Polaris RANGER XP 900 (2013) User guide

Page 1

2013 / 2014 RANGER XP 900 - 2014 RANGER

XP 900 / CREW 900

The information printed within this publication includes the latest product information at time of print. The most recent version of this Service Manual is available in electronic format at www.polarisdealers.com.

This Service Manual is designed primarily for use by certified Polaris Master Service Dealer equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position.

Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service Manual, contact an authorized dealer for service.

We value your input and appreciate any assistance you can provide in helping make these publications more useful. Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.

Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department, 2100 Hwy 55, Medina, MN 55340.

FOREWORD

technicians in a properly

Publication Printed August 2013 (PN 9924880 Rev 2- 1/10/2014)

© Copyright 2013 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

Page 2

SAFETY WARNINGS

Throughout this manual, important information is brought to your attention by the following symbols:

WARNING

SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle.

CAUTION

SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.

CAUTION

CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.

NOTE

NOTE provides key information by clarifying instructions.

IMPORTANT

IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

TRADEMARKS

POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:

Loctite, Registered Trademark of the Loctite Corporation

Nyogel, Trademark of Wm. F. Nye Co.

Fluke, Registered Trademark of John Fluke Mfg. Co.

Mity-Vac, Registered Trademark of Neward Enterprises, Inc.

Torx, Registered Trademark of Textron

Hilliard, Trademark of the Hilliard Corporation

Warn, Trademark of Warn Industries

FOX, Registered Trademark of FOX RACING SHOX

RydeFX, Registered Trademark of ArvinMeritor

Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer.

Page 3

2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900

Service Manual

Chapter Summary

CHAPTER 1: GENERAL INFORMATION

CHAPTER 2: MAINTENANCE

CHAPTER 3: ENGINE

CHAPTER 4: FUEL SYSTEM - GENERAL

CHAPTER 5: BODY / STEERING / SUSPENSION

CHAPTER 6: CLUTCHING

CHAPTER 7: FINAL DRIVE

CHAPTER 8: TRANSMISSION

CHAPTER 9: BRAKES

CHAPTER 10: ELECTRICAL

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GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

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

MODEL NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

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

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

VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . 1.3

VEHICLE INFORMATION . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . 1.4

PUBLICATION NUMBERS .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . 1.4

REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

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

GENERAL SPECIFICATIONS: 2013 - 2014 RANGER XP 900 / EPS .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . 1.6

DETAILED SPECIFICATIONS: 2013 - 2014 RANGER XP 900 / EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7

GENERAL SPECIFICATIONS: 2014 RANGER CREW 900 / EPS . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 1.8

DETAILED SPECIFICATIONS: 2014 RANGER CREW 900 / EPS .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9

CLUTCH CHART . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .1.10

MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . 1.11

CONVERSION TABLE. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . 1.11

STANDARD BOLT TORQUE SPECIFICATION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12

METRIC BOLT TORQUE SPECIFICATION.. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . .. . . . . . .1.12

SAE TAP / DRILL SIZES . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . .1.13

METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13

DECIMAL EQUIVALENTS .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14

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GENERAL INFORMATION

VEHICLE IDENTIFICATION

MODEL NUMBER DESIGNATION

Example: L15U2NAEFA

1 BUSINESS

UNIT

L=Small Vehicles (LEV)

* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively ** = 9th digit will be used on color/featured versions of models (not including the base) First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN. Digits 1 through 8 determine Digital Wrench calibration.

2 & 3

MODEL

YEAR

Decade & Year

FAMILY

G = GEM

U = eM1400

SEATING

1= 1 Passenger

2 = 2 Passenger B = Cargo Box

3 = 3 Passenger

4 = 4 Passenger

6 = 6 Passenger

CARGO

TYPE

A = Standard AE = EV

D = Heavy duty Long bed

S = Short Bed

M = Mid bed L = LSV

N = Not Defined C = Canada

L = Long Bed

7 & 8

MAKE

AF = LSV

VEHICLE

CLASSIFI-

CATION

E = European Vehicle

M = European Machine

F = Non —Road C = 3rd Variation

ENGINE DESIGNATION NUMBER

2013 MODELS: 1204420 / 1204799 875 - 13 4-Stroke DOHC Twin Cylinder, Liquid Cooled, Electric Start

2014 MODELS: 1204845 875 - 14 4-Stroke DOHC Twin Cylinder, Liquid Cooled, Electric Start

VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION

Example: 4XAKA09A0F3000000

VARIA-

TION

A = 1st Variation

B = 2nd Variation (import / base)

VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS

WORLD MFG. ID

CHASSIS

DRIVELINE

ENGINE

MODIFIER

ENGINE SIZE

CATEGORY

CHECK DIGIT

MODEL YEAR *

MFG. LOCATION

INDIVIDUAL SERIAL NO.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

4 X A K A 0 9 A 0 G 3 0 0 0 0 0 0

* Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G = 2016; H = 2017

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GENERAL INFORMATION

VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS

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

VEHICLE IDENTIFICATION NUMBER (VIN) - The VIN can be found stamped on a portion of the upper left frame rail above the airbox. Refer to Figure 1-1.

ENGINE SERIAL NUMBER - The engine model and serial number can be found on a decal applied to the MAG side of

the cylinder head (A) or stamped into the crankcase on the PTO side of the engine (B). Refer to Figure 1-2.

9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual © Copyright Polaris Sales Inc.

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GENERAL INFORMATION

VEHICLE INFORMATION

PUBLICATION NUMBERS

MODEL MODEL NO.

2013 RANGER XP 900 (CA)

2013 RANGER XP 900 EPS (CA)

2014 RANGER XP 900

2014 RANGER XP 900 EPS

2014 RANGER CREW 900

2014 RANGER CREW 900 EPS

(CA): California 50-State Models

R13UH88AC, AG, AO, AQ, AR, AZ (ACC, AGC, AOC, AQC, ARC, AZC)

R13UH9EAB, AG, AO, AR, AZ (ABC, AGC, AOC, ARC, AZC)

R14UH88AA, AAC, AC, ACC, , AR, ARC

R14UH9EAA, AAC, AB, ABC, AM, AMC, AR, ARC, AS, ASC, AW, AWC,

R14WH88AA, AAC, AR, ARC

R14WH9EAC, ACC, AM, AMC, AS, ASC

OWNER’S MANUAL

9924098 9924086

9924546 9924547

9924548 9924549

PARTS MANUAL

NOTE

When ordering service parts be sure to use the correct parts manual.

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

REPLACEMENT KEYS

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

SERIES# PART NUMBER

20 4010278

21 4010278

22 4010321

23 4010321

27 4010321

28 4010321

31 4110141

32 4110148

67 4010278

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68 4010278

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GENERAL INFORMATION

SPECIAL TOOLS

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

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GENERAL INFORMATION

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS: 2013 - 2014 RANGER XP 900 / EPS

MODEL NUMBERS: 2013: R13UH88AC, AG, AO, AQ, AR, AZ; R13UH9EAB, AG, AO, AR, AZ 2014: R14UH88AA, AC, AR, RC; R14UH9EAA, AC, AB, BC, AM, MC, AR, RC, AS, SC, AW, WC, AN, AI

CATEGORY DIMENSION / CAPACITY

Length

Width (cargo box)

Width (tires)

Height

Wheel Base 81 in. / 205.7 cm

Ground Clearance 12 in. / 30.5 cm

Turning Radius

Dry Weight 1360 lbs. / 617 kg

Cargo Box Capacity

Cargo Box Dimensions (inside dimensions)

Vehicle Payload (includes weight of riders, cargo and accessories)

Hitch Towing Capacity 2000 lbs. / 907 kg

Hitch Tongue Capacity 150 lbs. / 68 kg

116 in. / 295 cm

60 in. / 152.4 cm

58 in. / 147.3 cm

76 in. / 193 cm

161 in. / 409 cm

49-State: 1000 lbs. / 454 kg 50-State: 600 lbs. / 272 kg

36.5 x 54 x 11.5 in. (93 x 137 x 29 cm)

49-State: 1500 lbs. / 681 kg 50-State: 1100 lbs. / 499 kg

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DETAILED SPECIFICATIONS: 2013 - 2014 RANGER XP 900 / EPS

ENGINE

Platform

Engine Displacement

Number of Cylinders

Bore & Stroke (mm)

Engine Idle Speed

Engine Max Operating RPM

Lubrication

Oil Requirements PS-4 or PS-4 Extreme Duty

Oil Capacity 2.5 qts. (2.4 L)

Coolant Capacity 5 qts. (4.7 L)

Exhaust System 2 to 1 Headpipe / Single Silencer

Fuel System

Fuel System Type

Fuel Delivery Electronic Fuel Pump (in tank)

Fuel Pressure

Fuel Capacity 10 gal. (37.8 L)

Fuel Requirement 87 Octane (minimum)

Electrical

Alternator Rated Output 575 Watts @ 3000 RPM

Headlights

Tail Lights L.E.D. (10): 0.2 Watts x 2

Brake Lights L.E.D. (10): 2.9 Watts x 2

Ignition System Bosch ME17 (ECU Controlled)

Spark Plug Gap 0.030 in. (0.75 mm)

Battery

DC Outlets

Relays *Not in Fuse/Relay Box

Circuit Breaker

Fuses *Not in Fuse/Relay Box

4-Stroke DOHC Twin Cylinder, Liquid Cooled, Electric Start

875 cc

93 x 64.4 mm

1250 ± 50 RPM

7250 RPM

Wet Sump

Bosch ME17 EFI

58 +/- 2 psi (400 +/- 14 kPa)

Halogen: Low 55W / High 60W x 2

Johnson Controls / 575 CCA / 12V

(2) - Standard 12 Volt

Chassis / EFI / Fan / Fuel Pump EPS (OPT) / Rear Diff Solenoid*

Fan Motor: 20 Amp

Brake Lights: 10 Amp Drive: 10 Amp Fuel Pump: 10 Amp Accessory: 20 Amp ECM: 20 Amp Lights: 20 Amp EPS (OPT): 30 Amp*

DRIVETRAIN

Transmission Type

Transmission Gear Ratio: High Low Reverse

Front Gearcase Lubricant Requirements

Transmission Lubricant Requirements

Clutch (PVT) Type

Clutch Center Distance

Steering / Suspension

Toe Out

Front Suspension

Front Travel

Rear Suspension Independent (IRS)

Rear Travel

Wheels / Brakes

Front Wheel Size / Type

Rear Wheel Size / Type

Front Tire Make / Model / Size

Rear Tire Make / Model / Size

Tire Air Pressure

Brake System 4 Wheel Hydraulic Disc

Brake Fluid DOT 4

For the clutch chart, see Clutch Chart, page 1.10 after “DETAILED SPECIFICATIONS: 2014 RANGER CREW 900 / EPS”

GENERAL INFORMATION

Polaris Automatic PVT

Front: 3.48:1 / Rear: 10.40:1 Front: 8.56:1 / Rear: 25.59:1 Front: 7.67:1 / Rear: 22.92:1

Demand Drive Fluid

6.75 oz. (200 ml)

AGL 41 oz. (1200 ml)

Drive: Polaris, Basic, NonBraking Bearing

Driven: Team Rapid Reaction

10.5” (26.7 cm)

1/8 - 1/4 in. (3.2 - 6.35 mm)

Dual A-arm

10 in. (25.4 cm)

12 x 6 / Steel 12 x 6 / Cast Aluminum

12 x 8 / Steel 12 x 8 / Cast Aluminum

Carlisle / AT489 / 25 x 10 R12 Carlisle / PXT / 26 x 9 R12

Carlisle / AT489 / 25 x 11 R12 Carlisle / PXT / 26 x 11 R12

Front: 10 psi (69 kPa)

Rear: 12 psi (83 kPa)

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GENERAL INFORMATION

GENERAL SPECIFICATIONS: 2014 RANGER CREW 900 / EPS

MODEL NUMBERS: R14WH88AA, AR

MODEL NUMBERS: R14WH9EAC, AM, AS

CATEGORY DIMENSION / CAPACITY

Length

Width (cargo box)

Width (tires)

Height

Wheel Base 113 in. / 287 cm

Ground Clearance 12 in. / 30.5 cm

Turning Radius

Dry Weight 1570 lbs. / 712 kg

Cargo Box Capacity

Cargo Box Dimensions (inside dimensions)

Vehicle Payload (includes weight of operator, passenger, cargo and accessories)

Hitch Towing Capacity 2000 lbs. / 907 kg

Hitch Tongue Capacity 150 lbs. / 68 kg

148 in. / 376cm

60 in. / 152.4 cm

58 in. / 147.3 cm

76 in. / 193 cm

214 in. / 543.5cm

49-State: 1000 lbs. / 454 kg 50-State: 600 lbs. / 272 kg

36.5 x 54 x 11.5 in. (93 x 137 x 29 cm)

49-State: 1750 lbs. / 759 kg 50-State: 1350 lbs. / 712 kg

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DETAILED SPECIFICATIONS: 2014 RANGER CREW 900 / EPS

ENGINE

Platform

Engine Displacement

Number of Cylinders

Bore & Stroke (mm)

Engine Idle Speed

Engine Max Operating RPM

Lubrication

Oil Requirements PS-4 or PS-4 Extreme Duty

Oil Capacity 2.5 qts. (2.4 L)

Coolant Capacity 5 qts. (4.7 L)

Exhaust System 2 to 1 Headpipe / Single Silencer

Fuel System

Fuel System Type

Fuel Delivery Electronic Fuel Pump (in tank)

Fuel Pressure

Fuel Capacity 10 gal. (37.8 L)

Fuel Requirement 87 Octane (minimum)

Electrical

Alternator Rated Output 575 Watts @ 3000 RPM

Headlights

Tail Lights L.E.D. (10): 0.2 Watts x 2

Brake Lights L.E.D. (10): 2.9 Watts x 2

Ignition System Bosch ME17 (ECU Controlled)

Spark Plug Gap 0.030 in. (0.75 mm)

Battery

DC Outlets

Relays *Not in Fuse/Relay Box

Circuit Breaker

Fuses *Not in Fuse/Relay Box

4-Stroke DOHC Twin Cylinder, Liquid Cooled, Electric Start

875 cc

93 x 64.4 mm

1250 ± 50 RPM

7250 RPM

Wet Sump

Bosch ME17 EFI

58 +/- 2 psi (400 +/- 14 kPa)

Halogen: Low 55W / High 60W x 2

Johnson Controls / 575 CCA / 12V

(2) - Standard 12 Volt

Chassis / EFI / Fan / Fuel Pump EPS (OPT) / Rear Diff Solenoid*

Fan Motor: 20 Amp

Brake Lights: 10 Amp Drive: 10 Amp Fuel Pump: 10 Amp Accessory: 20 Amp ECM: 20 Amp Lights: 20 Amp EPS (OPT): 30 Amp*

DRIVETRAIN

Transmission Type

Transmission Gear Ratio: High Low Reverse

Front Gearcase Lubricant Requirements

Transmission Lubricant Requirements

Clutch (PVT) Type

Clutch Center Distance

Steering / Suspension

Toe Out

Front Suspension

Front Travel

Rear Suspension Independent (IRS)

Rear Travel

Wheels / Brakes

Front Wheel Size / Type

Rear Wheel Size / Type

Front Tire Make / Model / Size

Rear Tire Make / Model / Size

Tire Air Pressure

Brake System 4 Wheel Hydraulic Disc

Brake Fluid DOT 4

For the clutch chart, see Clutch Chart, page 1.10 after “DETAILED SPECIFICATIONS: 2014 RANGER CREW 900 / EPS”

GENERAL INFORMATION

Polaris Automatic PVT

Front: 3.48:1 / Rear: 10.40:1 Front: 8.56:1 / Rear: 25.59:1 Front: 7.67:1 / Rear: 22.92:1

Demand Drive Fluid

6.75 oz. (200 ml)

AGL 41 oz. (1200 ml)

Drive: Polaris, Basic, NonBraking Bearing

Driven: Team Rapid Reaction

10.5” (26.7 cm)

1/8 - 1/4 in. (3.2 - 6.35 mm)

Dual A-arm

10 in. (25.4 cm)

12 x 6 / Steel 12 x 6 / Cast Aluminum

12 x 8 / Steel 12 x 8 / Cast Aluminum

Carlisle / AT489 / 25 x 10 R12 Carlisle / PXT / 26 x 9 R12

Carlisle / AT489 / 25 x 11 R12 Carlisle / PXT / 26 x 11 R12

Front: 10 psi (69 kPa)

Rear: 12 psi (83 kPa)

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GENERAL INFORMATION

CLUTCH CHART

2013 - 2014 CLUTCH CHART - All RANGER XP 900 / RANGER CREW 900

YEAR/ MODEL

2013 All Models

2014 All Models (Except R14UH9EAB w/EBS and CREW Models)

2014 BROWNING EDITION R14UH9EAB w/EBS

2014 All CREW Models

ALTITUDE SHIFT WEIGHT DRIVE SPRING DRIVEN SPRING

0-1500 Meters (0-5000 Feet)

1500-3700 Meters (5000 - 12000 Feet)

0-1500 Meters (0-5000 Feet)

1500-3700 Meters (5000 - 12000 Feet)

0-1500 Meters (0-5000 Feet)

1500-3700 Meters (5000 - 12000 Feet)

0-1500 Meters (0-5000 Feet)

1500-3700 Meters (5000 - 12000 Feet)

27-89 (5138015)

27-83 (5632754)

27-89 (5138015)

27-83 (5632754)

27-89 (5138015)

27-83 (5632754)

27-89 (5138015)

27-83 (5632754)

Wht / Org (7043924)

Wht / Blu (7044111)

Wht/Blu (7044111)

Wht / Blu (7044111)

Blk/Red/Wht (3235317)

7044021

3234452 Red

7044015

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GENERAL INFORMATION

MISC. SPECIFICATIONS AND CHARTS

CONVERSION TABLE

UNIT OF MEASURE MULTIPLIED BY CONVERTS TO

ft-lbs

in-lbs x 0.0833 = ft-lbs

ft-lbs

in-lbs x 0.0115 = kg-m

Nm x 0.7376 = ft-lbs

kg-m x 7.233

kg-m x 86.796 = in-lbs

kg-m x 10 = Nm

inch x 25.4

inch x 2.54

mile (mi)

km x 0.6214 = mile

ounces (oz)

fluid ounces (fl oz) x 29.57 = cubic centimeters (cc)

cubic centimeters (cc)

grams (g)

pounds (lb) x 0.454 = kg

kilogram (kg)

cubic inches (cu in)

cubic centimeters (cc) x 0.061 = cubic inches

US quarts

liters (L)

US gallons x 3.785 = liters (L)

liters (L)

PSI x 6.895 = kilopascals (kPa)

kilopascals (kPa)

π (3.14) x Radius² x Height =

°C to °F: 9/5 (°C + 32) = °F

°F to °C: 5/9 (°F − 32) = °C

x 12 = in-lbs

x 1.356 = Nm

= ft-lbs

= mm

x 0.03937 = inch

= cm

x 1.6 = km

x 28.35

x .03381

x 0.035

x 2.2046 = lbs

x 16.387

x 0.946

x 1.057

x 0.264

x 0.145

= grams (g)

= fluid ounces

= ounces

= cc

= liters (L)

= US quarts

= US gallons

PSI

= cylinder volume

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Page 15

GENERAL INFORMATION

STANDARD BOLT TORQUE SPECIFICATION

BOLT SIZE

1/4-20

1/4-28

5/16-18

5/16-24

3/8-16

3/8-24

7/16-14

7/16-20

1/2-13

1/2-20

GRADE 2

FT-LB (NM)

5 (7) 8 (11) 12 (16)

6 (8) 10 (14) 14 (19)

11 (15) 17 (23) 25 (35)

12 (16) 19 (26) 29 (40)

20 (27) 30 (40) 45 (62)

23 (32) 35 (48) 50 (69)

30 (40) 50 (69) 70 (97)

35 (48) 55 (76) 80 (110)

50 (69) 75 (104) 110 (152)

55 (76) 90 (124) 120 (166)

METRIC BOLT TORQUE SPECIFICATION

BOLT

SIZE

M10

M12

M14

M16

M18

4.6 4.8 8.8 / 8.9 10.9 12.9

0.3 (0.5) 0.5 (0.7) 1 (1.3) 1.5 (2) 1.5 (2)

0.8 (1.1) 1 (1.5) 2 (3) 3 (4.5) 4 (5)

1.5 (2.5) 2 (3) 4.5 (6) 6.5 (9) 7.5 (10)

3 (4) 4 (5.5) 7.5 (10) 11 (15) 13 (18)

7 (9.5) 10 (13) 18 (25) 26 (35) 33 (45)

14 (19) 18 (25) 37 (50) 55 (75) 63 (85)

26 (35) 33 (45) 63 (85) 97 (130) 111 (150)

37 (50) 55 (75) 103 (140) 151 (205) 177 (240)

59 (80) 85 (115) 159 (215) 232 (315) 273 (370)

81 (110) 118 (160) 225 (305) 321 (435) 376 (510)

GRADE 5

FT-LB (NM)

GRADE

FT-LB (NM) DRY THREADS

GRADE 8

FT-LB (NM)

1.12

9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual

Page 16

GENERAL INFORMATION

SAE TAP / DRILL SIZES

THREAD

SIZE DRILL SIZE

#0–80 3/64 1/2–13 27/64

#1–64

#1–72 53 9/16–12 31/64

#2–56 51 9/16–18 33/64

#2–64 50 5/8–11 17/32

#3–48 5/64 5/8–18 37/64

#3–56

#4–40

#4–48

#5–40

#5–44 37 1–8 7/8

#6–32 36 1–12 59/64

#6–40

#8–32

#8–36

#10–24

#10–32

#12–24 17 1 1/2–12 1 27/64

#12–28 4.6 mm 1 3/4–5 1 9/16

1/4–20

1/4–28

5/16–18

5/16–24

3/8–16 O 2 1/2–4 2 1/4

3/8–24 Q 2 3/4–4 2 1/2

7/16–14

7/16–20 25/64

F 2–12

U 3–4

THREAD

SIZE DRILL SIZE

1/2–20 29/64

3/4–10 21/32

3/4–16 11/16

7/8–9 49/64

7/8–14 13/16

1 1/8–7 63/64

1 1/8–12 1 3/64

1 1/4–7 1 7/64

1 1/4–12 1 11/64

1 1/2–6 1 11/32

1 3/4–12 1 43/64

2–4 1/2 1 25/32

2 1/4–4 1/2 2 1/32

1 59/64

2 3/4

METRIC TAP / DRILL SIZES

TAP SIZE DRILL SIZE DECIMAL

3 x .50

3 x .60

4 x .70

4 x .75

5 x .80 #19 0.166 11/64

5 x .90

6 x 1.00

7 x 1.00

8 x 1.00 J 0.277

8 x 1.25

9 x 1.00 5/16 0.3125 5/16

9 x 1.25

10 x 1.25

10 x 1.50 R 0.339

11 x 1.50

12 x 1.50

12 x 1.75 13/32 0.406 13/32

#39

3/32

#30

1/8 0.125 1/8

#20

16/64

17/64

5/16

11/32

3/8

13/32

0.0995

0.0937

0.1285

0.161

0.196

0.234

0.265

0.3125

0.3437

0.375

0.406

NEAREST

FRACTION

3/32

1/8

5/32

13/64

15/64

9/32

17/64

5/16

11/32

3/8

13/32

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1.13

Page 17

GENERAL INFORMATION

DECIMAL EQUIVALENTS

FRACTION DECIMAL MM TO INCHES

1/64 0.0156″

1/32

3/64

1/16 0.0625″

5/64

3/32

7/64 0.1094″ 3 mm = 0.1181″

1/8

9/64

5/32 0.1563″ 4 mm = 0.1575″

11/64 0.1719″

3/16

13/64

7/32 0.2188″

15/64

1/4

17/64 0.2656″ 7 mm = 0.2756″

9/32

19/64

5/16 0.3125″ 8 mm = 0.3150″

21/64

11/32

23/64 0.3594″

3/8 0.375″

25/64

13/32

27/64 0.4219″ 11 mm = 0.4331″

7/16

29/64

15/32 0.4688″ 12 mm = 0.4724″

31/64

1/2

33/64 0.5156″

17/32 0.5313″

35/64

9/16

37/64 0.5781″ 15 mm = 0.5906″

19/32

39/64

5/8

0.0312″ 1 mm = 0.0394″

0.0469″

0.0781″ 2 mm = 0.0787″

0.0938″

0.1250″

0.1406″

0.1875″ 5 mm = 0.1969″

0.2031″

0.2344″ 6 mm = 0.2362″

0.25″

0.2813″

0.2969″

0.3281″

0.3438″ 9 mm = 0.3543″

0.3906″ 10 mm = 0.3937″

0.4063″

0.4375″

0.4531″

0.4844″

0.500″ 13 mm = 0.5118″

0.5469″ 14 mm = 0.5512″

0.5625″

0.5938″

0.6094″

0.625″ 16 mm = 0.6299″

FRACTION DECIMAL MM TO INCHES

41/64 0.6406″

21/32

43/64

11/16 0.6875″

45/64

23/32

47/64 0.7344″ 19 mm = 0.7480″

3/4

49/64

25/32

51/64 0.7969″

13/16

53/64

27/32 0.8438″

55/64 0.8594″ 22 mm = 0.8661″

7/8

57/64 0.8906″ 23 mm = 0.9055″

29/32

59/64

15/16 0.9375″ 24 mm = 0.9449″

61/64 0.9531″

31/32

63/64

1 1.000″

0.6563″ 17 mm = 0.6693″

0.6719″

0.7031″ 18 mm = 0.7087″

0.7188″

0.750″

0.7656″

0.7813″ 20 mm = 0.7874″

0.8125″ 21 mm = 0.8268″

0.8281″

0.875″

0.9063″

0.9219″

0.9688″ 25 mm = 0.9843″

0.9844″

1.14

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Page 18

MAINTENANCE

CHAPTER 2

MAINTENANCE

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

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

BREAK-IN PERIOD. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . 2.3

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

PRE-RIDE - 50 HOUR MAINTENANCE INTERVAL . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

50 - 500 HOUR MAINTENANCE INTERVAL. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

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

MAINTENANCE QUICK REFERENCE . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7

GREASE LUBRICATION POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

SERVICE PRODUCTS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . 2.11

GENERAL VEHICLE INSPECTION AND MAINTENANCE . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .2.12

PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . .. . . .2.12

SHIFT CABLE INSPECTION / ADJUSTMENT . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

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

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

FUEL PUMP / FUEL FILTERS . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . .. . . . . . . . . . .2.14

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

VENT LINE . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15

ENGINE INTAKE PRE-FILTER SCREEN SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15

AIR FILTER SERVICE .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

ENGINE AIR INTAKE EXPLODED VIEW . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .2.17

ENGINE . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . 2.18

ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

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

ENGINE CRANKCASE BREATHER HOSE INSPECTION .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . 2.20

ENGINE CYLINDER LEAKDOWN TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

VALVE CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

EXHAUST - SPARK ARRESTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .2.22

TRANSMISSION AND FRONT GEARCASE .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24

SPECIFICATION CHART ... . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . .2.24

TRANSMISSION LUBRICATION. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24

FRONT GEARCASE LUBRICATION .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

COOLING SYSTEM ... . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .2.27

LIQUID COOLING SYSTEM OVERVIEW. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27

COOLANT STRENGTH / TYPE ... . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . 2.27

COOLANT LEVEL INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27

COOLING SYSTEM HOSES. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . .2.28

RADIATOR INSPECTION / CLEANING . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . .. . . . . .2.29

COOLANT DRAIN / FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29

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2.1

Page 19

MAINTENANCE

PVT / FINAL DRIVE / WHEEL AND TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30

DRIVE CLUTCH / DRIVEN CLUTCH / BELT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30

PVT INTAKE PRE-FILTER SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .2.30

PVT DRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30

DRIVE SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31

WHEEL AND HUB TORQUE TABLE .. . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .2.31

WHEEL REMOVAL . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .2.31

WHEEL INSTALLATION . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .2.31

TIRE INSPECTION . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . .2.32

TIRE PRESSURE . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32

ELECTRICAL AND IGNITION SYSTEM . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . ..2.33

BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.33

BATTERY CHARGING / OFF SEASON STORAGE. . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .2.33

BATTERY REMOVAL . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . .2.33

BATTERY INSTALLATION .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . 2.33

CHASSIS / ENGINE ELECTRICAL GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.34

SPARK PLUG SERVICE. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .2.34

STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.36

STEERING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.36

TIE ROD END / WHEEL HUB INSPECTION . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . .. . . . . . . . . . 2.36

WHEEL TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.37

WHEEL TOE ADJUSTMENT. . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . .2.37

SUSPENSION . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . .2.39

SUSPENSION INSPECTION . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . .2.39

SPRING PRE-LOAD ADJUSTMENT .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . .. . . . . . . .2.39

SHOCK POSITION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.39

BRAKE SYSTEM .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.40

BRAKE FLUID INSPECTION . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .2.40

BRAKE HOSE AND FITTING INSPECTION . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . .2.40

BRAKE PAD / DISC INSPECTION .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 2.40

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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.

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.

BREAK-IN PERIOD

The break-in period consists of the first 25 hours of operation, or the time it takes to use 14 gallons (53 liters) of fuel. 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 25 hours or one month.

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

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MAINTENANCE

PRE-RIDE - 50 HOUR MAINTENANCE INTERVAL

MAINTENANCE INTERVAL

ITEM

Steering -

Front / Rear Suspension - -

Tires

Brake Fluid Level

Brake Pedal Travel

Brake System - -

Wheels / Fasteners

Frame Fasteners

Engine Oil Level - -

Engine Intake Pre-Filter

Screen (LH side)

PVT Intake Pre-Filter Screen (RH side)

▶

Air Intake Sediment Drain

Coolant Level

Head Lights / Tail Lights - Daily - Check operation

▶

Brake Pad Wear 10 H

■

▶

Air Filter 25 H

Battery

Engine Oil & Filter Change

▶

(Break-In Period)

Front Gearcase Lubricant(Demand Drive

▶

Fluid)

Transmission Lubricant

▶

(AGL Gearcase Lubricant)

▶

General Lubrication 50 H 3 M

Shift Cable / Linkage

■ Steering

Front / Rear Suspension

▶

■ Throttle Pedal 50 H 6 M

(WHICHEVER COMES FIRST)

HOUR-

- -

- Daily - Inspect; clean often

- Daily -

25 H

25 H 1 M

50 H 6 M

CALEN-

DAR

Pre-Ride

Daily

Monthly 100 (160) Inspect periodically

Monthly

Monthly 200 (320)

MILES

(KM)

- Inspect; clean often

200 (320) Inspect; replace as needed

250 (400)

500 (800) Lubricate all grease fittings, pivots, etc.

500 (800) Inspect, lubricate, adjust

500 (800) Lubricate (if applicable)

500 (800)

REMARKS

Make adjustments as needed. See Pre-Ride Checklist

Inspect drain on the bottom of the engine air intake hose for obstructions

Check level daily, change coolant every 2 years

Check terminals; clean; test

Perform a break-in oil and filter change at 25 hours or one month; perform every 100 hours or 6 months thereafter

Initial fluid level inspection; add lubricant if needed

Inspect for free movement; replace pedal assembly if needed

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▶ 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.

50 - 500 HOUR MAINTENANCE INTERVAL

MAINTENANCE

MAINTENANCE INTERVAL

ITEM

Air Intake Ducts / Adapters

Drive Belt 50 H 6 M

Cooling System

▶

Engine Oil Change

▶

Engine Oil Filter Change

Front Gearcase Lubricant

▶

(Demand Drive Fluid)

Transmission Lubricant

▶

(AGL Gearcase Lubricant)

■ Fuel System

▶

Radiator 100 H 12 M

Cooling Hoses

▶

Engine Mounts

▶

Exhaust Silencer / Pipe

■ Spark Plug

Wiring

▶

Clutches (Drive and

■ Driven)

■ Front Wheel Bearings

▶

Coolant

■

Brake Fluid 200 H 24 M

Spark Arrestor

■ Valve Clearance

■ Spark Plug Replacement

(WHICHEVER COMES FIRST)

HOU-

50 H 6 M

100 H 6 M

100 H 12 M

300 H 36 M

- - 5000 (8000) Inspect; adjust as needed

500 H 36 M

CALENDAR

24 M

REMARKS

MILES (KM)

500 (800) Inspect ducts for proper sealing/air leaks

500 (800) Inspect; replace as needed

500 (800)

1000 (1600)

1000 (1600) Replace oil filter during engine oil change

1000 (1600) Change lubricant

1000 (1600)

1000 (1600) Inspect; clean external surfaces

1000 (1600) Inspect for leaks

1000 (1600) Inspect, torque to specification

1000 (1600) Inspect

1000 (1600) Inspect; replace as needed

1000 (1600)

1000 (1600) Inspect; clean; replace worn parts

1000 (1600) Inspect; replace as needed

- Replace coolant

2000 (3200) Change every two years (DOT 4)

3000 (4800)

5000 (8000) Replace; torque to specification

Inspect coolant strength seasonally; pressure test system yearly

Perform a break-in oil change after the first 25 hours or one month of operation

Check for leaks at fill cap, fuel lines, fuel pump, and fuel rail

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

Clean out

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MAINTENANCE

MAINTENANCE INTERVAL

ITEM

Toe Adjustment

■

Headlight Aim

▶ 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.

(WHICHEVER COMES FIRST)

HOU-

CALENDAR

MILES (KM)

MAINTENANCE QUICK REFERENCE

REMARKS

Inspect periodically; adjust when parts are replaced

Adjust as needed

III.

Item Lube Rec. Method

Polaris PS-4 or Polaris PS-4 Extreme Duty 4-Cycle Engine Oil

Polaris 60/40 Antifreeze

Engine Oil

Engine Coolant

Add oil to proper level on dipstick

Maintain coolant level in coolant reservoir bottle.

Frequency*

Perform a break-in oil and filter change at 25 hrs or one month; perform every 100 hrs thereafter

Check level daily; change coolant every two years

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

MAINTENANCE

MAINTENANCE QUICK REFERENCE

III.

Item Lube Rec. Method

Maintain fluid level

3 Brake Fluid Polaris DOT 4 Brake Fluid

4 Front Gearcase Polaris Demand Drive Fluid

5 Transmission

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Polaris AGL Gearcase Lubricant

between “MAX and “MIN” lines on the master cylinder reservoir

Add lubricant until it is visible at the fill hole threads

Frequency*

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

Initial level check at 25 hours or 1 month; Change lubricant at 100 hours or every 12 months, whichever comes first

2.7

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MAINTENANCE

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

GREASE LUBRICATION POINTS

There are grease fittings at each A-arm pivot point, each rear stabilizer bar bushing, and on the propshaft yoke. Apply grease until all traces of water have been purged out at each of these areas.

Item Method Recommended Lube A-arm Pivot Bushings

Stabilizer Bar Bushings

Propshaft Yoke

2.8

Grease all fittings on each side of the vehicle

Grease the fitting (3 pumps maximum)

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Polaris All Season Grease

Frequency

Grease fittings every 500 miles (800 km); Grease before long periods of storage, and after thoroughly washing or submerging the vehicle

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2013 - 2014 RANGER XP 900 Lubrication Points

MAINTENANCE

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MAINTENANCE

2014 RANGER CREW 900 Lubrication Points

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SERVICE PRODUCTS AND LUBRICANTS

POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS

MAINTENANCE

PART NO. DESCRIPTION

Engine Lubricant

2870791

2876244

2876245

2878920

2878919

2540086

2879723

2879324

Gearcase / Transmission Lubricants

2878068

2878069

2878070

2877922

2877923

2870465

Grease / Specialized Lubricants

2871312 Grease Gun Kit

2871322

2871423

2871460

2871515

2871551

2871329

Coolant

2871323

2871534

Fogging Oil (12 oz. Aerosol)

PS-4 Synthetic 4-Cycle Engine Oil (Quart)

PS-4 Synthetic 4-Cycle Engine Oil (Gallon)

PS-4 Extreme Duty Synthetic 4-Cycle Engine Oil (Quart)

PS-4 Extreme Duty Synthetic 4-Cycle Engine Oil (Gallon)

Engine Oil Filter

Engine Oil Change Kit (PS-4)

Engine Oil Change Kit (PS-4 Extreme Duty)

AGL Gearcase Lubricant (1 Qt.) (12 Count)

AGL Gearcase Lubricant (1 Gal.) (4 Count)

AGL Gearcase Lubricant (2.5 Gal.) (2 Count)

Demand Drive Fluid (Quart)

Demand Drive Fluid (2.5 Gallon)

Oil Pump for 1 Gallon Jug

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

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

Starter Drive Grease (12 Count)

Premium U-Joint Lube (3 oz.) (24 Count)

Premium U-Joint Lube (14 oz.) (10 Count)

Dielectric Grease (Nyogel™)

60/40 Anti-Freeze (Gallon) (6 Count)

60/40 Anti-Freeze (Quart) (12 Count)

PART NO. DESCRIPTION

Additives / Sealants / Thread Locking Agents / Misc.

2871950

2871326

2870652

2872189

2871557

Loctite® Threadlock 242 (6 ml.) (12 count)

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

Fuel Stabilizer (16 oz.) (12 count)

DOT 4 Brake Fluid (12 count)

Crankcase Sealant, 3-Bond 1215 (5 oz.)

NOTE

The number count indicated by each part number in the

table above indicates the number of units that are

shipped with each order.

NOTE

Each item can be purchased separately at your local

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Polaris dealer.

2.11

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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.

• Engine Oil - Check for proper level on dipstick (refer to “Engine Oil Level” procedure)

• Tires - check condition and pressures

• Fuel tank - fill to proper level

• All brakes - check operation, fluid level and adjustment

• Throttle Pedal - check for proper operation

• Headlights/Taillights/Brakelights - check operation of all indicator lights, instrument cluster and switches

• Ignition switch - check for proper function

• Wheels - check for tightness of wheel nuts and axle nuts; check to be sure axle nuts are secured by cotter pins

• Air Filter - inspect filter element condition; replace if necessary

• Intake Pre-Filter Screens - Inspect both screens and clean with warm soapy water and low pressure compressed air if necessary

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

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

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

• Drive Shaft Boots - Inspect inner and outer boots for tears or damage on both front and rear drive shafts

• Check all suspension components for wear or damage

SHIFT CABLE INSPECTION / ADJUSTMENT

Shift cable adjustment may be necessary if symptoms include:

• No gear position or AWD display on instrument cluster

• Ratcheting noise on deceleration

• Inability to engage into a gear

• Excessive gear lash (noise)

• Gear selector moving out of desired range

1. Locate the shift cable (A) attached to the mount bracket (B) and transmission in the right rear wheel well area.

2. Inspect shift cable (A), dust boot (C) and the clevis pin and pivot bushings (D). Replace if worn or damaged.

FRAME, NUTS, BOLTS, AND FASTENERS

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

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3. If adjustment is required, loosen the lower jam nut (E) and pull the cable out of the mount bracket to move the upper jam nut (F).

4. Adjust the shift cable so there is the same amount of cable travel when shifting slightly past HIGH gear and PARK.

Page 30

5. Thread the upper or lower jam nut as required to obtain proper cable adjustment.

NOTE

This procedure may require a few attempts to obtain

the proper adjustment.

6. Once the proper adjustment is obtained, place the shift cable and upper jam nut into the mount. Tighten the lower jam nut (E) against the mount.

7. Start engine and shift through all gears to ensure the shift cable is properly adjusted. If transmission still ratchets after cable adjustment, the transmission will require service.

MAINTENANCE

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MAINTENANCE

FUEL SYSTEM AND AIR INTAKE

FUEL SYSTEM WARNING

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 waterand change

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

loss of consciousness ordeath in a short time.

Never drain the fuel when the engine is hot.Severe

burns may result.

FUEL PUMP / FUEL FILTERS

The fuel pump assembly (A) is located in the fuel tank under the driver’s seat.

The serviceable, high-volume, high-pressure, fuel pump assembly includes a non-serviceable preliminary filter (B).

NOTE

The preliminary filter (B) is non-serviceable. The fuel

pump must be replaced as an assembly. Refer to

Chapter 4 for fuel pump replacement and all other

information related to the EFI System.

Refer to Chapter 4 for fuel pump replacement and all

other information related to the EFI System.

2.14

FUEL LINES

1. Check the quick-connect fuel line (C) at the fuel pump for signs of wear, deterioration, damage or leakage. Replace line if necessary.

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MAINTENANCE

2. Tilt the rear cargo box and check the quick-connect fuel line (D) at the fuel rail for signs of wear, deterioration, damage or leakage. Replace line if necessary.

3. Be sure fuel lines are routed and retained properly.

NOTE

Make sure lines are not kinked or pinched.

VENT LINE

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

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

ENGINE INTAKE PRE-FILTER SCREEN SERVICE

It is recommended that the engine intake pre-filter be inspected daily. The filter should be inspected using the following procedure:

1. The engine intake pre-filter (A) is located just behind the driver hip bolster on the left side of the vehicle.

2. Press in (towards the front of the unit) on intake prefilter tab (B) to remove it.

3. Inspect the pre-filter. If necessary, clean with soapy water and dry with low pressure compressed air.

NOTE

Be sure vent line is not kinked or pinched.

Throttle Pedal Inspection

Inspect the throttle pedal (E) for free movement. Be sure the throttle pedal returns normally when released. Refer to Chapter 4 “Pedal Position Sensor (PPS)” if experiencing a lack of throttle response.

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2.15

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MAINTENANCE

AIR FILTER SERVICE

Inspect the air filter at the intervals outlined in the Periodic Maintenance Chart. In extremely dusty conditions, air filter replacement will be required more often.

1. Tilt the rear cargo box to access the airbox.

2. Release the (5) airbox cover latches (C) and lower the bottom cover (D) to access the air filter element.

3. Remove the air filter element (E).

NOTE

Leave the front portion of the lower airbox cover in the

hinges. It is not necessary to remove the lower cover

when servicing the air filter.

4. Inspect the airbox for oil or water deposits. Wipe away any deposits with a clean shop towel.

NOTE

If the filter has been soaked with fuel or oil it must be

replaced.

2.16

5. Inspect the air filter and replace if necessary.

NOTE

DO NOT attempt to clean the air filter.

6. Place the air filter into the airbox. Reposition the lower airbox cover and install the (5) retaining latches.

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ENGINE AIR INTAKE EXPLODED VIEW

MAINTENANCE

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MAINTENANCE

ENGINE

ENGINE OIL LEVEL

The 2013 - 2014 RANGER XP 900 / CREW 900 engine has a wet-sump design, meaning the engine oil is contained in the bottom of the crankcase. To check the oil level follow the procedure listed below:

Access the oil dipstick and oil fill cap by tilting the rear cargo box.

Polaris recommends the use of PS-4 Synthetic or PS-4 Extreme Duty Synthetic 4-Cycle Engine Oil.

FLUID CAPACITY

Recommended Engine Oil:PS-4 Synthetic (PN

2876244)Ambient Temp Range: -35° F to 100° FPS-4

Extreme Duty Synthetic (PN 2878920)Ambient Temp

Range: 0° F to 120° FCapacity: 2.5 Quarts (2.4 L)

1. Remove all cargo from the cargo box.

CAUTION

Always remove all cargo from the cargo box before

lifting the box to access the engine.

2. Position the vehicle on a level surface and place the transmission in PARK.

3. Stop the engine and allow it to cool down before removing the dipstick.

4. Pull up on the cargo box release lever to tilt the box.

5. From the right side of the vehicle, unlock the dipstick lever (A). Remove the dipstick and wipe it dry with a clean cloth.

7. Remove the dipstick and check the oil level.

8. Add the recommended oil as necessary to bring the oil level within the SAFE range on dipstick. Do not overfill (see NOTE below).

NOTE

A rising oil level between checks during cold weather

operation can indicate contaminants such as gas or

moisture collecting in the crankcase. If the oil level is

over the upper mark, change the oil immediately.

9. Add engine oil through the oil fill cap (B) located on top of the valve cover.

10. When finished, reinstall dipstick and lock the lever.

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.

The engine oil dipstick is located on the right front side of the engine. The engine oil fill cap is located on top of the valve cover. Access the oil dipstick and oil fill cap by tilting the rear cargo box

The crankcase drain plug is located on the bottom of the crankcase. Access the drain plug through the skid plate access hole located directly under the crankcase.

1. Position vehicle on a level surface and place the transmission in PARK.

2. Stop the engine and allow it to cool down.

3. Clean the area around the crankcase drain plug.

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

NOTE

Make certain the dipstick is inserted all the way into the

dipstick tube to keep the depth of the dipstick

2.18

consistent.

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CAUTION

Use caution when performing this procedure.Do not

allow hot engine oil to come into contact with skin, as

serious burns may result.

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MAINTENANCE

4. Place a drain pan under the engine crankcase and remove the drain plug (C). Allow the oil to drain completely.

5. Remove all cargo from the cargo box.

CAUTION

Always remove all cargo from the cargo box before

lifting the box to access the engine.

6. Pull up on the cargo box release lever to tilt the box.

7. Gently press the clutch outlet duct (D) out of the way to gain access to the oil filter (E).

8. Using the Oil Filter Wrench (PU-50105), turn the oil filter (E) counter-clockwise to remove it.

Oil Filter Wrench:PU-50105: 2.5” (64 mm)

9. Using a clean dry cloth, clean the filter sealing surface on the engine crankcase.

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

TORQUE

Oil Filter:Turn by hand until filter O-ring contacts sealing surface, then turn an additional 1/2 turn.

11. Replace the sealing washer on drain plug.

NOTE

The sealing surface on the drain plug should be clean

12. Reinstall the engine crankcase drain plug. Torque

and free of burrs, nicks or scratches.

drain plug to specification.

TORQUE

Crankcase Drain Plug:12 ft-lbs (16 Nm)

13. Remove oil fill cap (see “Engine Oil Level”). Fill engine with 2.5 quarts (2.4 L) of recommended engine oil.

FLUID CAPACITY

Recommended Engine Oil:PS-4 Synthetic (PN

2876244)Ambient Temp Range: -35° F to 100° FPS-4

Extreme Duty Synthetic (PN 2878920)Ambient Temp

Range: 0° F to 120° FCapacity: 2.5 Quarts (2.4 L)

14. Verify the transmission is still in PARK.

15. Start the engine and allow it to idle for 30 seconds.

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MAINTENANCE

16. Stop the engine and inspect for oil leaks. Wait at least 15 seconds before removing the dipstick.

17. Unlock the dipstick lever. Remove the dipstick and wipe it dry with a clean cloth (see “Engine Oil Level”).

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

NOTE

Make certain the dipstick is inserted all the way into the

dipstick tube to keep the depth of the dipstick

consistent.

19. Remove the dipstick and check the oil level.

20. Add the recommended oil as necessary to bring the oil level within the SAFE range on dipstick. Do not overfill.

21. When finished, reinstall the oil fill cap, oil dipstick and lock the lever.

22. Dispose of used oil and filter properly.

NOTE

Make sure hoses are not kinked or pinched.

ENGINE CYLINDER LEAKDOWN TEST

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.

Cylinder Leakage Service Limit: 20%If leakage exceeds

service limit, inspect the engine for the cause.

VALVE CLEARANCE INSPECTION

NOTE

Valve clearance inspection should be performed on a

cold engine, at room temperature.

1. Tilt the rear cargo box to access the valve cover.

2. Disconnect the negative (-) battery cable.

3. Remove the (8) screws that retain the outer clutch cover and remove the cover from the vehicle in order to rotate the engine (see Chapter 6 “Belt Removal”).

ENGINE CRANKCASE BREATHER HOSE INSPECTION

The engine crankcase is equipped with a breather hose. Inspect the breather hose for possible kinks or wear. The hose is form fitted for proper fit.

Follow the breather hose (A) from the crankcase fitting (B) to the airbox (C).

2.20

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MAINTENANCE

4. Remove the spark plug wires (D) from the engine.

5. Remove the (4) T40 bolts (E) and rubber isolators (F) retaining the valve cover (G). Note the location and use of the grounding washer (H) for assembly.

6. The engine will need to be rotated (4) times to inspect all (8) valve clearances. Two valves can be measured at each camshaft lobe position.

NOTE

Remove spark plugs to aid engine rotation.

7. Rotate the drive clutch counter-clockwise until the cam lobes above the valves you are inspecting are facing up.

NOTE

Replace rubber isolators (F) upon assembly.

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8. Measure the valve clearance using a feeler gauge.

9. If the valve clearance is out of specification, proceed to “Valve Clearance Adjustment” (see Chapter 3).

MEASUREMENT

Intake Valve Clearance (cold):.006 ± .002 in. (0.15 ±

0.05 mm)

MEASUREMENT

Exhaust Valve Clearance (cold):.008 ± .002 in. (0.20 ±

0.05 mm)

10. Repeat steps 7-9 until all (8) valves have been inspected.

11. If previously removed, apply anti-seize compound to the spark plug threads and reinstall the spark plugs. Torque spark plugs to specification.

TORQUE

Spark Plug Torque:7 ft-lbs. (10 Nm)

12. Inspect the valve cover seal and replace if necessary.

13. Replace the rubber isolators around each T40 bolt.

14. Install valve cover and the (4) T40 bolts. Torque bolts to specification.

TORQUE

Valve Cover Bolts:7 ft-lbs. (10 Nm)

15. Install the spark plug wires. Ensure wires are pushed down all the way so they engage onto the spark plugs.

NOTE

The engine will misfire if the spark plug wires are

installed incorrectly. The spark plug wires are marked

with PTO and MAG and should be installed to the

corresponding cylinder.

16. Install the outer clutch cover and (8) retaining screws (see Chapter 6 “Belt Installation”). Torque the screws to specification.

TORQUE

Outer Clutch Cover Screws: 45-50 in-lbs (5 Nm)

17. Connect the negative (-) battery cable to the battery.

18. Start the engine to ensure proper operation.

EXHAUST - SPARK ARRESTOR

WARNING

Do not clean spark arrestor immediately after the

engine has been run, as the exhaust system becomes

very hot. Serious burns could result from contact with

the exhaust components. Allow components to cool

sufficiently before proceeding. Wear eye protection and

gloves.

Never run the engine in an enclosed area. Exhaust

contains poisonous carbon monoxide gas that can

cause loss of consciousnessor death in a very short

time.

Periodically clean spark arrestor to remove accumulated carbon.

1. Remove the retaining screw (A) and nut (B).

2. Remove the spark arrestor (C) from the end of the silencer (D).

3. Use a non-synthetic brush to clean the arrestor screen. A synthetic brush may melt if components are warm. If necessary, blow debris from screen with compressed air.

4. Inspect the screen for wear and damage. Replace if needed.

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5. Reinstall the arrestor and torque the retaining screw to specification.

MAINTENANCE

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MAINTENANCE

TRANSMISSION AND FRONT GEARCASE

SPECIFICATION CHART

GEARCASE LUBRICANT CAPACITY

Transmission AGL Gearcase Lubricant

Front Gearcase Demand Drive Fluid

TRANSMISSION LUBRICATION

41 oz. (1200 ml) 10-14 ft-lbs. (14-19 Nm)

6.75 oz. (200 ml) 8-10 ft-lbs. (11-14 Nm)

4. Reinstall the fill plug and torque to specification.

NOTE

It is important to follow the transmission maintenance

intervals described in the Periodic Maintenance Chart.

The transmission lubricant 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 lubricant.

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

Transmission Lubricant Level Check

The fill plug is located on the rear portion of the transmission gearcase. Access the fill plug at the rear of the vehicle. Maintain lubricant level even with the bottom of the fill plug hole.

1. Position vehicle on a level surface.

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

5. Remove the fill plug (refer to “Transmission Lubricant

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

7. Remove drain plug and allow lubricant to drain

Fill / Drain Plug:10-14 ft-lbs (14-19 Nm)

Transmission Lubricant Change The drain plug is located on the bottom of the

transmission gearcase. Access the drain plug through the drain hole in the skid plate.

Level Check”).

completely.

FILL / DRAIN PLUG TORQUE

TORQUE

3. If lubricant level is not even with bottom threads, add

recommended lubricant as needed. Do not overfill.

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8. Clean the drain plug magnetic surface.

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

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MAINTENANCE

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

FLUID CAPACITY

Recommended Transmission Lubricant:AGL

Gearcase Lubricant(PN 2878068) (Quart)

Capacity: 41 oz. (1200 ml)

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

TORQUE

Fill / Drain Plug:10-14 ft-lbs (14-19 Nm)

12. Check for leaks. Dispose of used lubricant properly.

FRONT GEARCASE LUBRICATION

NOTE

It is important to follow the front gearcase maintenance

intervals described in the Periodic Maintenance Chart.

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 bottom right side of the front gearcase. Access the fill plug through the right front wheel well. Maintain fluid level even with the bottom of the fill plug hole.

1. Position vehicle on a level surface.

2. Locate the gearcase fill plug (A) through the right front wheel well area.

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

4. If fluid level is not even with the bottom threads, add the recommended fluid as needed. Do not overfill.

5. Reinstall the fill plug and torque to specification.

TORQUE

Fill / Drain Plug:8-10 ft-lbs (11-14 Nm)

Front Gearcase Fluid Change:

The drain plug is located on the bottom of the front gearcase. Access the drain plug through the access hole in the frame underneath the front gearcase.

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

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

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

9. Clean the drain plug magnetic surface.

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

11. Add the recommended amount of fluid through the fill hole. Maintain the fluid level even with the bottom threads of the fill plug hole.

FLUID CAPACITY

Recommended Front Gearcase Fluid:Polaris

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

Demand Drive Fluid

(PN 2877922) (Quart)

Capacity: 6.75 oz. (200 ml)

TORQUE

Fill / Drain Plug:8-10 ft-lbs (11-14 Nm)

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

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COOLING SYSTEM

MAINTENANCE

LIQUID COOLING SYSTEM OVERVIEW

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

As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle. As engine coolant temperature decreases the contracting (cooled) coolant is drawn back from the tank past the pressure cap and into the radiator.

NOTE

Some coolant level drop on new machines is normal as

the system is purging itself of trapped air. Observe

coolant levels often during the break-in period.

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

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

COOLANT STRENGTH / TYPE

Test the strength of the coolant using an antifreeze hydrometer.

COOLANT LEVEL INSPECTION

The recovery bottle (A) and radiator pressure cap (B) are located under the hood.

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

1. Position the vehicle on a level surface

2. Remove the hood from the front cab.

3. Check the coolant level in the recovery bottle (A). The coolant level must be maintained between the “MAX” and “MIN” levels indicated on the recovery bottle

• 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.

FLUID CAPACITY

Recommended Anti-Freeze/Coolant:Polaris Premium

(PN 2871534) (Quart)(PN 2871323) (Gallon)

Pre-Mixed Antifreeze

4. If the coolant level is below the “MIN” mark, inspect the coolant level in the radiator.

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.

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MAINTENANCE

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.

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

6. Reinstall the pressure cap.

NOTE

Use of a non-standard pressure cap will not allow the

recovery system to function properly.

7. Remove the recovery bottle cap and add coolant using a funnel.

8. Fill the recovery bottle to the “MAX” mark with the recommended pre-mix coolant. You may use a 50/50 or 60/40 mixture of antifreeze and distilled water as required for freeze protection in your area.

FLUID CAPACITY

Recommended Anti-Freeze/Coolant:Polaris Premium

Pre-Mixed Antifreeze

(PN 2871534) (Quart)(PN 2871323) (Gallon)

9. Reinstall the recovery bottle cap.

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

COOLING SYSTEM HOSES

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

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

2.28

3. Check tightness and condition of all hose clamps.

CAUTION

Do not over-tighten hose clamps at radiator, or radiator

fitting may distort.Radiator hose clamp torque is 36 in-

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lbs (4 Nm).

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MAINTENANCE

RADIATOR INSPECTION / 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.

COOLANT DRAIN / FILL

1. Allow the vehicle to cool down if recently operated.

2. Remove the hood from the front cab.

WARNING

Escaping steam can cause burns. Never remove the

pressure cap while the engine is warm or hot. Always

allow the engine to cool before removing the pressure

cap.

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

4. Place a drain pan under the lower radiator hose.

5. Slide the clamp back and remove the lower radiator hose to drain the coolant from the radiator.

6. Allow the coolant to completely drain. Properly dispose of the used coolant.

7. Reinstall coolant hose and reposition the spring clamp.

8. Remove the pressure cap. Using a funnel, add the recommended coolant to the top of the filler neck and fill the recovery bottle to the MAX level.

9. Refer to “Cooling System Bleeding Procedure” provided in Chapter 3.

FLUID CAPACITY

Recommended Coolant:Polaris Premium Pre-Mixed

(PN 2871534) (Quart)(PN 2871323) (Gallon)

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Antifreeze

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MAINTENANCE

PVT / FINAL DRIVE / WHEEL AND TIRE

DRIVE CLUTCH / DRIVEN CLUTCH / BELT SERVICE

Refer to Chapter 6 “Clutching (PVT)” for service and removal procedures.

PVT INTAKE PRE-FILTER SERVICE

It is recommended that the PVT intake pre-filter be inspected daily. The filter should be inspected using the following procedure:

1. The PVT intake pre-filter (A) is located just behind the passenger hip bolster on the right side of the vehicle.

2. Press in (towards the front of the unit) on intake prefilter tab (B) to remove it.

PVT DRYING

NOTE

After operating in water, the vehicle’s PVTsystem

should be checked immediately. Use the following

instructions to dry it out before operating.

The PVT drain plug (C) is located at the bottom of the outer clutch cover. Access the drain plug through the left rear wheel well.

1. Using a flat blade screwdriver, remove the PVT drain plug (C) and O-ring from the outer clutch cover.

3. Inspect the pre-filter. If necessary, clean with soapy water and dry with low pressure compressed air.

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2. Allow the water to drain out completely.

3. Reinstall the drain plug and O-ring.

4. Place the transmission in PARK, apply the brake and start the engine.

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

NOTE

Do not hold the throttle pedal wide open for more than 5

seconds.

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

7. Test the PVT system for belt slippage. If the belt slips, repeat the process or remove the outer clutch cover to inspect the PVT system (see Chapter 6 “Clutching (PVT)” for service and removal procedures).

NOTE

If the vehicle has ingested a large amount of water into the PVT system and has not been operated for a period

of time, be sure to check the PVT system components

for water damage.

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MAINTENANCE

DRIVE SHAFT BOOT INSPECTION

Inspect the front and rear drive shaft boots (D) for damage, tears, wear or leaking grease. If the boots exhibit any of these symptoms, they should be replaced. Check to see the boot clamps (E) are properly positioned.

WHEEL REMOVAL

1. Position the vehicle on a level surface.

2. Place the transmission in PARK and stop the engine.

3. Loosen the wheel nuts (F) slightly. If wheel hub removal is required, remove the wheel cap (G), cotter pin (H) and loosen the hub nut (J) slightly.

NOTE

Limited Edition models with aluminum wheels require a

thin wall socket to loosen or tighten the wheel nuts

without damaging the finish of the rim. The wheel nut

requires a 19mm thin wall socket with an O.D. less than

24.7mm to allow it to clear the rim.

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

5. Remove the wheel nuts (F) and remove the wheel (K).

Refer to Chapter 7 for drive shaft boot replacement.

WHEEL AND HUB TORQUE TABLE

ITEM SPECIFICATION

Wheel Nuts (Steel Wheels)

Wheel Nuts (Cast Aluminum Wheels)

Front Wheel Hub Castle Nuts

Rear Wheel Hub Castle Nuts

60 ft-lbs. (81 Nm)

120 ft-lbs. (163 Nm)

75 ft-lbs. (102 Nm)

110 ft-lbs. (149 Nm)

WHEEL INSTALLATION

1. Verify the transmission is still in PARK.

2. Install the wheel on the wheel hub with the valve stem toward the outside. Be sure rotation arrow on the tire (if applicable) point toward forward rotation.

3. Attach the wheel nuts (F) and finger tighten them.

4. Carefully lower the vehicle to the ground.

NOTE

Limited Edition models with aluminum wheels require a

thin wall socket to loosen or tighten the wheel nuts

without damaging the finish of the rim. The wheel nut

requires a 19mm thin wall socket with an O.D. less than

24.7mm to allow it to clear the rim.

NOTE

Do not lubricate the stud or the lug nut.

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MAINTENANCE

5. Torque wheel nuts (F) and/or hub nut (J) to the proper specification (see “Wheel and Hub Torque Table”).

6. If wheel hub nut was removed, install a new cotter pin (H) after the hub castle nut has been tightened. If the holes do not line up, turn the castle nut counterclockwise until the cotter pin can be installed.

CAUTION

If wheels are improperly installed it could affect vehicle

handling and tire wear. On vehicles with tapered wheel

nuts, make sure tapered end of nut goes into taper on

wheel.

TIRE INSPECTION

• Improper tire inflation may affect vehicle

maneuverability.

• When replacing a tire always use original equipment

size and type.

• The use of non-standard size or type tires may affect

vehicle handling.

WARNING

Operating with worn tires will increase the possibility of

the vehicle skidding easily with possible loss of control.

Worn tires can cause an accident.

Always replace tires when the useable tread depth has

worn out.

TIRE PRESSURE

Remove the valve stem cap and check tire pressure using the tire pressure gauge included in the vehicle’s tool kit.

CAUTION

Maintain proper tire pressure.Refer to the warning tire

Tire Pressure Inspection (Cold)

Front Rear

10 psi (69 kPa) 12 psi (83 kPa)

2.32

pressure decal applied to the vehicle.

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ELECTRICAL AND IGNITION SYSTEM

MAINTENANCE

BATTERY MAINTENANCE

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

WARNING

CALIFORNIA PROPOSITION 65 WARNING:Batteries,

battery posts, terminals and related accessories contain

lead and lead compounds, and other chemicals known

to the State of California to cause cancer and birth

defects or other reproductive harm.WASH HANDS

AFTER HANDLING.

WARNING

Battery electrolyte is poisonous. It contains sulfuric

acid. Serious burns can result from contact with skin,

eyes or clothing. Antidote:

External: Flush with water.

Internal: Drink large quantities of water or milk. Follow

with milk of magnesia, beaten egg, or vegetable oil. Call

physician immediately.

Eyes: Flush with water for 15 minutes and get prompt

medical attention.

Batteries produce explosive gases. Keep sparks, flame,

cigarettes, etc. away. Ventilate when charging or using

in an enclosed space. Always shield eyes when

working near batteries. KEEP OUT OF REACH OF

CHILDREN.

NOTE

Batteries must be fully charged before use or battery life will be reduced by 10-30% of full potential. Charge battery according to “Charging Procedure” provided in

Chapter 10. Do not use the vehicle’s stator/alternator to

charge a new battery.

BATTERY CHARGING / OFF SEASON STORAGE

Refer to Chapter 10 “Electrical” for charging and off season storage procedures.

BATTERY REMOVAL

1. Remove the passenger seat (right rear passenger seat on the CREW 900) and storage container to access the battery (A).

2. Disconnect the black (negative) battery cable (B).

3. Disconnect the red (positive) battery cable (C).

CAUTION

To reduce the chance of sparks, disconnect the black

(negative) cable first. When reinstalling the battery,

connect the black (negative) cable last.

4. Remove the fastener (D) retaining the battery holddown strap and lift the battery out of the vehicle.

BATTERY INSTALLATION

NOTE

Using a new battery that has not been fully charged can

damage the battery and result in a shorter life. It can

also hinder vehicle performance. Follow the battery

charging procedure in Chapter 10 “Electrical” before

1. Ensure the battery is fully charged.

2. Place the battery (A) in the vehicle. Install the holddown strap and retaining fastener (D).

3. Coat the terminals with dielectric grease or petroleum jelly.

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installing the battery.

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MAINTENANCE

4. Install and tighten the red (positive) cable (C) first.

5. Install and tighten the black (negative) cable (B) last.

6. Verify the cables are properly routed and reinstall the storage container and passenger seat.

CHASSIS / ENGINE ELECTRICAL GROUND

Inspect the ground cable connections. Remove ground terminals and clean if necessary.

1. Remove the passenger seat base and storage bin to access the chassis ground terminal (A), located below the starter solenoid (B) to the right of the battery.

SPARK PLUG SERVICE

Inspect and replace the spark plugs at the intervals outlined in the Periodic Maintenance Chart.

1. Tilt the rear cargo box to access the top of the engine.

WARNING

A hot engine can cause serious burns. Allow engine to

cool or wear protective gloves when removing the spark

plugs.

2. Remove both spark plug caps (A).

2. Inspect the chassis ground terminals. Be sure they are clean and tight.

3. Inspect the engine ground terminal (C), attached to the upper starter mounting bolt. The other end of the engine ground cable is attached to the chassis ground terminal (A).

4. Inspect the engine ground terminals. Be sure they are clean and tight.

NOTE

Note MAG and PTO reference decals (B) on spark plug

wires for reassembly.

3. Clean out plug wells with compressed air to remove any loose dirt or debris.

4. Rinse plug wells with water and dry with compressed air.

NOTE

Spark plug wells have drain holes built into the cylinder

head to allow water to drain out.

5. Remove spark plugs using a 5/8” spark plug socket with an extension.

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

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

8. Measure gap with a wire gauge. Adjust gap if necessary by carefully bending the side electrode.

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

MAINTENANCE

Recommended Spark Plugs:2013 Models: Champion

RG4YCX2014 Models: Champion XG4YCX

10. Apply anti-seize compound to the spark plug threads.

11. Install spark plugs and torque to specification.

TORQUE

Spark Plug:7 ft-lbs. (10 Nm)

12. Install the plug caps to the appropriate cylinder by referencing the MAG and PTO spark plug wire decals (B). Ensure wires are pushed down all the way so they engage onto the spark plugs.

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MAINTENANCE

STEERING

STEERING INSPECTION

Steering system components should be checked periodically for loose fasteners (A), worn tie rod ends (B), loose steering shaft U-joints (C), worn A-arm ball joints and general damage. Also check to make sure all cotter pins (D) are in place. If cotter pins are removed, they must be replaced.

Replace any worn or damaged steering components. Steering should move freely through the 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.

TIE ROD END / WHEEL HUB INSPECTION

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

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

• Elevate front end of machine so front wheels are off the ground. Check for any looseness in front wheel/ hub 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.

NOTE

Check front end alignment whenever steering

components are replaced.

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

2.36

Polaris MSD certified technician.

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

• Refer to Chapter 7 “Final Drive” for front hub or bearing carrier service procedures.

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MAINTENANCE

WHEEL TOE ALIGNMENT INSPECTION

NOTE

Make sure tire pressures are set the same on the right

and left tires.

1. Place machine on a smooth level surface and set steering wheel in a straight ahead position. Secure the steering wheel in this position.

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

WHEEL TOE ADJUSTMENT

If toe alignment is incorrect, repeat steps 3-5 of “Wheel Toe Alignment Inspection”, but instead measure the distance between vehicle center and each wheel. This will tell you which tie rod needs adjusting.

NOTE

It is important the height of both marks be equally

positioned to get an accurate measurement.

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

4. Rotate the tires 180° by moving the vehicle forward. Position chalk marks facing rearward, even with the hub/axle center line.

5. Again measure the distance between the marks and record. Call this measurement “B”. Subtract measurement “B” from measurement “A”. The difference between measurements “A” and “B” is the vehicle toe alignment. The recommended vehicle toe tolerance is 1/8” to 3/16” (3.2 to 4.8 mm) toe out. This means the front of the tire (A) is 1/8” to 3/16” (3.2 to

4.8 mm) wider than the measurement at the rear (B).

MEASUREMENT

Wheel Toe-Out:(A) - (B) = 1/8" to 3/16" (3.2 to 4.8 mm)

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Be sure steering wheel is straight ahead before

determining which tie rod needs adjustment.

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 end of the tie rod.

• Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified in “Wheel Toe Alignment Inspection”.

• 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.

NOTE

CAUTION

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MAINTENANCE

• After alignment is complete, torque jam nuts to specification.

TORQUE

Tie Rod Jam Nut:14 ft-lbs. (19 Nm)

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SUSPENSION

MAINTENANCE

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.

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 left and right sides equally.

NOTE

Adjusting all shock cams equally will only affect ride

height as the weight transfer will not be changed.

3. Reposition the upper shock mounts to the outside mounting holes (B).

Vehicle loads effect suspension spring pre-load requirements. Use Spanner Wrench (PN 2871095) to adjust pre-load as necessary to avoid bottoming of the shocks.

Shock Spanner Wrench:PN 2871095

4. Reinstall the upper shock mounting bolts and torque to specification.

TORQUE

Shock Mounting Bolts:40 ft-lbs (54 Nm)

SHOCK POSITION ADJUSTMENT

The front and rear shock position may be adjusted to provide a stiffer suspension operation if necessary.

1. Elevate vehicle and safely support the main frame.

CAUTION

Serious injury may result if machine tips or falls. Be

sure machine is secure before adjusting.

2. Remove the upper shock mounting bolts (A) from each side of the vehicle.

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BRAKE SYSTEM

BRAKE FLUID INSPECTION

Always check the brake pedal travel and inspect the brake fluid reservoir level before each operation. If the fluid level is low, add DOT 4 brake fluid only.

Brake fluid should be changed every two years. The fluid should also be changed anytime the fluid becomes contaminated, the fluid level is below the minimum level, or if the type and brand of the fluid in the reservoir is unknown.

The brake master cylinder reservoir (A) can be accessed through the front left wheel well.

1. Position the vehicle on a level surface.

2. Place the gear selector in Park.

3. View the brake fluid level in the reservoir. The level should be between the MAX and MIN level lines.

4. If the fluid level is lower than the MIN level line, add brake fluid until it reaches just below the MAX level line.

5. Install the reservoir cap and apply the brake pedal forcefully for a few seconds and check for fluid leakage around the master cylinder fittings and the brake caliper fittings.

BRAKE PAD / DISC INSPECTION

1. Check the brake pads for wear, damage, or looseness.

2. Inspect the brake pad surface for excessive wear.

3. Pads should be changed when the friction material is worn to 0.040″ (1 mm).

4. Check surface condition of the brake discs.

5. Measure the thickness of the front and rear brake discs.

BRAKE HOSE AND FITTING INSPECTION

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

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6. The disc (s) should be replaced if thickness is less than the specified service limit (see Chapter 9 for specifications).

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ENGINE

CHAPTER 3

ENGINE

GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 3.4

SPECIAL TOOLS . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . 3.4

ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . 3.5

OIL PRESSURE TEST.. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 3.5

ENGINE OIL FLOW CHART . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.7

ENGINE SERVICE SPECIFICATIONS .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . .. . . . . 3.8

ENGINE SPECIFICATIONS. . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . 3.8

ENGINE DETAIL - TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES . .. . . . . . . . . . . . . . . . .. . . .3.10

MAIN ENGINE COMPONENTS - TORQUE SPECIFICATION AND SEQUENCE ... . . .. . . . . . . . . . . . . . . . . 3.10

BALANCE SHAFT / CONNECTING RODS / CRANKCASE / CRANKSHAFT / PISTONS. . . . . . . . . . . . .. . . 3.11

CYLINDER / OIL COOLER / OIL FILTER / OIL PUMP / OIL SUMP / WATER PUMP.. . . . . . . . . . . . . . . . . . . .3.12

CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / IDLER GEARS / STATOR COVER . . . . . . . . .. . . . . . . . . . 3.13

SPARK PLUGS / STARTER / THERMOSTAT HOUSING / TRANS JOINT / VALVE COVER . . . . .. . . . . . ..3.14

ENGINE EXHAUST SYSTEM. . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . .3.15

EXHAUST REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .3.15

ENGINE COOLING SYSTEM . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . 3.16

COOLING SYSTEM PRESSURE TEST ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16

RADIATOR CAP PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16

RADIATOR FAN REMOVAL. . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . .3.17

RADIATOR REMOVAL / COOLANT DRAIN . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . .3.17

THERMOSTAT REPLACEMENT . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . .3.18

COOLING SYSTEM EXPLODED VIEW . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . .3.20

COOLING SYSTEM BLEEDING PROCEDURE . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . .3.21

WATER PUMP REMOVAL . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . .3.21

WATER PUMP INSTALLATION .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .3.22

WATER PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.23

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.27

ACCESSIBLE ENGINE COMPONENTS . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27

ENGINE REMOVAL . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . 3.27

ENGINE INSTALLATION.. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .3.30

ENGINE MOUNTING AND TORQUE VALUES .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.34

ENGINE BREAK-IN PERIOD . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . .3.35

ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . .3.35

ENGINE DISASSEMBLY / INSPECTION - TOP END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.36

VALVE COVER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.36

CAMSHAFT REMOVAL. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .3.36

CAMSHAFT SPROCKET INSPECTION. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.38

CAMSHAFT / CAMSHAFT BORE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.38

CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . 3.40

CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.40

CYLINDER HEAD WARP INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .3.40

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CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . .3.41

VALVE INSPECTION . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . 3.41

COMBUSTION CHAMBER CLEANING .. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .3.43

VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.43

ENGINE DISASSEMBLY / INSPECTION - LOWER END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.46

STATOR COVER REMOVAL / INSPECTION . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .3.46

WATER PUMP HOUSING REMOVAL . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . .3.47

FLYWHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.47

STARTER ONE-WAY CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .3.48

STARTER ONE-WAY CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.49

CRANKCASE DISASSEMBLY . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . 3.50

BALANCE SHAFT REMOVAL / INSPECTION . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . .. . . .3.52

CRANKSHAFT REMOVAL / INSPECTION . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . .3.53

CRANKCASE INSPECTION .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .3.56

CYLINDER / PISTON REMOVAL. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 3.56

CYLINDER INSPECTION . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . .3.57

PISTON DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . 3.58

PISTON RING REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.59

PISTON RING TO GROOVE CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . .3.60

PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .3.60

PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.61

CONNECTING ROD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.61

ENGINE ASSEMBLY - LOWER END .. . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . .3.63

BEARING SELECTION IDENTIFICATION LETTERS AND NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.63

CONNECTING ROD BEARING SELECTION.. . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 3.64

CRANKSHAFT MAIN BEARING SELECTION ... . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . ..3.64

UPPER CRANKCASE PREPARATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.65

PISTON RING INSTALLATION. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .3.65

PISTON / CONNECTING ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.66

CYLINDER / PISTON INSTALLATION. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .3.67

CRANKSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .3.68

BALANCE SHAFT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.69

LOWER CRANKCASE PREPARATION .. . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . .. . . . . . .3.70

CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . 3.70

FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . ..3.74

STATOR COVER INSTALLATION . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .3.75

ENGINE ASSEMBLY - TOP END ... . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . .3.76

CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . .3.76

VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . .3.77

CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .3.77

CAMSHAFT INSTALLATION / TIMING ... . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .3.78

CAMSHAFT TIMING - QUICK REFERENCE . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .3.82

VALVE CLEARANCE ADJUSTMENT... . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .3.83

INTAKE VALVE LASH - TAPPET SELECTION MATRIX . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . .3.86

EXHAUST VALVE LASH - TAPPET SELECTION MATRIX ... . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 3.87

VALVE COVER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.88

TROUBLESHOOTING . . . .. . . . . . .. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .3.89

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ENGINE / COOLING SYSTEM . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . .3.89

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GENERAL INFORMATION

SPECIAL TOOLS

Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/

TOOL DESCRIPTION PART NUMBER

Bench Mount Engine Stand Adapter

Clutch Center Distance Tool PU-50658

Cylinder Holding & Camshaft Timing Plate

Engine Stand (2” Bore)

Engine Stand Adapter (Mounts To The Engine)

Engine Stand Sleeve Adapter (Use With 2” Bore Stand)

Engine Stand Sleeve Adapter (Use With 2.375” Bore Stand)

Flywheel Puller

Mityvac® Pressure Test Tool

Oil Filter Wrench PU-50105

Oil Pressure Gauge

Oil Pressure Gauge Adapter

Piston Ring Compressor Pliers

Valve Spring Compressor PV-1253 or PV-4019 (Quick Release)

Valve Spring Compressor Adapter

Water Pump Mechanical Seal Installer

PW-47053

PU-50563

PU-50624

PU-50562

PU-50625

PW-47054

PA-49316

2870975

PV-43531

PU-50565

PV-43570-1

PV-43513-A

PU-50564

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ENGINE LUBRICATION SPECIFICATIONS

FLUID CAPACITY

Oil Capacity *

Approx. 2.5 Quarts (2.4 L)

Oil Filter Wrench

PU-50105 or 2.5” (64 mm)

Oil Filter

PN 2540086

Oil TypeAmbient Temp Range:-35° F to 100° F

PS-4 Synthetic Engine oil(PN 2876244) (Quart)

Oil TypeAmbient Temp Range:0° F to 120° F

PS-4 Extreme Duty Synthetic Engine Oil(PN 2878920)

(Quart)

Oil PressureMinimum Specification(using Polaris

engine oil at operating temperature)

10 PSI @ 1200 RPM 40 PSI @ 7000 RPM

*Additional oil may be required after complete engine disassembly. Check level after filling and add oil as needed.

OIL PRESSURE TEST

1. Attach the Oil Pressure Gauge Adapter (PU-50565) to the Oil Pressure Gauge (PV-43531).

Oil Pressure Gauge Adapter: PU-50565 Oil Pressure

Gauge: PV-43531

2. Tilt the rear cargo box to the raised position.

3. Clean the area around the main oil gallery plug (A), located in the upper crankcase on the MAG side of the engine.

4. Remove the plug (A) and insert the oil pressure adapter.

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5. 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 (Polaris PS-4 or PS-4 Extreme Duty) at

operating temperature, and may vary considerably if

any other oil is used or if engine is not up to

temperature.

Oil Pressure Specification (Engine Hot):Minimum @

1200 RPM: 10 PSI

6. Upon assembly, torque the crankcase gallery plug to specification.

TORQUE

Crankcase Gallery Plug:11 ft-lbs (15 Nm)

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ENGINE OIL FLOW CHART

ENGINE

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ENGINE

ENGINE SERVICE SPECIFICATIONS

ENGINE SPECIFICATIONS

CAMSHAFT / CYLINDER HEAD / CYLINDER

Cam Lobe Height - Intake (Standard) 1.5256" ± 0.0015" (38.75 ± 0.04 mm)

Cam Lobe Height - Intake (Service Limit) 1.5220" (38.66 mm)

Cam Lobe Height - Exhaust (Standard) 1.4961" ± 0.0015" (38.00 ± 0.04 mm)

Cam Lobe Height - Exhaust (Service Limit) 1.4925" (37.91 mm)

Camshaft Journal O.D. - All (Standard) 0.9035" - 0.9046" (22.949 - 22.978 mm)

Camshaft

Cylinder Head

Valve Seat

Valve Guide Valve Guide Inner Diameter

Valve

Valve Spring

Cylinder

Camshaft Journal O.D. - All (Service Limit) 0.9025" (22.923 mm)

Camshaft Journal Bore I.D. - All (Standard) 0.9055" - 0.9063" (23.000 - 23.021 mm)

Camshaft Journal Bore I.D. - All (Service Limit) 0.9072" (23.044 mm)

Camshaft Oil Clearance (Standard) 0.0009" - 0.0028" (0.022 - 0.072 mm)

Camshaft Oil Clearance (Service Limit) 0.0039" (0.1 mm)

Camshaft End Play (Standard) 0.0040" - 0.0100" (0.101 - 0.254 mm)

Camshaft End Play (Service Limit) 0.0157" (0.4 mm)

Cylinder Head - Surface Warp Limit 0.0039" (0.1 mm)

Cylinder Head - Standard Height 4.717" ± 0.0019" (119.8 ± 0.05 mm)

Valve Seat - Contacting Width - Intake (Standard) 0.0393" ± 0.0039" (1.0 ± 0.10 mm)

Valve Seat - Contacting Width - Intake (Service Limit) 0.0551" (1.4 mm)

Valve Seat - Contacting Width - Exhaust (Standard) 0.0590" ± 0.0039" (1.5 ± 0.10 mm)

Valve Seat - Contacting Width - Exhaust (Service Limit) 0.0748" (1.9 mm)

Valve Seat Angles

Valve Lash (Cold) - Intake 0.006" ± 0.002" (0.15 ± 0.5 mm)

Valve Lash (Cold) - Exhaust 0.008" ± 0.002" (0.20 ± 0.5 mm)

Valve Stem Diameter - Intake

Valve Stem Diameter - Exhaust

Valve Stem Oil Clearance - Intake

Valve Stem Oil Clearance - Exhaust Valve Overall Length - Intake 3.7704" (95.77 mm)

Valve Overall Length - Exhaust 3.8023" (96.58 mm)

Valve Spring Free Length (Standard) 1.7213" (43.72 mm)

Valve Spring Free Length (Service Limit) 1.6830" (42.75 mm)

Cylinder - Surface Warp Limit (mating with cylinder head)

Cylinder Bore - Standard 3.6614" ± 0.0003" (93 mm ± 0.008 mm)

Cylinder Out of Round Limit 0.001" (0.025 mm)

Cylinder Taper Limit 0.001" (0.025 mm)

Cylinder to Piston Clearance 0.0014" - 0.0026" (0.035 - 0.065 mm)

30.0° ± 1.5° / 45.0° ± 0.5° / 60.0° ± 1.5°

0.2165" - 0.2171" (5.500 - 5.515 mm)

0.2155" - 0.2161" (5.475 - 5.490 mm)

0.2147" - 0.2153" (5.455 - 5.470 mm)

0.0003" - 0.0015" (0.010 - 0.040 mm)

0.0011" - 0.0023" (0.030 - 0.060 mm)

0.002" (0.05 mm)

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PISTON / RINGS / CONNECTING ROD / CRANKSHAFT / BALANCE SHAFT

Piston

Piston Pin

Piston Ring

Connecting Rod

Crankshaft

Balance Shaft

Piston - Standard O.D. - Measured 90 degrees to pin,

0.51 in. (13 mm) up from piston skirt. See text.

Piston Pin Bore I.D. (Standard) 0.7876" - 0.7878" (20.004 - 20.009 mm)

Piston Pin Bore I.D. (Service Limit) 0.7893" (20.05 mm)

Piston Pin O.D. (Standard) 0.7872" - 0.7874" (19.995 - 20.000 mm)

Piston Pin O.D. (Service Limit) 0.7866" (19.98 mm)

Top Ring (Standard) 0.008" - 0.014" (0.20 - 0.36 mm)

Top Ring (Service Limit) 0.020" (0.5 mm)

Installed Gap

Ring to Groove Clearance

Connecting Rod Small End I.D. (Standard) 0.7879" - 0.7884" (20.015 - 20.025 mm)

Connecting Rod Small End I.D. (Service Limit) 0.7897" (20.06 mm)

1 - Marking Connecting Rod Big End Bore I.D. 1.7318" - 1.7321" (43.989 - 43.996 mm)

2 - Marking Connecting Rod Big End Bore I.D. 1.7321" - 1.7323" (43.996 - 44.003 mm)

3 - Marking Connecting Rod Big End Bore I.D. 1.7323" - 1.7326" (44.003 - 44.010 mm)

B - Marking Main Journal O.D. (Standard) 1.6140" - 1.6143" (40.996 - 41.004 mm)

G - Marking Main Journal O.D. (Standard) 1.6137" - 1.6140" (40.988 - 40.995 mm)

Y - Marking Main Journal O.D. (Standard) 1.6134" - 1.6137" (40.980 - 40.987 mm)

Main Journal O.D. (Service Limit) 1.6126" (40.960 mm)

B - Marking Rod Journal O.D. (Standard) 1.6118" - 1.6122" (40.942 - 40.950 mm)

G - Marking Rod Journal O.D. (Standard) 1.6115" - 1.6118" (40.934 - 40.941 mm)

Y - Marking Rod Journal O.D. (Standard) 1.6112" - 1.6115" (40.926 - 40.933 mm)

Rod Journal O.D. (Service Limit) 1.6104" (40.906 mm)

Crankshaft Runout Limit (PTO and MAG) Less than 0.001" (0.025 mm)

Auxiliary Sprocket Installed Depth 4.9527" ± 0.0078" (125.8 ± 0.2 mm)

Bearing Journal O.D. (Standard) 1.4939" - 1.4946" (37.946 - 37.962 mm)

Bearing Journal O.D. (Service Limit) 1.4921" (37.900 mm)

Second Ring (Standard) 0.015" - 0.025" (0.37 - 0.63 mm)

Second Ring (Service Limit) 0.028" (0.70 mm)

Oil Control Rails (Standard) 0.010" - 0.040" (0.25 - 1.02 mm)

Oil Control Rails (Service Limit) 0.059" (1.50 mm)

Top Ring (Standard) 0.0012" - 0.0037" (0.030 - 0.095 mm)

Second Ring (Standard) 0.0012" - 0.0030" (0.030 - 0.076 mm)

Service Limit

3.6592 ± 0.0003" (92.950 ± 0.008 mm)

0.0047" (0.12 mm)

ENGINE

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ENGINE DETAIL - TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES

MAIN ENGINE COMPONENTS - TORQUE SPECIFICATION AND SEQUENCE

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BALANCE SHAFT / CONNECTING RODS / CRANKCASE / CRANKSHAFT / PISTONS

ENGINE

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ENGINE

CYLINDER / OIL COOLER / OIL FILTER / OIL PUMP / OIL SUMP / WATER PUMP

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

ENGINE

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ENGINE

SPARK PLUGS / STARTER / THERMOSTAT HOUSING / TRANS JOINT / VALVE COVER

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ENGINE EXHAUST SYSTEM

EXHAUST REMOVAL / INSTALLATION

1. Tilt the rear cargo box to the raised position. Remove upper cargo box shock clip and pin. Allow cargo box to rest fully open.

2. Using spring puller PU-45485, remove the (2) exhaust springs (A) connecting silencer to headpipe.

3. Pull the two rear isolator mounts (B) toward the right side of the vehicle to disengage from frame mounting posts.

4. Pull silencer toward the rear of the vehicle to disengage silencer mounting post from front isolator mount (C).

5. Remove silencer through right side of vehicle frame.

6. Remove the (6) mounting bolts (D) retaining the headpipe to the engine.

7. Remove the headpipe from the vehicle.

8. To reinstall the exhaust system, reverse the removal steps.

ENGINE

NOTE

Install new exhaust gaskets and torque all hardware to

specification.

TORQUE

Headpipe Mounting Bolts:18 ft-lbs (24 Nm)

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ENGINE

ENGINE COOLING SYSTEM

Cooling System Specifications

CONDITION

Room Temperature 68° F (20° C)

Thermostat Open 180° F (82° C)

Fan Off

Fan On

Thermostat Full Open Lift

Engine Temperature Overheat Indicator

Engine Protection Level 1 - Power Limit

Engine Protection Ignition Misfire

Engine Protection Level 2 - Power Limit

Engine Protection Shutdown

ITEM SPECIFICATION

Cooling System Capacity 5 qts. (4.7 L)

Pressure Cap Relief

Polaris Premium Antifreeze2871534 - Quart2871323 -

Recommended Coolant

Use only high quality antifreeze/coolant mixed with distilled water in a 50/50 or 60/40 ratio, depending on freeze protection required in your area.

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

COOLANT TEMPERATURE ° F (°C)

194° F (90° C)

205° F (96° C)

203° F (95° C)

232° F (111° C)

237° F (114° C)

244° F (118° C)

252° F (122° C)

13 PSI

Gallon

COOLING SYSTEM PRESSURE TEST

1. Remove the hood from the front cab.

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

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

RADIATOR CAP PRESSURE TEST

1. Open the front hood (see Warning under “Cooling System Pressure Test”).

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

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

WARNING

Escaping steam can cause burns. Never remove the

pressure cap while the engine is warm or hot. Always

allow the engine to cool before removing the pressure

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ENGINE

RADIATOR FAN REMOVAL

1. Remove the hood from the front cab.

2. Using a 10mm socket, remove the (4) upper radiator bracket bolts (A) and (2) T-40 Torx- head bolts (B).

3. Remove the two upper radiator brackets (C) and position them to allow fan removal.

4. Using a 10mm socket, remove the (4) bolts (D) that retain the fan shroud to the radiator.

2. Remove the hood from the front cab.

WARNING

Escaping steam can cause burns. Never remove the

pressure cap while the engine is warm or hot. Always

allow the engine to cool before removing the pressure

cap.

3. Remove pressure cap to relieve any system pressure.

4. Place a drain pan under the lower radiator hose.

5. Slide the clamp back and remove the lower radiator hose to drain the coolant from the radiator. Allow the coolant to completely drain. Properly dispose of the used coolant.

6. Using a 10mm socket, remove the (4) upper radiator bracket bolts (A) and (2) T-40 Torx- head bolts (B).

5. Disconnect the fan motor electrical connector (E).

6. Lift up on the radiator/fan assembly to separate the fan shroud from the radiator.

7. Carefully pull the radiator fan up through the flexible portion of the hood liner. Take care not to damage the radiator cooling fins.

8. Service the radiator fan as needed.

9. Reverse this procedure for installation. Upon installation, be sure the lower radiator mounts are placed properly in the frame support.

RADIATOR REMOVAL / COOLANT DRAIN

1. Allow the vehicle to cool down if recently operated.

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7. Remove the two upper radiator brackets (C) and position them to allow radiator removal.

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

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ENGINE

9. Lift up on the flexible portion of the hood liner to access the upper radiator hose and remove the hose from the radiator.

10. Using a 10mm socket, remove the (4) bolts (D) that retain the fan shroud to the radiator.

11. Lift up on the radiator/fan assembly to separate the fan shroud from the radiator.

12. Carefully remove the radiator (F) through the flexible portion of the hood liner. Take care not to damage the radiator cooling fins.

THERMOSTAT REPLACEMENT

1. Remove the hood from the front cab.

WARNING

Escaping steam can cause burns. Never remove the

pressure cap while the engine is warm or hot. Always

allow the engine to cool before removing the pressure

cap.

2. Remove the pressure cap to relieve any system pressure.

3. Drain coolant to a level below the thermostat housing (see “Radiator Removal / Coolant Drain”).

4. Tilt the rear cargo box to the raised position. Remove upper cargo box shock clip and pin. Allow cargo box to rest fully open.

5. Loosen the hose clamp (A) and remove the coolant hose from the thermostat cover (B).

13. Service the radiator as needed.

14. Reverse this procedure for installation. Upon installation, be sure the lower radiator mounts are placed properly in the frame support.

15. After installation and reassembly, remove the pressure cap and fill the radiator and recovery bottle with coolant.

16. Refer to the “Cooling System Bleeding Procedure” provided in this chapter.

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6. Using an 8mm socket, remove the (2) bolts (C) that retain the thermostat cover (B) to the engine.

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7. Remove the thermostat cover (B), seal (D) and thermostat (E) from the engine.

NOTE

Thermostat has a pop-off relief to allow the bypass

system to operate until thermostat opens.

8. Clean thermostat mating surfaces on the engine and thermostat cover.

9. Install a new thermostat and seal into the cover and install the cover onto engine.

10. Install the thermostat cover bolts and torque the bolts to specification.

TORQUE

Thermostat Cover Bolts:89 ± 9 in-lbs (10 ± 1 Nm)

11. Install coolant hose back on the thermostat cover and securely tighten the hose clamp.

12. Fill cooling system and proceed to “Cooling System Bleeding Procedure” provided in this chapter.

ENGINE

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ENGINE

COOLING SYSTEM EXPLODED VIEW

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ENGINE

COOLING SYSTEM BLEEDING PROCEDURE

WARNING

Always wear safety glasses and proper shop clothing

when performing the procedures in this manual. Failing

to do so may lead to possible injury or death.

NOTE

If the coolant level is LOW in the radiator, or if there are

leaks in the system, the coolant system will not draw

coolant from the reservoir tank.

1. Allow engine and cooling system to cool down.

CAUTION

Escaping steam can cause burns. Never remove the

pressure cap while the engine is warm or hot. Always

allow the engine to cool before removing the pressure

cap.

2. Remove the hood from the front cab.

3. Remove the recovery bottle cap (A) and fill the bottle to the MAX line.

7. Open the bleed screw (C) to allow any trapped air to escape. Close the bleed screw once a steady stream of coolant begins to drain out.

8. Tighten the bleed screw to specification, top off coolant and properly install the pressure cap.

TORQUE

Coolant Bleed Screw:89 ± 9 in-lbs (10 ± 1 Nm)

9. Start the engine and allow it to idle until the coolant fan has cycled two times.

10. Allow engine and cooling system to completely cool down (see CAUTION).

11. Remove the pressure cap. Add the necessary amount of Polaris Premium Antifreeze to the radiator filler neck.

12. Open the bleed screw to allow any trapped air to escape. Close the bleed screw once a steady stream of coolant begins to drain out.

13. Tighten the bleed screw to specification, top off coolant and properly install the pressure cap.

TORQUE

Coolant Bleed Screw:89 ± 9 in-lbs (10 ± 1 Nm)

4. Remove the pressure cap (B) and add the necessary amount of Polaris Premium Antifreeze to the radiator filler neck.

5. Tilt the rear cargo box to the raised position.

6. Remove the upper exhaust heat shield to access the coolant bleed screw.

14. Fill the recovery bottle to the MAX line.

15. Reinstall the upper exhaust heat shield.

16. Reinstall the hood.

WATER PUMP REMOVAL

1. Allow engine and cooling system to cool down.

CAUTION

Be sure the engine has cooled and no pressure is built up in the cooling system before removing the pressure

cap. The coolant may be hot and could cause severe

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2. Remove passenger seat base and storage bin.

3. Disconnect the (-) negative battery cable.

4. Remove all debris and thoroughly clean water pump area and RH side of engine block.

5. Remove the hood.

6. Remove the pressure cap from the radiator.

7. Drain cooling system as outlined in this chapter.

8. Remove the exhaust system as outlined in this chapter.

9. Disconnect the (3) coolant hoses that are attached to the water pump. Note location and routing for installation. Be sure to catch and dispose of coolant properly.

10. Remove the (3) bolts retaining water pump to engine block. Note different bolt lengths for installation.

2. Lubricate new O-rings with fresh engine oil.

3. Remove the shop towel from the water pump drive access hole in the engine block.

4. Clean the O-ring sealing surface in the engine block using a clean shop towel.

5. Use a shop light to illuminate the water pump drive access hole in engine crankcase.

6. Note orientation of the water pump drive slot.

11. Remove water pump from engine by gently twisting and rocking the water pump housing while pulling outward.

12. Plug the water pump drive access hole in the engine block with a clean shop towel.

WATER PUMP INSTALLATION

1. Replace the (2) sealing O-rings on the water pump housing.

NOTE

Do not reuse the water pump O-rings. Always use NEW

O-rings each time the water pump is removed.

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7. Rotate water pump drive tab so it matches the angle of the drive slot in the engine.

CAUTION

The water pump drive tab and slot must be aligned

properly during installation. Severe engine or water

pump damage will occur if the tab and slot are not in

alignment during water pump installation.

8. Slide water pump into engine crankcase.

9. Be sure water pump is fully seated and the drive tab and slot are properly engaged.

10. Install the (3) water pump mounting bolts, noting location of shorter bolt and torque to specification.

13. Connect the (-) negative battery cable.

14. Fill and bleed cooling system as outlined in this chapter.

15. Install the hood, storage bin and passenger seat base (Chapter 5).

WATER PUMP SERVICE

NOTE

The water pump cover gasket can be replaced while

the water pump housing is still installed in the engine.

1. Remove water pump assembly as outlined in this chapter.

2. Remove the (3) bolts retaining water pump cover to water pump housing. Discard cover gasket.

3. Place the water pump drive tab vertically into a soft jaw vice.

TORQUE

Water Pump Mounting Bolts:89 in-lbs (10 Nm)

11. Install the (3) coolant hoses that attach to the water pump. Be sure orientation and routing are correct.

12. Install the exhaust system as outlined in this chapter.

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4. Remove the bolt and washer retaining the water pump impeller to the shaft. Inspect the impeller veins and water pump housing for damage. Replace if needed.

NOTE

The water pump impeller bolt is left hand threaded

(reverse thread).

5. Remove impeller from water pump shaft.

6. Using an appropriate arbor press, properly support the water pump housing and press out the water pump shaft from the impeller side.

7. Extract the mechanical seal and the oil seal from the water pump housing.

NOTE

A 5/32" (4 mm) diameter punch will fit in the lubrication

slot to aid in the removal of the oil seal. Be sure not to

damage the water pump shaft bearing surface.

9. Clean and inspect water pump shaft for excessive wear or damage. Replace water pump housing assembly if necessary, as shaft can not be purchased separately.

10. Thoroughly clean mechanical seal and oil seal bores.

11. Install a NEW oil seal into the water pump housing until fully seated.

12. Fully install the water pump shaft and (2) washers into the housing.

13. Place water pump drive tab vertically into soft jaw vice as previously shown in this procedure.

14. Install a NEW mechanical seal into the water pump housing using special tool PU-50564. Press the new mechanical seal in until it is flush with the water pump housing.

15. Rotate water pump shaft after seal installation to verify free movement.

16. Place impeller onto the water pump shaft.

17. Apply Loctite® 204 to the threads of the impeller bolt. Install washer and impeller bolt and torque to specification.

8. Inspect the water pump shaft bore for excessive wear or damage. Replace water pump housing assembly if necessary.

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TORQUE

Water Pump Impeller Bolt:89 in-lbs (10 Nm)(Apply

Loctite® 204 to bolt threads)

18. Clean water pump cover and housing gasket surfaces.

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19. Install a new water pump cover gasket.

20. Install the water pump cover and (3) retaining bolts. Torque bolts in sequence to specification.

TORQUE

Water Pump Cover Bolts:89 in-lbs (10 Nm)(Apply

Loctite®204to bolt threads)

ENGINE

21. Install (2) new water pump (O-rings) and lubricate them with fresh engine oil (see illustration below).

22. Install water pump assembly into engine as shown in the “Water Pump Installation” procedure.

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ENGINE

WATER PUMP EXPLODED VIEW

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ENGINE SERVICE

ENGINE

ACCESSIBLE ENGINE COMPONENTS

The following components can be serviced or removed with the engine installed:

• Camshaft(s)

• Camshaft Sprocket(s)

• Cylinder Head

• Flywheel

• Oil Cooler

• Starter Motor / Idler Gear Asm

• Stator (Alternator)

• Thermostat

• Valve Cover

• Water Pump

The following components require engine removal for service:

• Camshaft Timing Chain

• Connecting Rod(s)

• Counterbalance Shaft / Bearings

• Crankcase

• Crankshaft / Main Bearings

• Crankshaft Seal (PTO)

• Cylinder

• Oil Pump / Oil Pump Sprocket or Chain

• Piston / Rings

ENGINE REMOVAL

NOTE

Some engine repair procedures can be performed

without removing the engine assembly from the vehicle.

Refer to “Accessible Engine Components” for further

information.

The use of an overhead or portable engine hoist is the

only recommended method for removing and installing

the engine.

Have an assistant help guide the engine in and out of

the vehicle while using an engine hoist to prevent

personal injury or damage to vehicle components.

5. Lift up the passenger seat and disconnect the (-) negative battery cable from the battery.

6. Remove the PVT outer cover, drive and driven clutch, and inner cover (see Chapter 6 "PVT Disassembly").

CAUTION

Correct Drive Clutch Puller P/N 2872085

NOTE

Be sure to use the correct Drive Clutch Puller (PN

2872085) to prevent damage to crankshaft.

7. Remove the exhaust system from the vehicle (see “Exhaust Removal / Installation”).

8. Disconnect the harness from the T-MAP sensor (A), ETC (B), fuel injectors (C), rear differential relay and solenoid (D). Remove the (5) plastic tie straps (E) retaining the harness to the intake plenum.

WARNING

Always wear safety glasses and proper shop clothing

when performing the procedures in this manual. Failing

to do so may lead to possible injury or death.

1. If vehicle was recently operated, allow it to cool down before attempting to perform any work.

2. Thoroughly clean the engine and chassis.

3. Drain the engine oil and coolant prior to engine removal (see Chapter 2).

4. Remove rear cargo box from vehicle (see Chapter

5).

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9. Disconnect the CPS (F), vehicle speed sensor (G), ECT sensor (H) and transmission switch (I). Remove the (2) plastic tie straps (J) retaining the harness to the transmission.

10. Using an 8mm socket, remove the (2) bolts retaining the fuel rail and fuel injectors. Remove the fuel rail assembly from the intake and position the assembly to allow engine removal.

11. Remove the spark plug wires from the engine.

NOTE

The spark plug wires are marked with MAG and PTO.

Note during installation procedure.

13. Using a 13mm socket and wrench, remove the fastener (K) securing the bottom of the intake plenum to the rear transmission mount.

14. Using a long screwdriver, loosen both hose clamps (L) that retain the intake plenum runners to the cylinder head intake adaptors. Remove the intake plenum and electronic throttle control as an assembly.

12. Disconnect the stator harness in front of the engine.

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15. Use an overhead or portable engine hoist and suitable engine straps to secure engine in its current position.

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16. Using a 15mm socket, remove the (4) bolts from the left side (M) and right side (N), securing the transmission to the engine.

19. Remove (+) positive and (-) negative cables from the starter motor.

20. Place a suitable drain pan under the vehicle. Remove the coolant hoses from the thermostat cover (R) and water pump inlet (S). Dispose of used engine coolant properly.

21. With the help of an assistant and the engine hoist, raise the engine vertically out of the vehicle frame.

NOTE

Have an assistant help guide the engine in and out of

the vehicle while using an engine hoist to prevent

personal injury or damage to vehicle components.

22. Remove the starter motor bolts and starter motor from the engine.

23. Remove the (6) transmission joint bracket bolts and transmission joint bracket from the engine.

17. Using a 15mm socket, remove the (4) fasteners (P) securing the front of the engine to the mount bracket.

24. Install the engine stand adapter (PU-50562) onto the engine where the starter motor was located.

18. Remove the crankcase breather hose (Q) from the engine.

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25. Select the proper engine stand sleeve adapter and install it onto the engine stand adapter.

• Sleeve adapter for a 2” bore engine stand:

• (PU-50625)

• Sleeve adapter for a 2.375” bore engine stand:

• (PW-47054)

26. Place engine onto the engine stand (PU- 50624) for service.

ENGINE INSTALLATION

Use the following procedure to reinstall the engine assembly.

1. Attach engine with suitable lifting straps to an overhead or portable engine hoist.

2. Remove the engine stand adapter plate and install the starter motor back onto engine. Torque starter motor bolts to specification.

3. Install transmission joint bracket onto engine and torque fasteners to specification in sequence.

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TORQUE

Starter Motor Bolts: 7 ft-lbs (10 Nm)Trans Joint Bracket

4. Use the overhead or portable engine hoist and suitable engine straps to lower the engine into the vehicle frame.

Bolts: 44 ft-lbs (60 Nm)

NOTE

Have an assistant help guide the engine in and out of

the vehicle while using an engine hoist to prevent

personal injury or damage to vehicle components.

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5. Align both the front and rear engine mounting locations. Install the (4) front engine mounting fasteners (A) and hand tighten.

NOTE

DO NOT torque fasteners at this time.

6. Align transmission joint bracket mounting holes with the front transmission mounting holes.

7. Install the Clutch Center Distance Tool (PU-50658) onto the crankshaft and transmission input shaft to properly position the clutch center distance.

8. Loosen the (2) bolts (B) retaining the transmission coupler bracket (C) to the engine on the right side.

9. Install the (2) bolts (D) and transmission joint retainer plate (E) on the right side. Hand tighten the bolts so they remain loose at this time.

NOTE

DO NOT torque fasteners at this time.

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10. Install the (2) longer bolts into left side mounting holes. Torque left side mounting bolts to specification using the numbered sequence shown.

11. Torque right side mounting bolts to specification using the numbered sequence shown.

13. Torque the (4) front engine mount fasteners (A) to specification.

TORQUE

Front Engine Mount Fasteners:40 ft-lbs (54 Nm)

14. Remove the lifting straps and overhead or portable engine hoist.

15. Install the breather hose onto the crankcase at the front of the engine.

16. Install the (2) coolant hoses onto the engine.

17. Install (+) positive cable to the starter motor and (-) negative cable to the starter motor mounting bolt.

18. Install the intake plenum and throttle body assembly. Place the intake plenum runners into the cylinder head intake adapters.

TORQUE

Engine / Transmission Mounting Bolts:Step 1-2: 64 ftlbs (87 Nm)Step 3: 5 ft-lbs (7 Nm)Step 4-7: 44 ft-lbs

12. Remove the clutch center distance tool.

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(60 Nm)

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NOTE

Be sure the intake plenum runners are fully seated in

the intake adapters before tightening the hose clamps.

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19. Tighten the hose clamps to specification.

TORQUE

Intake Plenum Hose Clamps:35 in-lbs (4 Nm)

20. Install the fastener securing the bottom of the intake plenum to the rear transmission mount. Torque fastener to specification.

TORQUE

Lower Intake Plenum Fastener:22 ft-lbs (30 Nm)

21. Lightly lubricate both fuel injector O-rings and install the fuel injector / fuel rail assembly.

NOTE

Take care not to damage the O-rings upon installation.

22. Install the (2) bolts that retain the fuel rail assembly to the intake plenum and torque bolts to specification.

TORQUE

Fuel Rail Mounting Bolts:89 in-lbs (10 Nm)

23. Connect the stator harness at the front of the engine.

24. Connect the vehicle harness to the T-MAP sensor (F), ETC (G), fuel injectors (H), rear differential relay and rear differential solenoid (I).

25. Install (5) new plastic tie straps to retain the harness to the intake plenum.

26. Connect the CPS (J), vehicle speed sensor (K), ECT sensor (L) and transmission switch (M).

27. Install (2) new plastic tie straps to retain the harness to the transmission.

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28. Install the spark plug wires to the appropriate cylinder by referencing the MAG and PTO spark plug wire decals.

NOTE

Ensure plug wires caps are pushed down all the way so

they engage onto the spark plugs.

29. Install the exhaust system (see “Exhaust Removal / Installation”).

30. Install the PVT inner clutch cover, drive clutch, driven clutch, drive belt and outer clutch cover (see Chapter 6 “PVT Assembly”).

31. Install the rear cargo box assembly (see Chapter 5).

NOTE

Be sure to connect the tail light harness upon

installation.

32. Connect the (-) negative battery cable.

ENGINE MOUNTING AND TORQUE VALUES

33. Remove the radiator pressure cap and fill the cooling system with properly mixed anti-freeze / coolant.

34. Install a new oil filter. Lubricate the seal with engine oil prior to installation (see Chapter 2 “Maintenance”).

35. Add approximately 2.5 quarts (3.3 L) of Polaris PS-4 or PS-4 Extreme Duty Synthetic Engine Oil to the engine. Additional oil may be required after complete engine disassembly. Check level after filling and add oil as needed.

36. Follow the “Cooling System Bleeding Procedure” as outlined in this chapter.

37. Start engine and check for any oil or coolant leaks.

38. Check the engine oil level (see Chapter 2).

39. Refer customer to “Engine Break-In Period” upon returning vehicle to customer.

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ENGINE BREAK-IN PERIOD

The break-in period consists of the first 25 hours of operation. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.

CAUTION

Use only Polaris PS-4 or PS-4 Extreme Duty Synthetic

4-Cycle Engine Oil.Never substitute or mix oil brands.

Serious engine damage and voiding of warranty can

result. Do not operate at full throttle or high speeds for

extended periods during the first three hours of use.

Excessive heat can build up and cause damage to

close fitted engine parts.

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

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

3. Drive slowly at first to gradually bring engine up to operating temperature.

4. Vary throttle positions. Do not operate at sustained idle or sustained high speed.

5. Perform regular checks on fluid levels, controls and all important bolt torques.

6. Change oil and oil filter after 25 hour break-in period.

ENGINE

ENGINE LUBRICATION SPECIFICATIONS

FLUID CAPACITY

Oil Capacity *

Approx. 2.5 Quarts (2.4 L)

Oil Filter Wrench

PU-50105 or 2.5” (64 mm)

Oil Filter

PN 2540086

Oil TypeAmbient Temp Range:-35° F to 100° F

PS-4 Synthetic Engine oil(PN 2876244) (Quart)

Oil TypeAmbient Temp Range:0° F to 120° F

PS-4 Extreme Duty Synthetic Engine Oil (PN 2878920)

Oil PressureMinimum Specification(using Polaris

engine oil at operating temperature)

*Additional oil may be required after complete engine disassembly. Check level after filling and add oil as needed.

(Quart)

10 PSI @ 1200 RPM 40 PSI @ 7000 RPM

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ENGINE DISASSEMBLY / INSPECTION - TOP END

VALVE COVER REMOVAL

NOTE

The valve cover can be removed with the engine

1. Remove the four valve cover shoulder bolts isolators

Replace rubber isolators upon assembly.

2. Remove valve cover and valve cover seal. Replace isolators and valve cover seal evident.

3. Remove the spark plugs with clean shop towels to prevent any debris from falling into the combustion chamber.

installed in the chassis.

using a T40 driver.

NOTE

if oil leaks are

. Stuff spark plug holes

and

CAMSHAFT REMOVAL

NOTE

The camshafts can be removed with the engine

1. Rotate the engine so the PTO cylinder is at Top Dead Center (TDC) to relieve most of the valve spring pressure. The camshaft lobes should face out and the slots on the end of the camshafts should line up

installed in the chassis.

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2. Remove the cam chain tensioner cylinder. Replace the sealing washer or gasket upon reassembly.

NOTE

The engine may have a hydraulic (first image) or

mechanical (second image) cam chain tensioner.

from the

4. Remove the remaining two bolts that retain the front camshaft carriertand carefully lift the carrier off the camshafts.

5. Hold camshafts with an open-end wrenchy, and remove the top bolt from the camshaft sprocketsu.

6. Rotate the engine to allow access to the remaining bolt on each camshaft sprocketi.

3. Remove the two bolts retaining the fixed cam chain guiderand remove the assembly from the engine.

7. Remove the remaining bolt from each camshaft sprocket.

8. Lift the chain and sprockets off the camshafts to allow each sprocket to be removed.

9. Using a paperclip or other tool, hold cam chain up.

NOTE

The crankcase has a built-in lower guide to prevent the

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chain from falling off the crankshaft.

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10. Evenly loosen the four bolts retaining each rear camshaft carrieraand carefully lift the carriers off the camshafts.

11. Mark the intakesand exhaustdcamshafts to ensure proper assembly.

12. Carefully remove camshafts from the cylinder head.

CAMSHAFT SPROCKET INSPECTION

Inspect cam sprocket teeth for wear or damageq. Replace timing chain and sprockets if worn or damaged.

CAMSHAFT / CAMSHAFT BORE INSPECTION

Inspect all main journals and cam lobes as described below and compare to specifications. Replace camshaft (s) or cylinder head if worn beyond service limit or if any surface is pitted or damaged.

1. Visually inspect each cam lobe for wear or damage.

2. Measure the height of each cam lobe from the base circle to highest point on the lobe using a micrometer. Compare to specification.

NOTE

Replace camshafts if damaged or if any part is worn

past the service limit.

3.38

MEASUREMENT

Camshaft Lobe Height:

Intake: 1.5256 ± .0015" (38.75 ± .040 mm)

Service Limit: 1.5220" (38.66 mm)

Exhaust: 1.4961" ± .0015" (38.00 ± .040 mm)

Service Limit: 1.4925" (37.91 mm)

3. Visually inspect each camshaft journal for scoring, wear or damage.

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4. Measure the diameter of the camshaft journals using a micrometer. Compare to specification.

NOTE

Replace camshafts if damaged or if any part is worn

past the service limit.

MEASUREMENT

Camshaft Journal O.D.:

0.9035 - 0.9046" (22.949 - 22.978 mm)

Service Limit: 0.9025" (22.923 mm)

5. Temporarily install the camshaft carriers to measure the camshaft bore. Torque bolts in sequence to specification. Replace cylinder head if worn.

TORQUE

Camshaft Carrier Bolts:

89 in-lbs. (10 Nm)

NOTE

Replace cylinder head if camshaft journal bores are

damaged or if worn past the service limit.

MEASUREMENT

Camshaft Carrier Bore I.D.:

0.9055" - 0.9063" (23.000 - 23.021 mm)

Service Limit: 0.9072" (23.044 mm)

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

MEASUREMENT

Calculated Camshaft Oil Clearance:

0.0009" - 0.0028" (.022 - .072 mm)

Service Limit: .0039" (.10 mm)

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CYLINDER HEAD REMOVAL

NOTE

The cylinder head can be serviced with the engine

1. Disconnect coolant hose from thermostat housing if connected.

2. Remove the two outer M6 bolts cylinder headwto the cylinder.

3. Loosen the six cylinder head boltseevenly 1/8 turn at a time until all are loose.

4. Remove and discard the cylinder head bolts.

5. Tap cylinder head lightly with a soft faced hammer until loose.

Tap only in reinforced areas or on thick parts of the

installed in the chassis.

NOTE

cylinder head casting.

that retain the

CYLINDER HEAD WARP INSPECTION

1. Lay a straight edge across the surface of the cylinder head by inserting a feeler gauge between the straight edge and the cylinder head surface. If warp exceeds the service limit, replace the cylinder head.

at several different points and measure warp

MEASUREMENT

Cylinder Head Warp Limit:

.0039" (0.10 mm)

6. Remove the cylinder head and head gasket

NOTE

Once the cylinder head is removed, nothing retains the

cylinder to the engine. DO NOT rotate the engine without using the Cylinder Holding & Camshaft Timing Plate (PU-50563). Refer to Cylinder / Piston Removal,

page 3.56.

CYLINDER HEAD INSPECTION

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

CAUTION

Use care not to damage gasket sealing surface. All

gasket surfaces must be clean, dry and free of any oil

or grease upon assembly. Clean sealing surfaces with

rubbing alcohol or electrical contact cleaner. Do not

touch sealing surfaces of the new head gasket.

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CYLINDER HEAD DISASSEMBLY

CAUTION

Wear eye protection during cylinder head disassembly

and reassembly or when working with the valve springs.

NOTE

Keep mated parts together and in order with respect to

their location in the cylinder head for assembly

purposes. It is important to install cylinder head

components back in the same location. Mark each

component or place them in an organized rack as you

1. Remove the valve tappet the bottom side of the tappetw.

remove them.

and note the number on

2. Compress the valve spring by hand using valve spring compressor adapter (PV-43513-A).

3. Push down on spring and remove split keeperse.

4. Slowly release valve spring pressure and remove the compressor adapter.

5. Remove the valve retainer the valve stem seal / seaty. Discard the valve seal.

NOTE

Replace valve seals whenever cylinder head is

disassembled. Hardened, cracked or worn seals will

6. Lift up the cylinder head and push the valve

7. Repeat the previous steps to remove the remaining

8. Clean the combustion chamber and head gasket

cause excessive oil consumption.

keeping it in order for reassembly in the same valve guide.

valves.

surface.

VALVE INSPECTION

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

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, valve springtand

out,

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ENGINE

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

3. Check the end of the valve stem for flaring, pitting, wear or damage.

4. Inspect split keeper groove for wear or flaring in the keeper seat area.

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

MEASUREMENT

Valve Guide I.D.:

0.2165 - 0.2171" (5.500 - 5.515 mm)

7. Be sure to measure each guide and valve combination individually.

NOTE

The valve guides cannot be replaced.

NOTE

The valves can be re-faced or end ground, if necessary.

They must be replaced if extensively worn, burnt, bent

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

or damaged.

MEASUREMENT

Valve Stem Diameter:

Intake: 0.2155" - 0.2161" (5.475 - 5.490 mm)

Exhaust: 0.2147" - 0.2153" (5.455 - 5.470 mm)

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COMBUSTION CHAMBER CLEANING

WARNING

Wear eye protection during combustion chamber

1. Clean all accumulated carbon deposits from combustion chambers and valve seat area

cleaning.

NOTE

Carbon Clean Fuel Treatment (2871326) can be used

Do not use a metal scraper, a coarse wire brush or

abrasive cleaners to clean the cylinder head. Damage

2. Visually inspect cylinder head gasket surface and combustion chamber for cracks or damage. Pay close attention to areas around spark plug and valve seats.

to help remove carbon deposits.

may result.

VALVE SEAT RECONDITIONING

Valve seat reconditioning should be performed by a technician proficient in cylinder head reconditioning techniques. Reconditioning techniques vary, so follow the instructions provided by the valve reconditioning equipment manufacturer. Do not grind seats more than necessary to provide proper seat surface, width, and contact point on valve face.

WARNING

Wear eye protection or a face shield during cylinder

head disassembly and reassembly.

Valve Seat Inspection

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

head must be replaced.

Valve seat width and point of contact on the valve face is very important for proper sealing. The valve must contact the valve seat over the entire circumference of the seat, and the seat must be the proper width all the way around. If seat is uneven, compression leakage will result. If seat is too wide, seat pressure is reduced, causing carbon accumulation and possible compression loss. If seat is too narrow, heat transfer from valve to seat is reduced. The valve may overheat and warp, resulting in burnt valves.

Renewing Valve Seats

1. Install pilot into valve guide.

2. Apply cutting oil to valve seat and cutter.

3. Place 46° cutter on the pilot and make a light cut.

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

circumference of the seat, rotate the pilot 180° and make another light cut.

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

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

* If the contact area of the initial cut is greater than 75%, continue to cut the seat until all pits are removed and a new seat surface is evident.

NOTE

Remove only the amount of material necessary to

repair the seat surface.

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