Polaris 850-Hd-Eps 2009 Service Manual

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2009 Polaris Sportsman 850 EFi/HD/EPS series

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GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

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

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

VEHICLE IDENTIFICATION NUMBER (VIN). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . .1.2

VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

PUBLICATION NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3

REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

GENERAL: 2009 SPORTSMAN XP 850 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4

GENERAL: 2009 SPORTSMAN XP 850 EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4

DETAILED: 2009 SPORTSMAN XP 850 / XP 850 EPS. . . . . . . . . . . . . . . . . . . . . . . . . .1.5

MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

CONVERSION TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6

STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7

SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 .8

METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.8

DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.8

GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.9

1.1

GENERAL INFORMATION

VEHICLE IDENTIFICATION

Model Identification

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

Machine Model Number Identification

Y ear Designation

Engine Designation Number

EH085OLE.............................................................Twin Cylinder, 4-Cycle SOHC, Liquid Cooled, Electric Start

V ehicle Identification Number (VIN)

World

Mfg. ID

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

Vehicle Descriptor

A 0 9 Z N 8 5 A L

Basic Chassis

Designation

}

Engine Designation

}

Vehicle Identifier

Emissions & Model Option

}

Body Style

V e hicle and Engine Serial Number Locations

Whenever corresponding about a Polaris ATV, be sure to refer to the vehicle identification number (VIN) and the engine serial number.

The VIN can be found stamped on the lower frame rail on the front LH side of the ATV (see Figure 1-1). The engine serial number can be found on top of the engine located on the valve cover (see Figure 1-2).

Figure 1-1

Engine

Powertrain

Emissions

Model

Year

Check Digit

Plant No

Figure 1-2

Individual Serial Number

* This could be either

a number or a letter

VIN

1.2

Engine Serial

Number

GENERAL INFORMATION

VEHICLE INFORMATION

Publication Numbers

YEAR MODEL MODEL NO. OWNER’S MANUAL PN PARTS MANUAL PN

2009 SPORTSMAN XP 850

2009 SPORTSMAN XP 850 EPS

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

A09ZN85AL, AQ, AS, AT, AX, FL

A09ZX85AG, AL, AQ, AR, AS, AX, FS

9921854 9921857

9921976 9921977

Replacement Keys

Replacement keys can be made from the original key. T o identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. Should both keys become lost, replacement of the ignition switch assembly is necessary.

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, by phone at 1-800-328-6657 or on-line at http://polaris.spx.com/

1.3

GENERAL INFORMATION

SPECIFICATIONS

MODEL: 2009 SPORTSMAN XP 850

MODEL NUMBER:. . . . . . . . . A09ZN85AL, AQ, AS, AT, AX, FL

ENGINE MODEL:. . . . . . . . . . EH085OLE

Category Dimension

Length 83.25 in. / 211.5 cm Width 47.6 in. / 121 cm Height 50.75 in. / 129 cm Wheel Base 53 in. / 135 cm Ground Clearance 11.6 in. / 29.5 cm Turning Radius 84 in. / 213 cm (unloaded) Dry Weight 784 lbs. / 356 kg Front Rack Capacity 120 lbs. / 54 kg Rear Rack Capacity 240 lbs. / 109 kg Max. Weight Capacity 575 lbs. / 261 kg Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Weight 150 lbs. / 68 kg

MODEL: 2009 SPORTSMAN XP 850 EPS

MODEL NUMBER:. . . . . . . . . A09ZX85AG, AL, AQ, AR, AS, AX, FS

ENGINE MODEL:. . . . . . . . . . EH085OLE

Category Dimension

Length 83.25 in. / 211.5 cm Width 47.6 in. / 121 cm Height 50.75 in. / 129 cm Wheel Base 53 in. / 135 cm Ground Clearance 11.6 in. / 29.5 cm Turning Radius 84 in. / 213 cm (unloaded) Dry Weight 796 lbs. / 361 kg Front Rack Capacity 120 lbs. / 54 kg Rear Rack Capacity 240 lbs. / 109 kg Max. Weight Capacity 575 lbs. / 261 kg Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Weight 150 lbs. / 68 kg

1.4

GENERAL INFORMATION

2009 SPORTSMAN XP 850 / XP 850 EPS

XP MODELS: A09ZN85AL,AQ,AS,AT,AX,FL XP EPS MODELS: A09ZX85AG,AL,AQ,AR,AS,AX,FS ENGINE MODEL: EH085OLE

Engine

Platform Domestic Twin Cylinder, 4-Cycle Engine Model Number EH085OLE011 Engine Displacement 850 cc Number of Cylinders 2 Bore & Stroke (mm) 87 x 71.5 mm Compression Ratio 11.0:1 Compression Pressure 210 - 250 psi Engine Idle Speed 1200 Cooling System / Cap. Liquid Cooled / 2 qt. (1.9 l) Overheat Warning Instrument Cluster Indicator Lubrication Pressurized Wet Sump Engine Oil Requirement PS-4 Plus / 2 qt. (1.9 l)

Exhaust System

Fuel System Type Throttle Body / Size Mikuni Dual Bore / 40 mm Fuel Delivery Fuel Pressure 43 psi Fuel Capacity Fuel Requirements 87 Octane (minimum)

Alternator Output 475 W @ 1200 RPM / Peak 575 W Voltage Regulator 3-Phase / 32 Amp

Head Lights Brake Light 12V / 27 Watts

Tail Light 12V / 7 Watts Starting System Electric Ignition System Bosch EFI (ECU Controlled) Ignition Timing 6° ± 5° BTDC @ 1200 RPM Spark plug / Gap REA8MCL / .035 in. (.90 mm) Battery / Model / AH / CCA Deka / ETX30L / 30 AH / 365 Instrumentation Multifunction Instrument Cluster DC Outlet Standard Relays

(Located in Relay/Fuse Box)

Circuit Breaker Fan Motor: 20A Fuses

(Located in Relay/Fuse Box)

Stainless Steel Dual Header Pipe

w/ Dual Outlet Silencer

Fuel System

Bosch Multi-Port Sequential

Electronic Fuel Injection

Electronic Fuel Pump

XP EPS: 4.5 gal. (17 l)

Electrical

Pod: 12V / 50 Watts

Bumper: 12V / 50 Watts x 2

Chassis / Start Solenoid / Fan /

EFI / Bumper Lights

Lights: 20A / Drive: 20A /

Accessory: 20A / EFI: 20A /

Unswitched: 10A / EPS: 30A

± 50 RPM

(in tank)

XP: 5.25 gal. (20 l)

Drivetrain

Transmission Type

Transmission Fluid Type / Fluid Capacity

Front Gearcase Fluid Type / Fluid Capacity

Front Gearcase ADC Reservoir Fluid Type

Rear Gearcase Fluid Type / Fluid Capacity

Clutch Type PVT w/EBS Belt 3211123

Steering / Suspension

Toe Out 0-1/16 in. (0-.159 mm) Front Suspension Dual A-arm Front Travel 9.2 in. / 23.4 cm Rear Suspension Dual A-arm w/Rolled IRS Rear Travel 10.2 in. / 25.9 cm Shock Preload Adjustment

Front / Rear

Wheels / Brakes

Front Wheel Size / Bolt Pattern Tire Model / Size

Rear Wheel Size / Bolt Pattern Tire Model / Size

Tire Air Pressure

Brakes - Front & Rear Brake Fluid Polaris DOT 4 Brake Fluid

Automatic PVT

In-Line H-L-N-R-P

Synthetic Sportsman XP

Transmission Fluid /

32 oz. (946 ml)

Premium LT Demand Drive

Fluid / 9.3 oz. (275 ml)

Premium ADC

Front Drive Fluid

ATV Angle Drive Fluid /

7.1 oz. (210 ml)

Cam Adjustable

14 x 6 / 4-156

Carlisle T errathon / 26 x 8 - 14

14 x 8 / 4-156

Carlisle T errathon / 26 x 10 - 14

Front: 7 psi (48 kPa)

Rear: 5 psi (34.5 kPa)

Single Control

Hydraulic 4-Wheel Disc

CLUTCH CHART

Meters

(Feet)

Altitude

0-1800

(0-6000)

1800-3700

(6000 - 12000)

Shift

Weight

24-63

5632215

24-60

5632216

Drive

Spring

Red / Wht

7043349

Red / Wht

7043349

Driven Spring

Red / Wht

3235621

Red / Wht

3235621

1.5

GENERAL INFORMATION

MISC. SPECIFICATIONS AND CHARTS

Conversion Table

°C to °F:

9/5

(°C + 32) = °F °F to °C:

1.6

5/9

(°F - 32) = °C

GENERAL INFORMATION

Standard Torque Specifications

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.

1.7

GENERAL INFORMATION

SAE Tap / Drill Sizes

Decimal Equivalents

Metric Tap / Drill Sizes

1.8

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.: Mi 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.

le/miles.

1.9

GENERAL INFORMATION

NOTES

1.10

MAINTENANCE

CHAPTER 2

MAINTENANCE

PERIODIC MAINTENANCE CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2

BREAK-IN PERIOD / MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2

MAINTENANCE INTERVALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3

GREASE LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5

MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6

MAINTENANCE QUICK REFERENCE, CONTINUED..... . . . . . . . . . . . . . . . . . . . . . . . .2.7

LUBRICANTS / SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . 2.9

FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9

FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.9

FUEL FILTERS / VENT LINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10

THROTTLE OPERATION / ETC SWITCH / THROTTLE CABLE ADJUSTMENT . . . . . 2.10

AIR FILTER / PRE-FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11

ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

ENGINE OIL LEVEL / OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

ENGINE BREATHER HOSE / BREATHER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . .2.13

VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14

COMPRESSION AND LEAKDOWN TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15

EXHAUST SILENCER CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

ENGINE MOUNT FASTENER TORQUE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

TRANSMISSION AND GEARCASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17

TRANSMISSION LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

FRONT GEARCASE LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

FRONT GEARCASE ADC FLUID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

REAR GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21

COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21

COOLING SYSTEM HOSES / COOLANT STRENGTH / COOLANT TYPE . . . . . . . . .2.22

PVT / FINAL DRIVE / WHEEL AND TIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

PVT DRYING / DRIVE BELT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

DRIVE SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

WHEEL AND HUB TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24

WHEEL REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24

TIRE PRESSURE / TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

BATTERY REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

ENGINE / CHASSIS GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

STEERING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28

POWER STEERING UNIT (EPS MODELS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28

TIE ROD END / STEERING INSPECTION / TOE ALIGNMENT . . . . . . . . . . . . . . . . . .2.29

TOE ALIGNMENT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30

SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

SUSPENSION INSPECTION / SUSPENSION SPRING PRE-LOAD ADJUSTMENT . . 2.30

BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

BRAKE FLUID / BRAKE PAD / HOSE / FITTING INSPECTION . . . . . . . . . . . . . . . . . .2.31

AUXILIARY BRAKE PEDAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32

MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

2.1

MAINTENANCE

PERIODIC MAINTENANCE CHART

Periodic Maintenance Overview

Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use

genuine Pure Polaris parts available from your Polaris dealer.

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

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

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

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

Break-In Period

The break-in period consists of the first 20 hours of operation. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.

• Drive vehicle slowly at first while varying the throttle position. Do not operate at sustained idle.

• Pull only light loads.

• Perform regular checks on fluid levels and other areas outlined on the daily pre-ride inspection checklist.

• Change both the engine oil and filter after 20 hours or one month.

• See “Owner’s Manual” for additional break-in information.

Maintenance Chart Key

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

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

= SEVERE USE ITEM: See information provided above.

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

WARNING

Improperly performing the procedures marked  could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.

2.2

Maintenance Intervals

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 Lever Travel - Pre-Ride -



Brake System - Pre-Ride Wheels / Fasteners - Pre-Ride Frame Fasteners - Pre-Ride Engine Oil Level - Pre-Ride -



Air Filter, Pre-filter - Daily - Inspect;clean often

Coolant - Daily -

(whichever comes first)

Miles

(KM)

Inspect and make adjustments as needed. See Pre-Ride Checklist later in this chapter.

Check level daily, change coolant every two years

MAINTENANCE

Remarks

ADC Fluid - Daily - Check level daily, add as needed



Power Steering Unit



(if equipped) Head Lights / Tail Lights - Daily -



Air Filter (main element) - Weekly - Inspect; replace as needed



Brake Pad Wear 10 H Monthly 100 (160) Inspect periodically



Battery 20 H Monthly 200 (320) Check terminals; clean; test Engine Oil Change



(Break-in Period)

Front Gearcase Fluid 25 H Monthly 250 (400) Inspect level



Rear Gearcase Fluid 25 H Monthly 250 (400) Inspect level



Transmission Fluid 25 H Monthly 250 (400) Inspect level



- Daily - Inspect daily, clean often Check operation; apply dielectric grease if

replacing

20 H 1 M -

Perform a break-in oil change at one mont h or 20 hours, whichever comes first

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.

2.3

MAINTENANCE

Maintenance Interval

Item

Hours Calendar

General Lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots, cables, etc.





Throttle Cable /

ETC Switch Throttle Body Intake

Duct Drive belt 50 H 6 M 500 (800) Inspect; replace as needed

Cooling System 50 H 6 M 500 (800) Radiator 50 H 6 M 500 (800) Inspect; clean external surfaces



Cooling Hoses 50 H 6 M 500 (800) Inspect for leaks



Engine Oil Change 100 H 6 M 1000 (1600)



Oil Filter Change 100 H 6 M 1000 (1600) Replace with oil change



50 H 6 M 500 (800)

50 H 6 M 500 (800) Inspect ducts for proper sealing / air leaks

(whichever comes first)

Miles

Remarks

(KM)

Inspect; adjust; lubricate; replace if necessary

Inspect coolant strength seasonally; pressure test system yearly

Perform a break-in oil change at 20 hours or after one month of operation; change more frequently during cold weather operation

Front Gearcase Fluid - 12 M 1000 (1600) Change Fluid



Rear Gearcase Fluid - 12 M 1000 (1600) Change Fluid



Transmission Fluid - 12 M 1000 (1600) Change Fluid





Fuel System 100 H 12 M 1000 (1600)

Engine Mounts 100 H 12 M 1000 (1600) I nspect



Exhaust Pipe / Silencer 100 H 12 M 1000 (1600) Inspect



Sp ark Plug 100 H 12 M 1000 (1600) Inspect; replace as needed

Wiring 100 H 12 M 1000 (1600)



Clutches



(Drive and Driven)

 Front Wheel Bearings 100 H 12 M 1000 (1600) Inspect; replace as needed  Brake Fluid 200 H 24 M 2000 (3200) Change every two ye ars  ADC Fluid 200 H 24 M 2000 (3200) Change every two years

Spark Arrestor (if applicable)



Valve Clearance 1000 H - 10000 (16000) Inspect; adjust

 Toe Adjustment - Inspect periodically; adjust as needed

Headlight Aim - Adjust as needed

100 H 12 M 1000 (1600) Inspect; clean; replace worn parts

300 H 36 M 3000 (4800) Clean out; or remove clean out plug

Check for leaks at tank cap, fuel lines, fuel pump; replace lines every two years

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

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

E Emission Control System Service (California)  Have an authorized Polaris dealer perform these services.

2.4

MAINTENANCE

Grease Lubrication Points

There are grease fittings on each upper and lower front and rear A-arms, each rear bearing carrier, and on the front propshaft yoke. Apply a maximum of 3 pumps of grease at each of these areas.

Item Recommended Lube Method Frequency

Front Propshaft Yoke Front & Rear A-Arms Rear Bearing Carrier

Polaris Premium U-Joint Grease

Grease fittings (3 pumps maximum) every 500 miles (800 km).

Grease before long periods

of storage, and after pressure washing or submerging the ATV.

2.5

MAINTENANCE

Maintenance Quick Reference

III. # Item Lube Rec. Method Frequency*

Change after 1st month or first 20 hours of operation, 100

Engine Oil Polaris PS-4 PLUS 2W-50

Performance Synthetic

Add oil to proper level on dipstick

hours thereafter; Change more often (25 hours) in severe duty conditions or short trip cold weather operation

2 Transmission

3 Engine Coolant Polaris 60/40 Coolant

* More often under severe use, such as operated in water or under severe loads.

Synthetic Sportsman XP Transmission Fluid

Add fluid until it is visible at the fill hole threads

Maintain coolant level in coolant reservoir bottle.

Check level every 25 hours; change fluid yearly

Check level daily, change coolant every 2 years

2.6

MAINTENANCE

Maintenance Quick Reference, Continued.....

III. # Item Lube Rec. Method Frequency*

Front Gearcase

ADC Reservoir

5 Front Gearcase

6 Rear Gearcase

7 Brake Fluid Polaris DOT 4 Brake Fluid

* More often under severe use, such as operated in water or under severe loads.

Polaris Premium ADC Front Drive Fluid

Polaris Premium LT Demand Drive Fluid

Polaris ATV Angle Drive Fluid (ADF)

Maintain fluid level in ADC Reservoir to indicated level

Add fluid until it is visible at the fill hole threads

Maintain fluid level in both master cylinder reservoirs to indicated levels

Check level every 25 hours; change fluid every two years

Check level every 25 hours; change fluid yearly or 1000 mi.

Check level every 25 hours; change fluid yearly

Check level during pre-ride inspection; change fluid every two years

2.7

MAINTENANCE

LUBRICANTS / SERVICE PRODUCTS

Polaris Lubricants,Maintenance and Service Products

Part No. Description

Engine / Transmission Lubricant

2870791 Fogging Oil (12 oz. Aerosol) 2876244

2876245

2877606

2876251

2872277

2876160

2872276 2870465 Pump for Gallon Jug

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

2871312 Grease Gun Kit 2871322

PS-4 PLUS 2W-50 Performance Synthetic 4-Cycle Engine Oil (Quart)

PS-4 PLUS 2W-50 Performance Synthetic 4-Cycle Engine Oil (Gallon)

Gearcase Lubricants

Synthetic Sportsman XP Transmission Fluid (Quart)

Premium LT Demand Drive Fluid (Quart) (12 count)

Premium Demand Drive Hub Fluid (2.5 Gallon) (2 count)

ATV Angle Drive Fluid (Quart) (12 count)

ATV Angle Drive Fluid (2.5 Gallon) (2 Count)

Coolant

Grease / Specialized Lubricants

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

Additives / Sealants / Thread Locking Agent s / 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)

2872189 DOT 4 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)

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) 2871329 Dielectric Grease (Nyogel™)

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

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

2.8

MAINTENANCE

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 tire pressure

• Fuel and oil - fill both to their proper level; do not overfill

• All brakes - check operation (includes auxiliary brake)

• Throttle - check for free operation

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

• Engine stop switch (key switch) - check for proper function

• Wheels - check for loose wheel nuts

• Air cleaner element - check for dirt or water; clean or replace

• Steering - check for free operation, noting any unusual looseness in any area

• Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or other fasteners

• Engine coolant - check for proper level at the recovery bottle

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.

Frame, Nuts, Bolts, 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.

Controls

Check handlebar controls for proper operation, positioning and adjustment.

Fuel Lines

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

2. Be sure fuel lines are routed properly and secured with cable ties where applicable.

CAUTION

Make sure lines are not kinked or pinched

3. Replace all fuel lines every two years.

2.9

MAINTENANCE

Fuel Filters

There are two fuel filters located within the fuel pump assembly. The fuel pump is non-serviceable. If the internal fuel pump filters require service, the fuel pump and fuel tank must be replaced as an assembly.

NOTE: See the “Electronic Parts Catalog” for more information. For all other information related to the EFI System, refer to Chapter 3.

Electronic Throttle Control Switch (ETC) / Throttle Cable Adjustment

NOTE: Sportsman XP requires a new adjustment procedure.

1. Slide the boot back far enough to expose the inline cab le adjuster sleeve and loosen the adjuster locknut.

2. Remove the (4) screws and cover from the RH control.

3. With handlebars centered and wheels pointing forward, slowly turn the adjuster sleeve counter-clockwise (out) just until the gap is removed between the throttle arm and the throttle arm stop (see illustration below).

NOTE: While moving the adjuster sleeve, “flip” the throttle lever slightly to remove slack in the cable.

Vent Line

1. Check the vent line from the fuel tank for signs of wear, deterioration, damage or leakage. Replace the line every two years.

2. Verify vent line is routed properly and secured with an appropriate number of cable ties.

CAUTION

Make sure lines are not kinked or pinched

Throttle Operation

Check for smooth throttle opening and closing in all handlebar positions. Throttle lever operation should be smooth and lever must return freely without binding.

1. Place the gear selector in neutral.

2. Set parking brake.

3. Start the engine and let it idle.

4. Turn handlebars from full right to full left. If i dle speed increases at any point in the turning range, inspect throttle cable routing and condition. If cable is routed properly and in good condition, no adjustment is required.

5. Replace the throttle cable if worn, kinked, or damaged.

4. Turn the cable adjuster sleeve clockwise (in) 1.5 - 2 turns; tighten locknut and reinstall boot. After this adjustment there should be .079-.118” (2-3 mm) gap between thrott le arm and throttle arm stop.

5. Reinstall the RH control cover and ensure the O-ring is properly in place. Securely tighten the (4) screws.

6. Place the vehicle in PARK and start the engine. Turn the handlebars from full left to full right while listening for any change in engine speed. If engine speed changes, loosen the locknut and turn the adjuster sleeve clockwise (in) an additional 1/2 turn and repeat this step.

2.10

MAINTENANCE

Air Filter / Pre-Filter Service

It is advisable to replace the filter when it is dirty . However, in an emergency, it is permissible to clean the main filter if you observe the following practices.

• Never immerse the filter in water since dirt can be transferred to the clean air side of the filter.

• If compressed air is used never exceed a pressure of 40 PSI. Always use a dispersion type nozzle to prevent filter damage and clean from the inside to the outside.

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

Removal:

1. Remove the seat to access the airbox cover.

Cleaning:

4. Slip the pre-filter screen off of main element. Clean the prefilter with hot soapy water.

5. Rinse and dry thoroughly.

6. Inspect pre-filter screen for tears or damage.

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

Installation:

8. Inspect airbox cover seal for damage. It should adhere tightly to the cover and seal all the way around. Replace seal as needed.

9. Reinstall pre-filter screen over main filter. Be sure the screen covers entire surface of main filter without folds, creases, or gaps.

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

10. Install air filter assembly into the airbox and position it correctly before closing the airbox cover.

2. Unscrew the two knobs retaining the airbox cover and open the cover.

NOTE: Proper placement of the air filter is important to prevent air leaks.

11. Close airbox cover and secure cover by tightening the retaining knobs.

12. Check the intake boot for cracks, deterioration, abrasion, or leaks. Replace as needed.

3. Remove the air filter assembly from the airbox.

2.11

MAINTENANCE

ENGINE

Engine Oil Level

Polaris recommends the use of Polaris PS-4 PLUS synthetic engine oil. Always use PS-4 PLUS engine oil. Oil may need to be changed more frequently if Polaris engine oil is not used.

CAUTION

Mixing brands or using a non-recommended

engine oil may cause serious engine damage.

Always use the recommended engine oil. Never

substitute or mix engine oil brands.

1. Locate the engine oil dipstick on the left side of the ATV.

Engine Oil and Filter Change

Always change engine oil and filter at the intervals outlined in the Periodic Maintenance Chart. Always change the oil filter whenever changing the engine oil.

1. Position the ATV on a level surface.

2. Place the transmission in park.

3. Start engine and allow it to run for two to three minutes until the engine is warm.

4. Stop the engine.

5. Clean the area around the drain plug.

2. Position the ATV on a level surface.

3. Stop engine and remove the dipstick. Wipe i t dry with a clean cloth.

4. Reinstall and tighten the dipstick.

NOTE: The dipstick must be screwed in completely to ensure an accurate measurement.

5. Remove the dipstick and check the oil level.

6. Maintain the oil level in the safe range. Do not overfill.

6. Place a drain pan beneath the engine crankcase.

7. Using a 6 mm Hex socket, remove the drain plug and allow the engine oil to drain completely.

WARNING

Hot oil can cause serious burns to skin.

Do not allow hot oil to contact skin.

8. Replace the sealing washer on the drain plug.

2.12

MAINTENANCE

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

9. Reinstall drain plug and torque to 12 ft. lbs. (16 Nm).

= T

Engine Drain Plug: 12 ft. lbs. (16 Nm)

10. Locate oil filter through access hole in the skid plate. Place shop towels beneath the oil filter. Using oil filter wrench (PV-43527) turn oil filter counterclockwise to remove it.

16. Stop the engine and check for leaks.

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

18. Dispose of used oil and filter properly.

Engine Breather Hose

Be sure engine breather hose is routed properly and secured in place. CAUTION: Make sure line is not kinked or pinched.

Breather

Inspect

Airbox

11. Use a clean dry towel to clean the filter sealing surface on the crankcase.

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

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

= T

Oil Filter Torque:

Turn by hand until filter gasket contacts sealing

surface, then turn an additional 1/2 turn.

14. Remove dipstick and fill engine with 1.75 qts. (1.66 L) of the recommended engine oil.

Recommended Engine Oil:

Engine Breather Assembly

The engine breather assembly is located on top of the valve cover. Inspect and service the breather components as required.

PS-4 PLUS Synthetic 4-Cycle Engine Oil

(PN 2876244) (Quart)

15. Start the engine and allow it to idle for one to two minutes.

2.13

MAINTENANCE

Valve Clearance Adjustment

1. Remove the seat and both upper side panels.

2. Disconnect the shift linkage from the shift lever.

3. Remove the (2) screws retaining the lower portion of the air box.

4. Remove the hose from the breaker valve located on top of the valve cover.

5. Remove the push rivets retaining the right-hand portion of the rear cab to gain access to the bolts retaining the upper right-hand frame support.

6. Remove the (4) bolts retaining the frame support. Pull the support forward and down to remove it from the vehicle.

7. Remove the (2) Torx-head screws retaining the upper portion of the air box to the front cab.

8. Carefully disconnect the ECU by pulling the tab out while pulling down on the connector.

9. Loosen the hose clamp retaining the intake boot to the intake plenum and remove the boot.

10. Lift up on the air box and turn it sideways to gain access to the valve cover bolts.

MAG & PTO ADJUSTMENT PROCEDURE

14. Turn the drive clutch counter-clockwise until the cam

sprocket is in the MAG (#1) Adjustment Position.

MAG (#1)

Adjustment Position

Timing Pin in Vertical Position

TDC #1 (MAG) Cylinder

11. Remove the spark plug wires and spark plugs.

12. Remove the (6) valve cover bolts and valve cover.

13. Remove PVT cover so the engine can be rotated (see “Drive Belt Removal” procedure within this chapter).

Timing Marks Lined Up With Top of Head

at MAG (#1) Adjustment Position

15. Set the MAG cylinder valve lash by placing the feeler gauge blade between the lash adjuster and valve as shown.

2.14

MAG (#1)

MAINTENANCE

16. Loosen the jam nut and turn the lash adjuster until the valve lash is correct.

17. Set the intake and exhaust valve lash to specification.

= In. / mm.

Intake Valve Clearance: .006 in. (.15 mm)

= In. / mm.

Exhaust Valve Clearance: .009 in. (.23 mm)

18. Hold adjuster and torque the jam nut using a torque wrench w/10 mm crow’s foot adaptor. Verify clearance is still correct after tightening the jam nut.

= T

Rocker Jam Nut: 71-89 in. lbs. (8-10 Nm)

19. Turn the drive clutch counter-clockwise to rotate the cam sprocket 225° to the PTO (#2) Adjustment Position.

21. Repeat steps 16-18.

22. Clean sealing surfaces of the cylinder head and valve cover.

23. Inspect the condition of the valve cover bolt rubber isolators. If rubber has become hardened or cracked, replace them.

24. Install a new valve cover seal and install the valve cover. Torque the cover bolts to specification.

= T

Valve Cover Bolts:

89 in. lbs. (10 Nm)

25. Install the upper right-hand frame support and torque the (4) mounting bolts to specification.

= T

Upper Right-Hand Frame Support Bolts:

36 ft. lbs. (49 Nm)

26. Reassemble vehicle by reversing this procedure. Start the engine to ensure proper valve adjustment was performed.

PTO (#2)

Adjustment Position

20. Set the PTO cylinder valve lash by placing the feeler gauge blade between the lash adjuster and valve as shown.

Timing Marks at PTO (#2)

Adjustment Position

PTO (#2)

Compression and Leakdown Tests

NOTE: This engine does NOT have decompression components. Compression readings will vary in proportion to cranking speed during the test.

Smooth idle generally indicates good compression. Low engine compression is rarely a factor in running condition problems above idle speed. Abnormally high compression can be caused by worn or damaged exhaust cam lobes.

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

Measured Cylinder Compression

210-250 psi (full throttle)

Cylinder Leakage Service Limit: 10%

(Inspect for cause if leakage exceeds 10%)

2.15

MAINTENANCE

Exhaust Silencer Cleaning

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 exhaust silencer.

Wear eye protection.

Do not stand behind or in front of the vehicle

while purging the carbon from the silencer.

Never run the engine in an enclosed area.

Exhaust contains poisonous carbon monoxide.

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 silencer must be periodically purged of accumulated carbon as follows:

5. If particles are still suspected to be in the silencer, back the machine onto an incline so the rear of the machine is 1 ft. (30.5 cm) higher than the front. Place the transmission in park and block the wheels. Repeat steps 3 and 4 (see WARNING).

1 ft.

6. If particles are still suspected to be in the silencer, drive the machine onto the incline so the front of the machine is 1 ft. (30.5 cm) higher than the rear. Place the transmission in park and block the wheels. Repeat Steps 3 and 4 (see WARNING).

7. Stop the engine and allow the silencer to cool. Reinstall the clean out plug.

1. Remove the clean out plug on the bottom of the silencer.

2. Place the transmission in park, and start the engine.

3. Purge accumulated carbon from the exhaust system by momentarily revving the engine several times.

4. If some carbon is expelled, cover the exhaust outlets and lightly tap on the silencer around the clean out plug with a rubber mallet while revving the engine several more times.

Engine Mount Fastener Torque

Check engine mounting fasteners and ensure they are tight. Also inspect the condition of the rubber mounts. If rubber mounts are cracked or show signs of fatigue, replace them.

CAUTION

Wear protective gloves when covering the

exhaust outlets. Serious burns could result from

contact with exhaust components.

2.16

MAINTENANCE

TRANSMISSION AND GEARCASES

Transmission Lubrication

NOTE: It is important to follow the transmission maintenance intervals described in the Periodic Maintenance Chart. Regular fluid level inspections should be performed as well.

The transmission fluid leve l should be checked and changed in accordance with the maintenance schedule.

• Be sure vehicle is positioned on a level surface when checking or changing the fluid.

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

Transmission Fluid Level Check

The fill plug is located on the right-hand side of the transmission. Access the fill plug through the rear right-hand wheel well. Maintain the fluid level even with the bottom threads of the fill plug hole.

1. Position vehicle on a level surface.

Transmission Fluid Change

Access the drain plug through the rear right-hand wheel well. The plastic skid plate can be removed for better access to the drain plug.

1. Remove the fill plug (refer to “Transmission Fl uid Level Check”).

2. Place a drain pan under the transmission drain plug.

3. Remove the drain plug and allow fluid to drain complete ly.

2. Remove the fill plug and check the fluid level.

Fill Plug

10-14 ft. lbs.

(14-19 Nm)

Transmission fluid flush with the bottom of thread area.

3. If fluid level is not even with the b ottom threads, add the recommended fluid as needed. Do not overfill.

4. Reinstall the fill plug and torque to specification.

Drain Plug

10-14 ft. lbs. (14-19 Nm)

4. Clean the drain plug magnetic surface.

5. Reinstall drain plug with a new O-ring and torque to specification.

6. Add the recommended amount of fluid through the fill plug hole. Maintain the fluid level at the bottom of the fill plug hole when filling the transmission. Do not overfill.

Fill Plug

10-14 ft. lbs.

(14-19 Nm)

Recommended Transmission Lubricant:

Synthetic Sportsman XP Transmission Fluid

(PN 2877606) (Quart)

Capacity: 32 oz. (946 ml)

7. Reinstall fill plug with a new O-ring and torque to specification.

= T

Drain/Fill Plug Torque:

10-14 ft. lbs. (14-19 Nm)

= T

Drain/Fill Plug Torque:

10-14 ft. lbs. (14-19 Nm)

8. Check for leaks. Dispose of used fluid properly.

2.17

MAINTENANCE

Front Gearcase Lubrication

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

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

• Be sure vehicle is positioned on a level surface when checking or changing the fluid.

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

Front Gearcase Fluid Level Check

The fill plug is located on the right side of the fron t gearcase. Access the fill plug through the front right-hand wheel well or through the front lower bumper. Maintain the fluid level even with the bottom threads of the fill plug hole.

1. Position vehicle on a level surface.

2. Remove the fill plug and check the fluid level.

Fill Plug

8-10 ft. lbs. (11-14 Nm)

Front Gearcase Fluid Change:

The drain plug is located on the bottom side of the front gearcase. Access the drain plug through the access hole in the front skid plate.

1. Remove the fill plug (refer to “Front Gearcase Fluid Level Check”).

2. Place a drain pan under the front gearcase drain plug.

3. Remove the drain plug and allow fluid to drain completel y.

Drain Plug

8-10 ft. lbs.

(11-14 Nm)

4. Clean the drain plug magnetic surface.

Fill Plug

8-10 ft. lbs. (11-14 Nm)

Gearcase fluid flush with the bottom of thread area.

3. If fluid level is not even with the b ottom threads, add the recommended fluid as needed. Do not overfill.

4. Reinstall the fill plug and torque to specification.

= T

Drain / Fill Plug Torque:

8-10 ft. lbs. (11-14 Nm)

5. Reinstall drain plug with a new O-ring and torque to specification.

6. Add the recommended amount of fluid through the fill hole. Maintain the fluid level e ven with the bottom threads of the fill plug hole.

Recommended Front Gearcase Fluid:

Premium LT Demand Drive Fluid

(PN 2876251) (Quart)

Capacity: 9.3 oz. (275 ml)

7. Reinstall fill plug with a new O-ring and torque to specification.

= T

Drain / Fill Plug Torque:

8-10 ft. lbs. (11-14 Nm)

2.18

8. Check for leaks. Dispose of used fluid properly.

MAINTENANCE

Front Gearcase ADC Fluid

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

The front gearcase ADC fluid level should be checked and changed in accordance with the maintenance schedule.

Front Gearcase ADC Fluid Level Check

The ADC fluid reservoir is located underneath the front rack as shown below. Maintain the fluid level between the “MIN” and “MAX” levels indicated on the reservoir.

1. Disengage the anchors and remove front rack assembly.

2. Check the fluid level of the ADC reservoir.

5. Begin the bleeding process by filling reservoir to the “MAX” level with clean ADC Front Drive Fluid.

Recommended ADC Fluid:

Premium ADC Front Drive Fluid

(PN 2876144) (Quart)

6. Locate bleeder valves found on each side of the front gearcase and remove the protective caps.

Bleeder

Valve

Front

Gearcase

CapCap

Bleeder

Valve

3. If fluid level is below the minimum mark on the reservoir, remove the cap and add the recommended fluid.

4. Reinstall the cap and front rack assembly.

Front Gearcase ADC Fluid Change:

1. Position the vehicle on a level surface and allow the vehicle to sit for at least 30 minutes.

2. Thoroughly clean the areas around the ADC reservoir and bleeder valves.

3. Remove the reservoir cap and diaphragm assembly.

4. Make sure the fluid inside the reservoir is free of debris. If any debris is found, use a clean shop towel or suction device to remove it from the reservoir.

NOTE: Debris in the reservoir may result in inadequate bleeding and reduced performance of the system.

7. Attach a clean clear hose to one of the bleeder valves.

8. Slowly loosen the valve (counter-clockwise) and allow fluid and trapped air to flow from the fitting.

IMPORTANT: Do not allow ADC fluid in reservoir to drop below the “MIN” fill line. Close bleeder valve before the fluid level drops below the “MIN” fill line. Refilling an empty reservoir will result in air pockets becoming trapped.

9. Close the valve when clean (bubble-free) fluid begins to flow from the valve.

10. Repeat steps 7-9 on the remaining bleeder valve.

11. Torque the bleeder valves to specification and reinstall the protective caps.

= T

Bleeder Valve Torque: 80 in. lbs. (9 Nm)

12. Fill reservoir to a level midway between “MAX” and “MIN” fill lines. Verify no debris is found in reservoir fluid.

13. Install the reservoir cap and diaphragm securely and wipe clean any fluid residue.

2.19

MAINTENANCE

Rear Gearcase Lubrication

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

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

• Be sure vehicle is positioned on a level surface when checking or changing the fluid.

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

Rear Gearcase Fluid Level Check:

The fill plug is located on the right side of the rear gearcase. Maintain the fluid level even with the bottom threads of the fill plug hole.

1. Position the vehicle on a level surface.

2. Remove the fill plug and check the fluid level.

Rear Gearcase Fluid Change:

The drain plug is located on the bottom right-hand si de of the rear gearcase. Access the drain plug from the rear right-hand side of the ATV.

1. Remove the fill plug (refer to “Rear Gearcase Fluid Level Check”).

2. Place a drain pan under the rear gearcase drain plug.

3. Remove the drain plug and allow the fluid to drain completely.

Fill Plug

10-14 ft. lbs.

(14-19 Nm)

Fill Plug

10-14 ft. lbs.

(14-19 Nm)

Gearcase fluid flush with the bottom of thread area.

3. If fluid level is not even with the b ottom threads, add the recommended fluid as needed. Do not overfill.

4. Reinstall fill plug and torque to specification.

= T

Drain / Fill Plug Torque:

10-14 ft. lbs. (14-19 Nm)

Gearcase fluid flush with the bottom of thread area.

4. Clean the drain plug magnetic surface.

5. Reinstall drain plug with a new O-ring and torque to specification.

6. Add the recommended amount of fluid through the fill hole. Maintain the fluid level e ven with the bottom threads of the fill plug hole.

Drain Plug

10-14 ft. lbs.

(14-19 Nm)

Recommended Rear Gearcase Lubricant:

ATV Angle Drive Fluid (PN 2871653)

Capacity: 7.1 oz. (210 ml)

7. Reinstall fill plug with a new O-ring and torque to specification.

= T

2.20

Drain / Fill Plug Torque:

10-14 ft. lbs. (14-19 Nm)

8. Check for leaks. Dispose of used fluid properly.

MAINTENANCE

COOLING SYSTEM

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 bottle, past the pressure cap, and into the radiator.

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

CAUTION

Overheating of engine could occur if air is not

fully purged from system.

Polaris recommends the use of Polaris Premium 60/40 antifreeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water.

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

With the engine at operating temperature, the coolant level should be between the MAX and MIN marks on the coolant recovery bottle. If not, perform the following procedure.

1. Position the vehicle on a level surface.

2. View the coolant level in the recovery bottle. The coolant level can be viewed from inside the front right wheel well.

3. If the coolant level is below the “MIN” line on the bottle, remove the front rack assembly to access the radiator pressure cap and recovery bottle cap.

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.

Coolant Level Inspection

The pressure cap and recovery bottle are located underneath the front rack as shown below. Maintain the coolant level between the “MIN” and “MAX” levels indicated on the recovery bottle.

WARNING

Never remove the pressure cap when the

engine is warm or hot. Escaping steam can

cause severe burns. The engine must be cool

before removing the pressure cap.

4. Remove the pressure cap. Using a funnel, add coolant to the top of the radiator filler neck.

5. Reinstall the pressure cap.

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

6. Remove recovery bottle cap and add coolant using a funnel.

7. Fill recovery bottle to “MAX” level with Polaris Premium 60/40 Anti-Freeze/Coolant or a 50/50 mixture of antifreeze/coolant and distilled water as required for freeze protection in your area.

8. Reinstall the recovery bottle cap.

2.21

MAINTENANCE

9. If coolant was required, start engine and check for leaks. Make sure radiator fins are clean to prevent overheating.

10. Add coolant as needed. Maintain the coolant level between the “MIN” and “MAX” marks on the bottle.

11. Reinstall the front rack assembly.

Cooling System Hoses

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

Coolant Strength / Type

Test the strength of the coolant 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.

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

Recommended Anti-Freeze/Coolant:

Polaris 60/40 Anti-Freeze/Coolant

(PN 2871534) (Quart)

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).

NOTE: For further information on the engine cooling system, refer to Chapter 4.

2.22

MAINTENANCE

PVT / FINAL DRIVE / WHEEL AND TIRE

PVT Drying

NOTE: If operating the ATV through water, be sure to check the PVT system components for water ingestion. After operating in water, the ATV should be checked immediately.

1. Access the PVT drain plug on the bottom of the PVT cover using a long flat blade screwdriver between the frame and left-hand lower control arm from the rear of the ATV.

2. Remove the PVT drain plug and O-ring.

Drive Belt Removal

Refer to Chapter 7 “Clutching (PVT)” for more detail.

1. Elevate vehicle and remove the left rear wheel.

2. Remove the lower left-hand frame suppo rt.

3. Remove the (11) screws retaining the outer PVT co ver. Pull the PVT cover out the LH wheel well.

4. Insert the belt removal tool PN 2877408 into the driven clutch (tool included with vehicle’s tool kit).

NOTE: Make sure the tool is square with the moveable sheave surface of the driven clutch.

5. Rotate the tool to open the driven clutch.

6. Walk the belt out of the driven clutch and drive clutch, and remove the belt from the vehicle.

Drive Shaft Boot Inspection

Inspect the front and rear drive shaft boots for damage, tears, wear, or leaking grease. If the rubber boots exhibit any of these symptoms, replace the boot(s). Refer to Chapter 8 for drive shaft boot replacement.

3. Allow the water to drain out completely.

4. Reinstall the drain plug and O-ring.

5. Start the engine and shift into park.

6. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and clutches.

NOTE: Do not hold the throttle wide open for more than 10 seconds.

Rear

NOTE: Remove the CV boot shield from the front lower A-arms to inspect the front outer CV boots.

Front

7. Allow the engine RPM to return to idle, then shift into low gear.

8. Test the PVT system for belt slippage. If the belt slips, repeat the process.

2.23

MAINTENANCE

Wheel and Hub Torque Table

Item Nut Type Specification

Aluminum Wheels

Steel Wheels

Hub Retaining Nuts

(Front & Rear)

Tapered Nut

(Long)

Tapered Nut

(Short)

- 80 ft. lbs. (108 Nm)

75 ft. lbs. (102 Nm)

45 ft. lbs. (61 Nm)

Wheel Installation

1. Verify the transmission is still in PARK and the parking brake is locked.

2. Install the wheel hub, washers, and hub nut, if previously removed.

3. Place the wheel in the correct position on the wh eel hub. Be sure the valve stem is toward the outside and rotatio n arrows on the tire point toward forward rotation.

4. Install the wheel nuts and finger tighten them to align the center of the wheel holes with the center of the tapered nuts.

IMPORTANT: It is possible to torque the wheel nut on a steel rim without the nut being centered in the hole. Be sure to center the wheel nuts before applying torque to prevent wheel nuts from coming loose.

5. Carefully lower the vehicle to the ground.

6. Torque the wheel nuts and/or hub nut to the proper torque specification listed in the “Wheel and Hub Torque Table”.

Wheel Removal

1. Position the vehicle on a level surface.

2. Stop the engine, place the transmission in PARK and lock the parking brake.

3. Loosen the wheel nuts slightly. If wheel hub remov al is required, remove the cotter key and loosen the hub nut slightly.

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

5. Remove the wheel nuts and remove the wheel.

6. If hub removal is required, remove the hub nut and washers.

CAUTION

Improperly installed wheels could affect vehicle

handling and tire wear. On vehicles with tapered

rear wheel nuts, make sure tapered end of nut

goes into taper on wheel. Be sure to properly

torque and install all wheel nuts.

7. If the hub nut was removed, install a new cotter pin after the hub nut has been tightened.

2.24

MAINTENANCE

Tire Pressure

Tire Pressure Inspection (PSI - Cold)

Front Rear

7 psi (48 kPa) 5 psi (34.5 kPa)

Tire Inspection

WARNING

Operating an ATV with worn tires will increase

the possibility of the vehicle skidding and

possible loss of control.

Worn tires can cause an accident.

Always replace tires when the tread depth

measures 1/8” (.3 cm) or less.

CAUTION

Maintain proper tire pressure.

Refer to the warning tire pressure decal

applied to the vehicle.

Improper tire inflation may affect

ATV maneuverability.

When replacing a tire always use original

equipment size and type.

The use of non-standard size or type tires may

affect ATV 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)

ELECTRICAL AND IGNITION SYSTEM

Battery Maintenance

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

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.

NOTE: Absorbed Glass Mat (AGM) batteries are permanently sealed at the time of manufacture. AGM batteries are designed to minimize gassing and water loss, but can vent if overcharged.

IMPORTANT: Never attempt to open the battery. If the seal is broken, the battery will be ruined and will fail within a few weeks.

NOTE: If battery voltage is below 12.6V, fully charge the battery before putting into service. Charge for 35 hours at a voltage not to exceed 14.6V or 10 Amps. Voltage should reach at least 14.4V before end of charge.

2.25

MAINTENANCE

Battery Removal

1. Remove the seat to access the battery.

Retaining Screw

2. Disconnect battery negative (-) (black) cable first, followed by the positive (+) (red) cables.

CAUTION

To reduce the chance of sparks: Whenever

removing the battery, disconnect the negative

(black) cable first.

3. Remove the screw retaining the hold-down strap n ear the bottom front portion of the battery and remove the strap.

4. Lift the battery out of the ATV.

Battery Installation

IMPORTANT: Using a new battery that is not fully charged can damage the battery, resulting in a short battery life and can hinder performance. Follow the battery charging procedure before installation.

5. Place the spacers on top of the battery terminals. Be sure they are placed between the battery terminal and cable(s).

Positive

Cables

SpacerSpacer

6. Connect and tighten the positive (+) (red) battery cable first, followed by the negative (-) (black) battery cable.

Negative

Cable

CAUTION

To reduce the chance of sparks: Whenever

installing the battery, install the

negative (black) cable last.

7. Verify cables are properly routed and fasteners are tight.

NOTE: The cables should be safely tucked away at the front of the battery.

8. Reinstall the seat.

Spark Plug Service

1. Remove the seat and upper right-hand side panel.

2. Disconnect the shift linkage from the shift lever.

3. Remove the spark plug caps. Clean plug area so no dirt and debris can fall into engine when plugs are removed.

1. Ensure the battery is fully charged (see Chapter 12).

2. Place the battery into the ATV on its side with the positive (+) terminal towards the right side of the ATV.

3. Install the hold-down strap and the retaining screw .

4. Coat the battery terminals and bolt threads with Dielectric Grease (PN 2871329) or petroleum jelly.

2.26

4. Using a 14 mm deep-well socket with an extension, remove the spark plug.

MAINTENANCE

Spark Plug Inspection / Installation

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

2. Clean with electrical contact cleaner or a glass bead spark plug cleaner only. CAUTION: A wire brush or coated abrasive should not be used.

3. Measure gap with a wire gauge. Refer to specifications in the following illustration for proper spark plug type and gap. Adjust gap if necessary by carefully bending the side electrode.

Spark Plug Gap

Gap - .035" (0.90 mm)

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

Engine / Chassis Ground

Periodically inspect the electrical ground cable attachments. Cables and connections should be tight and corrosion-free.

Inspect the battery-to-chassis connection underneath the seat. This connection allows the chassis to provide a ground path.

Inspect the chassis-to-engine connection on the left side of the engine attached to the engine/transmission housing. This connection allows the engine to provide a ground path.

Recommended Spark Plug

Champion REA6MC or REA8MCL

Spark Plug Torque:

18 ± 1.5 ft. lbs. (25 ± 2 Nm)

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

6. Install spark plugs and torque to specification.

7. Make sure the high tension leads are retained by the airbox.

8. Reinstall the shift linkage, upper right-hand side panel, and seat.

2.27

MAINTENANCE

STEERING

Steering Inspection

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

Bolt

Carriage

Bolt

Bracket

Nut

Cotter

Screw

Bushings

Steering

Post

Nut

Upper Post

PS Unit

Steering

Bracket

Bolt

Drive

Brackets

Power Steering Unit (EPS Models)

The power steering unit can be accessed through the front left wheel well by removing the mud guard.

PS Unit

Frequently clean the areas around and on top of the power steering unit to allow for proper cooling.

Bolts Lower

Post

Washer

Nut

Cotter

Bolts

Jam Nut

Rod End

Tie Rod

Jam Nut

Rod End

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

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

WARNING

Due to the critical nature of the procedures

outlined in this chapter, Polaris recommends

steering component repair and adjustment be

performed by an authorized Polaris Dealer. Only

a qualified technician should replace worn or

damaged steering parts. Use only genuine

Polaris replacement parts.

IMPORTANT: Be sure to clean these areas thoroug hly after riding through muddy conditions.

2.28

MAINTENANCE

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.

3. Tie a length of string between two stands as shown in the following illustration. Position the stands so the st ring is flush or parallel with the side of the rear tire.

Stand

String

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

• If abnormal movement is detected, inspect the hub and wheel assembly to determine the cause.

Toe Alignment

Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8”-1/4” (3-6 mm) toe out.

1. Position the vehicle on a smooth level surface.

2. Set handlebars in a straight ahead position and secure handlebars in this position.

NOTE: The steering post frog can be used as an indicator of whether the handlebars are straight. The frog should always point straight back from the steering post.

NOTE: If available, you may use a long straight-edge instead of a string.

4. Measure the distance from the string to the rim at the front (1) and rear (2) of the front rim. The rear measurement should be 1/16”-1/8” (2-3 mm) more than the front measurement on each side of the vehicle to obtain the recommended 1/8”-1/4” (3-6 mm) toe out alignment.

5. Repeat the measurement procedure on the other side of the vehicle.

NOTE: If you discover improper alignment, refer to “Toe Alignment Adjustment” procedure.

= In. / mm.

Wheel Toe-out Alignment:

1/8 - 1/4” (3 - 6 mm)

2.29

MAINTENANCE

Toe Alignment Adjustment

If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell you which tie rod needs adjusting.

NOTE: Be sure handlebars are straight ahead before determining which tie rod(s) need adjustment.

CAUTION

During tie rod adjustment, it is very important that

the following precautions be taken when

tightening tie rod end jam nuts.

If the rod end is positioned incorrectly it will not

pivot, and may break

To adjust toe alignment:

• Hold tie rod end to keep it from rotating.

• Loosen jam nuts at both ends of the tie rod.

• Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe out setting.

• Important: When tightening the tie rod end jam nuts, the rod ends must be held parallel to prevent rod end damage and premature wear. Damage may not be immediately apparent if done incorrectly. See illustration.

SUSPENSION

Suspension Inspection

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

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

• Inspect each shock body for leakage.

Suspension Spring Pre-Load Adjustment

The front and rear shock absorber springs are adjustable. Rotate the adjuster cam either direction to increase or decrease spring tension. Always adjust both sides equally.

Operator weight and vehicle loading affect suspension spring pre-load requirements. Use Spanner Wrench (PN 2870872) to adjust pre-load as necessary to avoid bottoming of the shocks.

Shock Spanner Wrench

(PN 2870872)

2.30

MAINTENANCE

BRAKE SYSTEM

Brake Fluid 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 hand master cylinder reservoir to the indicated level inside reservoir.

Fluid Level “Eye”

• Check the fluid level “eye”. If it is clear, it is an indication that fluid is needed or the brake pads may be worn, which can reduce the fluid level.

Full

Low

• Check the fluid level of the auxiliary brake master cylinder reservoir. Add fluid to the indicated level.

Figure 2-31

• Use Polaris DOT 4 Brake Fluid (PN 2872189).

CAUTION

DO NOT OVERFILL!

Excess brake fluid may cause brake drag.

Fill to the indicated fill line or specification.

• Check brake system for fluid leaks, excessive travel or spongy feel.

• If required, add brake fluid to .25” - .30” (6 - 8 mm) from the top of the reservoir.

.25” - .30” (6 - 8 mm)

From the Top of Reservoir

• Check brake pads for wear, damage or looseness.

• Check surface condition of the disc.

• Inspect thickness of brake pad friction material.

Brake Pad Inspection

Inspect brake pad friction material for excessive wear.

Brake Pad Inspection

Brake Pad

Measure

Service Limit - .040” (1 mm)

Thickness

Hose / 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.

2.31

MAINTENANCE

Auxiliary Brake Pedal

The hydraulic auxiliary brake system requires no adjustment. Frequently check the brake fluid level for the auxiliary brake system by viewing the level in the master cylinder reservoir located underneath the front rack assembly (see Figure 2-31).

Foot Brake

• Check the effectiveness of the auxiliary brake by applying approximately 50 lbs. (23 kg) of downward force on the pedal.

• If brake pedal requires an excessive amount of travel to operate, inspect brake pads, pedal, linkage springs, rear master cylinder and hoses for wear, damage or leaka ge. Replace components as needed.

2.32

MAINTENANCE

MAINTENANCE LOG

Service Date Hours / Miles (km) Service Performed / Comments Dealer / Technician

20 Hours / 1 Month

(Break-In)

100 / 6 Months

2.33

MAINTENANCE

NOTES

2.34

ELECTRONIC FUEL INJECTION

CHAPTER 3

ELECTRONIC FUEL INJECTION

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2

FUEL TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4

FUEL LINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5

EFI SERVICE NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5

EFI SYSTEM LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6

EFI COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7

ELECTRONIC FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9

ELECTRONIC CONTROL UNIT (ECU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10

ECU SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10

ECU REMOVAL / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11

FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11

FUEL SENDER / PUMP TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.12

FUEL PUMP / FUEL TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.13

FUEL PUMP / FUEL TANK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.14

FUEL PRESSURE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14

FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14

FUEL INJECTOR SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.14

FUEL INJECTOR TEST / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15

CRANKSHAFT POSITION SENSOR (CPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16

CPS TEST / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16

TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP) . . . . . . . . . . . . . . . . . 3.17

T-MAP TEST / REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17

IDLE AIR CONTROL VALVE (IAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17

IAC TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17

IAC REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.18

THROTTLE POSITION SENSOR (TPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19

TPS RESISTANCE TESTS / TPS TESTER KIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.19

CHECKING TPS READING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20

TPS ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21

TPS REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.22

ENGINE COOLANT TEMPERATURE SENSOR (ECT) . . . . . . . . . . . . . . . . . . . . . . . . . 3.22

ECT SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.22

ECT SENSOR REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.23

IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23

IGNITION COIL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.23

IGNITION COIL AND HT LEAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.24

EFI DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25

INSTRUMENT CLUSTER TROUBLE CODE DISPLAY. . . . . . . . . . . . . . . . . . . . . . . . .3.25

FUEL SYSTEM TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28

EFI SYSTEM BREAK-OUT DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29

FUEL INJECTOR CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.30

IDLE AIR CONTROL (IAC) CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.31

CRANKSHAFT POSITION SENSOR (CPS) CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . .3.31

FUEL PUMP / FUEL LEVEL SENSOR CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.32

FUEL PUMP CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.33

FUEL GAUGE CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.33

ENGINE COOLANT TEMPERATURE SENSOR (ECT) CIRCUIT. . . . . . . . . . . . . . . . .3.34

THROTTLE POSITION SENSOR (TPS) CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.34

TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP) CIRCUIT. . . . . . . . .3.35

DIAGNOSTIC CONNECTOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.35

DIAGNOSTIC CONNECTOR CIRCUIT (EPS MODELS). . . . . . . . . . . . . . . . . . . . . . . .3.36

3.1

ELECTRONIC FUEL INJECTION

SPECIAL TOOLS

Part Numbers / Descriptions

PART

NUMBER

PU-43506-A Fuel Pressure Gauge Kit

PS-48762 Fuel Pressure Gauge Adaptor

2201519 Throttle Position Sensor Tester Kit

Digital Wrench™ Diagnostic Software

PU-47063

PU-47471

IMPORTANT: For the most recent information on Digital Wrench™ software and fileset downloads please visit the website: www.polaris.diagsys.com

(Includes most recent version of software and a serial number)

Digital Wrench™ SmartLink Module Kit (PU-47470, PU-47469, PU-47468)

PU-47470

PU-47469

PU-47468

TOOL DESCRIPTION

Digital Wrench™ PC Interface Cable

Digital Wrench™ Vehicle Interface Cable

Digital Wrench™ SmartLink Module

Fuel Pressure Gauge Kit - PU-43506-A

IMPORTANT: The EFI fuel system remains under high pressure, even when the engine is not running. Before attempting to service any part of the fuel system, the pressure must be relieved. The Fuel Pressure Gauge Kit has an integrated pressure relief valve that can be used to bleed off pressure.

Relief Valve

Adaptor shown is

included with kit.

Fuel Pressure Gauge Adaptor - PS-48762

Used in conjunction with PU-43506-A to check fuel pressure.

WARNING

* Gasoline is extremely flammable and explosive

under certain conditions.

* EFI components are under high pressure. Verify

system pressure has been relieved before

disassembly.

* Never drain the fuel system when the engin e is hot.

Severe burns may result .

* Do not overfill the tank. The tank is at full capacity

when the fuel reaches the bottom of the filler neck.

Leave room for expansion of fuel.

* Never start the engine or let it run in an enclosed

area. Gasoline powered engine exhaust fumes ar e

poisonous and can cause loss of consciousness and

death in a short time. * Do not smoke or allow open flames or sparks in or near the area where refueling is performed o r where

gasoline is stored.

* If you get gasoline in your eyes or if you should

swallow gasoline, seek medical attention immediately.

* If you spill gasoline on your skin or clothing,

immediately wash with soap and water and change

clothi n g .

* Always stop the engine and refuel outdoors or in a

well ventilated area.

7/16-20 Schrader

Throttle Position Sensor Tester Kit - 2201519

This tester allows the use of a digital multi-meter to test TPS function and perform the “TPS Adjustment” procedure. Polaris Dealers can order special tools from SPX Corporation.

3.2

ELECTRONIC FUEL INJECTION

Digital Wrench™ Diagnostic Software PU-47063

This dealer-only software installs on laptop computers equipped with a CD drive and serial port connection, and is designed to replace multiple shop tools often used to test EFI components. It also includes step-by-step diagnostic procedures to aid technician repair and troubleshooting.

Digital Wrench™ SmartLink Module Kit - PU-47471

This module kit contains the necessary cables and hardware to communicate between the vehicle ECU and the Digital Wrench™ diagnostic software. Polaris dealers can also order the following separately: SmartLink Module PU-47468, Vehicle Interface Cable PU-47469 and PC Interface Cable PU-

47470. This kit is available to Polaris dealers through our tool supplier, SPX (1-800-328-6657).

PU-47469

Digital Wrench™ - Download Website

Located at: www.polaris.diagsys.com

PU-47468

PU-47470

Digital Wrench™ - Diagnostic Connector

The diagnostic connector is located under the front rack, near the fuse box and rear brake reservoir.

3.3

ELECTRONIC FUEL INJECTION

FUEL TANK

Exploded View

Tank Vent

Rollover Valve

PFA Nut

Electrical Connector

Pressure Regulator

Fuel Pump*

Float Arm

PFA Gasket

Fuel Flow

Fuel Tank

Fuel Tank Assembly

*NOTE: Fuel Pump is NOT Serviceable

Fuel Rail

Fuel Injectors

Pressure Regulator

Fuel Filters

Fuel Pump Assembly

3.4

Quick Connect Fuel Line

ELECTRONIC FUEL INJECTION

FUEL LINE

Quick Connect Removal / Installation

CAUTION

Verify fuel system has been depressurized

before performing this procedure.

All EFI models use quick connect fuel lines. Refer to the following steps for fuel line removal / installation:

1. Thoroughly clean the connector and place a shop towel around the fuel line to catch any dripping fuel.

2. Squeeze the connector tabs together and lift up on the white retainer. NOTE: Use an O-ring pick or similar tool to disengage the inner white tab if the fuel tank is installed.

EFI SERVICE NOTES

For more convenient and accurate testing of EFI components, it is recommended dealers utilize the Digital Wrench™ Diagnostic Software (dealer only), or limited testing may be done manually using the procedures provided.

80% of all EFI problems are caused by wiring harness connections. Follow a common sense approach when diagnosing a potential EFI issue:

1. Disconnect the harness at the suspected sensor connector.

2. Inspect the connector ends for damage or contamination. If damaged, repair; if contaminated, clean. Reconnect and check function.

3. If problem persists, perform a sensor bench test according to the specific sensor requirements (if applicable).

4. If the sensor bench tests pass, disconnect the connector at the ECU and perform a continuity check between the sensor connector and the appropriate pin at the ECU connector (all connections for that sensor). Wiring resistance should be less than one (1) ohm.

Lift white retainer

before removing

3. Pull out on the fuel line and remove it from the pump outlet.

4. To install the line, verify the connector and fuel pump outlet are clean and free of debris.

5. Place the connector end over the fuel pump outlet and push the white retainer and tabs back into place.

NOTE: Confirm attachment by pulling on the fuel line.

6. Repeat this process when removing the fuel line from the fuel rail.

Fuel Pump

Outlet

5. If the resistance is high (or open), a wiring harness inspection is required (including a thorough inspection of the ECU connector for contamination or damage).

6. If the sensor passes and the wiring passes insp ection, and reconnecting the ECU does not resolve the issue, then at that point a known-good ECU (from another Polaris 850) may be used to test for problem resolution.

• Never attempt to service any fuel system component

while engine is running or ignition switch "on".

• USE CARE when removing or installing the ECU

connector, as well as all other harness connections on the unit. Properly connect and disconnect the ECU harness to minimize damage to the connector pins and locking mechanism.

• Although every precaution has been taken to prevent

water intrusion failure, avoid direct water or spray contact with system components.

• Do not disconnect or reconnect the wiring harness

connector to the ECU or any individual components with the ignition "on." This can send a damaging voltage spike through the ECU.

• Do not allow battery cables to touch opposite terminals.

Fuel Rail

• Never start the engine when the cables are loose or

poorly connected to the battery terminals.

• Never disconnect battery while engine is running.

• Always unplug ECU from the wire harness before

performing any welding on the unit.

3.5

ELECTRONIC FUEL INJECTION

EFI SYSTEM LAYOUT

Exploded View

1. Electronic Control Unit (ECU)

2. Temperature / Manifold Absolute Pressure Sensor (T-MAP)

3. Idle Air Control (IAC)

4. Crankshaft Position Sensor (CPS)

5. Fuel Injectors

6. Fuel Rail

7. Fuel Line (quick connect)

8. Fuel Pump / Regulator / Fuel Gauge Sender (inside fuel tank)

9. Engine Coolant Temperature Sensor (ECT)

10. Throttle Position Sensor (TPS)

11. Throttle Body

12. Ignition Coil

Located in the

Fuel Tank Asm.

3.6

ELECTRONIC FUEL INJECTION

EFI COMPONENTS

Identification / Location

1. Electronic Control Unit (ECU)

- Attached to the air box, located behind the LH side panel.

ECU

2. Temperature and Manifold Absolute Pressure Sensor (T-MAP)

- Located in the Integrated Air Fuel Manifold (IAFM).

4. Crankshaft Position Sensor (CPS)

- Located in the top portion of the magneto cover on the front of the engine.

CPS

5. Fuel Injectors

- Located in the Integrated Air Fuel Manifold (IAFM).

Fuel Rail

T-MAP

3. Idle Air Control (IAC)

- Located in front of the engine behind the frame support.

IAC

Pressure

Valve

6. Fuel Rail / Fuel Pressure Valve

- Attached to the top portion of the fuel injectors.

- Located on the PTO end of the fuel rail.

7. Fuel Line (Quick Connect)

- Located between the injector fuel rail and the fuel tank.

PTO

Fuel Injector

4 & 7

9 & 10

3.7

ELECTRONIC FUEL INJECTION

8. Fuel Pump / Regulator / Fuel Gauge Sender Assembly

- Located behind the right-hand side panel.

Fuel Pump

- Located in the fuel tank as an assembly.

Fuel Pump Assembly

10. Throttle Position Sensor (TPS)

- Located on the MAG end (front) of the throttle body.

TPS

11. Throttle Body

- Attached between the IAFM and the intake plenum.

Throttle Body

Intake

Plenum

IAFM

9. Engine Coolant Temperature Sensor (ECT)

- Located in the cylinder head below the thermostat housing, just above the throttle body.

ECT

3.8

12. Ignition Coil

- Located on the RH side of the airbox. The high tension leads are retained by the airbox.

Ignition Coil

ELECTRONIC FUEL INJECTION

General Information

The Electronic Fuel Injection (EFI) system is a complete engine fuel and ignition management design. This system includes the following principal components:

• Fuel Pump / Fuel Filters / Pressure Regulator

• Fuel Line

• Fuel Rail

• Fuel Injectors

• Throttle Body / lntegrated Air Fuel Manifold (IAFM)

• Electronic Control Unit (ECU)

• Ignition Coil

• Engine Coolant Temperature Sensor (ECT)

• Throttle Position Sensor (TPS)

• Crankshaft Position Sensor (CPS)

• Intake Air Temperature / Manifold Absolute

Pressure Sensor (T-MAP)

• Idle Air Control (IAC)

The ECU controls the amount of fuel being injected and the ignition timing by monitoring the primary senso r signals for intake air temperature, manifold absolute pressure (load), engine temperature, speed (RPM), and throttle position. These primary signals are compared to the programming in the ECU computer chip, and the ECU adjusts the fuel delivery and ignition timing to match the values.

During operation the ECU has the ability to re-adjust temporarily, providing compensation for changes in overall engine condition and operating environment, so it will be able to maintain the ideal air/fuel ratio.

During certain operating periods such as cold starts, warm up, acceleration, etc., a richer air / fuel ratio is automatically

calculated by the ECU.

Initial Priming / Starting Procedure

NOTE: The injection system must be purged of all air prior to the initial start up, and / or any time the system has been disassembled.

If the EFI system is completely empty of fuel or has been disassembled and repaired:

• Wire Harness Assembly

EFI Operation Overview

The EFI system is designed to provide peak engine performance with optimum fuel efficiency and lowest possible emissions. The ignition and injection functions are electronically controlled, monitored and continually corrected during operation to maintain peak performance.

The central component of the system is the Bosch Engine Control Unit (ECU) which manages system operation, determining the best combination of fuel mixture and ignition timing for the current operating conditions.

An in-tank electric fuel pump is used to move fuel from the tank, through the fuel line, to the fuel rail. The in-tank fuel pressure regulator maintains a system operating pressure of 43 psi and returns any excess fuel to the tank. At the engine, fuel is fed through the fuel rail and into the injectors, which inject into the intake ports. The ECU controls the amount of fuel by varying the length of time that the injectors are "on." This can range from

1.5-8.0 milliseconds depending on fuel requirements. The

controlled injection of the fuel occurs every other crankshaft revolution, or once for each 4-stroke cycle. The total amount of fuel needed for one firing of a cylinder is injected during each cycle. When the intake valve opens, the fuel/air mixture is drawn into the combustion chamber, ignited and burned.

1. Cycle the key switch from “OFF” to “ON” 6 times, waiting for approximately 3 seconds at each “ON” cycle to allow the fuel pump to cycle and shut down.

2. Once step 1 is completed, turn the key switch to “START” until the engine starts or 5 seconds has passed.

3. If the engine failed to start, repeat step 1 for 2 more cycles and attempt to start the engine.

If the engine fails to start, a problem may still exist, and should be diagnosed.

NOTE: Accurate testing of EFI components is recommended utilizing the Digital Wrench™

Diagnostic Software (dealer only).

3.9

ELECTRONIC FUEL INJECTION

ELECTRONIC CONTROL UNIT (ECU)

Operation Overview

The ECU is the brain or central processing computer of the entire EFI fuel/ignition management system. During operation, sensors continuously gather data which is relayed thro ugh the wiring harness to input circuits within the ECU. Signals to the ECU include: ignition (on/off), crankshaft position and speed (RPM), throttle position, engine coolant temperature, intake air temperature, intake manifold air pressure and battery voltage.

The ECU compares the input signals to the programmed maps in its memory and determines the appropriate fuel and spark requirements for the immediate operating conditions. The ECU then sends output signals to set the injector duration and ignition timing.

To prevent engine over-speed and possible failure, an RPMlimiting feature is programmed into the ECU. If the maximum RPM limit (8000) is exceeded, the ECU suppresses the injection signals, cutting off the fuel flow. This process repeats it self in rapid succession, limiting operation to the preset maximum.

Maximum RPM Limit: 8000

SPORTSMAN XP 850 RPM Limit:

Hard Limit - Fuel injector suppression occurs

• All Gears: 8000 RPM

Soft Limit - Spark timing suppression occurs

• All Gears: 7500 RPM

ECU Service

Never attempt to disassemble the ECU. It is sealed to prevent damage to internal components. Warranty is void if the case is opened or tampered with in any way.

All operating and control functions within the ECU are pre-set. No internal servicing or readjustment may be performed. If a problem is encountered, and you determine the ECU to be faulty, contact the Polaris Service Department for specific handling instructions. Do not replace the ECU without factory authorization.

During operation, the ECU continually performs a diagnostic check of itself, each of the sensors, and system performance. If a fault is detected, the ECU turns on the “Check Engine” light in the speedometer and stores the fault code in its fault memory. Depending on the significance or severity of the fault, normal operation may continue, or "Fail-Safe" operation (slowed speed, richer running) may be initiated. A technician can determine the cause of the “Check Engine” light by initiating the “Blink Code” sequence or by using Digital Wrench™. The ECU requires a minimum of 7.0 volts to operate. The memory in the ECU is operational the moment the battery cables are connected.

The relationship between the ECU and the throttle position sensor (TPS) is very critical to proper system operation. If the TPS is faulty, or the mounting position of the TPS to the throttle body is altered, the TPS must be adjusted.

For the purpose of troubleshooting, a known-good ECU from another Polaris Sportsman XP 850 of the same model may be

used without system or engine component damage.

3.10

ELECTRONIC FUEL INJECTION

ECU Removal / Replacement

1. Remove the seat and upper left-hand side panel (see Chapter 9 “Seat and Side Panels”).

2. With the ignition turned off, disconnect the wire harness from the ECU by pulling the black slider out away from the ECU while pulling down on the connector. Once the slider is fully extended, pull the connector from the ECU, using care not to damage the connector or locking mechanism.

FUEL PUMP

Operation

NOTE: All EFI units utilize quick connect fuel lines.

An electric fuel pump assembly is used to transfer fuel to the EFI system from inside the fuel tank. This assembly includes the fuel pump, regulator and fuel gauge sender. The pump is rated for a minimum output of 25 liters per hour at 4 3 psi and has a nonserviceable preliminary 65-micron filter.

Fuel pump is not serviceable, picture for reference only.

Regulator

Fuel Gauge

Sender

3. Remove the (4) screws retaining the ECU to the airbox and remove the ECU.

4. To install, reverse the previous steps. DO NOT apply dielectric grease to the connector, as it is a sealed connector. Tighten screws to 10 in. lbs. (1.1 Nm).

= T

ECU Retaining Screws

10 in. lbs. (1.1 Nm)

Preliminary Filter

65-micron

When the key switch is turned to "ON", the ECU activates the fuel pump, which pressurizes the system for start-up.

The ECU switches off the pump preventing the continued delivery of fuel in these instances:

• If the key switch is not promptly turned to the "start" position.

• If the engine fails to start.

• If the engine is stopped with the key switch "ON" (as in the case of an accident).

Fuel Pump

IMPORTANT: If replacing the ECU, you must reflash the new ECU with the correct calibration upon installation and prior to attempting to start the ve hicle.

3.11

ELECTRONIC FUEL INJECTION

Fuel Sender Test

If the fuel gauge reading on the instrument cluster is not working, or if the display reading differs in large comparison to the fuel in the tank, perform a resistance test on the fuel sender .

Disconnect the fuel pump / sending unit connection and measure the resistance between the Purple and Brown wires. If out of specification, replace the fuel pump / tank assembly.

Fuel Sender Resistance Specifications:

Full: 6 Ω

Empty: 90 Ω

Fuel Pump Test

NOTE: The fuel pump / tank assembly is a nonserviceable assembly and must be replaced if determined to be faulty. If a fuel delivery problem is suspected, make certain the pump is being activated by the ECU and EFI relay, all electrical connections are properly secured, the 20A EFI fuse is good , and a minimum of 7.0 volts is being supplied.

2. Locate the fuel pressure valve attached to the fuel rail.

Pressure Valve

3. Remove the black cap and attach the fuel pressure gauge kit and adaptor to the pressure valve. Route the clear hose into a portable gasoline container or the vehicle’s fuel tank.

4. Turn on the key switch to activate the pump and check the system pressure on the gauge. If system pressure of 43 psi ± 3 is observed, turn the key switch “off” and depress the valve button on the tester to relieve the system pressure.

CAUTION

Fuel is extremely flammable and may cause

severe burns, injury, or death.

Do not use any device that produces a flame or

electrical devices that may spark around

fuel or fuel vapors.

1. Couple the Fuel Pressure Gauge Adaptor (PS-48762) to the Fuel Pressure Gauge Kit (PU-43506-A).

PU-43506-A

Relief Valve

Adaptor shown is

included with kit.

PS-48762

7/16-20 Schrader

Fuel Pump Pressure: 43 psi ± 3

NOTE: If the fuel pressure is out of specification, replace the fuel pump / tank assembly.

5. If the pump did not activate (Step 4), disconnect the plug from the fuel pump. Connect a DC voltmeter across terminals “A” and “C” in the plug on the vehicle harness side. Turn on the key switch and observe voltage to ensure a minimum of 7 volts is present.

NOTE: If the voltage was below 7 VDC, test battery, ignition switch, EFI relay and wiring harness.

6. If the reading is between 7 and 14 volts, turn key switch off and connect an ohmmeter between the terminals “A” and “C”' in the plug on the pump harness to check for continuity within the fuel pump.

NOTE: If there was no continuity between the pump terminals, replace the fuel pump / tank assembly.

7. If voltage at the plug was within the specified range, and there was continuity across the pump terminals, reconnect the plug to the pump, making sure you have clean connections. Turn on the key switch and listen for the pump to activate.

NOTE: If the pump starts, verify you have the correct amount of fuel pressure.

8. If the pump still does not operate, check ECU operation by plugging in a known-good ECU of the same model.

NOTE: If the pump still does not operate, replace the fuel pump / tank assembly.

3.12

ELECTRONIC FUEL INJECTION

Fuel Pump / Fuel Tank Removal

IMPORTANT: Syphon as much fuel from the tank as possible before attempting to remove it from the ATV.

WARNING

Always wear safety goggles when working with high pressure or flammable fluids. Failure to do so could result in serious injury or complications.

NOTE: The fuel pump cannot be replaced as an individual component, the entire fuel pump and fuel tank must be replaced as an assembly. Refer to the “Electronic Parts Catalog” for the proper part number.

1. Remove the seat and both upper side panels (see Chapter 9 “Seat and Side Panels”).

2. Disconnect the negative battery cable.

3. Remove the (4) push rivets from each front mud guard and remove the guards from the vehicle (see Chapter 9 “Mud Guards”).

8. Remove the vent line from the fitting on top of the fuel tank.

Vent Fitting

9. Disconnect the fuel pump electrical harness.

Fuel Line

Connector

4. Remove the front rack assembly (see Chapter 9 “Front Rack”).

5. Remove the front cab assembly (see Chapter 9 “Front Cab”).

IMPORTANT: Be sure to cover the fuel tank inlet with a shop towel prior to front cab and fuel tank removal (see Chapter 9 “Front Cab”).

6. Remove the (4) screws from the bottom of the right-hand footwell.

7. Remove the (2) fuel tank mounting screws located on the upper portion of the fuel tank.

Pump

Harness

10. While holding a shop towel over the fuel line connector, disconnect the quick connect fuel line from the fuel pump.

NOTE: A small amount of fuel may come out of the fuel line or tank. Properly drain fuel into a suitable container.

11. Carefully pull the fuel tank out the right side of the ATV.

3.13

ELECTRONIC FUEL INJECTION

Fuel Pump / Fuel Tank Installation

1. Reinstall the fuel tank assembly through the right side.

2. Connect the fuel line to the fuel pu mp outlet and connect the fuel pump electrical harness.

3. Reinstall the vent line to the tank fitting.

4. Install the (2) fuel tank mounting screws and tighten securely.

5. Install the (4) screws into t he bottom portion of t he righthand footwell.

6. Install the front cab assembly (see Chapter 9 “Front Cab”).

7. Remove the shop towel from the fuel tank inlet, reconnect the fuel fill hose and tighten hose clamp securely.

8. Install the front rack assembly (see Chapter 9 “Front Rack”).

9. Install the front mud guards (see Chapter 9 “Mud Guards”).

10. Reconnect the negative cable to the battery.

11. Install the upper side panels and seat (see Chapter 9 “Seat and Side Panels”).

12. Test the fuel pump by turning on the key and listening for the pump to activate.

FUEL INJECTORS

Operation Overview

The fuel injectors mount into the Integrated Air Fuel Manifold (IAFM), and the fuel rail attaches to the top end of them. Replaceable O-rings on both ends of the injector prevent external fuel leaks and also insulate it from heat and vibration.

Pressure

Valve

When the key switch is on, the fuel rail is pressurized, and the EFI relay provides voltage to the injectors. During engine operation, the ECU completes the ground circuit, energizing the injectors. The valve needle in the injector is opened electromagnetically , and the pressure in the fuel rail forces fuel down through the inside. The “director plate” at the tip of the injector contains a series of calibrated openings which directs the fuel into the intake port in a cone-shaped spray pattern.

Damper

Fuel Injectors

FUEL PRESSURE REGULATOR

Operation Overview

The fuel pressure regulator maintains the required operating system pressure of 43 psi ± 3 psi. A rubber-fiber diaphragm divides the regulator into two separate sections, the fuel chamber and the pressure regulating chamber. The pressure regulating spring presses against the valve holder (part of the diaphragm), pressing the valve against the valve seat. The combination of atmospheric pressure and regulating spring tension equals the desired operating pressure. Any time the fuel pressure against the bottom of the diaphragm exceeds the desired (top) pressure, the valve opens, relieving the excess pressure, returning the excess fuel back to the tank.

Fuel Pressure Regulator Test

Refer to the “Fuel Pump Test” procedure.

Fuel Pressure Regulator Replacement

The regulator is a sealed, non-serviceable assembly. If it is faulty, the fuel tank assembly must be replaced. Refer to the “Fuel Pump / Tank Assembly Replacement” procedure.

The amount of fuel injected is controlled by the ECU and determined by the length of time the valve needle is held open, also referred to as the “injection duration” or “pulse width”. It may vary in length depending on the speed and load requirements of the engine.

Fuel Injector Service

Injector problems typically fall into three general categorieselectrical, dirty / clogged, or leakage. An electrical problem usually causes one or both of the injectors to stop functioning. Several methods may be used to check if the injectors are operating.

NOTE: Do not apply voltage directly to the fuel injectors. Excessive voltage will burn out the injectors. Do not ground the injectors with the ignition on. The injectors will open if the EFI relay is energized.

If an injector is not operating, it can indicate either a bad injector, or a wiring/electrical connection problem. Check as follows:

3.14

ELECTRONIC FUEL INJECTION

Injector leakage is very unlikely, but in rare instances it can be internal (past the tip of the valve needle), or external (weeping around the injector body). The loss of system pressure from the leakage can cause hot restart problems and longer cranking times.

Injector problems due to dirt or clogging are unlikely due to the design of the injectors, the high fuel pressure, the use of filters and the detergent additives in the gasoline. Symptoms that could be caused by dirty/clogged injectors include rough idle, hesitation/stumble during acceleration, or triggering of fault codes related to fuel delivery. Injector clogging is usually caused by a buildup of deposits on the director plate, restricting the flow of fuel, resulting in a poor spray pattern. Some contributing factors to injector clogging include; dirty air filters, higher than normal operating temperatures, short operating intervals and dirty, incorrect, or poor quality fuel. Cleaning of clogged injectors is not recommended; they should be replaced. Additives and higher grades of fuel can be used as a preventative

measure if clogging has been a problem.

Fuel Injector Test

If an injector is not operating, it can indicate either a bad injector, or a wiring/electrical connection problem. Check as follows:

• Remove the seat, left-hand side panel, and disconnect the fuel injector(s).

6. Carefully disconnect the ECU by pulling the tab out while pulling down on the connector.

7. Loosen the hose clamp retaining the intake boot to the intake plenum and remove the boot.

8. Lift up on the air box and turn it sideways to gain access to the fuel rail and fuel injectors.

9. Thoroughly clean the area around the fuel rail and injectors.

10. Disconnect the “quick connect” fuel line from the fuel rail.

11. Disconnect the harness from both fuel injectors.

12. Using a 10 mm wrench, remove the fuel rail mounting screws.

13. Carefully pull up on the fuel rail and fuel injectors and remove them from the vehicle as an assembly.

Fuel Rail

Injectors

• Using an ohmmeter, test for continuity by placing the test leads on each pin of the injector.

• Resistance specification is 13.8Ω - 15.2Ω (20°C, 68°F)

Fuel Injector Resistance Specification:

13.8Ω - 15.2Ω (20°C, 68°F)

Fuel Injector Replacement

NOTE: Engine must be cool. Depressurize the fuel system if possible.

1. Remove the seat and both upper side panels (see Chapter 9 “Seat and Side Panels”).

2. Remove the (2) screws retaining the lower portion of th e air box.

3. Remove the hose from the breaker valve located on top of the valve cover.

4. Remove the spark plug wires.

5. Remove the (2) Torx-head screws retaining the upper portion of the air box to the front cab.

14. Pry the two injector retaining tabs open and remove the injector(s) from the fuel rail.

NOTE: Use new O-rings (included with new injector) any time an injector is removed.

15. Lubricate the O-rings lightly with soapy water to aid installation.

16. Install the new injector and torque the fuel rail mounting screws to 6 - 9 ft. lbs. (8 - 12 Nm).

3.15

ELECTRONIC FUEL INJECTION

CRANKSHAFT POSITION SENSOR (CPS)

Operation Overview

The engine speed sensor is essential to engine operation, constantly monitoring the rotational speed (RPM) and position of the crankshaft.

CPS

“Removed”

A ferromagnetic 60-tooth ring gear with two consecutive teeth missing is mounted on the flywheel. The inductive speed sensor is mounted 1.0 ± 0.26 mm (0.059 ± 0.010 in.) aw ay from the ring gear. During rotation, an AC pulse is created within the sensor for each passing tooth. The ECU calculates engine speed from the time interval between the consecutive pulses. The twotooth gap creates an “interrupt” input signal, corresponding to specific crankshaft position. This signal serves as a reference for the control of ignition timing by the ECU. Synchro nization of the CPS and crankshaft position takes place during the first two revolutions each time the engine is started. This sensor must be properly connected at all times. If the sensor fails or becomes disconnected for any reason, the engine will stop running.

3. Connect an ohmmeter between the pin terminals as shown. A resistance value of 860 Ω ± 10% at room temperature

° C, 68° F) should be obtained.

(20

CPS Connector

Measure resistance

at these two pins

4. If resistance is correct, check the mounting, toothed ring gear (damage, runout, etc.), and flywheel key.

Crankshaft Position Sensor:

860Ω ± 10% (20° C, 68° F)

CPS Replacement

1. Disconnect sensor harness connector (see “CPS Test”).

2. Using a 6 mm hex wrench, remove the retaining bolt and remove the sensor from the magneto cover.

CPS Test

The crankshaft position sensor is a sealed, non-serviceable assembly. If fault code diagnosis indicates a problem with the CPS, test and correct as follows:

1. Remove the seat and left-hand side panel.

2. Locate and disconnect the CPS harness connector on the left side of the vehicle just below the ECU.

Disconnect

CPS

3. Install the new sensor using a light coating of oil on the Oring to aid installation.

4. Torque the retaining bolt to specification.

= T

CPS Retaining Bolt Torque:

7 ft. lbs. (10 Nm)

3.16

ELECTRONIC FUEL INJECTION

TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP)

Operation Overview

Mounted on the (IAFM), the temperature and manifold absolute pressure sensor (T-MAP) performs two functions in one unit.

T-MAP

Air passing through the intake is measured by the T-MAP and relayed to the ECU. These signals, comprised of separate air temperature and manifold absolute pressure readings, are processed by the ECU and compared to its programming for determining the fuel and ignition requirements during operation.

T-MAP Test

The temperature and manifold absolute pressure sensor (T-MAP) is a non-serviceable item. If it is faulty, it must be replaced. This sensor requires a 5 Vdc input to operate, therefore the T-MAP sensor should only be tested using the Digital

Wrench™ Diagnostic Software (dealer only).

IDLE AIR CONTROL VALVE (IAC)

Operation Overview

The Idle Air Control (IAC) is used to stabilize the idle quality of the engine at cold start-up and after warm-up operations.

IAC

Mounted in front of the engine, the IAC contains 1 stepper motor which receives varying voltage signal pulses from the ECU. These pulses determine the IAC plunger setting, thereby controlling the amount of air bypassing the closed throttle body for idle control. If the IAC is disconnected or inoperative, it will remain at it’s last operated position.

IAC Test

The IAC is a non-serviceable item. If it is faulty, it must be replaced. It can be ‘bench tested’ using the following method:

Set your meter to read Ohms. Check the resistance values at each of the following pin locations of the IAC. If any of the readings are out of specification, replace the IAC

IAC Valve Connector

T -MAP Replacement

1. Disconnect the sensor from the main harness.

2. Using a 10 mm wrench, remove the retaining bolt and sensor.

3. Install the new sensor using a light coating of oil on the Oring to aid installation.

4. Torque the retaining bolt to specification.

= T

T-MAP Retaining Bolt Torque:

35-53 in. lbs. (4-6 Nm)

IAC Resistance Readings

Pins Resistance Pins Resistance

1 - 2 30Ω ± 1.2Ω 4 - 5 30Ω ± 1.2Ω 2 - 3 30Ω ± 1.2Ω 5 - 6 30Ω ± 1.2Ω 1 - 3 60Ω ± 2.4Ω 4 - 6 60Ω ± 2.4Ω

3.17

ELECTRONIC FUEL INJECTION

IAC Replacement

1. Remove the seat and upper right-hand side panel (see Chapter 9 “Seat and Side Panels”).

2. Disconnect the shift linkage from the shift lever.

3. Remove the spark plug wires.

4. Remove the retaining screw from the lower right-hand side of the airbox.

5. Remove the push rivets retaining the right-hand portion of the rear cab to gain access to the bolts retaining the upper right-hand frame support.

6. Remove the (4) bolts retaining the upper right-hand frame support. Pull the support forward and down to remove it from the vehicle.

Remove

8. Remove the (3) Phillips-head mounting screws and remove the IAC from the housing.

9. Install the new IAC and torque the mounting screws to 17.7 in. lbs. (2 Nm).

= T

IAC Mounting Screw Torque:

17.7 in. lbs. (2 Nm)

Disconnect

Remove

7. Disconnect vehicle harness from IAC.

IAC

Disconnect

10. Reconnect vehicle harness to IAC.

11. Reinstall the throttle body and securely tighten the hose clamps.

12. Reinstall the side panel and seat.

3.18

ELECTRONIC FUEL INJECTION

THROTTLE POSITION SENSOR (TPS)

Operation Overview

The throttle position sensor (TPS) is used to indicate throttle plate angle to the ECU.

TPS

Mounted on the throttle body and operated directly off the end of the throttle shaft, the TPS works like a rheostat, vary ing th e voltage signal to the ECU in direct correlation to the angle of the throttle plate. This signal is processed by the ECU and compared to the internal pre-programmed “maps” to determine the required fuel and ignition settings for the amount of engine load.

The correct position of the throttle body

stop screw is established and set at the

factory. DO NOT remove the tamper proof

cap to adjust the throttle body stop screw or

alter its position in any manner. The stop

screw controls the air flow calibration

Throttle

Body

of the throttle body.

TPS Resistance Tests

The throttle position sensor (TPS) is a non-serviceable item. If it is faulty, it must be replaced. It can be tested using the following method:

Using an Ohm Meter:

With the test leads connected and the meter set to the ohms scale, observe the reading at the following pin locations of the TPS:

TPS Connector

TPS Resistance Readings

Pins Throttle Position Resistance

d-GND ----- ∞

c-d Closed 4kΩ - 5kΩ (reference) c-d Open c-e ----- 4kΩ − 6kΩ

1150Ω - 1250Ω

(reference)

TPS Tester Kit

The throttle position sensor (TPS) reading can be checked by using the TPS Tester Kit (2201519).

Set-up the TPS Tester Kit (2201519), according to the instructions that accompanied the tester. Make sure the 9 volt battery is new.

Throttle

Body

Stop Screw

(Factory Set)

DO NOT ADJUST

TPS Tester

P/N - 2201519

Use a New

9V Battery

3.19

ELECTRONIC FUEL INJECTION

Verify TPS Tester Reference Voltage

A 5 volt reference voltage signal from the TPS Tester harness is required for the TPS test to be accurate. Refer to the instructions provided with the TPS T ester Kit (2201519) or follow the bullet point steps below to check reference voltage.

Reference Voltage Test:

• Insert black voltmeter probe into the “Bk” test port.

• Connect the red voltmeter probe into the “R” test port

and verify the voltage is 4.99-5.01 Vdc. If this reading is low, verify the 9 volt battery is good or try a new 9 volt battery.

Checking TPS Reading

1. Remove the seat and upper left-hand side panel (see Chapter 9 “Seat and Side Panels”).

2. Assemble the TPS Tester according to the instructions. Refer to “TPS Tester Kit” for proper set-up and testing. Verify the 9 volt tester battery is new.

3. Disconnect vehicle harness from TPS.

Disconnect

TPS Reference Voltage

5 Vdc Input

IMPORTANT: Always use a fresh 9 Volt battery.

4. Plug the TPS Tester harness in the TPS harness.

5. Set your voltmeter to read Vdc. Connect the red voltmeter probe into the “R” test port and the black voltmeter probe into the “Y” test port (see Figure 3-20).

2201519 Tester

Black Probe

Red Probe

Black

Pink

Should Read

.700 ± .050 Vdc

Red

.700

3.20

Figure 3-20

6. Move the throttle open and closed slowly while reading the display. The voltage should increase and decrease smoothly without any “jumps” when the throttle is applied.

ELECTRONIC FUEL INJECTION

7. If voltage varies with throttle movement, continue on to the next step. If the sensor did not function correctly, replace it.

8. Allow the throttle lever to rest in the idle position. The voltmeter should read .700 ± .050 volts.

TPS Output Reading

.700 ± .050 Vdc

9. If the voltage does not read within the specification, proceed to the “TPS Adjustment” procedure. If the voltage reading is within specification, no adjustment is required.

TPS Adjustment

NOTE: This procedure should be performed after you have checked the TPS reading. Refer to “Checking TPS Reading” procedure before making any adjustments.

1. Loosen the hose clamp retaining the intake boot to the intake plenum.

7. Retighten TPS mounting screws and torque to specification.

= T

TPS Mounting Screws:

17.7 in. lbs. (2 Nm)

8. Verify voltage reading did not chang e. If voltage readi ng changed, repeat steps 5 - 7.

9. Reconnect the vehicle harness to the TPS.

10. Reinstall the throttle body and intake plenum. Torque bolts to specification.

2. Remove the (4) bolts retaining the intake plenum and throttle body.

3. Position the throttle body to access the TPS screws.

4. Make sure the TPS Tester harness is still connected to the TPS harness.

5. Loosen the TPS mounting screws.

6. Rotate the TPS until your voltmeter reads .700 ± .050 volts (see Figure 3-20).

= T

Intake Plenum Bolts:

7 ft. lbs. (10 Nm)

11. Install intake boot to intake plenum and securely tighten the hose clamp.

12. Reinstall the left-hand side panel and seat.

13. Start engine and test operation.

TPS Output Reading

.700 ± .050 Vdc

3.21

ELECTRONIC FUEL INJECTION

TPS Replacement

NOTE: The correct position of the TPS angle on the throttle body is established and set at the factory. If the TPS is replaced, repositioned or loosened it must be recalibrated. Refer to the “TPS Adjustment”

procedure.

1. Remove the seat and upper left-hand side panel (see Chapter 9 “Seat and Side Panels”).

2. Loosen the hose clamp retaining the intake boot to the intake plenum.

3. Remove the (4) bolts retaining the intake plenum and throttle body.

4. Position the throttle body to access the TPS harness and mounting screws.

5. Disconnect the harness from the TPS.

Disconnect

ENGINE COOLANT TEMPERATURE SENSOR (ECT)

Operation Overview

The engine coolant temperature sensor measures coolant temperature. The engine temperature sensor is a Negative Temperature Coef ficient (NTC) type sensor, as the temperature increases the resistance decreases.

6. Remove the (2) Phillips-head mounting screws and replace the TPS.

IMPORTANT: If replacing the TPS or throttle body, you must perform the “TPS Adjustment” procedure.

7. Refer to “TPS Adjustment” for setting the TPS voltage.

Coolant passes through the cylinder and by the sensor probe, varying a resistance reading which is relayed to the ECU. This signal is processed by the ECU and compared to its programming for determining the fuel and ignition requirements during operation. The ECU also uses this signal to determine when to activate the fan during operation.

ECT Sensor Test

To quickly rule out other components and wiring related to the ECT, disconnect the harness from the ECT sensor and start the engine. After a few seconds, the fan should turn on and the “Over Temp” indicator should display on the instrument cluster . This indicates all other components are working properly.

Refer to Chapter 4 for additional ECT information. Polaris dealers can test the sensor by using the Digital Wrench™ Diagnostic Software (dealer only).

ECT Sensor Resistance Readings

Temperature °F (°C) Resistance

32 °F (0 °C) 5.9k Ω ± 5%

68 °F (20 °C) 2.5k Ω ± 5%

3.22

176 °F (80 °C) 323 Ω ± 5%

212 °F (100 °C) 186 Ω ± 5%

ELECTRONIC FUEL INJECTION

ECT Sensor Replacement

1. Drain coolant to level below sensor.

2. Disconnect the ECT sensor from engine harness. Rem ove the T-MAP sensor to allow access to the ECT sensor.

ECT

3. Remove and replace the sensor, applying a light coating of thread sealant to aid installation.

4. Torque the ECT sensor to specification.

IGNITION COIL

Operation Overview

The ignition coil is used to provide high voltage to fire the spark plugs. When the ignition key is on, DC voltage is present in primary side of the ignition coil windings. During engine rotation, an AC pulse is created within the crankshaft position sensor for each passing tooth on the flywheel. The two-tooth gap creates an “interrupt” input signal, corresponding to specific crankshaft position. This signal serves as a reference for the control of ignition timing. The ECU then calculates the time interval between the consecutive pulses, and determines when to trigger the voltage spike that induces the voltage from the primary to the secondary coil windings to fire the spark plugs.

RH Side

of Airbox

= T

ECT Sensor Torque:

17 ft. lbs. (23 Nm)

Ignition Coil

Ignition Coil Tests

The ignition coil can be tested by using an ohm meter. Use the following illustrations and specification table to test the ignition coil.

Remove the seat and upper right-hand side panel to access the ignition coil.

Ignition Coil Resistance Readings

Test

Primary

Connection

Between 1 & 2 Between 3 & 2

Resistance

0.4 Ω

Between

Secondary

High Tension

5 k Ω

Lead Ends

3.23

ELECTRONIC FUEL INJECTION

Primary Test

Connector Pins 1 & 2, 2 & 3

Secondary Test

Measure Between End Caps

MAG (Short) Wire: 1390 Ω ± 2 %

PTO (Long) Wire: 1545 Ω ± 2 %

Measure Between

0.4 Ω

Ignition Coil and HT Lead Replacement

NOTE: The plug caps or coil ends are not removable. The high tension lead (coil wire) must be replaced as an assembly.

1. Remove the seat and upper right-hand side panel to access the ignition coil (see Chapter 9 “Seat and Side Panels”).

2. Disconnect the shift linkage and remove the high tension lead caps from the spark plugs.

3. Remove the high tension leads from the airbox.

4. Disconnect the harness from the ignition coil.

5. Using a T20 driver, remove the screw retaining the ignition coil to the airbox.

6. Remove the coil assembly and disconnect the high tension leads by pulling on the coil side end caps.

7. Install the new high tension leads.

NOTE: Be sure to install the PTO (long) wire on the coil terminal nearest the airbox.

8. Install the coil assembly and securely tighten the mounting screw.

9. Upon assembly, make sure the high tension leads are retained by the airbox.

3.24

10. Reinstall the shift linkage, upper right-hand side panel and the seat.

EFI DIAGNOSTICS

ELECTRONIC FUEL INJECTION

Instrument Cluster Trouble Code Display

Use the following procedure to display diagnostic trouble codes logged in the ECU if the Check Engine (MIL) icon is illuminated on the instrument cluster.

NOTE: In order to view the diagnostic codes on the instrument cluster, the Check Engine (MIL) icon must be illuminated.

1. Place the transmission in PARK.

2. Turn the ignition switch to the “ON” position.

3. Toggle through the LCD display using the “SELECT” button until the Check Engine (MIL) icon begins flashing.

4. When the Check Engine (MIL) icon is flashing, a set of two numbers will appear on the LCD.

5. The first number is located in the information area and can be 2 to 6 digits in length. This number represents the Suspect Parameter Number (SPN).

6. The second number is located in the clock area and can be 1 to 2 digits in length. This number represents the Failure Mode Identifier (FMI).

DIAGNOSTIC TROUBLE CODE TABLE

7. Use the “Diagnostic Trouble Code Table” as a reference.

8. Press and hold the “MODE” button to cycle through all currently active trouble codes.

PS MIL

MIL

NOTE: On vehicles equipped with power steering, the power steering (MIL) LED will illuminate and blink in place of the Check Engine (MIL) if there is a diagnostic problem with the power steering system.

SPN

FMI

Component Condition

Throttle Position Sensor (TPS)

Engine Temperature Sensor (ECT)

Intake Air Temperature (T-MAP)

Manifold Absolute Pressure Sensor (T-MAP)

Crankshaft Position Sensor (CPS)

Vehicle Speed Signal Plausibility Fault 84 2

Gear Sensor Signal

Voltage Too High 51 3 Voltage Too Low 51 4 Voltage Too High 110 3 Voltage Too Low 110 4 Temperature Too High 1 10 16 Engine Overheat Shutdown 110 0 Voltage Too High 105 3 Voltage Too Low 105 4 Voltage Too High 102 3 Voltage Too Low 102 4 Signal Out of Range 102 2 Circuit Fault 636 8 Plausibility Fault 636 2

Voltage Too Low 523 4 Voltage Too High 523 3 Signal Fault 523 2

Suspect Parameter Number

SPN

Failure Mode Indentifier

FMI

3.25

ELECTRONIC FUEL INJECTION

DIAGNOSTIC TROUBLE CODE TABLE

Component Condition

Driver Circuit Open / Grounded 651 5

Injector 1 (MAG)

Injector 2 (PTO)

Ignition Coil Primary Driver 1 (MAG) Driver Open / Grounded 1268 3 Ignition Coil Primary Driver 2 (PTO) Driver Circuit Short to B+ 1269 3

Fuel Pump Driver Circuit

Fan Relay Driver Circuit

Idle Air Control (IAC)

Driver Circuit Short to B+ 651 3 Driver Circuit Grounded 651 4 Driver Circuit Open / Grounded 652 5 Driver Circuit Short to B+ 652 3 Driver Circuit Grounded 652 4

Driver Circuit Open / Grounded 1347 5 Driver Circuit Short to B+ 1347 3 Driver Circuit Grounded 1347 4 Driver Circuit Open / Grounded 1071 5 Driver Circuit Short to B+ 1071 3 Driver Circuit Grounded 1071 4 Driver Circuit Open / Grounded 634 5 Driver Circuit Short to B+ 634 3 Driver Circuit Grounded 634 4

Suspect Parameter Number

SPN

Failure Mode Indentifier

FMI

Starter Enable Circuit

Chassis Relay

All Wheel Drive Control (AWD)

System Power

Throttle Safety Signal

Active Descent Control (ADC)

Position Out of Range 634 7 Driver Circuit Open / Grounded 1321 5 Driver Circuit Short to B+ 1321 3 Driver Circuit Grounded 1321 4 Driver Circuit Open / Grounded 520208 5 Driver Circuit Short to B+ 520208 3 Driver Circuit Grounded 520208 4 Driver Circuit Open / Grounded 520207 5 Driver Circuit Short to B+ 520207 3 Driver Circuit Grounded 520207 4 Voltage Too High 168 3 Voltage Too Low 168 4 Voltage Too High 520194 3 Voltage Too Low 520194 4 Signal Out of Range 520194 2 Throttle Stuck 520194 7 Driver Circuit Open / Grounded 520203 5 Driver Circuit Short to B+ 520203 3 Driver Circuit Grounded 520203 4

3.26

ELECTRONIC FUEL INJECTION

DIAGNOSTIC TROUBLE CODE TABLE

Component Condition

Idle Speed

Calibration Checksum/CRC Error 630 13 Steering Over Current Shut Down Current Above Normal or Grounded 520221 6 Steering Excessive Current Error Current Above Normal or Grounded 520222 6 Steering Torque or Speed Sensor

Partial Failure Steering Torque or Speed Sensor

Full Failure

EPAS Inverter Temperature

EPAS CAN Communications Receive Error

EPAS CAN Communications Transmit Error

Vehicle Speed (This is applicable when the EPAS module gets the vehicle speed from the ECM)

Engine Speed (This is applicable when the EPAS module gets the engine speed from the ECM)

Battery Voltage

Speed Too High 520211 3 Speed Too Low 520211 4

Condition Exists 520223 31

Condition Exists 520224 31

Greater than 110° C (230° F) 520225 16 Greater than 120° C (248° F) 520225 0

No RX Message for 2 Seconds 520226 2

No TX Message for 2 Seconds 520227 2

Received Vehicle Speed Has Error 84 19

Received Engine Speed Has Error 190 19

Too High 168 3 Too Low 168 4

Suspect Parameter Number

SPN

Failure Mode Indentifier

FMI

Position Encoder Error 520228 11

Software Error Illegal Memory Access 520229 12

EPAS Software Error

IC CAN Communication with EPAS EPAS Off Line (EPAS DM1 not seen) 520230 31 EEProm: Read/Write Failure 628 12

Software Error Stack Overrun 520229 12 Software Error Illegal Peripheral

Interrupt

520229 12

3.27

ELECTRONIC FUEL INJECTION

FUEL SYSTEM TROUBLESHOOTING

The correct position of the throttle body

stop screw is established and set at the

factory. DO NOT remove the tamper proof

cap to adjust the throttle body stop scre w or

alter its position in any manner. The stop

screw controls the air flow calibrat io n

of the throttle body.

Fuel Starvation / Lean Mixture

Symptoms: Hard start or no start, bog, backfire, popping through intake / exhaust, hesitation, detonation, low power, spark plug erosion, engine runs hot, surging, high idle, idle speed erratic.

• No fuel in tank

• Restricted tank vent, or routed improperly

• Fuel lines or fuel injectors restricted

• Fuel pump inoperative

• Air leak in system

• Intake air leak (throttle shaft, intake boot, gasket or grommet)

• Throttle stop screw tampering

• Failed sensor or disconnected wiring

Poor Idle

Symptom: Idle Too High (If greater than 1400 RPM when engine is warm)

• Throttle stop screw tampering

• Throttle cable sticking, improperly adjusted, routed incorrectly

• Failed sensor or disconnected wiring

• IAC stuck or inoperative

• Intake air leak

Symptom: Idle Too Low (if less than 1100 RPM when engine is warm)

• Plugged air filter

• Leaking injector (rich condition)

• Belt dragging

• Throttle stop screw tampering

• Failed sensor or disconnected wiring

Symptom: Erratic Idle

• Throttle cable incorrectly adjusted

• Air Leaks, dirty injector

• TPS damaged or misadjusted

• Tight valves

• Belt dragging

Rich Mixture

Symptoms: Fouls spark plugs, black, sooty exhaust smoke, rough idle, poor fuel economy, engine runs rough/ misses, poor performance, bog, engine loads up, backfire.

• Air intake restricted (inspect intake duct)

• Air filter dirty/plugged

• Poor fuel quality (old fuel)

• Fouled spark plug

• TPS setting incorrect

• Injector failure

• Failed sensor or disconnected wiring

• Throttle stop screw tampering

3.28

• Dirty air cleaner

•Engine worn

• Spark Plug fouled

• Throttle stop screw tampering

• Failed sensor or disconnected wiring

EFI SYSTEM BREAK-OUT DIAGRAMS

ELECTRONIC FUEL INJECTION

3.29

ELECTRONIC FUEL INJECTION

Fuel Injector Circuit (PTO)

Fuel Injector Circuit (MAG)

3.30

Idle Air Control (IAC) Circuit

ELECTRONIC FUEL INJECTION

Crankshaft Position Sensor (CPS) Circuit

3.31

ELECTRONIC FUEL INJECTION

Fuel Pump / Fuel Level Sensor Circuit

Wire Color Functions

Wire Color Function

BROWN Ground VT / WHT Fuel Level Sender Signal RED / BLUE EFI Relay Output Battery Voltage

3.32

Fuel Pump Circuit

ELECTRONIC FUEL INJECTION

Fuel Gauge Circuit

3.33

ELECTRONIC FUEL INJECTION

Engine Coolant Temperature Sensor (ECT) Circuit

Throttle Position Sensor (TPS) Circuit

3.34

ELECTRONIC FUEL INJECTION

Intake Air Temperature / Manifold Absolute Pressure Sensor (T-MAP) Circuit

Diagnostic Connector Circuit

3.35

ELECTRONIC FUEL INJECTION

Diagnostic Connector Circuit (EPS Models)

3.36

COOLING SYSTEM

CHAPTER 4

COOLING SYSTEM

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2

TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2

COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2

COOLING SYSTEM LAYOUT AND TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2

COOLING SYSTEM SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3

COOLING SYSTEM BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 .4

RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4

RADIATOR CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4

COOLANT DRAIN / RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4

WATER PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6

WATER PUMP IMPELLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.6

WATER PUMP MECHANICAL SEAL REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . .4.7

WATER PUMP SHAFT & BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . .4.8

STATOR COVER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.9

WATER PUMP ASSEMBLY / TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .4.10

STATOR COVER ASSEMBLY TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . .4.11

THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12

REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.12

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12

4.1

COOLING SYSTEM

SPECIAL TOOLS

PART NUMBER TOOL DESCRIPTION

2870975

PA-44995-A

PA-49378

PA-49316

Mity Vac™ Pressure

Test Tool

Wat er Pump

Mechanical Seal Installer Water Pump Bearing and

Coupler Press Tool

Water Pump Drive Nut /

Flywheel Puller

TORQUE SPECIFICATIONS

Fastener Size

Thermostat Housing 6 mm 89 in. lbs. (10 Nm) Water Pump

Impeller Bolt Water Pump Cover 6 mm 89 in. lbs. (10 Nm) Engine Temperature

Sensor (ECT) Sta tor / Magneto

Cover Bolts

6 mm 10 ft. lbs. (13.5 Nm)

3/8 NPT 17 ft. lbs. (23 Nm)

6 mm 89 in. lbs. (10 Nm)

EH085OLE

Torque

Cooling System Pressure Test

1. Remove the front rack (see Chapter 9 “Front Rack”).

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.

2. Remove the pressure cap from the radiator and pressure test the cooling system using a commercially available tester.

3. The system must retain 10 psi for five minutes or longer. If pressure loss is evident within five minutes, check the radiator, all cooling system hoses, hose clamps and water pump seal for leakage.

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 pressure cap and test using a cap tester (commercially available).

COOLING SYSTEM

Cooling System Layout and Testing

FLOW

Radiator

Thermostat

Cylinder

Head

Water Pump

Cylinder

4.2

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

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.

IMPORTANT: Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Polaris Premium 60/40 Antifreeze/Coolant is recommended for use in all cooling systems, and comes pre-mixed and ready to use.

Polaris Premium Antifreeze

2871534 - Quart

2871323 - Gallon

COOLING SYSTEM

850cc ENGINE COOLANT FLOW

Cooling System Specifications

The engine coolant temperature sensor is located in the engine cylinder head below the thermostat housing (see Chapter 3 for further information).

ECT Sensor

17 ft. lbs.

(23 Nm)

Resistance Reading @ Idle

Condition

Engine Shut Off 70 Ω ± 3% 284° F (140° C) Hot Lamp On

(engine misfire above idle)

Hot Lamp Blinking 100 Ω ± 3% 257° F (125° C) Fan On 215 Ω ± 3% 203° F (95° C) Fan Off 240 Ω ± 3% 192° F (89° C) Room

Temperature System Capacity 2 qts. (1.9 l) Radiator Cap

Relief Pressure

Approx. Reading

(Ohms)

90 Ω ± 3% 266° F (130° C)

2.5k Ω ± 3% 68° F (20° C)

Temperature

13 PSI

4.3

COOLING SYSTEM

Cooling System Bleeding Procedure

1. Place the vehicle in PARK.

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 the front rack to access the radiator pressure cap and recovery bottle.

3. Remove the pressure cap and top off coolant. Leave the pressure cap off at this point.

4. Remove recovery bottle fill cap and fill the bottle to the “MAX” line. Reinstall the recovery bottle cap.

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

5. Start the engine and allow it to idle for 5-1 0 minutes until the thermostat opens and allows coolant to travel through the entire system.

NOTE: When the thermostat opens the radiator coolant level will drop significantly.

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

7. With the engine still idling, top off the radiator with Polaris Premium Antifreeze. If no air bubbles are seen at the radiator filler neck, the system should be purged of air.

RADIATOR

Radiator Cleaning

1. Check radiator air passages for restrictions or damage.

2. Carefully straighten any bent radiator fins.

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

CAUTION

Washing the vehicle with a high-pressure

washer could damage the radiator fins and impair the radiators effectiveness. Use of a high-pressure washer is not recommended.

8. Reinstall the radiator pressure cap

WARNING

Be sure to install the radiator pressure

cap before shutting off the engine.

Coolant may spit out of the radiator.

9. Stop the engine and allow it to cool. Top off the radiator with coolant. If you hear or see a “glug” at the filler neck or the coolant level drops indicating that coolant has been pulled into the system, fill the radiator first before filling the recovery bottle.

10. Any air remaining in the system should continue to bleed out through the recovery bottle

11. Repeat this procedure if you are still having difficulty bleeding the system.

4.4

Coolant Drain / Radiator Removal

Coolant Drain

1. Remove the front rack to access the pressure cap (see Chapter 9 “Front Rack”).

WARNING

Never drain the coolant when the engine and radiator are warm or hot. Hot coolant can cause severe burns. Allow engine and radiator to cool.

2. Slowly remove the pressure cap to relieve any cooling system pressure.

3. Place a suitable drain pan underneath the radiator on the right-hand side of the vehicle.

COOLING SYSTEM

4. Drain the coolant from the radiator by removing the coolant hose from the lower right-hand portion of the radiator.

Drain Here

5. Completely drain the coolant and properly dispose of it.

Radiator Removal

1. Drain coolant from the radiator (see previous procedure).

2. Remove the front rack (see Chapter 9 “Front Rack”).

3. Remove the hose from the left-hand portion of the radiator.

5. Carefully pull rearward on the lower portion of the recovery bottle to disengage the lower tab. Then lift up on the bottle and remove it from the radiator fan shroud.

6. Remove the (2) screws retaining the fuse/ relay box to the frame to allow enough room for the radiat or to tilt back during removal.

7. Remove the (2) fasteners retaining the upper portion of the radiator to the frame.

4. Remove the recovery bottle return line from the radiator.

Remove

2nd- Lift Up

1st- Pull Back

8. Disconnect the fan motor.

9. Tilt the radiator back and lift upward to allow the lower grommets to clear the frame support holes. Remove the radiator from the vehicle out the right-hand side through the wheel well. Take care not to damage the cooling fins during removal.

10. Reverse procedure for installation. When installing the recovery bottle, insert the upper portion of the bottle into the shroud first, then push the lower tab on the bottle into the shroud until it snaps into place.

11. After installation and reassembly, remove the pressure cap and fill the radiator and recovery bottle with coolant.

12. Refer to the “Cooling System Bleeding Procedure” in this chapter.

4.5

COOLING SYSTEM

WATER PUMP SERVICE

Water Pump Impeller Removal

NOTE: The water pump impeller, mechanical seal, drive coupler, pump shaft, and pump shaft bearing can be serviced without removing the engine.

1. Remove the fuel tank (see Chapter 3).

2. Remove the (4) screws retaining the engine skid plate and remove the plate from the vehicle.

3. Place a drain pan under the front portion of the engine.

4. Slide the spring clamp back and remove the coolant inlet hose from the water pump housing.

6. Remove the coolant by-pass hose from the water pump cover fitting.

7. Remove the (10) cover screws (A) and pump cover (B).

Coolant

Inlet Hose

5. Slowly drain the coolant into the drain pan. Dispose of used coolant properly.

Drain

HERE

Shown with engine removed for clarity.

8. Remove gasket, impeller bolt, washer, and impeller.

4.6

COOLING SYSTEM

Water Pump Mechanical Seal Replacement

Perform the “Water Pump Impeller Removal” procedure.

1. Disconnect the stator and CPS wire harnesses.

Stator

CPS

2. Remove the (8) stator cover screws.

3. Carefully remove the stator cover taking care not to damage the plastic coolant pipe.

5. Support the stator cover by the stator mounting boss, using an aluminum or PVC pipe section or other suitable support block (C) positioned inside the stator housing as shown.

Do not attempt to press water pump shaft out of stator housing without first supporting the cover by the stator boss, or cover may be damaged.

6. Press shaft down until flush with end of mechanical seal or until the seal spring starts to compress.

CAUTION

The flywheel contains powerful magnets. Use

caution when removing the stator cover.

DO NOT place fingers between cover and

crankcase at any time during the removal

process or injury could result.

4. Remove the CPS, stator wire guide, and stator from the cover.

7. Select a suitable arbor (D) and press the shaft through the seal until the shaft assembly is removed.

4.7

COOLING SYSTEM

Water Pump Mechanical Seal Replacement (Cont.)

8. Protect water pump cover gasket surface and turn cover over. Drive mechanical seal out from stator side of cover.

9. Clean housing thoroughly.

11. Turn cover over and drive new mechanical seal squarely into housing using seal installer.

PA-44995-A

12. Install impeller. Torque bolt to 10 lb-ft. (13.5 Nm)

13. Rotate impeller and check for smooth rotation.

Water Pump Shaft & Bearing Replacement

1. Press new shaft / bearing assembly from kit into cover from stator side as shown, using the recessed end of Bearing and Coupler Press Tool PA-49378.

If pump shaft assembly (shaft, drive coupler hub, and bearing( is in good condition, proceed to the next step. If any of these parts require replacement, refer to the “Water Pump Coupler Shaft & Bearing Replacement” procedure.

10. Press pump shaft / bearing assembly into housing until firmly seated.

4.8

PA-49378

2. Press until bearing is fully seated in cover.

CAUTION

Be sure bearing is fully seated in cover after

Step 2, or severe crankshaft damage will result.

COOLING SYSTEM

7. Rotate impeller and check for smooth rotation.

8. Refer to the following pages for water pump assembly and torque information.

Stator Cover Installation

3. Install new coupler hub (A) from kit onto sh aft.

4. Press coupler squarely onto shaft until fully seated.

1. Orientate the pump shaft tab to line up with the stator mounting bolt closest to the CPS sensor.

2. Rotate flywheel so coupler nut slot is in the 12:00 position.

Rotate slot to

12:00 position

5. Turn cover over and drive new mechanical seal squarely into housing using seal installer.

PA-44995-A

6. Install impeller. Torque bolt to 10 lb-ft. (13 .5 Nm).

3. Install new O-rings on the plastic coolant pipe. Lubricate the O-rings with P80 (rubber lubricant) or lithium grease.

CAUTION

The flywheel contains powerful magnets. Use

caution when installing the stator cover.

DO NOT place fingers between cover and

crankcase at any time during the installation

process or injury could result.

4. Carefully install the stator cover.

5. Check the water pump coupler engagement by turning the impeller bolt with a ratchet and 10 mm deep-well socket.

6. Refer to the following pages for stator cover assembly and torque information.

4.9

COOLING SYSTEM

Water Pump Assembly / Torque Specifications

89 in. lbs. (10 Nm)

Stator wire routing

See procedure

10 ft. lbs.

(13.5 Nm)

89 in. lbs. (10 Nm)

See procedure

TORQUE SEQUENCE

4.10

Stator Cover Assembly Torque Specifications

COOLING SYSTEM

89 in. lbs.

(10 Nm)

Crankshaft Position Sensor (CPS)

Lubricate

New O-Rings

Coolant

Pipe

1/8 NPTF

Coolant

Fitting

89 in. lbs.

(10 Nm)

TORQUE SEQUENCE

Use weather strip or contact cement to hold damper rubber (A) on water

pump coupler nut (B) during stator cover installation.

4.11

COOLING SYSTEM

THERMOSTAT

Removal (Engine Installed)

1. Drain coolant so the coolant level is below the thermostat housing (see “Coolant Drain / Radiator Removal”).

2. Remove the (2) screws from the rear portion of the air box.

3. Locate the thermostat housing on the left side of the valve cover next to the fuel rail.

Shown with air box

removed for clarity.

Thermostat

Housing

4. Remove the (2) screws and lift the housin g up far eno ugh to remove the thermostat with the coolant line still attached.

TROUBLESHOOTING

Cooling System

Overheating

• Low coolant level

• Air in cooling system

• Wrong type/mix of coolant

• Faulty pressure cap or system leaks

• Restricted system (mud or debris in radiator fins causing restriction to air flow, passages blocked in radiator, lines, pump, or water jacket, accident damage)

• Lean mixture (fuel system restriction)

• Fuel pump output weak

• Electrical malfunction

• Water pump failure/ Loose impeller

• Engine Coolant Temperature Sensor failure

• Cooling fan inoperative or turning too slowly (perform current draw test)

Installation

1. Install the thermostat, thermostat cover, and the (2) screws. Torque screws to specification.

89 in. lbs.

(10 Nm)

= T

Thermostat Housing Screws:

89 in. lbs. (10 Nm)

• Low oil level

• Spark plug incorrect heat range

• Faulty hot lamp circuit

• Thermostat stuck closed or not opening completely

Temperature Too Low

• Thermostat stuck open

Leak at Water Pump Weep Hole

• Faulty water pump mechanical seal

• Worn pump shaft or pump shaft bearing

2. If servicing while the engine is in the vehi cle, perform the “Cooling System Bleeding Procedure”.

4.12

ENGINE

CHAPTER 5

ENGINE

GENERAL INFORMATION - ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3

ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3

OIL PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3

OIL FLOW DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.4

ENGINE SPECIFICATIONS - EH085OLE-011. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.5

ENGINE ASSEMBLY VIEWS AND TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7

TORQUE & TORQUE SEQUENCE - MAIN ENGINE COMPONENTS . . . . . . . . . . . . . .5.7

VALVE COVER / BREATHER VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.8

CAMSHAFT CARRIER / CAMSHAFT / ROCKER ARM. . . . . . . . . . . . . . . . . . . . . . . . . .5.9

CYLINDER HEAD / VALVE / IAFM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.10

VALVE & SPRING HEIGHT DETAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.11

PISTON / CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.12

CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.13

CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.14

CRANKCASE - UPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.15

BALANCE SHAFT / BALANCE SHAFT TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.16

CRANKCASE (LOWER) WITH OIL PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.17

WATER PUMP COUPLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.18

WATER PUMP / WATER PUMP COUPLER / STATOR / FLYWHEEL . . . . . . . . . . . . .5.19

DRIVE COUPLER (REAR) / STARTER GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.20

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21

ACCESSIBLE ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.21

TOP-END SERVICE (ENGINE IN CHASSIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.21

CRANKCASE CYLINDER SERVICE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . .5.21

ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.21

ENGINE INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.25

ENGINE DISASSEMBLY AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26

VALVE COVER / BREATHER VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.26

ROCKER CARRIER / CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.26

ROCKER ARM / ROCKER ARM SHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . .5.27

CAMSHAFT / CAMSHAFT BORE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.28

CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.28

CYLINDER HEAD CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.28

CYLINDER HEAD WARP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.29

CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.29

VALVE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.30

COMBUSTION CHAMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.31

VALVE GUIDE REMOVAL / INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.31

VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.32

CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.34

VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.34

CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.35

CAMSHAFT / CARRIER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.36

CAMSHAFT / CAMSHAFT CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . .5.36

CAMSHAFT TIMING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.37

CAM CHAIN TENSIONER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.38

CAMSHAFT TIMING - QUICK REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.39

CRANKCASE DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.40

CRANKCASE (LOWER) / OIL PUMP DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .5.41

CRANKCASE DISASSEMBLY (UPPER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.43

PISTON / CONNECTING ROD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.43

COUNTERBALANCE SHAFT REMOVAL / INSPECTION. . . . . . . . . . . . . . . . . . . . . . .5.44

COUNTERBALANCE SPLIT GEAR REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . .5.44

5.1

ENGINE

CRANKSHAFT / CAM CHAIN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.46

CAM CHAIN / SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.46

CRANKCASE INSPECTION (LOWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.46

CRANKSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.46

CONNECTING ROD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.47

CONNECTING ROD BIG END BEARING SELECTION . . . . . . . . . . . . . . . . . . . . . . . .5.48

PISTON / PISTON RING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.48

PISTON RING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.48

PISTON RING INSTALLED GAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.49

PISTON PIN BORE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.49

CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.49

PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.50

HONING - IMPORTANT INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.50

ENGINE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.51

CRANKCASE PREPARATION - UPPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.51

PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.51

PISTON / CONNECTING ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.52

PISTON / CONNECTING ROD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.52

CRANKSHAFT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.53

OIL PASSAGE TUBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.53

CRANKCASE ASSEMBLY - UPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.54

BALANCE SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.55

BALANCE SHAFT TIMING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.56

CRANKCASE PREPARATION (LOWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.57

CRANKCASE SEALANT AND TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.58

CRANKCASE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.59

WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.59

WATER PUMP IMPELLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.59

MECHANICAL SEAL / COUPLER SHAFT & BEARING REPLACEMENT . . . . . . . . . . 5.59

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.60

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.60

5.2

GENERAL INFORMATION - ENGINE

Special Tools

Tool Description Part Number

CRANKSHAFT HOLDING TOOL PA-49318

CRANKSHAFT SEAL INSTALLER PA-49320

FLYWHEEL / WATER PUMP DRIVE NUT PULLER PA-49316

FUEL PRESSURE TEST ADAPTOR PS-48762

MITY VAC

PISTON RING COMPRESSOR PLIERS PV-43570-1

PISTON RING COMPRESSOR BAND - 87mm PV-43570-3

UNIVERSAL DRIVER HANDLE PU-45543

VALVE SPRING COMPRESSOR PV-1253 or PV-4019 (Quick Release)

VALVE SPRING COMPRESSOR ADAPTOR PV-43513-A

WATER PUMP BEARING AND COUPLER PRESS PA-49378

WATER PUMP DRIVE NUT / FLYWHEEL PULLER PA-49316

WATER PUMP MECHANICAL SEAL INSTALLER PA-44995-A

‘ PRESSURE TEST TOOL 2870975

OIL FILTER WRENCH PV-43527 (2 1/2 in. / 65mm)

ENGINE

Engine Lubrication Specifications

Capacity - Approximately 2 U.S. Quarts (1.9 l) Oil Type - Polaris PS4 Plus 2W-50 Synthetic Filter Wrench - PV-43527 or equivalent Oil Pressure Specification - 10-25 PSI @ Idle RPM (using Polaris PS4 Plus 2W-50 Synthetic), Engine at

operating temperature.

Oil Pressure Test

1. Remove center Main Oil Ga llery plug (A) from right side of upper crankcase.

2. Insert a 1/4” NPT oil pressure gauge adaptor and oil pressure gauge.

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

NOTE: Test results are based on the use of the recommended engine oil at operating temperature, and may vary considerably if any other oil is used or if engine is not up to temperature.

Oil Pressure at Idle RPM (Engine Hot):

Standard: 25 PSI Minimum: 10 PSI

5.3

ENGINE

Oil Flow Diagram

Balance Shaft

Bearings

Carrier bolt passages feed Center and PTO camshaft main journals

Mag end cylinder head bolt passage (exhaust side)

Balance Shaft Bearings

Holes in rocker arm shafts feed rocker arms and rollers

PTO End

Oil Pressure Regulator (+ 85 PSI)

Upper Crankcase Main Oil Gallery

Connecting Tube (lower crankcase to upper crankcase)

Passage in lower crankcase

Oil Filter

Oil Pump

Pickup Screen

MAG End

Cam chain tensioner

Upper crankcase

Oil Sump

5.4

Gravity & Splash Lubrication

Pressure Lubrication Circuit

Engine Specifications - EH085OLE-011

CYLINDER HEAD (IN. / MM)

Cam Lobe Height - Intake (Standard) 0.897" (22.795 mm) Cam Lobe Height - Exhaust (Standard) 0.908" (23.067 mm) Camshaft Journal Outer Diameter - (All) .8632" ± 0.0004" (21.925 ± 0.01 mm)

Camshaft

Rocker Arm and

Shaft

Camshaft Journal Bore Inner Diameter - (All) .8661" ± 0.0004" (22.000 ± 0.01 mm) Camshaft Oil Clearance 0.0034" ± 0.0008" (0.086 ± 0.02 mm) Camshaft End Play 0.008" ± 0.004" (0.20 ± 0.10 mm) Rocker Shaft O.D. (Intake and Exhaust) 0.5501" (13.973 - 13.984 mm) Rocker Arm I.D. (Intake and Exhaust) 0.5514" - 0.5525" (14.006 - 14.033 mm) Rocker Shaft Bore I.D. (Intake and Exhaust) 0.5514" - 0.5525" (14.006 - 14.033 mm)

ENGINE

Cylinder Head

Valve Seat

Valve Guide

Valve

Cylinder Head - Surface warp limit 0.004" (0.1 mm) Cylinder Head - Standard height 3.611" (91.71 mm)

Valve Seat - Contacting Width - Intake

Valve Seat - Contacting Width - Exhaust

Valve Seat Angle 45.5° ± 0.25° Valve Guide Inner diameter 0.217" + .0005" - 0.0 (5.52 + .012 - 0.0 mm) Valve Guide Protrusion Above Head - Intake 0.361" ± 0.010" (9.18 ± 0.25 mm) Valve Guide Protrusion Above Head - Exhaust 0.276" ± 0.010" (7.00 ± 0.25 mm)

Valve Lash (Cold) - Intake 0.006" (.152 mm ± 0.025 mm)

Valve Lash (Cold) - Exhaust 0.009" (.228 mm ± 0.025 mm)

Valve Margin Thickness - Intake 0.016" (.41 mm)

Valve Margin Thickness - Exhaust 0.023" (.59 mm) Valve Stem Diameter - Intake 0.2163" ± 0.0003" (5.49 5 ± 0.0075 mm)

Valve Stem Diameter - Exhaust 0.2159" ± 0.0003" (5.485 ± 0.0075 mm)

0.047" ± 0.008" - 0.0039" (1.20 ± 0.20 mm)

Valve Stem Oil Clearance - Intake 0.0014" ± 0.0005" (0.035 ± 0.0135 mm) Valve Stem Oil Clearance - Exhaust 0.0018" ± 0.0005" (0.045 ± 0.0135 mm) Valve Stem Overall Length - Intake 4.6681" ± 0.012" (118.57 ± 0.30 mm) Valve Stem Overall Length - Exhaust 4.5649" ± Valve Spring Free Length 1.861" (47.26 mm)

Valve Spring

Valve Spring Installed Height

.012" (115.95 ± 0.30 mm)

Intake - 1.650" (41.91 mm) Exhaust - 1.650" (41.91 mm)

5.5

ENGINE

CYLINDER / PISTON (IN. / MM)

Cylinder

Piston

Piston Pin

Piston Ring

Connecting Rod

Crankshaft

Cylinder - Surface warp limit (mating with cylinder head)

Cylinder Bore - Standard 3.4252" ± .0005 (87 mm ± .01mm) Cylinder Out of Round Limit 0.0003" (0.0075 mm) Cylinder to Piston Clearance .0021" ± .0013" (.053 ± .03mm) Piston - Standard O.D. - Measured 90 degrees to

pin, 1.3 in. (33.0 mm) down from piston crown. Piston Pin Bore I.D. (Standard) 0.7877" ± .0002" (20.007 ± .004 mm) Piston Pin Outside Diameter 0.7873" ± .0001" (19.9975 ± .0025 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)

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

Top Ring - Standard 0.008” - 0.014” (0.20 - 0.36 mm) Top Ring - Service Limit 0.016” (0.41 mm)

Installed

Gap

Ring to Groove

Clearance Connecting Rod Small End I.D. 0.7886” + 0.000 / - .015” (20.030 + 0.000 / - .015 mm) Connecting Rod Small End

Diametral Clearance Connecting Rod Big End

Side Clearance Connecting Rod Big End

Diametral Clearance Cranksh

Main Journal Diameter (Standard) 2.1642” - 2.1649” (54.97 - 54.99 mm) Connecting Rod Journal Diameter (Standard) 1.7718” - 1.7726” (45.005 - 45.025 mm)

Second Ring - Standard 0.014” - 0.024” (0.36 - 0.61 mm) Second Ring - Service Limit 0.032” (0.81 mm) Oil Ring Rails - Standard 0 .0 20” ± 0.010” (0.51 ± 0.25 mm) Oil Ring Rails - Service Limit 0.032” (0.81 mm) T op Ring - Standard 0.0024” ± 0.0008” (0.060 ± 0.020 mm)

Second Ring - Standard 0.0028” ± 0.0008” (0.070 ± 0.020 mm)

aft Runout Limit (See procedure)

PTO End Less than .001” (0.025 mm)

MAG End Less than .001” (0.025 mm)

0.004" (0.10 mm)

3.4231" ± .0008" (86.947 ± .02 mm)

0.0004" ± .0002" (0.0095 ± 0.0065 mm)

0.00098” ± .0004” (0.025 ± 0.010 mm)

0.012” ± 0.0039” (0.30 ± .10 mm)

0.0098” - .0023” (0.025 - .059 mm)

5.6

ENGINE ASSEMBLY VIEWS AND TORQUE VALUES

Torque & Torque Sequence - Main Engine Components

ENGINE

89 lb-in. (10 Nm)

VALVE COVER

6 5

13 lb-ft. (18 Nm)

26 lb-ft. (35 Nm) + 90° (see procedure)

89 lb-in. (10 Nm)

CYLINDER HEAD

13 lb-ft. (18 Nm)

9 lb-ft. (12 Nm)

CAMSHAFT CARRIER OIL PUMP COVER

89 lb-in. (10 Nm)

14 lb-ft. (19 Nm)

STATOR COVER STARTER GEAR

89 lb-in. (10 Nm)

WATER PUMP COVER

M9 = 26 lb-ft. (35 Nm) M6 = 89 lb-in. (10 Nm)

CRANKCASE

1715

5.7

Polaris 850-Hd-Eps 2009 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual