALIGNMENT TOOL

PU-45498 CAM SPANNER WRENCH

PU-45838 GEAR HOLDER

PA-44995 WATER PUMP MECHANICAL SEAL INSTALLER

PU-45543 UNIVERSAL DRIVER HANDLE

PA-45483 MAIN SEAL INSTALLER

PU-45658 CRANKSHAFT MAIN SEAL SAVER

PA-45401 WATER PUMP SEAL SAVER

2870975 MITY VAC

PU-45778 OIL SYSTEM PRIMING TOOL

 PRESSURE TEST TOOL

GENERAL ENGINE SERVICE

Accessible Components

Following Components can be serviced or removed with th e engine installed: (See Page 3.17 for 6x6 Valve Cover R & R)

• Flywheel

• Alternator (Stator)

• Starter Motor/Drive

• Cylinder Head (6x6: See Page 3.17)

• Cylinder (6x6: See Page 3.17)

• Piston / Rings (6x6: See Page 3.17)

• Camshaft (6x6: See Page 3.17)

• Rocker Arms (6x6: See Page 3.17)

• Oil pump / Water Pump / Oil Pump Drive Gear

• Gear Train Components

Following Components Require Engine Removal for service:

• Counterbalance Shaft or Bearings

• Connecting Rod

•Crankshaft

Piston Identification

Four stroke engine rings have a rectangular profile. See “PISTON RING INST ALLED GAP” for ring installation. Use the information below to identify pistons and rings.

Engine Model Piston Diameter

EH068OLE 80 mm

Cooling System Specifications

Condition Specification

Thermostat Open 180° F (8° C Thermostat Full Open Lift 6 mm at 203° F (95° C) Thermostat Closed 171° F (77° C ) System Capacity 3.25 Quarts (2.13L) Radiator Cap Pressure Relief 13 PSI

Polaris Premium Antifreeze

2871534 - Quart

2871323 - Gallon

• Crankshaft Main Bearings

• Crankcase

3.13

ENGINE

Recommended Coolant

Use only high quality antifreeze/coolant mixed with distilled water in a 50/50 or 60/40 ratio, depending on freeze protection required in your area. CAUTION: Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine dam age. Polaris Premium 60/40 Antifreeze/Coolant is recommended for use in all cooling systems and comes pre-mixed, ready to use.

Radiator

Thermostat

Cylinder

Head

Water Pump

Cylinder

Radiator Cap Pressure Test

WARNING

Never remove radiator cap when engine is

warm or hot. The cooling system is under

pressure and serious burns may result.

Allow the engine and cooling system to cool

before servicing.

1. Remove radiator cap and test cap using a commercially available cap tester.

2. The radiator cap relief pressure is 13 psi. Replace cap if it does not meet this specification.

Radiator Cap

Cooling System Pressure Test

1. Open front hood.

2. Remove surge tank hose from coolant filler neck.

3. Connect a Mity Vac nipple and pressurize system to 10 psi. The system must retain 10 psi for five minutes or longer. If pressure loss is evident within five minutes, check the radiator, hoses, clamps and water pump seals for leakage.

Coolant Flow Diagram

 (PN 2870975) to the filler neck

Surge Tank

From

Thermostat Housing

3.14

To Water Pump

Radiator

Cooling System Exploded View

ENGINE

Engine Inlet Hose

Surge Tank

Fan

Shroud

Engine Outlet Hose

Drain Plug

Radiator Inlet Hose

Radiator Outlet Hose

Radiator Cap

Radiator

Cooling System Bleeding Procedure

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.

NOTE: If the coolant level is LOW in the radiator, or if there are leaks in the system, the coolant system will not draw coolant from the reservoir tank.

NOTE: Use this procedure when a unit overheats and no apparent leaks in the cooling system are found.

PROCEDURE 1:

1. Park machine on a flat surface. Place the vehicle in Neutral and set the parking brake.

CAUTION

Be sure the engine has cooled and there is no

pressure built up in the cooling system before

removing the radiator cap. The coolant may be

hot and could cause severe injury or burns.

2. Remove radiator cap (A) and top off coolant.

3. Remove surge tank fill cap (B) and fill the surge tank to the full line.

3.15

ENGINE

4. Leave the cap off of the radiator to allow any possible air to escape. Start the engine and let it idle for 5-10 minutes or until the thermostat opens and allows coolant to flow through the system.

5. Slightly loosen the bleed screw (C) on the thermostat cover to let air escape. If no air is present, a steady stream of coolant will stream out. If air is present, the screw will bubble and sputter as the air escapes.

Top LH Side of Engine

6. Squeeze the coolant lines by hand to help purge the system of air.

7. Add Polaris Premium Antifreeze to the radiator if the level goes down.

8. Tighten the bleed screw to 70 ± 10 in.lbs. (8 ± 1.13 Nm) on the thermostat housing and properly install the radiator cap.

WARNING

Be sure to install the radiator cap before

shutting off the engine.

Coolant may spit out of the radiator.

9. Stop the engine and let cool, top off the radiator filler neck with coolant. If you hear or see a “glug” at the filler neck or there is a dropping of the coolant level, indicating that coolant has been pulled into the system. Fill the surge tank only after you have completely filled the cooling system at the radiator filler neck.

10. Repeat this procedure, if overheating still occurs. If overheating occurs after repeating this procedure, proceed to Procedure 2.

PROCEDURE 2:

1. Drive the machine onto a slight incline or use properly weight rated ramps. Place the machine in Neutral and set the parking brake. Block the rear wheels. The radiator neck should be above the level of the top of the engine.

CAUTION

Be sure the engine has cooled and there is no

pressure built up in the cooling system before

removing the radiator cap. The coolant maybe

hot and could cause severe injury or burns.

2. Remove radiator cap and top off coolant. Fill the surge tank to the full line.

3. Leave the cap off of the radiator to allow any possible air to escape. Start the engine and let it idle for 5-10 minutes or until the thermostat opens and allows coolant to flow through the system.

NOTE: If there is air in the system you will see air bubbles forming through the radiator fill neck.

4. Add coolant as needed. If no bubbles are seen at the filler neck, the system should be purged of air.

5. Install the radiator cap and turn off the machine.

WARNING

Be sure to install the radiator cap before

shutting off the engine.

Coolant may spit out of the radiator.

3.16

ENGINE

Valve Cover Removal - 6x6 Models (Engine Installed)

The RANGER 6x6 models have a different engine mounting system that makes it more difficult to access and remove the engine valve cover. Use the procedure provided in this section of the chapter to remove the valve cover and allow for engine top-end component service.

1. Remove the seat base.

2. Remove the clamp from the valve cover breather hose and remove the hose and valve cover vent.

Screws (7)

Breather Hose

Vent

3. Remove the 7 screws that retain the valve cover.

4. Remove the front dog house cover located in the floor panel of the RANGER. The valve cover will have to be removed through the dog house.

Floor Panel

Valve Cover

Dog House

Cover

5. Remove the heat shield shown below and loosen the exhaust mounts.

Loosen Remove

6. Remove the upper engine mount.

7. Loosen the lower engine mount bolts, but DO NOT completely remove them.

8. Remove the front engine mount bolts from the engine case.

NOTE: You may need to support the engine during this step by using a jack or by using wooden blocks between the engine and frame.

Upper Mount

Remove

Lower Mount

Loosen

9. Move the engine to allow the valve cover to be removed through the dog house cover hole.

10. To reinstall, reverse steps 1-9. Torque all bolts to specification as listed earlier in this chapter.

NOTE: It may be necessary to use a pry bar to get the bolts back in during reassembly.

Front Mount

3.17

ENGINE

Engine Removal

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.

1. Clean work area.

2. Thoroughly clean the engine and chassis.

3. Disconnect battery (-) negative cable.

4. Remove the following parts as required:

• Seat

• Storage unit under driver seat (Refer to chapter 5)

5. Remove middle dog house cover and remove exhaust pipe bolts.

12. Disconnect the air intake hose (D) from the air b ox and remove the air intake hose.

13. Disconnect the Throttle Position Sensor at the electrical connector (E). Remove the clamps that secure the throttle body (F) to the air intake boot and engine intake boot. Remove the throttle body (F). Insert a shop towel into the engine intake to prevent dirt from entering the intake port.

6. Remove springs from exhaust pipe and remove pipe.

7. Refer to PVT System in Chapter 6 to remove o uter clutch cover, drive belt, drive clutch, driven clutch, and inner cover.

8. Drain coolant and engine oil.

9. Remove the air breather line (A).

10. Remove PV T exhaust duct (B).

11. Remove the exhaust shield (C).

3.18

14. Relieve the fuel pressure in the fuel rail (refer to Chapter 4, “FUEL INJECTION”) for proper procedure. Carefully remove the fuel rail (G) and injectors.

15. Remove the sp ark plug high tension leads (H).

ENGINE

16. Remove the crank posit ion sensor (I) located on the mag cover.

17. Disconnect the coolant temperature sensor (J) from the left side of the cylinder.

NOTE: Use caution when lifting the engine out of frame. Use an engine lift or other means if the engine is too heavy to be lifted manually.

22. For engine installation, rev erse procedures.

Engine Installation Notes

18. Disconnect the coolant hoses. Properly dispose of any antifreeze from the engine or hoses.

19. When removing starter cables, note and mark ground cable and positive (+) cable mounting angle and locations. Remove the cables.

20. Remove all engine mount nuts and / or engine mount plates.

21. With all hoses and wires disconnected, the engine can be pulled straight out of the chassis.

NOTE: Rotating the engine to the left 90 degrees (valve cover facing left), may ease engine removal.

After the engine is installed in the frame, review this checklist and perform all steps that apply:

General Items

1. Install previously removed components using new gaskets, seals, and fasteners where applicable.

NOTE: Properly route all electrical harnesses and re-attach any fasteners or protective tubing. Check for any possible rubbing points of electrical wires.

2. Perform regular checks on fluid levels, controls, and all important areas on the vehicle as outlined in the daily preride inspection checklist (refer to Chapter 2 or the Owner's Manual).

PVT System

1. Adjust center distance of drive and driven clutch. (Chapter 6)

2. Adjust clutch offset, alignment, and belt deflection. (Chapter 6)

3. Clean clutch sheaves thoroughly and inspect inlet and outlet ducts for proper routing and sealing. (Chapter 6)

Transmission

1. Inspect transmission operation and adjust linkage if necessary. Refer to Chapter 2 and Chapter 8.

3.19

ENGINE

Exhaust

1. Replace exhaust gaskets. Seal connections with high temp silicone sealant.

2. Check to be sure all springs are in good condition.

Bleed Cooling System

NOTE: Follow coolant bleeding procedure outlined earlier in this chapter

Engine Break-In Period

The break-in period for a Polaris RANGER engine is defined as the first ten hours of operation, or the time it takes to use two full tanks of gasoline. No single action on your part is as important as a proper break-in period. Careful treatment of a new engine will result in more efficien t performance and longer life for the engine. Perform the following procedures carefully.

CAUTION

Use only Polaris Premium 0-40W All Season

synthetic oil or equivalent.

Never substitute or mix oil brands.

Serious engine damage and voiding of

w a r r a n t y c a n r e s u l t .

Do not operate at full throttle or high speeds for

extended periods during the first three hours of

use. Excessive heat can build up and cause

damage to close fitted engine parts.

1. Fill fuel tank with unleaded or leaded fuel which has a minimum pump octane number of 87= (R+ M)/2.

2. Check oil level indicated on dipstick. Add oil if necessary (Refer to Chapter 2, “Engine Oil Level” ).

Cylinder Hone Selection And Honing Procedure

Cylinders may be wet or dry honed depending upon the hone manufacturer’s recommendations. Wet honing removes more

material faster and leaves a more distinct pattern in the bore.

CAUTION

A hone which will straighten as well as remove

material from the cylinder is very important.

Using a common spring loaded glaze breaker

for honing is not advised for nicasil cylinders.

Polaris recommends using a rigid hone or arbor

honing machine. Cylinders may be wet or dry

honed depending upon the hone manufacturer's

recommendations.

Wet honing removes more material faster and

leaves a more distinct pattern in the bore.

Honing To Deglaze

A finished cylinder should have a cross-hatch pattern to ensure piston ring seating and to aid in the retention of the fuel/oil mixture during initial break in. Hone cylinder according to hone manufacturer's instructions, or these guidelines:

• Honing should be done with a diamond hone. Cylinder could be damaged if the hone is not hard enough to scratch the nicasil lining.

• Use a motor speed of approximately 300-500 RPM, run the hone in and out of the cylinder rapidly until cutting tension decreases. Remember to keep the hone drive shaft centered (or cylinder centered on arbor) and to bring the stones approximately 1/2, (1.3 cm) above and below the bore at the end of each stroke.

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. Pull only light loads during initial break in.

6. Pull only light loads during initial break-in.

7. Change oil and oil filter after break-in period at 25 hours.

3.20

• Release the hone at regular intervals and inspect the bore to determine if it has been sufficiently de-glazed, and to check for correct cross-hatch.

NOTE: Do not allow cylinder to heat up during honing.

• After honing has been complet e d, in spect cylinder for thinning or peeling.

ENGINE

If cylinder wear or damage is excessive, it will be necessary to replace the cylinder. The cylinders are lined with a nicasil coating and are not repairable. Hone only enough to de-glaze the outer layer of the cylinder bore.

Example of Cross Hatch Pattern

IMPORTANT: Clean the cylinder after honing

Oil Pressure Test

1. Remove blind plug/sender from left side of crankcase.

2. Insert a 1/8 NPT oil pressure gauge adaptor into the crankcase and attach the gauge.

3. Start engine and allow it to reach operating temperature, monitoring gauge indicator.

NOTE: Use only Polaris Premium 0W-40 Synthetic Engine Lubricant.

Oil Pressure at 5500 RPM (Engine Hot):

Standard: 39 PSI

Minimum: 35 PSI

Cleaning the Cylinder After Honing

It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material. Wash the cylinder in a solvent, then in hot, soapy water. Pay close attention to areas where the cylinder sleeve meets the aluminum casting (transfer port area). Use electrical contact cleaner if necessary to clean these areas. Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris Lubricant.

Engine Lubrication Specifications

Capacity - Approximately 2 U.S. Quarts (1.9 l)

Oil Type - Polaris Premium 0W-40 Synthetic

Filter Wrench - PV-43527 or equivalent

- Oil Pressure Specification -

35-39 PSI @ 5500 RPM, Polaris 0W-40

Synthetic, Engine at operating temperature.

3.21

ENGINE

Oil Flow Chart

This chart describes the flow of oil through the 700 engine. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through the oil filter. If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element. At this point, the oil is supplied to the main oil galley through a crankcase passage. Oil is then diverted three ways from the main oil galley, with the first path entering the camshaft bores, onto the rear balance shaft journal and then draining back into the crankcase sump. The second oil path from the main oil galley feeds the lifter bores and then drains back to the crankcase sump. The third oil path flows through a crankcase galley to the MAG side crankshaft journal and also

to the front balance shaft journal and onto the crankcase sump. The oil pressure switch is fed off the main oil galley.

3.22

ENGINE DISASSEMBLY AND INSPECTION

Cylinder Head Assembly Exploded View

Rocker Arms

Retainer Locks (keepers)

Spring Retainers

Springs

ENGINE

Push Rods

Valve Spring Seats

Cylinder Head

Valves

Valve S eals

Hydraulic Lifters

3.23

ENGINE

Rocker Arms

1. Mark or tag rocker arms in order of disassembly to keep them in order for reassembly.

2. Inspect the wear pad at the valve end of the rocker arm for indications of scuffing or abnormal wear. If the pad is grooved, replace the rocker arm.

NOTE: Do not attempt to true this surface by grinding.

3. Check the rocker arm pad and fulcrum seat for excessive wear, cracks, nicks or burrs.

5. If the push rod (A) is visibly bent, it should be replaced.

Cylinder Head Removal

1. Loosen the six cylinder head bolts evenly 1/8 turn each in a criss-cross pattern until loose.

2. Remove bolts (A) and tap cylinder head (B) lightly with a soft face hammer until loose. CAUTION: Tap only in reinforced areas or on thick parts of cylinder head casting to avoid damaging the head or cylinder.

3. Remove cylinder head (B) and head gasket (C) from the cylinder (D).

Push Rods

1. Clean push rods (A) in a suitable solvent. Blow dry push rods with compressed air.

2. Use compressed air to confirm the oil passage is clear in the center of the push rod.

WARNING

Always wear safety glasses when working with

compressed air to prevent personal injury.

3. Check the ends of the push rods (A) for nicks, grooves, roughness or excessive wear.

4. The push rods (A) can be visually checked for straightness while they are installed in the engine by rotating them with the valve closed. Push rods can also be checked with a dial indicator or rolled across a flat surface to check for straightness.

3.24

ENGINE

Cylinder Head Inspection

Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon.

CAUTION

Use care not to damage sealing surface.

Cylinder Head Warp

1. Lay a straight edge (A) across the surface of the cylinder head (B) 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.

Valve Seal / Spring Service (On Engine)

NOTE: The following procedure is only for servicing the top end of the valve train when replacing valve springs or replacing valve seals.

In some cases the valve train can be serviced while the cylinder head is still on the engine. Keep all parts in order with respect to their location in the cylinder head.

WARNING

Wear eye protection or a face shield during

cylinder head disassembly and reassembly.

1. Having already removed the valve cover, rocker arms and pushrods, align the cylinder to be worked on at top dead center (TDC). Install the Valve Pressure Hose (PU-

45652) into the spark plug hole. Hook the hose to an air compressor and supply 50 to 100 psi to the hose. This will seat the valves during valve spring removal. Do not remove air from the hose at anytime until reassembly is completed.

Measure at different

points on the surface.

Cylinder Head Warp Limit:

.004" (.1016 mm) max

= In. / mm.

2. Using the Valve Spring Compressor (PU-45257), compress the valve spring and remove the valve keepers.

NOTE: A small parts magnet (A) can aid in the removal of the retainers (B).

PU-45257

NOTE: To prevent damage to the valve seals, do not compress the valve spring more than is needed to remove the valve keepers.

3. Remove spring retainer and spring.

4. The valve seals are now serviceable.

3.25

ENGINE

Cylinder Head Disassembly

1. Carefully remove the cylinder components.

2. Place the hydraulic lifters (C), pushrods (D), and rocker arms (E) in a safe, clean area.

4. Remove valve guide seals.

IMPORTANT: It is recommended to replace seals whenever the cylinder head is disassembled. Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup.

5. Mark the valves with a white pen. Remove the valves from the cylinder head. This will ensure that the valves are properly placed during engine reassembly.

Mark the Valves

3. Measure free length of spring with a Vernier caliper. Compare to specifications. Replace spring if measurement is out of specification.

V alve Spring

Free Length

= In. / mm.

Valve Spring Free Length:

Std: 1.735" (44.069 mm)

3.26

Valve Inspection

ENGINE

1. Remove all carbon from valves with a soft wire wheel or brush.

2. Check valve face for runout, pitting, and burnt spots. To check for bent valve stems, mount valve in a drill or use “V” blocks and a dial indicator.

3. Check end of valve stem for flaring, pitting, wear or damage (A).

= In. / mm.

Valve Stem Diameter:

Intake: 0.2356" + 0.00039"

(5.985 + 0.01 mm)

Exhaust: 0.2351" + 0.00039"

(5.972 + 0.01 mm)

6. Measure valve guide (C) inside diameter at the top middle and end of the guide using a small hole gauge and a micrometer. Measure in two directions.

4. Inspect split keeper groove for wear or flaring of the keeper seat area (B).

NOTE: The valves can be re-faced or end ground, if necessary. They must be replaced if extensively worn, burnt, bent, or damaged.

5. Measure diameter of valve stem with a micrometer in three places, then rotate 90 degrees and measure again (six measurements total). Compare to specifications.

Measure valve stem in several places. Rotate the valve 90 degrees and measure for wear.

= In. / mm.

Valve Guide I.D.:

0.23672" + 0.000295" (6.0617 + 0.0075 mm)

7. Subtract valve stem measurement from the valve guide measurement to obtain stem to guide clearance. NOTE: The valve guides cannot be replaced. Be sure to measure each guide and valve combination individually.

3.27

ENGINE

Combustion Chamber

1. Clean all accumulated carbon deposits from combustion chamber and valve seat area with carbon cleaner and a soft plastic scraper.

IMPORTANT: Do not use a wire brush, metal scraper, or abrasive cleaners to clean the bottom of the cylinder head. Extensive damage to the cylind er head may result. Wear safety glasses during cleaning.

Combustion Area

NOTE: Valve seat width and point of contact on the valve face is very important for proper sealing. The valve must contact the valve seat over the entire circumference of the seat, 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.

Valve Seat Reconditioning

NOTE: Polaris recommends that the work be done by a local machine shop that specializes in this area.

NOTE: The cylinder head valve guides cannot be replaced.

WARNING

Wear eye protection or a face shield during

cylinder head disassembly and reassembly.

Valve Seat Inspection

Inspect valve seat in cylinder head for pitting, burnt spots, roughness, and uneven surface. If any of the above conditions exist, the valve seat must be reconditioned. If the valve seat is

cracked the cylinder head must be replaced.

Follow the manufacturers instructions provided with the valve seat cutters in the Cylinder Head Reconditioning Kit (PN

2200634). Abrasive stone seat reconditioning equipment can

also be used. Keep all valves in order with their respective seat.

1. Install pilot into valve guide.

2. Apply cutting oil to valve seat and cutter.

3. Place 46

 cutter on the pilot and make a light cut.

3.28

ENGINE

4. Inspect the cut area of the seat: * If the contact area is less than 75% of the circumference of the

seat, rotate the pilot 180

* If the cutter now contacts the uncut portion of the seat, check the pilot. Look for burrs, nicks, or runout. If the pilot is bent it must be replaced.

* If the contact area of the cutter is in the same place, the valve guide is distorted from improper installation

* If the contact area of the initial cut is greater than 75%, continue to cut the seat until all pits are removed and a new seat surface is evident. NOTE: Remove only the amount of material necessary to repair the seat surface.

5. To check the contact area of the seat on the valve face, apply a thin coating of Prussian Blue paste to the valve seat. If using an interference angle (46 marker to the entire valve face (A).

 and make another light cut.

) apply black permanent

NOTE: When using an interference angle, the seat contact point on the valve will be very narrow, and is a normal condition. Look for an even and continuous contact point all the way around the valve face (A).

Proper Seat Contact

on Valve Face

Bottom 60

Seat 45

Top 30

6. Insert valve into guide and tap valve lightly into place a few times.

7. Remove valve and check where the Prussian Blue indicates seat contact on the valve face. The valve seat should contact the middle of the valve face or slightly above, and must be the proper width.

* If the indicated seat contact is at the top edge of the valve face and contacts the margin area (B) it is too high on the valve face.

Use the 30

* If too low, use the 60 area is centered on the valve face, measure seat width.

* If the seat is too wide or uneven, use both top and bottom cutters to narrow the seat.

* If the seat is too narrow, widen using the 45 check contact point on the valve face and seat width after each cut.

 cutter to lower the valve seat.

 cutter to raise the seat. When contact

 cutter and re-



Seat

Width

= In. / mm.

Valve Seat Width:

Intake Std: .028" (.7 mm)

Limit: .055" (1.4 mm)

Exhaust Std: .039I (1.0 mm)

Limit: .071" (1.8 mm)

3.29

ENGINE

8. Clean all filings from the area with hot soapy water, rinse, and dry with compressed air.

9. Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the valve.

NOTE: Lapping is not required with an interference angle valve job.

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.

Cylinder Head Reassembly

NOTE: Assemble the valves one at a time to maintain proper order.

1. Apply engine oil to valve guides and seats.

2. Coat valve stem with molybdenum disulfide grease or 0W-40 Synthetic oil.

3. Install valve carefully with a rotating motion to avoid damaging valve seal.

4. Valve seals should be installed after the valves are in the head to avoid valve seal damage. Install new valve seals on valve guides.

5. Dip valve spring and retainer in clean engine oil and install.

6. Place retainer on spring and install Valve Spring Compressor (PU-45257). Install split keepers with the gap even on both sides.

NOTE: A small magnet can be used to aid in the installation of the keepers.

PU-45257

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 valve(s).

12. Thoroughly clean cylinder head and valves.

7. Repeat procedure for remaining valves. When all valves are installed, tap lightly with soft faced hammer on the end of the valves to seat the split keepers.

NOTE: To prevent damage to the valve seals, do not compress the valve spring more than necessary to install the keepers.

3.30

ENGINE

Valve Sealing Test

1. Clean and dry the combustion chamber area (A).

2. Pour a small amount of clean solvent onto the intake port and check for leakage around each intake valve. The valve seats should hold fluid with no seepage.

3. Repeat for exhaust valves by pouring fluid into exhaust port.

Cylinder Removal

1. Follow engine disassembly procedures to remove rocker cover and cylinder head.

2. Tap cylinder (A) lightly with a rubber mallet in the reinforced areas only until loose.

3. Rock cylinder forward and backward while lifting it from the crankcase, supporting pistons and connecting rods. Support pistons with Piston Support Block (PN 2870390).

Valve Lifter Removal / Inspection

1. Remove the valve lifter's by reaching into the crankcase and pushing the lifter up through the lifter bore by hand.

2. Thoroughly clean the lifters in cleaning solvent and w ipe them with a clean lint-free cloth.

3. Mark the lifters with a white pen if using the lifters for reassembly. This will ensure that the lifters are properly placed during engine reassembly.

Mark Hydraulic Lifter

4. Check the lifters for wear or scores.

5. Check the bottom end of lifter to make sure that it has a slight convex.

6. If the bottom surface has worn flat, it may be used with the original camshaft only.

Inspect Hydraulic Lifter

NOTE: Lifters that are scored, worn, or if the bottom is not smooth should be replaced with new lifters and cam as an assembly. If replacing the lifters, the camshaft should also be replaced.

3.31

ENGINE

Piston Removal

1. Remove circlip (A). Mark the piston with a white pen to ensure proper orientation (if reused) during assembly.

NOTE: If the pistons are to be reused, reassemble the pistons in the same cylinder and direction from which they were removed.

NOTE: New pistons are non-directional and can be placed in either cylinder.

The oil control ring is a three piece design consisting of a top and bottom steel rail and a center expander section. The top rail has a locating tab on the end which fits into a notch (B) in the upper oil ring land of the piston.

To Remove:

A) Remove the top rail first followed by the bottom rail. B) Remove the expander.

Compression

Rings

Oil Ring

2. Remove piston circlip and push piston pin out of piston. If necessary, heat the crown of the piston slightly with a propane torch. CAUTION: Do not apply heat to the piston rings. The ring may lose radial tension.

3. Remove top compression ring:

*Using a piston ring pliers: Carefully expand ring and lift it off the piston. CAUTION: Do not expand the ring more than the amount necessary to remove it from the piston, or the ring may break.

*By hand: Placing both thumbs as shown, spread the ring open and push up on the opposite side. Do not scratch the ring lands.

4. Repeat procedure for second ring.

5. Remove the oil control ring.

3.32

ENGINE

Cylinder Inspection

1. Remove all gasket material from the cylinder sealing surfaces.

2. Inspect the top of the cylinder (B) for warp using a straight edge (A) and feeler gauge (C). Refer to Ill. 1 and Ill. 2.

Measure at different

points on surface.

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). Record measurements. If cylinder is tapered or out of round beyond .002", the cylinder must be replaced.

1/2” Down From Top of Cylinder

= In. / mm.

Cylinder Warp: .004" (0.1 mm) Max.

1/2” Up From Bottom

= In. / mm.

Cylinder Taper Limit:

.002" (9.05mm) Max.

Cylinder Out of Round:

Limit: .002" (.0 mm) Max.

700 Standard Bore Size

(Both Cylinders): 3.1496

" (80 mm)

3.33

ENGINE

Piston-to-Cylinder Clearance

Measure piston outside diameter at a point 5 mm up from the bottom of the piston at a right angle to the direction of the piston pin.

Subtract this measurement from the maximum cylinder measurement obtained in Step 5.

5 mm

Piston

Piston Pin

Piston to Cylinder Clearance:

See “700 EFI Engine Service

Specifications” on page 3.11

2. Measure piston pin O.D. Replace piston and/or piston pin if out of tolerance.

Piston Pin Measurement Locations

Piston Pin O.D.:

See “700 EFI Engine Service

Specifications” on page 3.11

3. Measure connecting rod small end ID.

Piston O.D.:

See “700 EFI Engine Service

Specifications” on page 3.11

Piston / Rod Inspection

1. Measure piston pin bore.

Piston Pin Bore:

See “700 EFI Engine Service

Specifications” on page 3.11

Connecting Rod Small End I.D.:

See “700 EFI Engine Service

Specifications” on page 3.11

3.34

ENGINE

4. Measure piston ring to groove clearance by placing the ring in the ring land and measuring with a thickness gauge. Replace piston and rings if ring-to-groove clearance exceeds service limits.

Piston

Ring

Feeler Gauge

See “700 EFI Engine Service

Specifications” on page 3.11

Piston Ring Installed Gap

1. Place each piston ring (A) inside cylinder (B) using piston to push ring squarely into place as shown.

3. If the bottom installed gap measurement exceeds the service limit, replace the rings. If ring gap is smaller than the specified limit, file ring ends until gap is within specified range.

NOTE: Always check piston ring installed gap after re-boring a cylinder or when installing new rings. A re-bored cylinder should always be scrubbed thoroughly with hot soapy water, rinsed, and dried completely. Wipe cylinder bore with oil immediately to remove residue and prevent rust.

Starter Drive Bendix Removal / Inspection

1. Remove stator housing bolts and remove housing.

2. Remove the flywheel nut and washer. Install Flywheel Puller (PN 2871043) and remove flywheel.

NOTE: Do not thread the puller bolts into the flywheel more than 1/4, or stator coils may be damaged.

3. Remove starter bendix assembly (A). Note the thrust washers located on both sides of the bendix.

25-50 mm

Piston Ring Installed Gap

See “700 EFI Engine Service

Specifications” on page 3.11

NOTE: Ring should be installed with the mark facing upward.

2. Measure installed gap with a feeler gauge (C) at both the top and bottom of the cylinder.

IMPORTANT: A difference in end gap indicates cylinder taper. The cylinder should be measured for excessive taper and out of round.

4. Inspect the thrust washer for wear or damage and replace if necessary.

5. After the bendix is removed, remove the two bo lts retaining the starter. Tap on the starter assembly (B) with a soft faced mallet to loosen the starter from the crankcase.

3.35

ENGINE

6. Inspect gear teeth on starter drive (A). Replace starter drive if gear teeth are cracked, worn, or broken.

7. Inspect the bendix bushing (C) in the mag co ver for wear. Replace as needed.

Flywheel / Stator Removal / Inspection

1. Remove stator housing bolts and remove housing.

2871043

4. Use caution when removing the wir e holddown (B) and the

stator assembly (D). Do not tap or bump the gear /stator housing cover or the stator. This could cause the seal around the gear/stator housing cover and the crankcase to break, causing a leak.

Remove Stator

Cover

2. Remove flywheel nut and washer.

3. Install Flywheel Puller (PN 2871043) and remove flywheel (A).

CAUTION

Do not thread the puller bolts into the flywheel

more than 1/4, or stator coils may be damaged.

5. Remove the bendix (E) if necessary.

Engine Crankcase Disassembly / Inspection

1. Remove the stator cover (A) and water pump cover (B).

3.36

ENGINE

2. Remove the nylok nut (C), washer (D), and water pump impeller (E). Remove part of the water pump seal behind the impeller.

3. Remove flywheel nut and washer.

4. Install Flywheel Puller (PN 2871043) and remove flywheel (F).

CAUTION

5. Remove the starter bendix (G), wire holddown plate (H), and the woodruff key (I) from the crankshaft. The stator does not have to be removed at this point.

6. Remove the gear/stator housing bolts and remove the gear/ stator housing cover (J) and gasket from the crankcase. Be sure to catch the excess oil from the crankcase.

Do not thread the puller bolts into the flywheel

more than 1/4, or stator coils may be damaged.

2871043

7. Note the positions of the gears in the photo.

Camshaft Gear

Crank Gear

Counterbalance Gear

3.37

ENGINE

8. Use a white pen to accent the timing marks on the following gears: camshaft gear (K), crankshaft gear (M), or counterbalance gear (N) This will ensure proper gear alignment and timing during reassembly of the gears.

Water Pump Gear

Timing Marks

CAUTION

Wear safety glasses at all times. Use caution

when working with the top gear.

The springs could cause injury or become lost

should they pop out.

12. Remove all three springs using one of the tapered pins from

the Tapered Pins (PU-45497-1).

NOTE: If replacing one of the gears, it is recommended that all of the gears be replaced. A gear kit is available in the parts book.

9. Use the Cam Gear Tooth Alignment Tool (PU-45497-2) (O) to align the cam split gear assembly. With the split gear aligned, remove the bolt and cam gear assembly.

NOTE: Install the Cam Gear Tooth Alignment Tool (PU-45497-2) into the assembly hole counter clockwise from the timing mark as shown.

10. Inspect the cam gear teeth and check to make sure there is spring tension offsetting the teeth between the two gears. If there is no tension, check the springs inside of the cam gear assembly.

3 Loaded Springs

PU-45497-1

13. With a white marking pen, accent the timing mark on the gear that contains the springs.

11. The cam gear assembly contains three loaded springs. To open the cam gear assembly:

* Place the cam gear on a flat surface with the timing mark side facing up.

* While holding both gears together, lightly work a small flathead screwdriver between the two gears.

* Remove the top gear. The springs should stay in place.

3.38

Accent Timing Marks

ENGINE

14. Inspect the gear teeth and the three tabs on the gears for wear.

Inspect Teeth & Tabs

Replace 3 Springs

15. Install the new springs into the grooves of the cam gear.

Install Springs

To Assemble:

* Hold the spring with one finger. * Start the pointed end of the tapered pin into the cam gear hole

and slowly push the dowel through the hole until the end of the dowel is almost flush with the spring.

* Perform this procedure with all three tapered pins. * Do not push the pins too far through or the springs will pop

out.

NOTE: Do not remove the tapered pins at this time.

17. Note in the photograph that the Tapered Pins (PU-45497-

1) are below flush with end of the springs. This helps to

align the three gear tabs during the next step.

16. Insert the pointed dowels from the Tapered Pins (PU- 45497-1) into the cam gear.

PU-45497-1

Cam Gear Spring Installation Tool Kit:

(PU-45497)

Tapered Pins:

(PU-45497-1)

Cam Gear Tooth Align Tool:

(PU-45497-2)

18. Line up the two gears using the timing marks and the three gear tabs that were referenced earlier. Push the gears back together, using both hands and hold securely.

Align Timing Marks

3.39

ENGINE

19. Once the gears are pressed together, firmly hold the gears together with one hand. Carefully remove the Tapered Pins (PU-45497-1) by pulling them out one at a time with the other hand.

20. After the tapered pins are removed, be sure the cam gear assembly is held together tightly. Place the cam gear assembly on a flat surface. Use the Cam Gear Tooth Alignment Tool (PU-45497-2) to align the teeth of the cam gears, as shown in the picture.

NOTE: Install the Cam Gear Alignment Tool (PU45497-2) into one assembly hole counter clockwise from the timing mark.

21. To remove the balance shaft gear, the flat side of the camshaft (P) must face the balance shaft gear. To rotate the camshaft, use the Cam Spanner Wrench (PU-45498) to rotate the camshaft so the flat side of the camshaft faces the balance shaft gear.

PU-45498

NOTE: This Cam Spanner Wrench (PU-45498) is only needed to rotate the camshaft when the entire valve train is assembled. If the rocker arms are removed, the cam-shaft can be turned by hand.

22. Remove t he bolt and nut from the balance shaft gear. Try to remove the balance shaft gear. If the gear does not come off manually, use the Flywheel Puller (PN 2871043) to remove the balance shaft gear.

PU-45497-2

NOTE: For ease of installing the Cam Gear Alignment Tool (PU-45497-2) (R), use a twisting motion when pushing down on the tool.

2871043

3.40

ENGINE

23. Inspect the crankshaft gear (Q) for broken or worn teeth. If the crankshaft gear does not need to be replaced, it does not need to be removed. If the crankshaft gear is damaged, remove the crankshaft gear with the Flywheel Puller

(PN 2871043).

24. Install the two puller bolts (R). Tighten the puller bolts up so that the bolts are at equal length.

26. Rotate the water/oil pump gear (S), so that all four bolts are visible though the gear. Remove the four bolts with a hex wrench. Pull out the pump.

27. Inspect the oil pump rotors for wear. Mark the rotors with a white pen to ensure upon reassembly that the correct sides of the rotors are installed and mesh with the same edges as previously installed.

Mark Rotors

25. Install the Flywheel Puller (PN 2871043) and remove th e

crankshaft gear, if needed.

2871043

NOTE: If replacing the old rotors, new replacement rotors will fit into the old oil/water pump housing.

28. Use a feeler gauge to measure the clearance between the two rotors. Measure the gap between the two rotor tips as shown below. The clearance should not exceed 0.006" (0.15 mm).

Max Tip Clearance

0.006” (0.15 mm)

3.41

ENGINE

29. Remove the oil pressure relief. The oil pressure relief consists of a bolt, washer, spring, and valve (dowel). Inspect the valve (dowel) for signs of possible obstructions. Use compressed air to blow out any debris.

30. Reinstall the valve (dowel chamfered end first). Install the spring, washer, and bolt. Torque to specification .

22 ± 2 ft. lbs. (30 ± 3 Nm).

31. Carefully press the gear off the assembly while supporting the housing assembly.

Press Off Gear

CAUTION

Wear appropriate safety gear during this

procedure. Protective gloves, clothing and eye

wear are required.

32. Remove the snap ring from the assembly. Place the housing in a support and press out the bearing/shaft assembly.

Chamfer

End First

= T

22  2 ft. lbs. (30  3 Nm)

NOTE: Be sure to place the tapered en d of the va lve (dowel) in first. If the valve is installed incorrectly, oil pressure and oil priming problems will occur.

Press out shaft

and bearing

assembly.

Bearing

Retaining Ring

33. Place the shaft in a press to remove the bearing.

Press Off Bearing

3.42

ENGINE

34. Press shaft into the new bearing..

Press On Bearing

35. Press the bearing/shaft assembly using the bearing's outer race. Do not use the shaft to press the assembly into the housing, as bearing damage may result. Install retaining ring.

Press Bearing / Shaft

Assembly using

outer race only

37. Remove thrust plate (U).

38. Remove PTO end engine mount. Remove crankcase bolts. Tap on the reinforced areas on the cases using soft hammer. Carefully separate the two crankcase halves.

Separate

Crankcase Halves

36. Press gear onto shaft while supporti ng the housing.

NOTE: Only remove the oil baffle if the baffle is damaged. When removing the oil baffle bolts, use a heat gun to heat the bolts and loosen the Loctite This will prevent any possible damage to the bolt s or to the crankcase casting.

39. Remove and clean oil pick up (V) and oil baffle weldment (W).

.

3.43

ENGINE

40. Remove balance shaft an d crankshaft.

41. Remove and inspect crankshaft main journal bearings for

abnormal wear. It is recommended to replace the bearings anytime the engine is disassembled.

Camshaft Inspection

1. Thoroughly clean the cam shaft.

2. Visually inspect each cam lobe for wear, chafing or damage.

3. Measure height of each cam lobe using a micrometer. Compare to specification.

Cam Lobe Height

= In. / mm.

Cam Lobe Height

(Intake & Exhaust):

Std: 1.3334" (33.8674 mm)

4. Measure camshaft journal outside diameters (O.D.).

= In. / mm.

3.44

Camshaft Journal O.D. :

A. (Mag): 1.654" ± .00039" (42 ± .010 mm)

B. (Ctr.): 1.634" ± .00039" (41.50 ± .010 mm)

C. (PTO): 1.614" ± .00039" (41 ± .010 mm)

ENGINE

5. Measure ID of camshaft journal bores.

= In. / mm.

Camshaft Journal Bore I.D.:

(Mag): 1.656" ± 0.00039" (42.07± 0.010 mm)

(Ct r. ) 1.637" ± 0 .0 0039" (4 1. 58 ± 0.010 m m)

(PTO) 1.617" ± 0.00039" (41.07 ± 0.010 mm)

6. Calculate oil clearance by subtracting journal O.D.'s from journal bore I.D.'s. Compare to specification.

= In. / mm.

Calculated Camshaft Oil Clearance:

Std: 0.0027" (.070mm) Limit: .0039" (.10 mm)

NOTE: Replace camshaft if damaged or if any part is worn past the service limit.

NOTE: Replace engine block if camshaft journal bores are damaged or worn excessively.

1. Install oil pick up (A), if removed. Torque to specification.

2. Install oil baffle weldment (B). Torque bolts to specification.

= T

Oil Baffle Weldment &

Oil Pick Up Bolt Torque:

60 ± 6 in. lbs. (6.8 ± 0.68 Nm)

3. Install the balance shaft. Inspect balance shaft clearance (C) in both gearcase halves. Rotate balance shaft to ensure that there is clearance between it and oil baffle weldment.

ENGINE REASSEMBLY

Crankcase Reassembly

CAUTION

After any reassembly or rebuild, the engine must

be primed using the Oil Priming Adapter (PU-

45778) and a 3/4-full oil filter before initial startup. Follow Steps 45-46 of this section to prime

the engine and to help aid proper break-in.

NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2870585) to remove any debris. This will ensure proper sealing when installing bolts.

NOTE: Always install new balance shaft bearings.

3.45

ENGINE

4. Apply assembly lube to cam journals and balance shaft bearing surfaces of the MAG case halve. Install camshaft and balance shaft.

5. Install crankshaft assembly and apply engine oil to crank pins and rods (D). Apply assembly lube to the main journals and bearings.

7. Assemble the crankcase halves. Apply LocTite™ 242 (PN

2871949) to the threads and pipe sealant to the bolt flanges. Torque bolts to specification following torque pattern at beginning of this chapter.

= T

Crankcase Bolt Torque:

22 + 2 ft. lbs. (30 + 3 Nm)

Torque in sequence

8. Lubricate cam lobes and valve lifters with Moly Lube Grease.

Apply Moly Lube

Cam Lobes

6. Apply Crankcase Sealant (PN 2871557) to the top gearcase

halve.

NOTE: Do not apply sealant to cam relief hole (E).

Lifters

9. Lubricate lifters with engine oil and install in the original order as removed in disassembly. Apply Lubricant or Moly Lube to the ends of the lifters.

NOTE: Always repl ace the camshaft and lifters as a set.

3.46

ENGINE

10. Lubricate connecting rods with 0W-40 eng ine oil .

11. Install new cylinder gasket on crankcase. Align gasket on the dowel pins for proper gasket alignment.

13. Install piston assem blies into cylinder aligning the piston pin holes, to ensure proper alignment of the pistons to the connecting rods upon assembly. Partially install the piston pins into the pistons.

NOTE: To help align the pistons, slide a rod that is close to the same diameter as the wrist pin holes to properly align them in the cylinder.

14. Position cylinder and piston assemblies onto the connecting rods and push the piston pins through the piston and connecting rods.

12. Orientate the pist on rings on the pisto n before installat ion into the cylinders. Set the gaps of the rings every 120° (See Illustration Below).

Piston Ring

Orientation

1. Top Ring

2. Second Ring

3. Oil Ring

2 3

Push in Piston Pins

15. Install the piston pin circlips. The circlip ends should be installed at the 12 O'clock position.

Piston Pin Cirlcip in

12 O’clock position

3.47

ENGINE

NOTE: While installing in piston circlips, cover all engine passages. The clip could fall into the engine during installation.

16. Install cam shaft thrust plate (G) with new bolts. Torque bolts to specification.

NOTE: New bolts have patch lock on the threads and do not require Loctite™.

17. Assemble rotors as marked when disassembled. Use a cleaner to remove the marks previously made on the rotors.

Line Up Marks

18. Appl y assembly lube or oil to the rotors on the oil pump shaft.

NOTE: The application of lubrication aids in priming the oil pump during initial engine start up.

Lubricate Rotors

= T

Thrust Plate Screw Torque:

115 ± 12 in.lbs. (13 ± 1.35 Nm)

19. Align the bolt holes and install oil pump assembly into crankcase. Rotate the rotors in the housing during installation, as this checks for binding if new rotors are used.

NOTE: For assembly of the gears, the cam gear and the crankshaft gear are stamped with “This Side Out." This indicates the side of the gear that faces outward or away from the case.

3.48

NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2870585) to remove any debris. This will ensure proper sealing when installing bolts and new Loctite™.

ENGINE

20. Inst all oil pump housing bolts (H). The new bolts contain patch lock, so Loctite Torque bolts to specification and follow the torque sequence at beginning of the chapter.

 is not needed on the new bolts.

NOTE: Occasionally spin the oil pump when installing bolts to check for binding of the rotors.

= T

Oil Pump Bolt Torque:

84  8 in.lbs. (9.50  0.90 Nm)

* Torque in Sequence

21. Apply Loctite 242 (PN 2871949) to the crankshaft.

22. Before installing the crankshaft gear (I), heat the crankshaft gear to 250 F (121C) on a hot plate (J).

CAUTION

The crankshaft gear is extremely hot! Severe

burns or injury can occur if the gear is not

handled with extreme care and caution. Follow

the procedure below to help ensure safety.

23. Use extreme caution when removing the crankshaft gear from the hot plate. Use a pair of pliers and leather gloves when handling the crankshaft gear.

24. Install the crankshaft gear (I) onto the crankshaft.

NOTE: For assembly of the gears, the cam gear and the crankshaft gear are stamped with This Side Ou t." This indicates the side of the gear that fac es outwar d or away from the case.

3.49

Polaris RANGER XP 700 4X4, 2008 ranger 700 xp Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual