GENERAL INFORMATION

CHAPTER 1
GENERAL INFORMATION
1
MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
UNIT SERIAL NUMBER (VIN) AND EMISSIONS DECAL LOCATIONS . . . . . . . . . . . . . 1.3
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

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PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

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MODEL: 2009 RANGER RZR 170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
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DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
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1.1
GENERAL INFORMATION

MODEL INFORMATION
Model Identification
The machine model number must be used with any correspondence regarding warranty or service.

Machine Model Number Identification

R 09 VA 17 AD

}
}

}
}
Model Year Emissions &
Designation Model Option
Basic Chassis
Designation Engine Designation

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Engine Designation Number
S35C ................................................................................................. Single Cylinder, Air/Oil Cooled, OHV 4 Stroke, Electric Start

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VIN Identification
World
Mfg. ID Vehicle Description Vehicle Identifier

9- k. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4 X A V A 1 7 A * 9 P 0 0 0 0 0 0
}

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Model
Engine Year Individual Serial No.
Body Style
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Emissions Plant No. * This could be either
Powertrain a number or a letter
Check Digit
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Engine Serial Number Location

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

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ENGINE SERIAL NUMBER

1.2
 GENERAL INFORMATION
Unit Serial Number (VIN) and Emissions Decal Locations
The machine model information decal (A) and vehicle identification number (VIN) are important for identification. The VIN number 1
(B) is stamped on a portion of the front left frame rail close to the left front wheel.

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A
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B
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The engine emissions decal (C) is attached to the frame support, accessible through the front right wheel well.
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1.3
GENERAL INFORMATION

VEHICLE INFORMATION

Publication Numbers

Model Model No. Owners Manual PN Parts Manual PN

9922131 (produced before 2/10/2009)
2009 RANGER RZR 170 R09VA17AA 9922132
9922569 (produced after 2/10/2009)

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

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

www.purepolaris.com.

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Paint Codes

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Painted Part Color Description Polaris Number
Frame / Bumpers / Racks Gloss Black P-067
Plastic - Hood / Dash / Fenders Indy Red P-293
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Replacement Keys
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Replacement keys can be made from the original key. Polaris offers replacement key blanks (0453013) that can be cut to match the
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original. Should both keys become lost, ignition switch replacement is required.
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P/N 0453013
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SPECIAL TOOLS
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools
maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris
product. Dealers may order special tools through Polaris official tool supplier, SPX Corporation, by phone at 1-800-328-6657 or
on-line at http://polaris.spx.com/.

1.4
 GENERAL INFORMATION
GENERAL SPECIFICATIONS
1
MODEL: 2009 RANGER RZR 170
MODEL NUMBER: R09VA17AA
ENGINE MODEL: S35C
Category Dimension / Capacity
Length 85 in. / 216 cm
Width 48 in. / 122 cm
Height 55 in. / 139.7 cm
Wheel Base 65 in. / 165 cm

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Ground Clearance 6 in. / 15.2 cm
Dry Weight 500 lbs. / 227 kg
Gross Vehicle Weight 840 lbs. / 381 kg

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Maximum Weight 300 lbs. / 81.7 kg
Capacity (Includes people, cargo, accessories)

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1.5
GENERAL INFORMATION
MODEL: 2009 RANGER RZR 170 Drivetrain
Transmission Type Polaris Automatic CVT
MODEL NUMBER: R09VA17AA
ENGINE MODEL: S35C Shift Type In Line Shift - H / N / R
Engine Transmission Oil Requirements Polaris AGL
Main Gearcase 23.7 oz. (700 ml)
Single Cylinder, Air/Oil Cooled
Platform Drive Belt 0454497
4-Stroke
Engine Model Number S35C Drive Chain - Type / # Links 520 / 30
Engine Displacement 169cc Steering / Suspension
Number of Cylinders 1 Front Suspension Single A-arm
Bore & Stroke (mm) 61 x 57.8 mm Front Travel 5 in. / 12.7 cm
Compression Ratio 9.5:1 Rear Suspension Dual Shock Swingarm

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Compression Pressure 130-160 psi @ W.O.T. Rear Travel 5 in. / 12.7 cm
Engine Idle Speed 1700 100 RPM Shock Preload Adjustment Cam Adjustable
Engine Max Operating RPM 8000 200 RPM Front / Rear (Factory Setting - Softest)

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Lubrication Wet Sump Toe Out 1/8-1/4 in. / 3-6.35 mm
Above 32 F ( 0 C ) Wheels / Brakes
Polaris YOUTH oil Front Tire Size 19 x 7 - 8
Oil Requirements Below 32 F ( 0 C ) Rear Tire Size 20 x 10 - 9
20W-40 oil

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Oil Capacity
Exhaust System
37 oz.. / 1.1 liters
Single Headpipe / Single Silencer
Bolt Pattern
Tire Air Pressure - Front / Rear

Brake - Front / Rear

110mm
3 psi (20.7 kPa)
Foot Actuated - 4 Wheel
Hydraulic Disc
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Fuel System
Carburetor Type Keihin Brake Fluid DOT 4
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Pilot Jet 35
JETTING CHART
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Main Jet 100

Ambient Temperature
Air Screw 2 1/4 Turns Out (initial)
Altitude Below 40 F Above +40 F
Jet Needle 2MKNN - #4 clip position
Below 5 C Above +5 C
Fuel Delivery Fuel Pump
0-3048
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Fuel Filters See Chapter 4 102 100

Meters (0-10000)
2.5 gal. (9.5 liters) (Feet)
Fuel Capacity / Requirement Above 3048 98
87 Octane (minimum) 100
(Above 10,000) #3 needle clip position
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Electrical
Alternator Max Output 80 Watts @ 3000 RPM CLUTCH CHART
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2 - Single Beam
Lights: Main Headlights Altitude Shift Weight
Daytime Running Lamps (DRL)
Tail / Brake 5 Watts / 21 Watts 0-3048
6 @ 17 grams
Starting System Electric Start Meters (0-10,000)
Ignition System CDI (Feet) Above 3048 *** 6 @ 15 grams
Ignition Timing Non-Adjustable (Above 10,000) PN 0454619

NGK CR6HSA ***15 gram weights are optional and are not a High Altitude
Spark plug / Gap
.024-.028 in. (0.6-0.7 mm) (H.A.) Warranty item.
GTX12-BS / Low Maintenence
Battery
12 Amp Hr. / 12 Volt
Fuses Main: 20 Amp

1.6
 GENERAL INFORMATION
MISC. SPECIFICATIONS AND CHARTS
Conversion Table
1

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

1.7
GENERAL INFORMATION
Standard Torque Specifications
The following torque specifications are to be used only as a general guideline. There are exceptions in the steering, suspension, and
engine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque.

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1.8
 GENERAL INFORMATION
SAE Tap / Drill Sizes Decimal Equivalents
1

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Metric Tap / Drill Sizes

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1.9
GENERAL INFORMATION
Glossary of Terms
ABDC: After bottom dead center.
ACV: Alternating current voltage.
Alternator: Electrical generator producing voltage alternating current.
ATDC: After top dead center.
BBDC: Before bottom dead center.
BDC: Bottom dead center.
BTDC: Before top dead center.
CC: Cubic centimeters.
Center Distance: Distance between center of crankshaft and center of driven clutch shaft.
Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm).
CI: Cubic inches.
Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch.
Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face.
Clutch Weights: Rollers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close
and grip the drive belt.

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Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers
on V blocks or resting in crankcase. Measure at various points especially at PTO.
DCV: Direct current voltage
CVT: Centrifugal Variable Transmission (Drive Clutch System)

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DCV: Direct current voltage.
Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the
cylinder bore.
Electrical Open: Open circuit. An electrical circuit which isn't complete.
Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire
touching the chassis).
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End Seals: Rubber seals at each end of the crankshaft.
Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.
ft.: Foot/feet.
Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.
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g: Gram. Unit of weight in the metric system.
gal.: Gallon.
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ID: Inside diameter.
in.: Inch/inches.
Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.
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kg/cm: Kilograms per square centimeter.

kg-m: Kilogram meters.
Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.
l or ltr: Liter.
lbs/in: Pounds per square inch.
Left or Right Side: Always referred to based on normal operating position of the driver.
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m: Meter/meters.
Mag: Magneto.
Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings.
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Mechanical energy is converted to electrical energy in the stator.

mi.: Mile/miles.
mm: Millimeter. Unit of length in the metric system. 1 mm = approximately .040".
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Nm: Newton meters.

OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow.
oz.: Ounce/ounces.
Piston Clearance: Total distance between piston and cylinder wall.
psi.: Pounds per square inch.
PTO: Power take off.
PVT: Polaris Variable Transmission (Drive Clutch system)
qt.: Quart/quarts.
Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.
Reservoir Tank: The fill tank in the liquid cooling system.
Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat.
RPM: Revolutions per minute.
Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall.
Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings.
Stator Plate: The plate mounted under the flywheel supporting the battery charging coils.
TDC: Top dead center. Piston's most outward travel from crankshaft.
Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit.
Watt: Unit of electrical power. Watts = amperes x volts.
WOT: Wide open throttle.
1.10
 MAINTENANCE
CHAPTER 2
MAINTENANCE
PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PERIODIC MAINTENANCE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PRE-RIDE - 25 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2
30 - 100 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
MAINTENANCE REFERENCES / SERVICE LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . 2.6
FRONT AND REAR VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
RH AND LH SIDE VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7

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LUBRICANTS / SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
MAINTENANCE REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 2.10
PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10

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FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
SHIFT CABLE INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
SHIFT CABLE REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
9- k.
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CHOKE CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
PILOT AIR SCREW ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
VENT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
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FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
FUEL VALVE LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
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CARBURETOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16

FUEL PUMP / FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
THROTTLE PEDAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
THROTTLE STOP SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
THROTTLE FREEPLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
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THROTTLE CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
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ENGINE OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20

ENGINE CRANKCASE VENTILATION SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . 2.21
ENGINE/TRANSMISSION MOUNT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
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COMPRESSION / LEAKDOWN TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22

INTAKE VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
EXHAUST VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
EXHAUST - SPARK ARRESTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
TRANSMISSION SPECIFICATION CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
TRANSMISSION OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
FINAL DRIVE / WHEEL AND TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
WHEEL REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
WHEEL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
DRIVE CHAIN LUBRICATION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26

2.1
MAINTENANCE
ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
BATTERY OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
BATTERY CHARGING (MAINTENANCE FREE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
ENGINE TO FRAME GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
STEERING WHEEL FREEPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
STEERING INSPECTION / TIE ROD ENDS AND HUBS . . . . . . . . . . . . . . . . . . . . . . . 2.30
TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

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SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
SPRING PRELOAD ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32

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BRAKE PAD / DISC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34

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2.2
 MAINTENANCE
PERIODIC MAINTENANCE CHART
Periodic Maintenance Overview
Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment
and lubrication of important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement
2
parts, use genuine Polaris parts available from your Polaris dealer.
NOTE: Service and adjustments are critical. If youre 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

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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

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Racing or race-style high RPM use
Prolonged low speed, heavy load operation
Extended idle
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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
r
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.
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Maintenance Chart Key

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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
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authorized Polaris dealer.

= SEVERE USE ITEM -- See Above

a

E = Emission Control System Service (California).

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NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.

WARNING

Improperly performing the procedures marked with acould

result in component failure and lead to serious injury or death.
Have an authorized Polaris dealer perform these services.

2.3
MAINTENANCE
Pre-Ride - 25 Hour Maintenance Interval
Periodic Maintenance Chart

Maintenance Interval
Item (whichever comes first) Remarks
Hours Calendar Miles (KM)
Steering - Daily -
Front-Suspension - Daily -
Rear-Suspension - Daily -
Tires - Daily -
Brake Pedal Travel - Daily -

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Brake Fluid Level - Daily -
Check each day before driving the vehicle.
Daytime Running Lights - Daily -
Make adjustments as needed. See the Pre-

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Drive Chain - Daily - Ride Checklist in the Owners Manual.
Brake Lamp / Tail Lamp - Daily -
Throttle - Daily -
Wheels / Fasteners - Daily -

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Frame Fasteners
Engine Oil Level
E
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-
Daily

Daily
-

Fuel Level - Daily -

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Air Filter (main element) - Daily - Inspect; clean often, replace as needed
E
7- Sh

Open CVT drain as needed, check often if

CVT Housing - Weekly -
operating in wet conditions
Brake Pad Wear 10 H 1M 100 (160) Inspect regularly

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Idle Speed 10 H 1M 100 (160) Check; adjust as needed

Choke 10 H 1M 100 (160) Check for proper operation
E
a

Engine Oil Change Perform a break-in oil change after the first
(Break-In Period) 10 H 1M 100 (160)
10 hours of operation
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Transmission Oil Perform break-in oil change after the first

(Break-In Period) 10 H 1M 100 (160)
10 hours of operation
Drive Chain Adjust and lubricate after the first 10 hours
(Break-In Period) 10 H 1M 100 (160)
of operation
Check clearance after the first 10 hours of

Valve Clearance 10 H 1M 100 (160) operation; Adjust to specification if
E
required
Battery 25 H Monthly 250 (400) Check terminals; clean; test
Transmission Oil 25 H 12 M 250 (400) Inspect level; change yearly

Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
Have an authorized Polaris dealer perform these services.

2.4
 MAINTENANCE
30 - 100 Hour Maintenance Interval
Periodic Maintenance Chart
Maintenance Interval
Item (whichever comes first) Remarks
Hours Calendar Miles (KM)
Oil Change 30 H 6M 300 (480) Lubricate all grease fittings, pivots, & cables 2
Clean filter at every oil change; clean annually
Oil Pre-Filter Screen 30 H 6M 300 (480)
if operated less than 10 hours
General Lubrication 50 H 3M 500 (800) Lubricate all grease fittings, pivots, & cables
Check clearance; adjust to specification if

Valve Clearance 50 H - 500 (800) required; perform break-in adjustment after the

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E
first 10 hours of operation
Carburetor Float Bowl 50 H 6M 500 (800) Drain bowl periodically and prior to storage
Throttle Cable /

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50 H 6M 500 (800) Inspect; adjust; lubricate; replace if necessary
E ETC Switch

Choke Cable 50 H 6M 500 (800) Inspect; adjust; lubricate; replace if necessary
E
Carburetor Air Intake
E
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Ducts / Flange
Shift Cables
Brake Pad Wear
r 50 H

50 H
6M

6M
500 (800)

500 (800)
Inspect for proper sealing / air leaks

Inspect; lubricate; adjust

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

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Drive Belt 50 H - 500 (800) Inspect; replace as needed
Check for leaks at tank cap, lines, fuel valve,
Fuel System 100 H 12 M 600 (1000)
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E filter, carburetor, replace lines every two years

Fuel Filter 100 H 12 M 600 (1000) Replace yearly
E
Engine Mounts 100 H 12 M 600 (1000) Inspect
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Exhaust Emissions / Inspect secondary air system filter and

100 H 12 M 600 (1000)
E Muffler / Pipe exhaust - clean as required

Ignition Timing 100 H 12 M 600 (1000) Inspect
a

E
Spark Plug 100 H 12 M 600 (1000)
Clean; check condition; adjust gap;
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E replace as needed
Inspect for wear, routing, security; apply
Wiring 100 H 12 M 600 (1000) dielectric grease to connectors subjected to
water, mud, etc.
CVT Clutches / Drive Belt
100 H - 600 (1000) Inspect;clean; replace worn parts
(Drive and Driven)
Wheel / Axle Bearings 100 H 12 M 600 (1000) Inspect; replace as needed
Spark Arrestor 100 H 12 M 600 (1000) Clean
Inspect periodically; adjust when parts are
Toe Adjustment - - -
replaced
Idle Speed - - - Adjust as needed
Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
Have an authorized Polaris dealer perform these services.

2.5
MAINTENANCE
MAINTENANCE REFERENCES / SERVICE LOCATIONS
Front and Rear View

Daytime Running
Lamps
Grease Steering Pivots

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Grease A-arm Pivots

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Inspect Brake Pads
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Trail / Brake Lamp

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Inspect Exhaust
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Inspect / Clean Air Filter

Clean / Lubricate Chain Inspect Brake Pads

2.6
 MAINTENANCE
RH and LH Side Views

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2.7
MAINTENANCE

LUBRICANTS / SERVICE PRODUCTS NOTE: Each item can be purchased separately at

your local Polaris dealer.
Polaris Lubricants, Maintenance and Service
Products Part No. Description
Additives / Sealants / Thread Locking Agents / Misc.
Part No. Description
2870585 Loctite Primer N, Aerosol, 25 g
Engine Lubricant
Loctite Thread Sealant 565
2871956
2870791 Fogging Oil (12 oz. Aerosol) (50 ml.) (6 Count)
Polaris YOUTH Synthetic 0W-40 4-Cycle Loctite Threadlock 242
2876248 2871949
Engine Oil (Quart) (50 ml.) (10 Count)
Polaris Semi - Synthetic 20W-40 4-Cycle Loctite Threadlock 242

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2872175 2871950
Engine Oil (Quart) (6 ml.) (12 Count)
Gearcase / Transmission Lubricants Loctite Threadlock 262
2871951
(50 ml.) (10 Count)

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AGL - Synthetic ATV Gearcase Lubricant
2873602
(1 Qt.) (12 Count) Loctite 518 Gasket Eliminator / Flange
2870587
AGL - Synthetic ATV Gearcase Lubricant Sealant (50 ml.) (10 Count)
2873603
(1 Gal.) (4 Count) Premium Carbon Clean
2871326
2873604 9- k.
AGL - Synthetic ATV Gearcase Lubricant
(2.5 Gal.) (2 Count)
ATV Angle Drive Fluid
2870652
(12 oz.) (12 Count)
Fuel Stabilizer (16 oz.) (12 Count)
Black RTV Silicone Sealer
2871653
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2871957
(8 oz.) (12 Count) (3 oz. tube) (12 Count)
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ATV Angle Drive Fluid Black RTV Silicone Sealer
2872276 2871958
(2.5 Gal) (2 Count) (11 oz. cartridge) (12 Count)
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Premium Demand Drive Fluid LT 2872189 DOT 4 Brake Fluid (12 Count)
2871654
(1 Qt.) (12 Count)
2871557 Crankcase Sealant, 3-Bond 1215 (5oz.)
2870465 Oil Pump for 1 Gallon Jug
2872893 Engine Degreaser (12oz.) (12 Count)
Grease / Specialized Lubricants
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2871312 Grease Gun Kit NOTE: The number count indicated by each part
number in the table above indicates the number of
Premium All Season Grease units that are shipped with each order.
2871322
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(3 oz. cartridge) (24 Count)

Premium All Season Grease
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2871423
(14 oz. cartridge) (10 Count)
2871460 Starter Drive Grease (12 Count)
2871329 Dielectric Grease (Nyogel)
Chain Lubricant, Aerosol
2872348
(16 oz.) (12 Count)

2.8
 MAINTENANCE
MAINTENANCE REFERENCES
Item Ref. Rec. Lube / Fluid Method Frequency*
Change after 10 hrs, and then
Polaris YOUTH 40W Engine every 50 hours, 6 months or
Engine Oil Page 2.7
Oil or 20-W40 Synthetic.
(Ambient air temperatures
Add oil to proper level on
dipstick.
100 hours thereafter; Change
more often in extremely dirty 2
apply- see page 2.19) conditions, or short trip cold
weather operation.
Fill reservoir between MAX Fill as required. Change
Brake Fluid Page 2.7 DOT 4 (PN 2872189)
and MIN lines. brake fluid every 2 years.
AGL Synthetic Gearcase Add lube to bottom of fill

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Transmission Page 2.7 Change annually***
Lubricant (PN 2873602) plug threads. 24 oz. (710 ml)
Front A -Arm and
Polaris Premium All Season Locate grease fittings and
Steering Pivot Page 2.6 Semi-annually**
Grease (PN 2871423) grease with grease gun.

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Bushings

* More often under severe use, such as operated in water or under severe loads.
**Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information)
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***Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)
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2.9
MAINTENANCE

GENERAL VEHICLE INSPECTION 1. Locate the shift cable in the rear wheel well area.
AND MAINTENANCE
Pre-Ride / Daily Inspection Shift Cables

Perform the following pre-ride inspection daily, and when Dust Boot
servicing the vehicle at each scheduled maintenance.

Tires - check condition and pressures

Shift Cable
Fuel tank - fill to proper level Mount

All brakes - check operation and adjustment

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Throttle - check for free operation and closing Clevis Pin

Running lights/Taillight/Brakelight - also check

2. Inspect shift cable, clevis pin, pivot bushings, and dust

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operation of all indicator lights and switches
boot. Replace if worn or damaged.
Ignition switch - check for proper function
3. If adjustment is required, loosen the lower jam nut and pull
Wheels - check for tightness of wheel nuts and axle the cable out of the mount to move the upper jam nut.
nuts; check to be sure axle nuts are secured by cotter
pins 9- k.
Air cleaner element - check for dirt; clean or replace
r Upper
Jam Nut

Steering - check for free operation noting any unusual

99 a
looseness in any area

Loose parts - visually inspect vehicle for any damaged

7- Sh

or loose nuts, bolts or fasteners

Check all front and rear suspension components for

wear or damage.
Lower
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Jam Nut
Frame, Nuts, Bolts, and Fasteners
4. Adjust the shift cables so there is an equal amount of lever
a

Periodically inspect the torque of all fasteners in accordance

with the maintenance schedule. Check that all cotter pins are in travel when shifting past the Neutral detent into HIGH (H)
place. Refer to specific fastener torques listed in each chapter. and REVERSE (R).
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5. Thread the upper jam nuts as required to obtain proper cable

Shift Cable Inspection / Adjustment adjustment without binding.
Shift cable adjustment may be necessary if symptoms include:
NOTE: This procedure may require a few attempts to
Ratcheting noise on deceleration obtain the proper adjustment.

Inability to engage into a gear
Excessive gear clash (noise)
Gear selector moving out of desired range
6. Once the proper adjustment is obtained, tighten the lower
jam nut 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, verify the idle RPM is set correctly,
otherwise the transmission may require service.

2.10

Shift Cable Replacement
Shift cable replacement may be necessary if symptoms include:
Inability to engage into a gear
Inability to adjust cables for proper operation
Gear selector moving out of desired range
1. Locate the shift cables in the rear wheel well area.
2. Loosen the lower and upper jam nuts and remove the
cables.
MAINTENANCE
8. Raise the vehicle and support it with jackstands in order to
access the underside to remove the cables.
IMPORTANT: Document location of cable ties and
routing prior to removal. This is important for
reassembly.
9. Install new cables and adjust for proper operation and lever
travel without binding.
IMPORTANT: Do not allow cables to hang below
2
vehicle frame.
10. Once installed, lower the vehicle. Start engine and shift
through all gears to ensure the shift cables are properly
adjusted. If transmission still ratchets after cable
adjustment, verify the idle RPM is set correctly, otherwise

86 m
Upper
Jam Nut the transmission may require service.
11. Reassemble the console cover, seats and shift knob as
outlined in Chapter 5.

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Lower
Jam Nut
99 a
3. Inspect shift cable arm. Replace if worn or damaged.
7- Sh

4. Remove the shift knob to prepare for seat panel removal.

Refer to Chapter 5.

5. Refer to Chapter 5 for console cover removal in order to

access the shift cable mount on the lever assembly.
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6. Loosen the lower and upper jam nuts and remove the
cables.
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Upper
Jam Nut

Lower
Jam Nut

7. Inspect shift lever assembly. Replace parts as required if

worn or damaged.

2.11
MAINTENANCE

FUEL SYSTEM AND AIR INTAKE
Air Filter Service
It is recommended that the air filter be inspected as part of
pre-ride inspection. If riding in extremely dusty conditions,
apply a small amount of grease to the seal under the air box cap.
In extremely dusty conditions, air filter cleaning will be required
more often.
The filter should be serviced using the following procedure.
Removal
4. Inspect the air filter element for tears or damage.
NOTE: Filter is washable. Do not discard.
5. Wash the filter in warm soapy water and allow it to air dry.
6. Apply air filter oil (commercially available) to the filter,
following the directions on the label.
NOTE: If unable to clean the filter, replace it.
NOTE: Service the filter more frequently if vehicle is
operated in wet conditions, dusty conditions or at
high throttle openings for extended periods.
Installation

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1. The air box is located on the upper frame by the rear LH
wheel. Access the air box by removing the panel located at 1. Verify the air box and support screen are thoroughly clean.
the top of the rear cab (under rear basket, if installed). 2. Install a clean, pre-oiled foam filter over the filter support.

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NOTE: Apply a small amount of general purpose
grease to the sealing edge of the air box cap seal
Air Box Access before installing.
3. Install air box cap and secure with clips.
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2. Unlatch the clips and remove the air box cap. Inspect the
seal. It should adhere tightly to the cover and seal all the
way around.
87 rt

Secure Clips
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4. Reattach the access panel and tighten the fasteners

sufficiently.

3. Remove air filter and the filter support screen.

2.12
 MAINTENANCE
Choke Cable Adjustment 3. Remove the retaining screws and pull the choke assembly
out at the dash.
Verify free play of 3/16 (4.76 mm) and smooth operation of the
choke cable at the dash.

Decrease

2
Increase

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CHOKE CABLE FREEPLAY

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4. Raise the vehicle and support it with jackstands in order to
access the underside.
IMPORTANT: Document location of cable ties and
routing prior to removal. This is important for
reassembly.
9- k.
Adjustments to the freeplay can be made by loosening the choke
cable bracket at the carburetor and moving the cable in or out to
gain the desired freeplay.
5. Pull the cable out from under the dash and the underside of
the vehicle.
6. Route the new cable from front-to-back, through the
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If smooth choke operation is not obtainable, inspect choke cable retainers at the bottom of the frame, following the routing
99 a
for kinks or sharp bends in routing. noted during disassembly. Place cable ties at the
appropriate locations.
Choke Cable Replacement
7- Sh

IMPORTANT: Do not allow cable to hang below

vehicle frame.
The choke cable is replaced as an assembly.
7. Reinstall the choke assembly into the dash. Hand-tighten
1. Engine is off. Place the vehicle in neutral and apply the fasteners sufficiently, using care not to over-tighten.
parking brake.
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8. Reinstall the choke cable onto the carburetor.

2. Remove the cable end from the carburetor.
9. Adjust cable to desired freeplay.

If smooth choke operation is not obtainable, inspect for kinks,

a

sharp bends in the routing or a linkage obstruction.

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2.13
MAINTENANCE
Idle Speed Adjustment Pilot Air Screw Adjustment
1. Start engine and warm it up thoroughly.
CAUTION
2. Adjust idle speed by turning the slide adjustment screw in
(clockwise) to increase or out (counterclockwise) to
The pilot air screw is calibrated at the factory to
decrease RPM. (Refer to illustration).
meet EPA / CARB regulations for air quality
standards. Cleaning of the pilot circuit must be
performed by a certified repair shop to ensure
air quality standards are not exceeded.
Idle Speed
Screw 1. Using a portable tachometer, start the engine and verify
IDLE SPEED the idle speed is set to specification. Always check throttle

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cable freeplay after adjusting idle speed and adjust if
necessary.
Decrease 2. Using D-shaped screwdriver Special Tool PA-47361
adjust the pilot air screw setting, turn the screw clockwise

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until engine idle RPM begins to decrease. Stop turning at
this point and note the screw setting.

Increase

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PILOT AIR SCREW
99 a
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Idle Speed Increase

1700 100
Decrease
NOTE: Always check throttle cable freeplay after
87 rt

adjusting the idle speed and readjust if necessary.

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Pilot Air Screw Base Setting:

2.25 turns out (initial)

Special Tool:
PA-47361

3. Slowly turn mixture screw counterclockwise until idle

speed returns to Idle RPM. Continue turning
counterclockwise until idle RPM begins to drop. Stop
turning at this point and note the screw setting

4. Center the mixture screw between points in Step 2 and 3.

5. Readjust idle speed if not within specification.

2.14
 MAINTENANCE
Vent Lines Fuel Filter
1. Check fuel tank, crankcase, carburetor and transmission The fuel filter should be replaced in accordance with the
vent lines for signs of wear, deterioration, damage or Periodic Maintenance Chart or whenever sediment is visible
leakage. Replace every two years. in the filter.

2. Verify vent lines are routed properly and secured with

cable ties.
Fuel Filter Location - Located in-line between fuel pump
and carburetor inlet. 2
Fuel System

WARNING

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Gasoline is extremely flammable and explosive
under certain conditions.
Always stop the engine and refuel outdoors or in

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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.
9- k.
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,
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To service the fuel filter:
1. Shut off fuel supply at fuel valve.
immediately wash it off with soap and water
and change clothing. 2. Remove line clamps at both ends of the filter.
99 a
Never start the engine or let it run in an enclosed
area. Engine exhaust fumes are poisonous and 3. Remove fuel lines from filter.
7- Sh

can result loss of consciousness or death 4. Install new filter and clamps onto fuel lines.
in a short time.
Never drain the fuel when the engine is hot. 5. Turn fuel valve to ON.
Severe burns may result. 6. Start engine and inspect for leaks.
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2.15
MAINTENANCE
Fuel Valve Location Fuel Pump / Fuel Lines
The fuel valve is located on the passenger side of the vehicle NOTE: Thoroughly clean the exterior of all fuel
below the gas cap. Always turn off the fuel when the vehicle is related components before servicing.
not in use
The RZR170 fuel pump is located in the right rear wheel well.

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Turn knob to operate
the fuel valve

9- k.
Carburetor Draining
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2.
Check the fuel lines for signs of wear, deterioration,
damage or leakage. Replace if necessary.

Be sure fuel line is routed properly.

The carburetor float bowl should be drained before extended IMPORTANT: Make sure line is not kinked or pinched.
99 a
periods of storage, or periodically to remove accumulated
moisture or sediment from the bowl. 3. Replace fuel lines every two years.
7- Sh

1. Turn fuel valve to the OFF position. NOTE: For all other information related to the fuel
2. Place a container beneath the bowl drain hose. System, refer to Chapter 4.
3. Loosen drain screw and allow fuel in the float bowl and fuel
line to drain completely.
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Close

Open
Drain Screw

4. Tighten drain screw.

5. Turn fuel valve to ON and check for fuel leaks.
6. Start engine and recheck for leaks.
2.16

Throttle Pedal Inspection
If the throttle pedal has excessive play due to cable stretch or
cable misadjustment, it will cause a delay in throttle response.
Also, the throttle may not open fully. If the throttle pedal has no
play, the throttle may be hard to control, and the idle speed may
be erratic.
MAINTENANCE
Throttle Stop Speed Control
Use the following procedure to control how far the throttle
opens.
IMPORTANT: This procedure should be performed
by consumers only when they determine that their
child is capable of handling the additional speed. 2

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Throttle Pedal

9- k.
Check the throttle pedal play periodically in accordance with the
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SPEED
Jam Nut
Stop Screw
Periodic Maintenance Chart and adjust if necessary.
Decrease / Increase
99 a
7- Sh

1. Loosen the jam nut.

2. Turn the screw clockwise to increase speed or counter-

clockwise to reduce speed.
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3. Tighten the jam nut after adjusting.

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2.17
MAINTENANCE
Throttle Freeplay Adjustment Throttle Cable Replacement
Inspection
1. Place the transmission in the Neutral (N) position. WARNING
2. Start the engine and warm it up thoroughly. Follow the factory cable routing as installed to
3. Measure the distance the throttle pedal moves before the prevent cable pinching, binding or damage.
engine begins to pick up speed. Freeplay should be 1/16
- 1/8 (1.5 - 3 mm). Do not allow cable to hang below vehicle frame.
Failure to install properly could result in loss of
Adjustment vehicle control, resulting in severe injury or death.
1. The throttle cable adjuster is located at the throttle pedal 1. Engine is off. Place the vehicle in neutral and apply the
housing, outside of the cab well.

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parking brake.
2. Remove the foot pedal ETC cover screws and ONE left-
side housing mounting screw.

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9- k.
Throttle Cable
Adjuster
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99 a
7- Sh

2. Slide back the cable adjuster boot. Pivot Bearing

3. Using an open-end wrench, loosen the adjustment jam nut.
4. Using an open-end wrench, move the cable adjuster until NOTE: Pivot bearing inside the housing is a slip-fit
1/16 to 1/8 (1.5 - 3 mm) of freeplay is achieved at the and will require some light prying to separate the
throttle pedal.
87 rt

housing. Use caution.

NOTE: While adjusting, lightly move the throttle
3. Remove the cable from the housing and the ball-end from
pedal in and out.
the throttle pedal arm.
a

5. Re-tighten the jam nut.

6. Apply a small amount of grease to the inside of the boot and
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slide it over the cable adjuster to its original position.

2.18
 MAINTENANCE
4. Remove the carburetor slide assembly from the carburetor 12. Install the new cable onto the carburetor slide assembly and
body and disconnect the throttle cable. install the slide into the carburetor. Hand-tighten the slide
5. Raise the vehicle and support it with jack stands in order to cap sufficiently.
access the underside of the vehicle. 13. Place the throttle cable end into the foot pedal housing.
IMPORTANT: Document location of cable ties and
routing prior to removal. This is important for 14. Place a new gasket on the housing and install the cover.
reassembly.
6. Remove the panduit straps retaining the throttle cable to the
Torque the retaining screws to specification.
2
frame and brake line.
7. Pull the throttle cable out through the back of the vehicle
and discard the cable.
8. Route the new cable from back-to-front, through the

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retainers at the bottom of the frame, following the routing
noted during disassembly.

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Pivot Bearing

9- k.
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=T
ETC Throttle Housing Screws:
8.5-10 ft. lbs. (11.5-13.5 Nm)
99 a
7- Sh

=T
9. Fasten the cable with cable ties at the same locations they Throttle Pedal Mounting Screws:
were previously removed. 16-20 ft. lbs. (21-27 Nm)
10. Continue to route the cable towards the front of the vehicle
87 rt

using the brake line routing as a general guide. 15. Start the engine and allow it to warm up.
16. Measure the distance the throttle pedal moves before the
engine begins to pick up speed. Freeplay should be 1/16" -
a

1/8" (1.5 - 3 mm).

If freeplay is correct, proceed to step 21.
P

If adjustment is required, refer to Throttle Freeplay

Adjustment procedure.
17. After reassembly and adjustment, field test vehicle to
ensure proper throttle operation.

11. Use cable ties to retain the throttle cable, using the same
locations they were previously removed.
NOTE: Be sure to route the throttle cable inside the
retainers.

2.19
MAINTENANCE

ENGINE Engine Oil Change

1. Position the vehicle on a level surface.
Engine Oil Level
Maintain the oil level within the safe range on the dipstick. Do 2. Clean area around the drain plug.
not overfill.
3. Run engine until warm.
To check the oil level:
4. Stop the engine.
1. Position the vehicle on a level surface.

2. Remove the dipstick. Wipe it dry with a clean cloth. CAUTION

Hot oil can cause serious burns to skin. Do not

86 m
allow hot oil to come in contact with skin.

5. Place a drain pan beneath the engine crankcase.

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6. Remove the drain plug and pre-filter screen. Allow the oil
to drain completely.

Dipstick

9- k.
r
Safe Range
99 a
{

7- Sh

Add Oil Full Drain Plug

3. Reinstall the dipstick completely.

87 rt

4. Remove the dipstick and check the oil level.

7. Wash the oil pre-filter screen with solvent to remove any
a

NOTE: Rising oil level between checks in cool debris. Allow the screen to air dry.
weather driving, can indicate moisture collecting in
P

the oil reservoir. If the oil level is over the full mark,
change the oil.

5. Add the recommended oil as needed.

NOTE: Do not fill the over the normal oil operating

range. Filling over the normal operating range could
cause a mist of oil to enter the air box. 8. Inspect the O-ring on drain plug, replace if needed.
6. Reinstall the dipstick. NOTE: The sealing surfaces on the drain plug and
crankcase should be clean and free of burrs, nicks
or scratches.

9. Reassemble the pre-filter screen and spring to the pre-filter

plug.

2.20
 MAINTENANCE
10. Reinstall the drain plug. Torque to specification. Engine Crankcase Ventilation System
Inspection
=T The engine is equipped with a crankcase ventilation. Follow
the breather hoses from the airbox to the engine and inspect
Crankcase Drain Plug: 18 ft. lbs. (23 Nm)
the hoses for possible kinks or wear. The hoses are form-fitted
11. Remove the dipstick. Add recommended oil. Do not for a proper fit. 2
overfill.

Recommended Engine Oil:

Polaris Synthetic Youth 4-Stroke Oil

86 m
SAE 40 (Above 32F)
Quart - (PN 2876248)
Gallon - (PN 2876249)

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Polaris Semi-Synthetic Oil
20W-40 (Below 32F)
Quart - (PN 2872175)
9- k.
r Gallon - (PN 2872176)

Capacity:
NOTE: Make sure lines are not kinked or pinched.
37 oz. (1.1 ltr)
99 a
Engine/Transmission Mount Locations
Periodically inspect engine/transmission upper and lower
7- Sh

12. Reinstall the dipstick.

mounts for cracks or damage.
13. Start the engine. Allow it to idle for a short period.
14. Stop the engine and inspect for leaks.
87 rt

15. Check the oil level. Add oil as needed to bring the level to
the Safe Range on the dipstick.

IMPORTANT: Over-filling engine crankcase will result

a

in oil entering the air box. Maintain the recommended

oil level.
P

2.21
MAINTENANCE
Compression / Leakdown Test
IMPORTANT: Use of a compression tester adaptor
that is too long WILL CAUSE DAMAGE to the cylinder
head. The adaptor length should be no longer than
the length of the spark plug threads (1/2 or 12.07mm).
Compression tester adaptor threads
should not exceed spark plug threads.
1/2 (12.07mm)
Intake Valve Clearance Adjustment
1. Remove the valve cover and secondary air pipe assembly.
2. Verify cam lobes are pointed down.
3. Insert the correct thickness feeler gauge between end of
intake valve stem and adjuster screw.
4. When clearance is correct, hold adjuster screw and tighten
locknut securely.
5. Re-check the valve clearance.
6. Repeat adjustment procedure if necessary until clearance is
correct with locknut secured.

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= In. / mm.
Cylinder Compression
Valve Clearance:

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Standard: 130 - 160 psi .003 (.07 mm)

Cylinder Leakage
Exhaust Valve Clearance Adjustment
Service Limit: 15%
9- k.
Inspect if leakage exceeds 15% 1.
2.
3.
Remove the valve cover and secondary air pipe assembly.
Verify cam lobes are pointed down.
Insert the correct thickness feeler gauge between end of
exhaust valve stem and adjuster screw.
r
4. Loosen locknut and turn adjuster screw until there is a slight
99 a
drag on feeler gauge.
5. When clearance is correct, hold adjuster screw and tighten
7- Sh

locknut securely.
6. Re-check the valve clearance.
7. Repeat adjustment procedure if necessary until clearance is
correct with locknut secured.
87 rt

= In. / mm.
a

Valve Clearance:
.003 (.07 mm)
P

2.22
 MAINTENANCE
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
2
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

86 m
cause loss of consciousness or death in a very
short time.

To remove accumulated carbon, clean the spark arrestor at the

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interval recommended in the Periodic Maintenance Chart.

1. Remove the retaining screws and remove the arrestor from

the end of the silencer.
2.

3.
9- k.
Use a non-synthetic brush to clean the arrestor screen. A
synthetic brush may melt if components are warm.
Inspect the screen for wear and damage.
required.
r
Replace if

4. Reinstall the arrestor and torque the fasteners to

99 a
specification.
7- Sh

Silencer

Screen
87 rt
a
P

Retaining Arrestor
Screws

=T
Spark Arrestor Fasteners
7 ft. lbs. (9.5 Nm)

2.23
MAINTENANCE

TRANSMISSION
Transmission Specification Chart

DRAIN / LEVEL CHECK

GEARCASE LUBRICANT CAPACITY FILL PLUG TORQUE
PLUG TORQUE

Transmission AGL - Synthetic ATV

24 oz. (710 ml) 18 ft. lbs. (24 Nm) 30-45 in. lbs. (3-5 Nm)
(Main Gearcase) Gearcase Lubricant

Transmission Oil Change Transmission Oil Level Check:

NOTE: It is important to follow the transmission and The fill plug is located on the side of the gearcase next to the shift
lever bell crank. Maintain the fluid level even with the bottom

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gearcase maintenance intervals described in the of the fill plug hole.
Periodic Maintenance Chart.

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Transmission Specifications

Specified Lubricant:
AGL Synthetic Gearcase Lubricant
9- k.
(PN 2873602)

Approximate Capacity at Change:

r Transmission Oil Fill/Check

23.7 oz. (700 ml)

99 a

Drain / Level Plug Torque:

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

Fill Plug Torque: Be sure vehicle is positioned on a level surface when

checking or changing fluid.
18 ft. lbs. (24 Nm)
Check vent hose to be sure it is routed properly and
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unobstructed.

1. Position vehicle on a level surface.

a

2. Remove the fill plug.

P

3. Add the recommended fluid through the fill plug hole until
it is at the bottom the check plug hole.

4. Reinstall the check/fill plug and torque to 30-45 in. lbs. (3-
5 Nm) or tighten by hand sufficiently.

2.24
 MAINTENANCE
Transmission Oil Change: FINAL DRIVE / WHEEL AND TIRE
1. Remove the level check plug (refer to Lubricant Level
Check). Wheel, Hub, and Spindle Torque Table
2. Place a drain pan under the main gearcase drain plug.
Item Nut Type Specification
3. Remove the drain plug and allow to drain completely.

Aluminum Wheels
Lug Nut
(#1)
90 ft. lbs. (122 Nm) 2
Flange Nut
Steel Wheels 27 ft. lbs. (37 Nm)
(#2)
Hub Retaining Nuts
- 40 ft. lbs. (54 Nm)
(Front & Rear)

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4. Clean the drain plug.
#1 #2
5. Reinstall the drain plug with a new o-ring and torque to

9- k.
specification.
r
=T
Aluminum Wheel
90 ft. lbs. (122 Nm)
Steel Wheel
27 ft. lbs. (37 Nm)

Transmission Drain Plug Torque: NOTE: Do not lubricate the stud or the lug nut.
99 a
18 ft. lbs. (24 Nm)

6. Add the recommended fluid through the fill plug hole. Wheel Removal
7- Sh

Maintain the fluid level at the bottom of the fill plug hole 1. Position the vehicle on a level surface.
when filling. Do not overfill.
7. Reinstall the fill plug. 2. Place the transmission in gear and stop the engine.
8. Check for leaks. Discard the used lubricant properly.
87 rt

3. Loosen the wheel nuts slightly. If wheel hub removal is

required, remove the cotter pin and loosen the hub nut
slightly.
a

4. Elevate the appropriate side of the vehicle by placing a

suitable jack and stand under the frame.
P

5. Remove the wheel nuts and remove the wheel.

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

Wheel Installation
1. Verify the transmission is in gear.

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

removed.

3. Place the wheel in the correct position on the wheel hub.

Be sure the valve stem is toward the outside and rotation
arrows on the tire point toward forward rotation.

4. Attach the wheel nuts and finger tighten them.

2.25
MAINTENANCE
5. Carefully lower the vehicle to the ground.
6. Torque the wheel nuts and/or hub nut to the proper torque WARNING
specification listed in the torque table at the beginning of
this section. Operating a RANGER 170 with worn tires will
7. If hub nut was removed, install a new cotter pin after the increase the possibility of the vehicle skidding
hub nut has been tightened. easily with possible loss of control.

Use a new Worn tires can cause an accident.

cotter pin
Note
Tire Rotation Always replace tires when the tread depth
measures 1/8", (.3 cm) or less.

Tire Pressure

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Hub Nut

CAUTION

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Maintain proper tire pressure.
Refer to the warning tire pressure decal
Valve stem applied to the vehicle.
Wheel Nuts (4) facing outward

9- k.
r
CAUTION
Tire Pressure Inspection (Cold)
Front Rear
3 psi (20.7 kPa) 3 psi (20.7 kPa)
If wheels are improperly installed it could affect
99 a
vehicle handling and tire wear. On vehicles with
tapered rear wheel nuts, make sure tapered end
Drive Chain Lubrication and Adjustment
7- Sh

of nut seats properly into taper on wheel. Lubricate the drive chain with Polaris chain spray lube or an
approved chain lube at the interval specified in the Periodic
Tire Inspection Maintenance Chart. Lubricate more often under severe use, such
as in dirty or wet conditions.
Improper tire inflation may affect vehicle
87 rt

maneuverability. IMPORTANT: Washing the drive chain with a high

pressure washer or solvents can cause premature
When replacing a tire always use original equipment wear and chain failure. Do not use a high pressure
size and type. washer or gasoline to clean the drive chain. Operating
a

The use of non-standard size or type tires may affect the vehicle with improper rear drive chain deflection
vehicle handling. can result in severe damage to the transmission and
P

drive components. Always make sure the chain

Tire Tread Depth adjusted within the stated specifications.

Always replace tires when tread depth is worn to 1/8" (3 mm) or 1. Check the amount of chain slack by moving the vehicle
less. slightly forward to gain slack at the top side of the chain.
2. Raise the rear of the vehicle and support securely under the
Tread mainframe. Allow the swing arm to hang at full shock
Depth 1/8" (3 mm) extension without touching the ground. This establishes the
tightest chain position.

2.26

3. Pull down on the chain tensioner to move it out of the way,
then measure chain deflection. It should have 1/4"-1/2" (6-
12 mm) deflection.
MAINTENANCE
ELECTRICAL AND IGNITION SYSTEM
Battery Maintenance
Keep battery terminals and connections free of corrosion. If
cleaning is necessary, remove the corrosion with a stiff wire
brush. Wash with a solution of one tablespoon baking soda and
one cup water. Rinse well with tap water and dry off with clean 2
shop towels. Coat the terminals with dielectric grease or
petroleum jelly.

WARNING

86 m
Battery electrolyte is poisonous. It contains
sulfuric acid. Serious burns can result from
contact with skin, eyes or clothing. Antidote:

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External: Flush with water.

Internal: Drink large quantities of water or milk.

Follow with milk of magnesia, beaten egg, or
9- k.
r vegetable oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get

prompt medical attention.
99 a
Batteries produce explosive gases.
Keep sparks, flame, cigarettes, etc. away.
7- Sh

Ventilate when charging or using in an enclosed

space. Always shield eyes when
working near batteries.
KEEP OUT OF REACH OF CHILDREN.
87 rt

4. Loosen the four rear housing mount bolts (two on each end
NOTE: Batteries must be fully charged before use or
of axle).
battery life will be reduced by 10-30% of full
5. Loosen the chain adjuster locknuts. potential. Charge battery for 3-5 hours at a current
a

6. Turn the chain adjusters evenly to achieve 1/4"-1/2" (6-12 equivalent to 1/10 of the batterys rated amp/hour
mm) chain deflection. capacity. Do not use the vehicles stator/alternator
to charge a new battery.
P

7. Torque the chain adjuster locknuts. Hold the adjuster stud

securely while tightening the nut to avoid breaking the stud.

=T
Chain Adjuster Locknuts: 18 ft. lbs. (25 Nm)

8. Torque the four rear housing mount bolts.

=T
Rear Housing Mounting Bolts: 43 ft. lbs. (60 Nm)

2.27
MAINTENANCE
Battery Removal Battery Off Season Storage
1. Remove or pull the drivers seat forward to access the Whenever the vehicle is not used for a period of three months or
battery. more, remove the battery from the vehicle, ensure that it's fully
charged, and store it out of the sun in a cool, dry place. Check
battery voltage each month during storage and recharge as
Battery
needed to maintain a full charge.

NOTE: Battery charge can be maintained by using a

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

86 m
point.

Battery Charging (Maintenance Free)

56 co
The sealed battery is already filled with electrolyte and has been
sealed at the factory. Never pry the sealing strip off or add any
2. Disconnect the black (negative) battery cable. type of fluid to this battery.

3.

4.
9- k.
Disconnect the red (positive) battery cable.

Remove the rubber strap and lift the battery out of the
vehicle.
r The single most important thing about maintaining a sealed
battery is to keep it fully charged. Since the battery is sealed and
the sealing strip cannot be removed, you must use a voltmeter or
multimeter to measure the DC voltage at the battery terminals.

1. Check the battery voltage with a voltmeter or multimeter.

99 a
CAUTION The battery voltage should read 12.8 VDC or higher.
7- Sh

2. If the voltage is less than 12.8 volts, charge the battery at

To reduce the chance of sparks: Whenever
1.2 amps or less until battery voltage is 12.8 VDC or
removing the battery, disconnect the black
greater.
(negative) cable first. When reinstalling the
battery, install the black (negative) cable last. NOTE: When using an automatic charger, refer to
the charger manufacturers instructions for battery
87 rt

charging directions. When using a constant current

Battery Installation
charger, follow the guidelines in the following table:
IMPORTANT: Using a new battery that has not been
a

fully charged can damage the battery and result in a State of Charge
shorter life. It can also hinder vehicle performance. Voltage Action
Charge Time
P

Follow the battery charging procedure before

installing the battery. None, check
None
100% 12.8 - 13.0 VDC again in 3
Required
1. Ensure the battery is fully charged. months
May need slight
2. Place the battery in the battery holder and secure with charge, check
rubber strap. 75% - 100% 12.5 - 12.8 VDC 3 - 6 hrs
again in 3
months
3. Coat the terminals with dielectric grease or petroleum jelly.
50% - 75% 12.0 - 12.5 VDC Needs Charge 5 - 11 hrs
4. Connect and tighten the red (positive) cable first. At least 13
hrs, verify
5. Connect and tighten the black (negative) cable last. 25% - 50% 11.5 - 12.0 VDC Needs Charge
state of
charge
6. Verify that cables are properly routed and reinstall the
drivers seat. 0% - 25% 11.5 VDC or less Needs Charge 20 hrs

2.28
 MAINTENANCE
Spark Plug Service 6. Measure gap with a wire gauge. Refer to specifications in
the following illustration for proper spark plug type and
1. Clean plug area so no dirt or debris can fall into the gap. Adjust gap if necessary by carefully bending the side
cylinder when the plug is removed. electrode.
Spark Plug Gap
WARNING

A hot exhaust system and engine can cause serious

2
burns. Allow engine to cool or wear protective
gloves when removing the spark plug.
Gap - .024-.028" (0.6-.07 mm)
2. Remove the spark plug cap.
7. If necessary, replace spark plug with proper type.

86 m
CAUTION: Severe engine damage may occur if the
incorrect spark plug is used.
8. Apply anti-seize compound to the spark plug threads.

56 co
9. Install spark plug and torque to specification.

Recommended Spark Plug:

NGK CR6HSA
9- k. Spark Plug Torque:
11 ft. lbs. (15 Nm)
r
99 a

Engine To Frame Ground

7- Sh

Inspect engine ground cable connection. Be sure it is clean and

3. Remove spark plug. tight. The ground cable runs from the engine starter motor to the
4. Inspect electrodes for wear or carbon buildup. Look for a ground terminal location under the drivers seat.
sharp outer edge on the electrode, with no rounding or
erosion.
87 rt

Inspect electrode for

wear or buildup
a
P

Ground
Terminal Location

5. Clean with electrical contact cleaner or a glass bead spark

plug cleaner only. CAUTION: A wire brush or coated
abrasive should not be used.

2.29
MAINTENANCE

STEERING Steering Inspection / Tie Rod Ends and Hubs

To check for play in the tie rod end, grasp the steering
Steering Inspection
tie rod and pull in all directions feeling for movement.
The steering components should be checked periodically for
loose fasteners, worn tie rod ends, ball joints, and damage. Also
check to make sure all cotter pins are in place. If cotter pins are
removed, they must not be reused. Always use new cotter pins.

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.

86 m
NOTE: Whenever steering components are
replaced, check front end alignment.

56 co
WARNING
Elevate front end of machine so front wheels are off the
Due to the critical nature of the procedures outlined in ground. Check for any looseness in front hub and wheel
this chapter, Polaris recommends steering assembly by grasping the tire firmly at top and bottom
9- k.
component repair and adjustment be performed
by an authorized Polaris MSD-certified technician
when replacing worn or damaged steering parts.
first, and then at front and rear. Try to move the wheel
and hub by pushing inward and pulling outward.

Use only genuine Polaris replacement parts.

r
Check for Loose Wheel or Hub
99 a
Steering Wheel Freeplay
7- Sh

Check the steering wheel for specified freeplay and operation.

1. Position the vehicle on level ground.

2. Lightly turn the steering wheel left and right.
3. There should be 0.8-1.0 (20-25 mm) of freeplay.
87 rt

4. If there is excessive freeplay or the steering feels rough,

inspect the following components.
a

If abnormal movement is detected, inspect the hub and

Tie Rod Ends wheel assembly to determine the cause (possible loose
Steering Shaft U-Joints wheel nuts or loose front hub components).
P

Steering Gearbox
Refer to Chapter 5 for front hub service procedures.

U-Joints

Tie Rod Location

Gearbox

2.30
 MAINTENANCE
Toe Alignment Inspection Toe Adjustment
1. Place machine on a smooth level surface. If toe alignment is incorrect, measure the distance between
vehicle center and each wheel. This will tell you which tie rod
2. Set steering wheel in a straight ahead position and secure needs adjusting.
the steering wheel in this position.
NOTE: Be sure steering wheel is straight ahead
3. Place a chalk mark on the center line of the front tires
approximately 10 (25.4 cm) from the floor or as close to
before determining which tie rod(s) need 2
adjustment.
the hub/axle center line as possible.

CAUTION

During tie rod adjustment, it is very important that

86 m
the following precautions be taken when
tightening tie rod end jam nuts.
If the rod end is positioned incorrectly it will not

56 co
pivot, and may break.

To adjust toe alignment:

Hold tie rod end to keep it from rotating.

9- k.
Measurement B
r Chalk Mark
Measurement A
Loosen jam nuts at both ends of the tie rod.

Shorten or lengthen the tie rod until alignment is as

required to achieve the proper toe setting as specified in
NOTE: It is important that the height of both marks
Toe Alignment Inspection.
99 a
be equally positioned in order to get an accurate
measurement. IMPORTANT: When tightening the tie rod end jam
7- Sh

nuts, the rod ends must be held parallel to prevent rod

4. Measure the distance between the marks and record the
measurement. Call this measurement A.
5. Rotate the tires 180 by moving vehicle forward or
backward. Position chalk marks facing rearward, even with
87 rt
end damage and premature wear. Damage may not be
immediately apparent if done incorrectly.
After alignment is complete, torque jam nuts to
specification. Keep tie rod parallel to the mounting

the hub/axle center line. surface.

6. Again measure the distance between the marks and record.
a

Call this measurement B. Subtract measurement B =T

from measurement A. The difference between
measurements A and B is the vehicle toe alignment.
P

Tie Rod Jam Nut Torque:

The recommended vehicle toe tolerance is 1/8 to 1/4 12-14 ft. lbs. (16-19 Nm)
(.3 to .6 cm) toe out. This means the measurement at the
front of the tire (A) is 1/8 to 1/4 (.3 to .6 cm) wider than
the measurement at the rear (B).

= In. / mm.

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

2.31
MAINTENANCE

SUSPENSION BRAKE SYSTEM

Spring Preload Adjustment Brake Fluid Inspection
The front and rear shock absorber springs are adjustable by Always check the brake pedal travel and inspect the brake fluid
rotating the adjustment cam to change spring tension preload. reservoir level before each operation. If the fluid level is low,
add DOT 4 brake fluid only.

WARNING
Uneven adjustment may cause poor handling of the
vehicle, which could result in an accident and
serious injury or death. Always adjust all spring
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 fluid master cylinder reservoir can be accessed

86 m
preloads equally.
through the left front wheel well.
Suspension Spring Adjustment
1. Position the vehicle on a level surface. Engine off.

56 co
1. Position the vehicle on a level surface and stop the engine.
2. Place the transmission in gear and lock the parking brake.
2. Raise and safely support the front or rear of the vehicle off
the ground to allow the suspension to fully extend. 3. View the brake fluid level in the reservoir. The level should
be between the MAX and MIN level lines.
NOTE: The tires should not be touching the ground.

3.
9- k.
To adjust the shock spring preload, rotate the adjustment
cam clockwise to increase spring tension or counter-
r 4. If the fluid level is lower than the MIN level line, add brake
fluid until it reaches the MAX level line.

clockwise to decrease spring tension using the supplied 5. Install the reservoir cap and apply the brake pedal
spanner wrench. forcefully for a few seconds, then check for fluid leaks
99 a
around the master cylinder and brake caliper fittings.
7- Sh
87 rt
a
P

Decrease Increase
Preload Preload

Special Tool:
Shock Spanner Wrench

4. Each notch of the adjustment will add 6% - 8% more

preload to the spring over the primary position.

2.32
 MAINTENANCE
Brake Pad / Disc Inspection
1. Check the brake pads for wear, damage, or looseness.

2. Inspect the brake pad wear surface for excessive wear.

3. Pads should be changed when the friction material is worn

to .040 (1 mm). 2

86 m
Measure Pad Material

56 co
Thickness Service Limit:
.040" (1 mm)

4.

5.
9- k.
Check surface condition of the brake discs.

Measure the thickness of the front and rear brake discs.

r
6. The disc(s) should be replaced if thickness is less than .170
99 a
(4.32 mm).

Measure Brake Disc Thickness

7- Sh

Rear Front
Disc Disc
87 rt
a

Service Limit:
P

.170" (4.32 mm)

Brake Hose and Fitting Inspection

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

2.33
MAINTENANCE
MAINTENANCE LOG

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

86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P

2.34
 ENGINE
CHAPTER 3
ENGINE
TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
ENGINE TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
TORQUE PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
ENGINE EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
3

86 m
PISTON IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
ACCESSIBLE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
ENGINE SERVICE DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7

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OIL FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
ENGINE SYSTEMS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
BREATHER / OIL SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
EMISSIONS SECONDARY AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
COOLING SHROUD REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
9- k.ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
ENGINE INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
TOP-END DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
ENGINE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
r
FINDING TOP DEAD CENTER (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
99 a
CAM CHAIN TENSIONER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
ROCKER ASSEMBLY
DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
7- Sh

CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15

CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
CYLINDER HEAD WARP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
87 rt

COMBUSTION CHAMBER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17

CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
a

CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21

VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
P

CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22

CAM CHAIN FOLLOWER / TENSIONER GUIDE REMOVAL . . . . . . . . . . . . . . . . . . . . 3.22
PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
CYLINDER HONE SELECTION / HONING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . 3.24
HONING TO DEGLAZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
PISTON INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25

3.1
ENGINE
BOTTOM-END DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26
STARTER DRIVE GEAR REMOVAL AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 3.26
FLYWHEEL REMOVAL / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
CRANKSHAFT ONE WAY GEAR / DRIVE SPROCKET
REMOVAL AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28
STARTER DRIVE ONE-WAY CLUTCH
REMOVAL AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29
BALANCE SHAFT SPROCKET
REMOVAL AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29
OIL PUMP REMOVAL / DRIVE CHAIN INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . 3.30
CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
CRANKCASE SEPARATION AND
CAM CHAIN REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
CRANKSHAFT REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32

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CRANKSHAFT / CAM CHAIN / SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . 3.33
CRANKCASE / BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
CRANKCASE OIL STRAINER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33
ENGINE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34

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BEARING / SEAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
CRANKCASE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
CHAIN GUIDE/TENSIONER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35
CRANKSHAFT, BALANCE SHAFT AND STARTER DRIVE GEAR INSTALLATION . . 3.35
OIL PUMP AND CHAIN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
9- k.
PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37
PISTON INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38
CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39
CYLINDER HEAD AND CAMSHAFT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . 3.39
r
CAMSHAFT TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40
99 a
ROCKER ARM / SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
ROCKER ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
CAM CHAIN TENSIONER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45
7- Sh

INTAKE VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45

EXHAUST VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45
STARTER DRIVE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46
FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46
STATOR INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46
87 rt

STATOR HOUSING INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.47

EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.49
SPARK PLUG FOULING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.49
a

GENERAL TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.49

P

3.2
 ENGINE
TOOLS Oil Pump Sprocket Nut 6mm 7-8 (9-11 Nm)
Special Tools
Oil pump baffle plate 6mm 4-5 (5-7 Nm)
PART NUMBER TOOL DESCRIPTION
Stator Assembly 6mm 7-8 (9-11 Nm)
2870390 Piston Support Block
PA-45153 Flywheel Puller Stator Housing 6mm 7-8 (9-11 Nm)
Transmission Output
PA-49959
Shaft Collar Tool Valve Cover 6mm 7-8 (9-11 Nm)
Balance Shaft Slotted
PA-47344
Nut Socket
Crankshaft Slotted Nut
Valve Adjuster Lock Nut 5mm 4-5 (5-7 Nm) 3
PA-49335

86 m
Socket Starter Motor 6mm 5-7 (7-9 Nm)
Flywheel Puller Adaptor
PA-49336
(Use with PA-45153) Spark Plug 12mm 11 (15 Nm)

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TORQUE SPECIFICATIONS Pulse Coil Screws 5mm 4-5 (5-7 Nm)

Engine Torque Specifications

Torque Patterns
9- k. TORQUE SPECIFICATIONS

Fastener
r
Thread
Size
ES35C
Ft. Lbs. (Nm)
Tighten cylinder head, cylinder base, and crankcase fasteners in
3 steps following the sequence outlined. Refer to the table for
torque specifications.

Camshaft Chain Guide

6mm 5-7 (7-9 Nm)
99 a
Pivot Bolt 3 2
5
Camshaft Chain 6 mm
6mm 5-7 (7-9 Nm)
Tensioner
7- Sh

Camshaft Chain 6
6mm 5-7 (7-9 Nm) 1 4
Tensioner Cap
Carburetor Intake 6mm 7-8 (9-11 Nm) Cylinder Base / Head and
Rocker Assembly
87 rt

Cylinder/Head Nuts 10mm 18 (25 Nm)

Cylinder Base Screws 6mm 5-7 (7-9 Nm) 1

a

Crankcase (inner) 6mm 14-15 (19-21 Nm)

RH Crankcase - (Inside Stator Cover)
P

Crankshaft Slotted Nut 14mm 43 (58 Nm)

Balancer Shaft Slotted
14mm 43 (58 Nm) 1 5
Nut 8
Exhaust Nuts 6mm 7-8 (9-11 Nm) 6

Flywheel Nut 14mm 43 (58 Nm)

3
Cooling Fan 6mm 4-5 (5-7 Nm) 2

Oil Drain Bolt

14mm 18 (25 Nm)
(Crankcase) 9
4 7
Oil Pump
6mm 4-5 (5-7 Nm)
Screws RH Crankcase - Stator Cover

3.3
ENGINE
ENGINE INFORMATION
Engine Exploded Views
Crankcase Cylinder / Cylinder Head

86 m
56 co
9- k.
r
99 a
7- Sh

Crankshaft and Piston Valve Train

87 rt
a
P

3.4
 ENGINE
Engine Lubrication Accessible Components
Oil Type:** The following components can be serviced or removed with the
Above 32F engine installed in the frame:
Polaris Youth 4-Stroke Oil (40 W)
Quart - (PN 2876248) Flywheel
Gallon - (PN2876249)
Alternator/Stator
Below 32F Starter Motor/Starter Drive
Polaris Semi-Synthetic Engine Oil (20W-40)
Quart - (PN 2872175) Oil pump / Chain
Gallon - (PN2872176)

Capacity: Approximately 37 oz. (1.1 ltr.)

Rocker Arms
Carburetor
3

86 m
Drain Plug (Engine Oil): 18 ft. lbs. (23 Nm) Transmission Components

Screen Fitting: 11 ft. lbs. (15 Nm) Valves

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Oil Pressure Specification: Not Applicable Cylinder Head
Cylinder
** For break-in period after engine top end service, use an SAE
40W mineral based oil to ensure complete piston ring seating to Piston/Rings
cylinder wall. Change to above recommendation after 10 hours.
9- k.
Piston Identification
r Camshaft
The following components require engine removal for service:
Cam Chain and Sprockets
The piston may have or may not have an identification mark for
piston placement. If the piston has an identification mark, follow Crankshaft
99 a
the directions for piston placement below. If the piston does not
Crankshaft Main Bearings
have an identification mark, the direction for placement of the
7- Sh

piston does not matter. Crankcase/Bearings

Note the directional and identification marks when viewing the Balancer/Bearings
pistons from the top. The letters IN must always be toward the NOTE: Cam chain service requires crankshaft
intake side of the engine. The other numbers are used for removal, as the chain is located on the pto side of
87 rt

identification as to diameter, length and design. Four stroke the engine.

engine rings are rectangular profile. Any numbers or letters on
the rings (except oil control rings) must be positioned upward. NOTE: Crankshaft components are not serviceable.
See text for oil control ring upper rail installation.
a

Replace crankshaft as an assembly.

Engine Model Oversize Standard Piston

P

No. Available (mm) Identification

IN marking on
ES35C N/A top of piston
toward intake

3.5
ENGINE
Engine Service Data

Cylinder Head / Valvetrain ES35C

Rocker arm ID .3936 - .4007" (10.00 - 10.18 mm)
Rocker Arm/Shaft
Rocker shaft OD .3925 - .3931" (9.972 - 9.987 mm)
Std 1.1730" (29.795 mm)
In
Limit 1.1574" (29.40 mm)
Camshaft Cam lobe height
Std 1.1637" (29.56 mm)
Ex
Limit 1.1480" (29.16 mm)
Cylinder Head Surface warpage limit .002 (.05 mm)
In Std .003" (.07 mm)

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Valve Clearance
Ex Std .003" (.07 mm)
Std .039" (1.0 mm)
In

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Limit .063" (1.6 mm)
Valve Seat Angle Contacting width
Std .039" (1.0 mm)
Ex
Limit .063" (1.6 mm)
In .1958 - .1960" (4.975 - 4.980 mm)
Valve
9- k.
r Stem diameter Ex
Limit
In
.1950 - .1956" (4.955 - 4.970 mm)
.1921" (4.9 mm)
.1968 - .1973" (5.0 - 5.012 mm)
Valve Guide Inner Diameter Ex .1968 - .1973" (5.0 - 5.012 mm)
99 a
Limit .1980" (5.03 mm)
Inner 1.275" (32.4 mm)
Free Length
7- Sh

Valve Spring Outer 1.385" (35.2 mm)

Squareness 0.075 (1.9 mm)
Cam Chain Install new as a part of any crankshaft removal
87 rt

KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;
PTO: Power Take Off
a
P

3.6
 ENGINE
Engine Service Data

Cylinder / Piston / Connecting Rod ES35C

Surface warpage limit (mating with cylinder head) .002 (0.05 mm)

Cylinder bore Std 2.4015 - 2.4019" (61 - 61.01 mm)

Taper limit .002 (0.05 mm)
Cylinder Out of round limit .002 (0.05 mm)
Std .00039 - .0015" (0.01 - 0.04 mm)
Piston to cylinder clearance
Limit .0039" (0.1 mm) 3

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Boring Limit Not Applicable

Std 2.4003 - 2.4011" (60.97 - 60.99 mm)

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Outer diameter 1st O.S. Not Applicable
Piston
2nd O.S. Not Applicable
Pin Bore - Inner Diameter .5906 - .5908" (15.002 - 15.008 mm)
Pin outer diameter clearance in piston .00015 - .00047 (.004 - .012 mm)
9- k.
Piston Pin
Degree of fit Piston Pin must be a push (by hand) fit at 68 F (20 C)

Std .0059 - .013" (.15 - .35 mm)

r
Top ring
Limit .0196" (0.5 mm)
99 a

Second Std .0059 - .013" (.15 - .35 mm)

Piston Ring Piston Ring Installed gap
7- Sh

ring Limit .0196" (0.5mm)

Std .0079 - .0314" (0.2 - 0.8 mm)
Oil ring
Limit .059" (1.5 mm)
Std .00078 - .0023" (0.02. - 06 mm)
87 rt

Top ring
Standard clearance - Limit .0035" (0.09 mm)
Piston Ring
piston ring to ring groove Std .00078 - .0023" (0.02 - 0.06 mm)
Second
a

ring Limit .0035" (0.09 mm)

Connecting rod small end ID .5903 - .5916 (15.01 - 15.028 mm)
P

Connecting Rod Connecting rod big end axial clearance Std .0039 - .011" (0.1 - 0.3 mm)

Connecting rod big end radial clearance Std Not Applicable

Crankshaft end runout 0.0015" (0.04 mm)

Crankshaft
Crankshaft end runout - limit 0.0039" (0.1 mm)

Oil pump chain Install new as a part of any oil pump replacement

Cam Shaft Chain Install new as a part of any crankshaft replacement

KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;
PTO: Power Take Off.

3.7
3.8
ENGINE
Oil Flow Diagram

P
a
87 rt
7- Sh
99 a
r
9- k.
56 co
86 m
 ENGINE
ENGINE SYSTEMS SERVICE
Breather / Oil Separator
The breather / oil separator is located on the upper rear cab support. This system provides ventilation for the valve cover and engine
crankcase to the air box. A one-way valve (A) allows pulses from the crankcase to travel in one direction only, thereby vacuuming
the crankcase. NOTE: Over-filling of crankcase will result in oil in the air box. Always keep oil volume at recommended level.

7-8 ft. lbs. (9-11 Nm)

86 m
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A
9- k.
r
99 a

7-8 ft. lbs. (9-11 Nm)

7- Sh

To Valve Cover
87 rt
a

To Crank Case
P

3.9
ENGINE
Emissions Secondary Air System
The secondary air system is located on the upper rear cab support and engine. This system introduces air into the exhaust system
for more complete burning of the exhaust emissions. The air control valve (A) is operated by intake manifold pulses from the intake
manifold, which releases the air to the one-way valve (B) to combine with the pull of the exhaust gas stream from the cylinder head.
Check the air control valve (A), one-way valve (B), filter housing (C) and related components according to the maintenance schedule
in Chapter 2 for proper operation and emissions compliance.

7-8 ft. lbs. (9-11 Nm)

86 m
C
A Air In

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9- k.
r 16 ft. lbs. (22 Nm)
To Intake (impulse)

Air To Cylinder Head Exhaust Passage

99 a
7- Sh

7-8 ft. lbs. (9-11 Nm)

87 rt
a
P

7-8 ft. lbs. (9-11 Nm)

3.10
 ENGINE
Cooling Shroud Removal/Installation
The cooling shroud directs air generated by the fan around the cylinder and casing for cooling.

REMOVAL:

1. Remove the carburetor and intake.

2. Remove the exhaust pipe.

3. Remove the screws that attach the fan shroud (A) to the housing (C).

4. Remove the bolts that attach the fan shroud to the stator housing.
3
5. Remove the screws that attach the upper and lower housings together (C).

86 m
6. Remove the bolt that attaches the housing to the engine case on the PTO side.

7. Separate the upper and lower housings at the snap-hooks and lift housings away from the engine.

56 co
INSTALLATION:

8. Install the upper and lower housings (C), making sure the snap-hooks are secure. Install the housing screws and attaching bolt
into the engine case. Hand tighten sufficiently, using care not to over-tighten.

9.
9- k.
Install the fan shroud (A) and attaching screws to housing (C). Install the fan shroud bolts to the stator housing. Hand tighten
sufficiently, using care not to over-tighten.
r
10. Install the exhaust pipe onto the cylinder. Torque pipe flange fasteners to 7-8 ft. lb. (9-11 Nm).
99 a
11. Install the carburetor and intake. Torque fasteners to 7-8 ft. lb. (9-11 Nm).
A
Cooling Shroud Exploded View
7- Sh

MAG View PTO View

A. Fan Shroud
87 rt

C B
a
P

B. Air Horn Assembly

C. Housing

3.11
ENGINE
Engine Removal Engine Installation Notes
1. Clean work area. After the engine is installed in the frame, review this checklist
and perform all steps that apply:
2. Thoroughly clean the engine and chassis.
General Items
3. Disconnect battery.
Install previously removed components using new
4. Drain engine oil.
gaskets, seals, and fasteners where applicable.
5. Disconnect spark plug high tension lead.
Perform checks on fluid levels, controls, and all
6. Disconnect all electrical wires from the engine. important areas on the vehicle as outlined in the daily
pre-ride inspection checklist (refer to Chapter 2).
7. Remove the following parts as required:

86 m
CVT System
Rear Cab Assembly (Refer to Chapter 5)
8. Remove exhaust pipe. Clean clutch sheaves thoroughly and inspect inlet and
outlet ducts for proper routing and sealing.

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9. Remove the carburetor. Insert a clean shop towel into the
carburetor flange to prevent dirt from entering the intake. Inspect clutch rollers, shoes and springs before
reassembly.
10. At the starter motor, note the chassis ground cable location
and remove it. Transmission

cable.
9- k.
11. Mark the positive (+) cable mounting angle and remove
r Inspect transmission operation and adjust linkage if
necessary.

12. Remove the transmission shift cables from the transmission Exhaust
and secure out of the way.
99 a
Replace exhaust gaskets. Seal connections if desired
13. Raise the rear of the unit until the wheels are off the ground. with high temp sealant.
7- Sh

Secure with jackstands under the frame.

14. Remove the drive chain.
15. Remove the top rear shock bolts and allow the swing arm
to drop. (OPTIONAL - Refer to Chapter 5 to remove the
87 rt
After running the engine, verify all bolted exhaust
connections are tight and in good condition.
Engine Mount Torque

axle and swing arm as an assembly) Front Mount

16. Remove all engine mount bolts and / or engine mount Rear Mounts
a

plates.
Engine Break In Period
17. Using the aid of an assistant, lift and remove engine out the
P

rear of the vehicle. 4 Cycle Engine Break-In Period is defined as the first 10 hours
of engine operation or 2 full tanks of fuel.

Use only Polaris Youth (40w) Oil, or API certified

SH oil equivalent.

Use fuel with a minimum octane of 87 (R+M)/2

method.

Change break-in oil at 10 hours or 100 miles, whichever

comes first.

3.12
 ENGINE
TOP-END DISASSEMBLY Cam Chain Tensioner Inspection
1. Remove the two cam chain tensioner flange bolts. NOTE:
Engine Removal/Installation
The plunger is under spring tension. Maintain inward
Refer to page 3.12 for engine removal / installation notes. pressure on the tensioner body while removing.

Finding Top Dead Center (TDC)

1. Remove the cooling shroud.

2. Remove the inspection cap from the stator housing.

3. Remove the valve cover and emissions pipe assembly. 3

To position the crankshaft at Top Dead Center (TDC) on the

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compression stroke:
4. Rotate the engine slowly in the direction of rotation while
watching the intake valve open and start to close.

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5. Continue to rotate slowly while watching the camshaft
sprocket marks and timing mark in the inspection hole.
2. Allow the cam chain tensioner plunger to extend outward
Single TDC Mark Aligned to the end of its travel. Inspect tensioner and plunger (A)
for wear or damage.
9- k.
TDC Mark
r
Rotation
99 a
A
7- Sh

6. The engine is at Top Dead Center when the single (TDC)

mark on flywheel is visible within the inspection hole and
87 rt

the cam sprocket hole is facing upward. NOTE: The

sprocket marks should align with the gasket surface, the
cam lobes must be pointed downward and the rockers 3. Using a small flat blade screwdriver, turn the tensioner
a

must have valve clearance at this point. clockwise to retract the plunger. The plunger should move
smoothly in and out of the tensioner body.
P

4. Tap lightly on tensioner body with a soft face hammer to

loosen and remove tensioner if required.

5. Replace tensioner assembly if any part is worn or damaged.

3.13
ENGINE
Rocker Assembly 5. Remove each rocker arm shaft using a hex bolt. NOTE:
Disassembly and Inspection Place the hex bolt head in a vise and lightly tap the rocker
housing with a non-marring hammer to pull the rocker
NOTE: Orientation of the components is important arm shafts.
for reassembly. Mark components as needed before
disassembly.

1. Remove the valve cover and secondary air injection pipe

as an assembly.

2. Loosen each of the four cylinder head nuts evenly 1/4 turn
each time in a cross pattern until loose.

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6. Measure O.D. of rocker shafts for out-of-round. Inspect for
wear or damage. Replace if excessive wear is evident.
NOTE: Orientation of the rocker shafts is important for
reassembly. Place only the exhaust rocker shaft into the
9- k.
r C
exhaust side of the cam support.
99 a
3. Remove the nuts and tap the rocker assembly with a plastic
hammer to loosen, then remove. Mark or tag rocker arms
to keep them in order for assembly.
7- Sh

Exhaust
4. Inspect each rocker arm cam follower surface. If there is
any damage or uneven wear, replace the rocker arm.
NOTE: Always inspect camshaft lobes if rocker arms are
worn or damaged.
87 rt
a

Inspect
P

3.14
 ENGINE
7. Measure I.D. of each rocker arm for out-of-round and 3. Remove the cam chain from the sprocket by tilting the cam
visually inspect the I.D. surface. Replace arm if excessive assembly and simultaneously lifting the chain.
wear is evident.

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8. Inspect the lash adjusters for wear, pitting, or damage to
4. If not removing the cylinder for other service, secure the

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threads of the adjuster or locknut. Replace all worn or
cam chain with a wire to prevent it from falling into the
damaged parts. NOTE: The end of the lash adjuster is
crankcase.
hardened and cannot be ground or re-surfaced.
Camshaft Inspection
Camshaft Removal
9- k.
NOTE: Cam chain tensioner must be removed
before performing this procedure.
r 1. Inspect cam sprocket teeth for wear or damage. Replace if
necessary.

1. Verify the valve cover and cam chain tensioner have been
99 a
removed.

2. Remove the 4 cylinder head bolts evenly by loosening each

7- Sh

one 1/4 turn at a time until loose. Tap the rocker assembly
with a non-marring hammer to loosen and remove the
assembly.
Inspect for Areas of
Tooth Wear or Damage
87 rt

2. Inspect the compression release mechanism. This is a one-

a

way rotating shoulder that lifts the exhaust valve slightly

during start-up. If the one-way mechanism is not
functioning, replace the cam. Verify the stop bracket and
P

spring is functioning correctly. Replace if excessive wear

of components is found.
Compression Release
One-Way Operation

3.15
ENGINE
3. Visually inspect each cam lobe and bearing for wear, Cylinder Head Removal
chafing or damage.
NOTE: Cam chain and tensioner must be removed. If
no crankshaft service is being performed, secure
Bearings
cam chain with mechanics wire to avoid chain falling
into the crankcase.

1. Verify the valve cover and tensioner are removed.

2. Remove the two 6mm cylinder/head base screws.

3. Loosen each of the four cylinder head nuts evenly 1/4 turn
each time in a cross pattern until loose.
Lobe Height

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Compression Release-One-way stop
9- k.
r
99 a
4. Remove the nuts and tap the rocker assembly with a plastic
hammer until loose. Remove.
7- Sh

5. After removing the camshaft and securing the cam chain,

tap the cylinder head lightly with a plastic hammer until
= In. / mm. loose. CAUTION: Tap only in reinforced areas or on
thick parts of cylinder head casting to avoid damaging
casting.
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Cam Lobe Height:

6. Remove cylinder head (A) and head gasket (B).
Intake
a

Std: 1.1730 (29.795 mm)

Limit: 1.1574 (29.40 mm)
P

Exhaust
Std: 1.1637 (29.56 mm)
Limit: 1.1480 (29.16 mm)

4. Thoroughly clean the cam shaft.

5. Measure height of each cam lobe using a micrometer.

Replace cam if worn below minimum height.

Replace camshaft if damaged or if any part is worn excessively. A

B

3.16
 ENGINE
Cylinder Head Inspection Cylinder Head Disassembly
1. Thoroughly clean cylinder head surface to remove all
traces of gasket material and carbon. WARNING

CAUTION Wear eye protection or a face shield during

Use care not to damage sealing surface.
If there is damage found on the cylinder head
combustion chamber, it is recommended the
component be replaced.
cylinder head disassembly and reassembly.
NOTE: Keep all parts in order with respect to their
location in the cylinder head.
NOTE: Valves have inner and outer springs.
3
1. Using a valve spring compressor, compress the valve

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Cylinder Head Warp Inspection springs and remove the split keeper. NOTE: To prevent
1. Lay a straight edge across the surface of the head at several loss of tension, do not compress the valve spring more than
different points and measure warpage by inserting a feeler necessary.

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gauge between the straight edge and the cylinder head
surface. If warpage exceeds the service limit, replace the
cylinder head.Milling the

9- k.
r
99 a
7- Sh

2. Remove spring retainer and spring.

A
87 rt

= In. / mm.
a

Cylinder Head Warp Limit: .002 (.05 mm)

P

Combustion Chamber Inspection

Clean all accumulated carbon deposits from combustion
chamber and valve seat area with a soft wire brush. Inspect the
combustion chamber for cracks and/or damage from foreign
debris.
NOTE: The valve springs should be positioned with
the tightly wound coils against the cylinder head on
progressively wound springs (A).

3. Push valve out, keeping it in order for reassembly in the

same guide.

3.17
ENGINE
4. Measure free length of the inner and outer springs with a
Vernier caliper, Ill.1. Check spring for squareness as
shown in Ill.2. Replace spring if measurements are out of
specification.
Valve Inspection
1. Remove all carbon from valve with a soft wire wheel.
2. Check valve face for runout, pitting, and burned spots. To
check for bent valve stems, mount valve in a drill or use V
blocks and use a dial indicator.

Valve Spring
Free Length

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III.1

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

Coil Fatigue / Squareness

99 a
7- Sh

III.2
5. Remove valve seals. NOTE: Replace seals whenever the
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cylinder head is disassembled. Hardened, cracked or worn 4. Inspect split keeper groove for wear or flaring of the keeper
valve seals will cause excessive oil consumption and seat area (B). NOTE: The valves cannot be re-faced or end
carbon buildup. ground. Valves must be replaced if worn, bent, or damaged.
a

5. Measure diameter of valve stem with a micrometer in three

places and in two different directions (six measurements
P

total). Replace if excessive wear is evident.

Measure valve stem in
several places

3.18
 ENGINE
6. Measure valve guide inside diameter at the top middle and Cylinder Head Reconditioning
end of the guide using a small hole gauge and a micrometer.
NOTE: Servicing the valve guides and valve seats
Measure in two directions, front to back and side to side.
requires special tools and a thorough knowledge of
reconditioning techniques.

CAUTION

Wear eye protection when

performing cylinder head service.

Follow the manufacturers instructions provided with the valve 3

cutting kit (commercially available). Abrasive stone seat

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reconditioning equipment can also be used. Keep valves in order
with their respective seat.

NOTE: Valve seat width and point of contact on the

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7. Subtract valve stem measurement to obtain stem to guide valve face is very important for proper sealing. The
clearance. NOTE: Be sure to measure each guide and valve valve must contact the valve seat over the entire
combination individually. circumference of the seat, and the seat must be the
proper width all the way around. If the seat is
8. Replace valve and/or guide if clearance is excessive.
9- k.
NOTE: If valve guides are replaced, valve seats must
be reconditioned.
r
Refer to Valve Seat
uneven, compression leakage will result. If the seat
is too wide, seat pressure is reduced, causing
carbon accumulation and possible compression
loss. If the seat is too narrow, heat transfer from
Reconditioning for procedure. valve to seat is reduced and the valve may overheat
99 a
and warp, resulting in burned valves.
Valve Seat Reconditioning
1. Install pilot into valve guide.
7- Sh

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.
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a
P

Too Uneven Good Too

Wide Narrow

2. Apply cutting oil to valve seat and cutter.

3.19
ENGINE
3. Place 46 cutter on the pilot and make a light cut. 7. Remove valve and check where the Prussian Blue or
black marker indicates seat contact on the valve face. The
valve seat should contact the middle of the valve face or
slightly above, and must be the proper width (A).
(B)

(A)

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4. Inspect the cut area of the seat.
Proper Seat Contact On Valve Face

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If the contact area is less than 75% of the circumference
of the seat, rotate the pilot 180 and make another light
If the indicated seat contact is at the top edge of the
cut.
valve face and contacts the margin area(B) it is too high
If the cutter now contacts the uncut portion of the seat, on the valve face. Use the 30 cutter to lower the valve
9- k.
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
r seat.

If too low use the 60or 75 cutter to raise the seat.

When contact area is centered on the valve face,
valve guide is distorted from improper installation and
must be replaced. Be sure the cylinder head is at the measure seat width.
99 a
proper temperature and replace the guide. If the seat is too wide or uneven, use both top and
If the contact area of the initial cut is greater than 75%, bottom cutters to narrow the seat.
7- Sh

continue to cut the seat until all pits are removed and a
new seat surface is evident. NOTE: Remove only the If the seat is too narrow, widen using the 45 cutter and
amount of material necessary to repair the seat surface. re-check contact point on the valve face and seat width
after each cut.
5. To check the contact area of the seat on the valve face, apply
Top 30o
87 rt

a thin coating of Prussian Blue paste to the valve seat. If o o

Seat 45 or 46
using an interference angle (46)apply black marker to the Bottom 60o or 75o
entire valve face (A).
a
P

(A)

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

3.20
 ENGINE
NOTE: When using an interference angle, the seat 12. Clean rocker assembly, cylinder head, valves, and camshaft
contact point on the valve will be very narrow, and is oil supply passages thoroughly.
a normal condition. Look for an even and
continuous contact point on the black marker, all the
way around the valve face.

Seat
Width
Intake Exhaust
3

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13. Spray electrical contact cleaner into oil passages and dry

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using compressed air.
8. Clean all filings from the area with hot soapy water, rinse,
and dry with compressed air. Cylinder Head Assembly
9. Lubricate the valve guides with clean engine oil, and apply
9- k.
oil or water based lapping compound to the face of the
valve. Lapping is not required with an interference angle.

10. Insert the valve into its respective guide and lap using a
r CAUTION

Wear eye protection during assembly.

lapping tool or a section of fuel line connected to the valve
NOTE: Assemble the valves one at a time to
99 a
stem.
maintain proper order.
7- Sh

1. Install new valve seals on valve guides.

87 rt
a
P

11. Rotate the valve rapidly back and forth until the cut sounds
smooth. Lift the valve slightly off of the seat, rotate 1/4 turn,
and repeat the lapping process. Do this four to five times
2. Apply engine oil to valve guides and seats.
until the valve is fully seated, and repeat process for the
other valve. 3. Coat valve stem with molybdenum disulfide grease.

4. Install valve carefully with a rotating motion to avoid

damaging valve seal.

3.21
ENGINE
5. Dip valve springs and retainer in clean engine oil and install Cylinder Removal
springs with closely spaced coils toward the cylinder head.
Follow engine disassembly procedures to remove the valve
cover, rocker assembly, camshaft and cylinder head.

1. Remove cam chain guide at front of cylinder.

Closely spaced 2. Tap cylinder lightly with a soft-faced hammer in reinforced

coils toward areas only until loose. NOTE: Orientation of the dowels
cylinder head (arrows) is important for oil flow. Note their position for
reassembly.

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6. Place retainer on springs and install valve spring

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compressor. Compress spring only enough to allow split
keeper installation and prevent loss of spring tension.
Install split keepers with the gap even on both sides.

9- k.
r
3. Rock cylinder back and forth while lifting it from the
99 a
crankcase, piston and connecting rod. Support piston with
Piston Support Block (PN 2870390).
7- Sh

Cam Chain Follower / Tensioner Guide

Removal
1. Remove bolt securing the tensioner guide to crankcase
(A). NOTE: CVT disassembly is required to gain access
87 rt

to the tension guide bolt. Refer to Chapter 7.

7. Repeat procedure for remaining valve.

8. When all valves are installed, tap lightly with soft faced
a

hammer on the end of the valves to seat the keepers.

P

Valve Sealing Test A

1. Clean and dry the combustion chamber area.

2. Pour a small amount of cleaning solvent into each port and

check for leakage around each valve. The valve seats
should hold fluid with no leaking.

2. Remove chain guides and inspect for cracks, wear or

damage. Replace assemblies as required.

3.22
 ENGINE
Piston Removal Cylinder Inspection
1. Remove circlip from either side of piston. 1. Remove all gasket material from the cylinder sealing
surfaces.

2. Inspect the top of the cylinder for warpage using a straight

edge and feeler gauge.

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

3. 9- k.
Remove the compression rings, starting with the top ring. = In. / mm.

Cylinder Warp:
r
.002 (.05 mm) MAX
99 a

3. Inspect cylinder for wear, scratches, or damage.

7- Sh

4. Inspect cylinder for taper and out of round with a

telescoping gauge or a dial bore gauge. Measure in two
different directions, front to back and side to side, on three
different levels (1/2 down from top, in the middle, and
1/2 up from the bottom).
87 rt

1/2 Down From Top of Cylinder

a

* Using a piston ring pliers: Carefully expand ring and lift it off X Y
the piston. CAUTION: Do not expand the ring more than the
P

amount necessary to remove it from the piston, or the ring may

break.
Y
X
* By hand: Placing both thumbs as shown, spread the ring open
and push up on the opposite side. Use care to not scratch the ring
lands.
Y
4. Repeat procedure for second ring. X

5. The oil control ring is a three piece design consisting of a

top and bottom steel rail and a center expander section. 1/2 Up From Bottom
Remove the top rail first followed by the bottom rail and
expander.

3.23
ENGINE
5. Record measurements. If cylinder is tapered or out of round It is very important that the cylinder be thoroughly cleaned after
beyond specification, the cylinder must be honed, bored or honing to remove all grit material. Wash the cylinder in a
replaced. solvent, then in hot, soapy water. Use electrical contact cleaner
if necessary to clean these areas. Rinse thoroughly, dry with
compressed air, and oil the bore immediately with Polaris 4
= In. / mm. Cycle Lubricant to prevent the formation of surface rust.

If cylinder wear or damage is excessive, it will be necessary to

Cylinder Taper: replace the cylinder. Hone only enough to deglaze the outer
Limit: .002 (.05 mm) Max. layer of the cylinder bore.
Cylinder Out of Round:
Limit: .002 (.05 mm) Max.

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Cylinder Hone Selection / Honing Procedure

CAUTION

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A hone which will straighten as well as remove
material from the cylinder is very important.
Using a common spring loaded glaze breaker for
9- k.
honing is not advised. Polaris recommends
using a rigid hone or arbor honing machine.

Cylinders may be wet or dry honed depending upon the hone

r
EXAMPLE OF CROSS HATCH PATTERN
manufacturers recommendations. Wet honing removes more
material faster and leaves a more distinct pattern in the bore. Piston Inspection
99 a

1. Measure piston outside diameter at a point 7 mm up from

Honing to Deglaze
7- Sh

the bottom of the piston at a right angle to the direction of

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

Use a motor speed of approximately 300-500 RPM, run 7mm

the hone in and out of the cylinder rapidly until cutting
a

tension decreases. Remember to keep the hone drive

shaft centered (or cylinder centered on arbor) and to
bring the stones approximately 1/2 (1.3 cm) above and Piston
P

below the bore at the end of each stroke. Piston Pin

Release the hone at regular intervals and inspect the

bore to determine if it has been sufficiently deglazed,
and to check for correct cross-hatch. NOTE: Do not 2. Subtract this measurement from the maximum cylinder
allow cylinder to heat up during honing. measurement obtained earlier.

After honing has been completed, inspect cylinder for

thinning or peeling. = In. / mm.
IMPORTANT: Clean the Cylinder After Honing
Piston to Cylinder Clearance
Std: .00039- .0015 (0.01- 0.04 mm)
Limit: .0039 (.1 mm)

3.24
 ENGINE
3. Measure piston pin bore. Replace piston if out-of-round Piston Ring Installed Gap
1. Place each piston ring inside cylinder using piston to push
ring squarely into place as shown.

Piston ring end gap installed

Feeler Gauge
Piston Pin Bore
Cylinder
25-50 mm
3
4. Measure piston pin O.D. Replace piston pin if out-of-round.

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Piston Ring

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= In. / mm.

9- k. Piston Pin Measurement Locations

Piston Ring Installed Gap:

Top Ring
Std: .0059- .013 (.15-.35 mm)
r
5. Measure connecting rod small end ID. Replace crankshaft Limit: .0196 (0.5 mm)
if out-of-round.
99 a
Second Ring
Std: .0059- .013 (.15-.35 mm)
Limit: .196 (0.5 mm)
7- Sh

Oil Ring
Std: .0079-.0314 (0.2- 0.8 mm)
Limit: .059 (1.5 mm)
87 rt

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

NOTE: Measure at two points in the cylinder A

a

difference in end gap indicates cylinder taper. The

cylinder should be measured for excessive taper
P

6. Measure piston ring to groove clearance by placing the ring and out of round.
in the ring land and measuring with a thickness gauge.
Replace piston and rings if ring-to-groove clearance 3. If the installed gap measurement exceeds the limit, replace
exceeds service limits. the rings. If using new rings and the measurement is too
small, file the ring ends to achieve the proper gap.
Piston
NOTE: Always check piston ring installed gap after
re-boring a cylinder or when installing new rings. A
Ring re-bored cylinder should always be scrubbed
thoroughly with hot soapy water, rinsed, and dried
completely. Wipe cylinder bore with an oil rag
immediately to remove residue and prevent rust.
Feeler Gauge

3.25
ENGINE
BOTTOM-END DISASSEMBLY 4. Remove the start drive gear and shaft by pulling the shaft
and tilting the gear slightly.
Starter Drive Gear Removal and Inspection
1. Remove the fan from the hub.

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5. Measure the OD of the starter drive shaft on both ends for

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out-of-round.

2. Remove the fan hub by removing the flywheel nut, washer 6. Measure the ID of the bushing in the stator housing (A) and
and pulling the hub from the crankshaft. in the crankcase (B) in two directions 90 apart to
determine if out-of-round. Calculate the clearance. Replace
9- k.
r components if clearance is excessive.

Washer
99 a
7- Sh

A B

Flywheel Nut
87 rt

3. Remove stator housing bolts and remove housing.

a

7. Inspect gear teeth on starter drive. Replace starter drive if

gear teeth are cracked, worn, or broken.
P

8. Inspect the stator housing bearing. Replace if worn, rough

or damaged.

3.26
 ENGINE
Flywheel Removal / Inspection 3. Inspect the flywheel for loose components, cracks or other
damage. Replace flywheel if any damage is found.

CAUTION

Avoid damage to the flywheel or crankshaft end.

Do not strike components or special tools with
hammers or heavy objects.

1. Before removing the flywheel, remove the shaft collar (A)

from the crankshaft. NOTE: Shaft collar installation is
important for proper loading of the flywheel upon
reassembly.
3

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A

9- k.
r
99 a

2. Install Flywheel Adapter PA-49936 and Puller PA-45153

and remove the flywheel.
7- Sh

NOTE: PA-45153 has left-hand threads which

correspond with the left-hand threads on PA-49936.
Use caution to avoid thread damage to flywheel or
tools.
87 rt
a
P

PA-49
93 6

PA-45153

Flywheel Special Tools

Flywheel Adapter PA-49936
Flywheel Puller PA-45153

3.27
ENGINE
Crankshaft One Way Gear / Drive Sprocket 3. Remove the starter drive one-way gear assembly (A) from
Removal and Inspection the crankshaft.

1. Remove the baffle plate.

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4. Remove drive sprocket (D) and woodruff key from the
2. Using the Slotted Nut Socket PA-49935, remove the crankshaft.
crankshaft slotted nut (C) and washer (B) from the starter
drive one-way gear assembly (A). 5. Inspect sprocket teeth of both gears for wear or damage.

9- k.
NOTE: Slotted nut is left-hand thread.
r
Removal
99 a
7- Sh

Inspect for Areas of

Tooth Wear or Damage

6. Inspect woodruff key for wear. Replace if damaged.

87 rt

PA-49935
7. Replace any worn or damaged parts.
a

A
P

C Install

PA-49959
Remove

Slotted Nut Socket Tool

PA-49935

3.28
 ENGINE
Starter Drive One-way Clutch Balance Shaft Sprocket
Removal and Inspection Removal and Inspection
1. The cooling shroud, stator housing and flywheel must be 1. The cooling shroud, stator housing and flywheel and
removed prior to accessing the one-way starter drive. starter drive one-way gear must be removed prior to
accessing the balance shaft gear and oil pump gear
2. Pull the starter drive assembly from the crankshaft. Inspect
the bearing surfaces and drive teeth for signs of wear or 2. Using Slotted Nut Socket PA-47344, remove the balance
gouging. Replace the one-way clutch as an assembly if it shaft slotted nut and washer.
is not working properly. Assembly should turn in one
direction only. NOTE: Slotted nut is right-hand thread.

Drive Gear 3
One-way Assembly E

86 m
D
C

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PA-47344
9- k.
r Bearing

C
NOTE: One-way clutch components are not
serviceable. Replace the component as an
99 a
assembly. B
3. Do not add specialized lubricants or greases to the bearing
7- Sh

A Remove
or one-way components, as this may cause undesirable
operation.
87 rt

PA-47344
Install
a

Slotted Nut Socket

P

PA - 47344

3.29
ENGINE
3. Remove the oil pump galley cover, oil pump gear and chain Oil Pump Removal / Drive Chain Inspection
to facilitate removal of the balance shaft sprocket.
NOTE: Oil pump is a replace-only assembly.

1. Remove the oil pump galley cover, pump gear nut, and
balancer shaft nut prior to chain and sprocket removal.

2. Inspect the sprockets and chain for wear or damage. Inspect

chain for wear or damage. Replace chain anytime the oil
pump is replaced or if excessively worn.
Note: Install new chain as
part of oil pump repair.

86 m
4. Remove the oil pump gear nut.

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9- k.
r
3. Remove the oil pump retaining screws and pull the pump
from the engine case.
99 a
7- Sh

5. Remove drive sprocket (A), chain (B), pump sprocket (C)

and the woodruff key from the balance shaft.
87 rt
a

A
P

6. Inspect sprockets and gear teeth for wear or damage.

7. Inspect woodruff key for wear.

8. Replace any worn or damaged parts.

3.30
 ENGINE
4. Thoroughly clean all oil passages with clean solvent.

5. Install a new pump with the oil galley pointed down as

shown.

Install with the oil galley pointing down

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6. Torque screws to specification.

9- k.
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99 a
7- Sh

=T
Oil Pump Screw Torque:
87 rt

4-5 ft. lbs. (5-7 Nm)

a
P

3.31
ENGINE
CRANKCASE DISASSEMBLY NOTE: Tapping the pto end of the crankshaft with a
soft-face hammer may also separate the cases. Use
NOTE: Engine must be removed from the frame to care not to damage the crankshaft end or cases.
perform any crankcase or crankshaft removal. Crankcase Separator Tool
PA-46087
NOTE: The starter, starter drive, flywheel, stator, oil
pump and transmission can be serviced with the
engine in the frame.

Crankcase Separation and

Cam Chain Removal
NOTE: Stator housing, flywheel and gears are
previously removed for this procedure. Use care

86 m
during the removal process to avoid damage to the
cam chain.

NOTE: Cylinder head and cylinder removal must be

56 co
performed prior to this procedure. 3. Watch the gap along the crankcase mating surface and
separate the crankcase evenly.
NOTE: Always replace the pto crankshaft seal after
performing this procedure. 4. Once the crankshaft bearing is free from the case, the
crankshaft and cam chain can be removed by hand for
1. 9- k.
Remove two case bolts (circled) from the magneto side
crankcase.
r replacement.
99 a
7- Sh
87 rt
a

2. Separate crankcase using a press or by pressing on the pto Crankshaft Removal

end of the crankshaft using special tool (PA-46087).
P

1. Support the MAG side crankcase on blocks. Press the

crankshaft out using a press or special tool (PA-46087).
Use care not to damage the crankshaft oil passage on the
mag end crankshaft end.

NOTE: Tapping the pto end of the crankshaft with a

soft-face hammer may also separate the cases. Use
care not to damage the crankshaft end or cases.

3.32
 ENGINE
Crankshaft / Cam Chain / Sprocket 5. Remove cam chain. Inspect chain for wear or damage.
Inspection Replace if worn excessively or as part of any crankshaft
repair.
1. Inspect the crankshaft main bearings and cam chain
sprocket for wear or damage.
Note: Install new chain as
a part of crankshaft repair.

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Crankcase / Bearing Inspection
NOTE: Due to extremely close tolerances and
minimal wear, the bearings must be inspected NOTE: Removal and installation of new seals is
visually, and by feel. Look for signs of discoloration, recommended anytime the crankcase is
9- k.
scoring or galling. Turn the outer race of each
bearing. The bearings should turn smoothly and
quietly. The inner race of each bearing should fit
disassembled.

1. Inspect the bearings in the crankcase.

tightly in the crankshaft. The outer race should be
r
NOTE: Due to extremely close tolerances and
firm with minimal side to side movement and no minimal side wear, the bearing must be inspected
99 a
detectable up and down movement. visually and by feel. Look for signs of discoloration,
scoring or galling. Turn the inner race of bearing.
2. Replace the crankshaft if the components fail visual
7- Sh

The bearing should turn smoothly and quietly. The

inspection.
3. The connecting rod utilizes a roller bearing. Clearance is
minimal and cannot be measured. Visually inspect bearing
journal for scoring, damage or excessive wear. Replace
87 rt
outer race should fit tightly in the crankcase. The
inner race should be firm with minimal side to side
movement and no detectable up and down
movement.

crankshaft if it fails visual inspection.

2. To remove crankcase bearings, use a blind hole bearing
puller.
a

NOTE: Bearings are damaged during the removal

procedure and should not be re-used.
P

3. Remove all traces of gasket material from the crankcase

mating surfaces. Inspect the surfaces closely for nicks,
burrs or damage.

Crankcase Oil Strainer Inspection

1. Remove drain plug.

2. Remove oil strainer and visually inspect for any damage or

obstructions in screen.
4. Check oil passages to make sure they are clear.
3. Replace oil strainer if it fails visual inspection.

3.33
ENGINE
ENGINE REASSEMBLY 2. Install the balance shaft into the mag side of the crankcase.

Bearing / Seal Installation

Mag-side
NOTE: To ease crankcase bearing installation, warm Crankcase
the crankcase until hot to the touch. Placing the
bearings in a freezer prior to installation will assist
the assembly process.

1. Install the bearings so the numbers are visible.

2. Drive or press the new bearings into the crankcase, using

the proper driver.

86 m
CAUTION
3. Install a new gasket onto the pto case half. Applying a thin
Press bearings only on outer race of bearing to amount of crankcase sealer to the gasket will help hold it

56 co
prevent bearing damage. in place.

3. Install new seals with the lip facing in. 4. Mate the mag side case, balancer and crankshaft to the PTO
side. During installation of the crankshaft, loop the cam
chain down into the chain room and over the pto end.
9- k. CAUTION

Press seals only on outer diameter

r
5. Press the mag and pto assembles together using a press.
Verify the balance shaft is seated and both shafts turn freely
to prevent damage. once installed.
99 a
NOTE: Tapping the mag end of the crankshaft with a
Crankcase Reassembly soft-face hammer may also install the crankshaft in
7- Sh

the PTO side. Use care not to damage the crankshaft

Crankshaft and Cam Chain Installation end.
Lubricate all bearings with clean engine oil before assembly.
1. Support the mag side crankcase cover on blocks high
enough to allow the crankshaft to drop. Install the
87 rt

crankshaft using a hydraulic tool. Press on the pto end of

the crankshaft. Use care not to damage the crankshaft end.
a

NOTE: Tapping the end of the crankshaft with a soft-

face hammer may also install the crankshaft. Use
P

care not to damage the crankshaft end.

6. Loop the cam chain through the chain room and secure with
mechanics wire.

3.34
 ENGINE
7. Install the two mag side flange bolts and torque to Crankshaft, Balance Shaft and Starter Drive
specification. Gear Installation
1. Install woodruff keys on the balancer shaft and crankshaft.

2. Install and align the marks of the balance shaft gear and the
crankshaft gear as shown.

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Alignment marks

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=T
Crankcase Bolt Torque:
14 - 15 ft. lbs. (19-21 Nm) 3. Install the oil pump drive sprocket, washer and slotted nut
onto the balance shaft.
9- k. Crankcase Sealant
PN 2871557
r
99 a

Chain Guide/Tensioner Installation

7- Sh

1. Install the chain guide and tighten the mounting bolt to

specified torque.
87 rt

4. Using Slotted Nut Socket PA-47344, tighten the nut to the

specified torque.
B
a
P

=T
Install A
Chain Guide Bolt Torque:
5-6.5 ft. lbs. (7-9 Nm)
=T
Balance Shaft Slotted Nut Torque:
43 ft. lbs. (59 Nm)
Special Tool:
PA-47344

3.35
ENGINE
5. Install the Starter Drive one-way gear assembly, washer 7. Install the baffle plate and torque to specification.
and slotted nut.

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6. Using Slotted Nut Socket PA-49935, tighten the crank shaft
nut to the specified torque. NOTE: Slotted nut is left hand
=T

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threaded.
Baffle Plate Screw Torque:
5-7 ft. lbs. (7-9 Nm)

9- k.
r Oil Pump and Chain Installation
NOTE: Oil pump is not a serviceable assembly. Do
not disassemble pump. Replace entire component.

1. Inspect the oil pump sealing surface on the crankcase.

99 a
Install Apply a liberal amount of engine oil to the surfaces and
pump.
7- Sh

NOTE: Do not use gasket sealer on the pump

=T mating surfaces.

Crankshaft Slotted Nut Torque: 2. Install oil pump as shown. Install and torque screws to
87 rt

43 ft. lbs. (59 Nm) specification.

Special Tool:
PA-49935
a
P

Install with the oil galley pointing down

=T
Oil Pump Cover Screw Torque:
4-5 ft. lbs. (5-7 Nm)

3.36
 ENGINE
3. Install the chain (A) over the sprocket on the balance shaft Piston Ring Installation
gear (B).
NOTE: Apply clean engine oil to all ring surfaces
and ring lands. Always check piston ring installed
A B
gap before rings are installed on piston. If the piston
C has been in service, clean any accumulated carbon
from the ring grooves and oil control ring holes.

1. Oil Control Ring: Place the oil control ring expander in

oil ring groove with the end gap facing forward. The
expander has no up or down marking and can be installed
D
either way. The ends should butt squarely together and
must not overlap.
3

86 m
2. Install the oil ring top rail with the end gap at least 30 from
4. Loop the chain around the oil pump drive sprocket (C) and the end of the expander.
install the sprocket onto the oil pump shaft. NOTE: The oil 3. Install the bottom rail with the gap at least 30 from the end

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pump sprocket and shaft have a D configuration for of the expander on the side opposite the top rail gap.
alignment.
Top
5. Install the pump gear washer and nut. Torque to Ring Profile
specification.
9- k.
r
Install chamfer up

Second
99 a
Ring Profile
7- Sh

4. Second Ring: Install the second ring with the mark facing
up (if applicable). Position the end gap toward the rear
(intake) side of the piston.
87 rt

5. Top Ring: Install the top ring with the chamfered edge
facing up (if applicable).
=T
a

6. Check to make sure the rings rotate freely in the groove

Oil Pump Gear Nut Torque: when compressed by hand. Verify that the ring gaps are
P

5-7 ft. lbs. (7-9 Nm) 120 degrees apart from each other before installation.

6. Install the oil baffle plate (Item D -See illustration) and

torque screws to specification.

=T
Oil Pump Baffle Plate Screw Torque:
5-7 ft. lbs. (7-9 Nm)

3.37
ENGINE
Piston Installation 5. Place the dowel pins in the PTO side of the crankcase and
install a new cylinder base gasket.

CAUTION

Do not re-use circlips. Circlips become

deformed during the removal process. Do not
compress the new clip more than necessary to
prevent loss of radial tension. Severe engine
damage may result if circlips are re-used or
deformed during installation.

1. Install a new circlip on one side of the piston with the end

86 m
gap facing up or down.

2. Apply clean engine oil all components before assembly.

Generously lubricate the connecting rod (both ends) and
6. Lubricate the piston and rings with assembly lube and

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crankshaft main bearing area.
install a ring compressor on the piston assembly. Verify
3. Install the wrist pin and piston onto the connecting rod. that the ring gaps are 120 degrees apart from each other
IMPORTANT: Install the piston on the connecting rod before installation.
with the IN casting mark facing the intake side of engine.
9- k.
The piston pin should be a push fit into the piston.
r
99 a
7- Sh
87 rt
a

4. Install the other circlip with the gap facing up or down. (See
note with Step 3 above). Push the piston pin in both
directions to make sure the clips are properly seated in the
P

groove.

3.38

Cylinder Installation
NOTE: Clean the gasket surfaces on the crankcase
and cylinder. Remove all traces of old gasket
material and apply a new base gasket
ENGINE
Cylinder Head and Camshaft Installation
NOTE: Verify the gasket surfaces on the cylinder
head and cylinder are clean. Remove all traces of old
gasket material.

1. Verify the cylinder base dowel pin(s) and a new base 1. Install the dowel pin(s) and a new cylinder head gasket
gasket are installed. Position the Piston Support Block (PN over the cylinder studs.
2870390) (A) beneath the piston skirt to support the piston
during cylinder installation.

NOTE: Route cam chain through the cylinder chain

room and secure it, holding it up while rotating the 3
engine to avoid damage to the chain, drive sprocket

86 m
teeth or tensioner blade.

2. Apply clean engine oil liberally to the bore and tapered area
of the cylinder. Place the cylinder on to the studs.

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3. Loop the cam chain through the cylinder chain room and
secure with mechanics wire. Seat the cylinder fully on the
piston and support block.

9- k.
r
2. Pull the cam chain through the cylinder head chain room
and secure with mechanics wire.

3. Place the cylinder head onto the cylinder.

99 a
4. Install the two 6 mm base bolts, but do not tighten at this
time.
7- Sh

5. Install the cam according to the Cam Shaft Timing

procedure. Verify the cam chain is in place around the
crankshaft gear.
87 rt

NOTE: Verify camshaft timing is accurate before

installing the rocker and tensioner assemblies.
4. Push the rings into the cylinder taper using a non-metallic,
blunt-edge tool while pushing the cylinder down. This will
a

help push the piston past the ring taper into the cylinder.

5. Remove the support block once the piston rings are inside
P

the cylinder. Seat the cylinder firmly on the base gasket.

6. Install the cam chain guide and dowel pins into the cylinder.
Verify the bottom end of the guide is seated properly in the
crankcase.

3.39
ENGINE
Camshaft Timing

CAUTION

Serious engine damage will result if the

camshaft is not properly timed to the crankshaft.

IMPORTANT CAMSHAFT TIMING NOTE: In order to time the camshaft to the crankshaft, the piston must be precisely located
at Top Dead Center (TDC). This can be accomplished using one of two methods.

1. Install the cam chain over the crankshaft.

When the stator housing is removed, use Method 1. This method uses the camshaft gear marks and the crankshaft keyway to establish

86 m
TDC (see Method 1 illustration). It is important to note that this method can only be used when the stator housing is removed and
the crankshaft keyway is in view. The camshaft sprocket alignment marks are parallel to the gasket surface, and camshaft lobes are
pointing down. Cam chain plate links are not used to time the camshaft.

56 co
When the stator housing is installed, use Method 2. This method establishes Top Dead Center (TDC) by aligning the single mark
on the flywheel in the timing inspection hole (see Method 2 illustration). The camshaft sprocket alignment marks are parallel to the
gasket surface, and camshaft lobes are pointing down. Cam chain plate links are not used to time the camshaft.

Camshaft Installation - Timing Method 1

9- k.
Reference Illustration Page 3.41

Stator housing is removed. NOTE: Use this method only when the stator is removed and cam shaft drive sprocket is in view.
r
1. Rotate the crankshaft until the keyway on the crankshaft is pointed UP (keyway facing upward) and the piston is at TDC.
99 a
2. Align the cam chain onto the teeth of the crankshaft sprocket. Use a wire to pull the chain up through the cylinder and cylinder
head and to hold it in place. Secure and maintain tension so that the chain does not fall off the crankshaft sprocket.
7- Sh

3. Apply engine assembly lubricant to the camshaft main journals and cam lobes. Lubricate automatic compression release
mechanism with clean engine oil.
4. Orientate the camshaft for installation with the lobes facing downward.
5. Disconnect the wire securing the cam chain and loop the cam chain over the camshaft sprocket while verifying the cam is inserted
87 rt

with the alignment marks parallel to the gasket surface.

a
P

TDC
Cam Alignment

6. Verify all cam timing marks to verify proper cam timing, and install the rocker arm assembly (see Method 1 illustration). Torque
the cylinder stud nuts to specification.
NOTE: Do not rotate engine until rocker assembly and tensioner are installed.
7. Install the tensioner. Torque fasteners to specification.
8. After tensioner installation, rotate engine at least two revolutions and re-check marks/timing.

3.40
 ENGINE

Method 1 - Camshaft Timing with Stator Housing Removed

Sprocket marks aligned with gasket surface at TDC on

compression stroke (cam lobes facing downward)

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56 co
9- k.
r
99 a
7- Sh
87 rt
a
P

Crankshaft Keyway UP

3.41
ENGINE
Camshaft Installation - Timing Method 2
Reference Illustration Page 3.43

Stator housing is installed. NOTE: Use this method only when the stator is installed and cam shaft drive sprocket is in view.

1. Rotate the crankshaft until the single (TDC) timing mark (Top Dead Center) on the flywheel is view in the center of the timing
inspection window. Be sure to use the single TDC mark when installing the cam. Do not use any advance marks (if evident).

2. Align the cam chain onto the teeth of the cam chain drive sprocket. Use a wire to pull the chain up through the cylinder and
cylinder head and to hold it in place. Secure the chain. Secure and maintain tension so that the chain does not fall off the
crankshaft sprocket.

3. Apply engine assembly lubricant to the camshaft main journals and cam lobes. Lubricate automatic compression release
mechanism with clean engine oil.

86 m
4. Orientate the camshaft for installation with the lobes facing downward.

5. Disconnect the wire securing the cam chain and loop the cam chain over the sprocket while verifying the cam is inserted with
the alignment marks parallel to the gasket surface.

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6. Check all cam timing marks to verify proper cam timing, and install the rocker arm assembly. Torque the cylinder stud nuts to
specification.

NOTE: Do not rotate engine until tensioner and rocker assembly is installed.

7.

8.
9- k.
Install the tensioner. Torque fasteners to specification.

After tensioner installation, rotate engine at least two revolutions and re-check marks/timing.
r
99 a
7- Sh
87 rt
a
P

3.42
 ENGINE

Method 2 - Camshaft Timing Using Flywheel TDC Mark

86 m
Sprocket marks aligned

56 co
with gasket surface at
TDC on compression stroke
(cam lobes facing downward)

9- k.
r
99 a
7- Sh
87 rt

Single TDC Mark Aligned

a

TDC Mark
P

Rotation

Cam Timing
(View through timing inspection hole)
Position crankshaft at TDC

3.43
ENGINE
Rocker Arm / Shaft Assembly 3. Install cylinder head nuts and torque to specification.
Torque in 3 step cross pattern
1. Apply engine assembly lube to all components and
3
assemble the arms, shafts and decompression components
into the rocker assembly. 1 2
4
IMPORTANT: Install rocker shafts in their correct
positions. The exhaust side shaft is shorter and is
held in place by the cylinder stud. The intake side
shaft has a half-moon section that aligns with the
cylinder stud to hold it in place.

86 m
5

56 co
.
Exhaust

=T
9- k.
Intake
Cylinder Head Nut Torque:
18 ft. lbs. (25 Nm)
2. Apply engine lube to the shafts and cam follower surfaces.
r
4. Torque the cylinder base screws to specification.
99 a
Rocker Assembly Installation
5. Adjust valves according to the VALVE CLEARANCE
1. Apply engine lube to all components and assembly arms, ADJUSTMENT procedures.
7- Sh

shafts and decompression components of the rocker

assembly. 6. Install valve cover and secondary air assembly with new
gaskets. Torque bolts to specification.
87 rt
a
P

2. Verify the cam is still in the TDC position before installing

the rocker assembly onto the cylinder studs.
=T
Valve Cover/ Secondary Air Pipe Bolt Torque:
7-8 ft. lbs. (9-11 Nm)

3.44
 ENGINE
Cam Chain Tensioner Installation Intake Valve Clearance Adjustment
1. Using a small flat blade screwdriver, turn the tensioner 1. Remove the valve cover and secondary air pipe assembly.
clockwise to retract the plunger (B) all the way into the
tensioner body. 2. Verify cam lobes are pointed down.

3. Insert the correct thickness feeler gauge between end of

intake valve stem and adjuster screw.

4. When clearance is correct, hold adjuster screw and tighten

locknut securely.
B
5. Re-check the valve clearance.
3
6. Repeat adjustment procedure if necessary until clearance is

86 m
correct with locknut secured.

56 co
= In. / mm.

2. Keeping the plunger retracted, install the tensioner Valve Clearance:

assembly with a new gasket and tighten the bolts to .003 (.07 mm)
specification.
9- k.
r
Exhaust Valve Clearance Adjustment
1. Remove the valve cover and secondary air pipe assembly.

2. Verify cam lobes are pointed down.

99 a

3. Insert the correct thickness feeler gauge between end of

7- Sh

exhaust valve stem and adjuster screw.

4. Loosen locknut and turn adjuster screw until there is a slight

drag on feeler gauge.

5. When clearance is correct, hold adjuster screw and tighten

87 rt

locknut securely.

6. Re-check the valve clearance.

a

=T
7. Repeat adjustment procedure if necessary until clearance is
correct with locknut secured.
P

Tensioner Bolt and Cap Torque:

5-7 ft. lbs. (7-9 Nm)

3. Release the tensioner and install the tensioner cap. Torque = In. / mm.
cap to specification.

4. Slowly rotate engine two to three revolutions and re-check Valve Clearance:
cam timing once chain is tight. .003 (.07 mm)

3.45
ENGINE
Starter Drive Assembly Stator Installation
1. Be sure the washer is positioned on the back of the drive NOTE: The stator, flywheel, and starter drive
gear. components can be serviced with the engine in the
frame.

1. Install the stator and pulse coil. Route the wires

appropriately to avoid contact with any moving parts.
Torque bolts to specification.

86 m
56 co
Starter Drive Grease:
(PN 2871460)

2.
9- k.
Apply Starter Drive Grease (PN 2871460) to the drive
bushings in the cases and install.
=T
Stator Bolt Torque:
r
3. Install stator housing and torque bolts to specification. 7-8 ft. lbs. (9-11 Nm)
99 a

Flywheel Installation Pulse Coil Bolt Torque:

4-5 ft. lbs. (5-7 Nm)
7- Sh

Install flywheel key, flywheel and the flywheel spacer. Proceed

to Stator Housing Installation if the stator assembly is already 2. Apply a small amount of Crankcase Sealant (PN 2871557)
installed.
to the stator wire grommet and install into the housing
cavity.
87 rt
a
P

IMPORTANT: Flywheel spacer installation is critical

for proper clamp-load when applying torque to the
flywheel nut. Verify spacer is installed before
assembly of the stator housing to the crankcase.

3.46
 ENGINE
Stator Housing Installation 3. Install the fan hub, washer, and flywheel nut. Torque the
flywheel nut to specification.
NOTE: The stator, flywheel, starter drive, and stator
can be serviced with the engine in the frame.

1. Apply a small amount of Crankcase Sealant (PN 2871557)

to the mounting surface and install a new gasket. Install the
dowel pins if removed.

86 m
56 co
=T
Flywheel Nut Torque:
43 ft. lbs. (58 Nm)

2. 9- k.
Install the housing. Torque bolts in sequence to
specification.
r 4. Install the fan and fan bolts. Tighten bolts evenly to
specification.

=T
99 a

Fan Bolt Torque:

7- Sh

4-5 ft. lbs. (5-7 Nm)

5. Install the cooling shroud and tighten the fasteners

sufficiently. Use care not to over-tighten.
87 rt
a

3
10 7
P

5
4
(#1, #2 RH case bolts)

11
6 9
RH Crankcase - Stator Cover

=T
Stator Housing Bolt Torque:
7-8 ft. lbs. (9-11 Nm)

3.47
ENGINE
Exhaust System
The exhaust silencer should be cleaned of accumulated carbon and all fasteners checked in accordance with the periodic maintenance
table in Chapter 2. Replace the exhaust gasket and clean the spark arrestor anytime engine rebuilding is performed. Torque all
fasteners to specification.

Silencer Gasket

86 m
56 co
Spark Arrestor

7-8 ft. lbs. (9-11 Nm)

9- k.
r
7-8 ft. lbs. (9-11 Nm)
99 a
7-8 ft. lbs. (9-11 Nm)
7- Sh
87 rt
a
P

3.48
 ENGINE
TROUBLESHOOTING Engine Does Not Turn Over
Dead battery
Spark Plug Fouling
Starter motor does not turn
Spark plug cap loose or faulty
Engine seized, rusted, or mechanical failure
Choke cable adjustment or plunger/cable sticking
Start components damaged
Foreign material on choke plunger seat or plunger
Engine Runs But Will Not Idle
Incorrect spark plug heat range or gap
Restricted carburetor pilot system
Carburetor inlet needle and seat worn
Jet needle and/or needle jet worn or improperly
adjusted
Carburetor misadjusted
3
Choke not adjusted properly

86 m
Excessive carburetor vibration (loose or missing needle Low compression
jet locating pins)
Crankcase breather restricted
Loose jets in carburetor or calibration incorrect for

56 co
altitude/temperature Air filter restriction
Incorrect float level setting Engine Idles But Will Not Rev Up
CVT system calibrated incorrectly or components worn Spark plug fouled/weak spark
or mis-adjusted
9- k.
Fuel quality poor (old) or octane too high
Low compression
Broken throttle cable
Obstruction in air intake
Air box removed (reinstall all intake components)
r
Restricted exhaust
Incorrect or restricted carburetor jetting
99 a
Weak ignition (loose coil ground, faulty coil, stator, or
ETC switch) ETC switch limiting speed
7- Sh

ETC switch mis-adjusted Reverse speed limiter limiting speed

Restricted air filter (main or pre-cleaner) or breather Carburetor vacuum slide sticking/diaphragm damaged
system
Incorrect ignition timing
Improperly assembled air intake system
87 rt

Restricted exhaust system

Restricted engine breather system
Cam lobe worn
Oil contaminated with fuel
Engine Has Low Power
a

Restricted crankcase vent

Spark plug fouled
General Troubleshooting
P

Cylinder, piston, ring, or valve wear or damage (check

Engine Turns Over But Fails to Start compression)
No fuel CVT not operating properly
Dirt in fuel line or filter Restricted exhaust muffler
Fuel will not pass through fuel valve Dirty carburetor
Fuel pump inoperative/restricted Cam lobe worn
Tank vent plugged
Carb starter circuit
Engine flooded
Low compression (high cylinder leakage)
No spark (Spark plug fouled)

3.49
ENGINE
Piston Failure - Scoring
Lack of lubrication
Dirt entering engine through cracks in air filter or ducts
Engine oil dirty or contaminated
Excessive Smoke and Carbon Buildup
Excessive piston-to-cylinder clearance
Worn rings, piston, or cylinder
Worn valves, guides or seals
Restricted crankcase vent

86 m
Air filter dirty or contaminated
Low Compression

56 co
Decompressor stuck
Cylinder head gasket leak
No valve clearance or incorrectly adjusted

9- k.
Cylinder or piston worn
Piston rings worn, leaking, broken, or sticking
Bent valve or stuck valve
r
Valve spring broken or weak
99 a

Valve not seating properly (bent or carbon accumulated

on valve area)
7- Sh

Rocker arm sticking

Backfiring
ETC or speed limiter system malfunction
87 rt

Fouled spark plug or incorrect plug or plug gap

Carburetion faulty - lean condition
a

Intake / Exhaust system air leaks

Ignition system faulty:
P

Spark plug cap cracked/broken

Ignition coil faulty
Ignition or kill switch circuit faulty
Ignition timing incorrect
Sheared flywheel key
Poor connections in ignition system
System wiring wet
Cam lobe worn or Valve sticking
Lean condition

3.50
 BODY / SUSPENSION / STEERING
CHAPTER 5
BODY / SUSPENSION / STEERING
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
BODY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
SEAT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
SEAT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
FRONT BUMPER REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
FRONT CAB REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3

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ROCKER PANEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
REAR BUMPER REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
REAR CAB REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
SERVICE PANEL (SEAT SHIELD) REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6

56 co
CONSOLE COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
KEY SWITCH / INDICATOR LIGHT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
DECAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8

5
BODY EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
CAB FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
9- k.
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
CAB FRAME ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
r
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
FRONT A-ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
99 a
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
A-ARM REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
FRONT HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
7- Sh

HUB REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14

HUB SEAL AND BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
HUB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
SHOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
SHOCK EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
87 rt

SHOCK REMOVAL / REPLACEMENT / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 5.16

REAR SWING ARM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
a

SWING ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18

SWING ARM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
REAR AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
P

AXLE HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20

AXLE HOUSING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
AXLE HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
AXLE REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23
STEERING WHEEL / STEERING SHAFT / GEARBOX EXPLODED VIEW . . . . . . . . . 5.23
STEERING SHAFT REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
STEERING GEARBOX REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
TIE ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26
TIE ROD END / TIE ROD / STEERING KNUCKLE ASSEMBLY EXPLODED VIEW. . . 5.26
TIE ROD REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.28
FRONT WHEEL EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.28
REAR WHEEL EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.28
WHEEL REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.29

5.1
BODY / SUSPENSION / STEERING
GENERAL INFORMATION
Special Tools
Description
Shock Spring Compressor Tool
Shock Spanner Wrench
Torque Specifications
Fastener
86 m
Body Fasteners
Body Component Fasteners
56 co
Seat Retaining Nuts
Seat Support Bolts
Cab Frame Fasteners
9- k. Steering Fasteners
Steering Pivot Tube Bolts
Steering Wheel Adjustment Bolt
r 16-17 ft. lbs. (22-23 Nm)
Steering Shaft Pinch Bolts
99 a
Tie Rod Plate Pinch Bolt
Steering Gearbox Mounting Bolts
7- Sh
Steering Wheel Fasteners
Tie Rod End Castle Nuts
Tie Rod End Jam Nuts
87 rt
Suspension Fasteners
AArm to Frame Fasteners
a
AArm to Spindle Castle Nuts
Front Shock Mounting Bolts
P
Rear Shock Mounting Bolts
Swing Arm Mounting Bolts
Final Drive Fasteners
Front Hub Castle Nut
Rear Hub Castle Nut
Front / Rear Wheel Nuts
Rear Axle Housing Bolts
Rear Axle Clamp Bolts
Front Sprocket Bolts
Chain Tensioner Bolt
Chain Guard Bolts
5.2
BODY REMOVAL
Seat Removal
1. Lift up the seat latch lever located under the right front
Part Number
edge of the drivers seat.
2870623
N/A - Part of tool kit. Seat Latch Lever
Torque
16 in. lbs. (1.8 Nm)
10 ft. lbs. (13.5 Nm)
36 ft. lbs. (49 Nm)
20 ft. lbs. (27 Nm)
10 ft. lbs. (13.5 Nm)
2. While holding the lever upward, slide the seat completely
forward to remove it from the seat mounting rails.
29-37 ft. lbs. (39-50 Nm)
17 ft. lbs. (23 Nm)
21 ft. lbs. (28 Nm)
11 ft. lbs. (15 Nm)
25 ft. lbs. (34 Nm)
1214 ft. lbs (1719 Nm)
30 ft. lbs. (41 Nm)
30 ft. lbs. (41 Nm)
36 ft. lbs. (49 Nm) 3. To remove the passenger seat, remove the two nuts located
at the front of the seat mounting rails. Lift the front of the
43 ft. lbs. (58 Nm) seat up and slide it forward to remove it from the vehicle.
72 ft. lbs. (98 Nm)
40 ft. lbs (55 Nm)
40 ft. lbs (55 Nm)
27 ft. lbs. (37 Nm)
72 ft. lbs (98 Nm)
36 ft. lbs (49 Nm)
87 in. lbs. (9.8 Nm)
84 in. lbs (10 Nm)
84 in. lbs (10 Nm)
 BODY / SUSPENSION / STEERING
Seat Installation 2. Remove the (4) screws retaining the front bumper to the
frame.
1. Lift up the seat latch lever located under the right front
edge of the drivers seat. 3. Disconnect the daytime running lights as shown and
remove the bumper from the vehicle.
2. While holding the lever upward, line up the seat guides with
the seat mounting rails and slide the seat rearward to install
it. Adjust the seat to the appropriate distance and be sure
the seat is latched
3. To install the passenger seat, place the seat mounts into the
mounting loops on the frame support and install the front
retaining nuts.

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Mounting
Loops 4. Reverse this procedure to reinstall the front bumper.
Tighten all fasteners securely. 5
9- k.
r
=T
Body Component Fasteners:
99 a
16 in. lbs. (1.8 Nm)
4. Torque the front retaining nuts to specification.
7- Sh

Front Cab Removal / Installation

=T
1. Remove the (6) push rivets retaining the rear portion of the
front cab to the frame.
Passenger Seat Retaining Nuts:
10 ft. lbs. (13.5 Nm)
87 rt

Front Bumper Removal / Installation

a

1. Remove the (2) push rivets from each side of the front
bumper.
P

2. Remove the (2) push rivets from each side, retaining the
front cab to the front bumper.

5.3
BODY / SUSPENSION / STEERING
3. Remove the (3) fasteners from each side, retaining the front 7. Remove the (2) screws retaining the choke bracket.
cab to the rocker panels.

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8. Disconnect the indicator lights and key switch harness

56 co
4. Using a 6 mm Allen socket, remove the (4) bolts retaining connections under the dash as shown.
the front cab frame to the rear cab frame.
Key Switch

9- k.
r
99 a
7- Sh

Disconnect

9. Remove the front cab from the vehicle.

87 rt

10. Reverse this procedure to reinstall the front cab. Tighten all
fasteners securely.
a

=T
P

Body Component Fasteners:

5. Remove the (2) fasteners retaining the front cab frame to 16 in. lbs. (1.8 Nm)
the main frame. Note the orientation of the (4) spacers
during removal. 11. Torque the cab frame bolts and fasteners to specification.

6. Carefully remove the front cab frame from the vehicle.

=T
Cab Frame Fasteners:
20 ft. lbs. (27 Nm)

5.4
 BODY / SUSPENSION / STEERING
Rocker Panel Removal Rear Cab Removal
1. Remove the (3) bolts from each side, retaining the lower 1. Remove the driver and passenger seats from the vehicle
portion of the rocker panels. (see Seat Removal).
2. Remove the (3) push rivets from each side, retaining the 2. Remove the (4) fasteners retaining the front of the rear cab
upper portion of the rocker panels. to the frame.
3. Remove the (3) fasteners from each side, retaining the 3. Remove the (2) fasteners retaining the top portion of the
rocker panels to the front cab. rear cab to the frame.
4. Remove the (4) fasteners from each side, retaining the 4. Remove the (2) push rivets from each side, retaining the
rocker panels to the rear side panels. rear side panels to the rear cab.
5. Remove the (4) fasteners from each side, retaining the rear

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side panels to the rocker panels.

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5
9- k.
r
99 a
7- Sh

5. If removing the RH rocker panel, remove the screw 6. Remove the (8) remaining fasteners retaining the rear cab
retaining the fuel valve knob and the (2) screws retaining and rear bumper to the frame.
the fuel valve to the rocker panel.
87 rt

Rear Bumper Removal / Installation

1. Remove the push rivet from each side of the rear bumper.
a
P

7. Remove the rear cab from the vehicle as an assembly.

8. Reverse this procedure to reinstall the rear cab. Tighten all
fasteners securely.
2. Remove the (6) screws retaining the rear bumper to the
frame. =T
3. Reverse this procedure to reinstall the rear bumper. Tighten Body Component Fasteners:
all fasteners securely. 16 in. lbs. (1.8 Nm)

5.5
BODY / SUSPENSION / STEERING
Service Panel (Seat Shield) Removal Console Cover Removal
1. Remove the seats (see Seat Removal). 1. Remove the seats (see Seat Removal).
2. Remove the (7) bolts and (2) push rivets retaining the 2. Remove the service panel (see Service Panel Removal).
service panel.
3. Remove the (2) bolts retaining the seat support to the frame.

Seat Support

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56 co
Service Panel

3. Disengage the service panel from the sides of the rear cab
4. Disconnect the battery leads and unhook the fuse holder
9- k.
and remove the panel from the vehicle.
r from the console cover.
99 a
Unhook
7- Sh

Disconnect
87 rt
a

5. Remove the (4) bolts and (3) push rivets retaining the
P

console cover.

Console Cover

5.6
 BODY / SUSPENSION / STEERING
6. Remove the (2) nuts retaining the front portion of the Key Switch / Indicator Light Replacement
drivers seat adjustment rail.
1. Disconnect the key switch harness or indicator light
connectors located under the dash as shown.

Key Switch

Remove

86 m
Indicator
Lights
Disconnect

56 co
7. Remove the shift knob cap. Remove the fastener and shift
knob from the shift lever.
2. If removing the key switch, loosen and remove the retaining
nut. Remove the key switch from underneath the dash.
5
9- k.
r
99 a

Shift Knob
7- Sh

Loosen
Nut
87 rt

8. Lift the console cover out from the vehicle as an assembly

3. If removing an indicator light, loosen and remove the
a

retaining nut(s) located under the dash. Remove the

indicator light(s) from the dash.
P

Indicator Lights

IMPORTANT: Be sure to route the battery cables

through the console cover prior to removal to prevent
from damaging the cables or fuse holder.
NOTE: The indicator lights are a complete
assembly. Bulb replacement is not possible.

5.7
BODY / SUSPENSION / STEERING
Decal Replacement

WARNING

The following procedure involves the use of an

open flame. Perform this procedure in a well
ventilated area, away from gasoline or other
flammable materials. Be sure the area to be
flame treated is clean and free of gasoline
or flammable residue.

WARNING

86 m
Do not flame treat components that are installed
on the vehicle. Remove the component from the

56 co
vehicle before flame treating.

The plastic body components are made of plastic polyethylene

material. Therefore, they must be flame treated prior to

9- k.
installing a decal to ensure good adhesion. The flame treating
procedure can also be used to reduce or eliminate the whitish
stress marks that are sometimes left after a plastic component is
bent, flexed, or damaged.
r
99 a
7- Sh
87 rt
a
P

To flame treat the decal area:

1. Pass the flame of a propane torch back and forth quickly
over the area where the decal is to be applied until the
surface appears slightly glossy. This should occur after just
a few seconds of flame treating. Do not hold the torch too
close to the surface (2-3 inches from the flame tip is
recommended). Keep the torch moving to prevent damage.

2. Apply the decal on one edge first. Slowly lay down

remainder of the decal while rubbing lightly over the decal
surface to eliminate any air bubbles during the application.

5.8
 BODY / SUSPENSION / STEERING
Body Exploded View

86 m
56 co
5
9- k.
r
99 a
7- Sh
87 rt
a
P

5.9
BODY / SUSPENSION / STEERING
CAB FRAME
Exploded View

86 m
56 co
9- k.
r
99 a

Cab Frame Assembly

7- Sh

1. Install the rear cab frame to the mounting brackets at each 7. Refer to the Owners Manual for the Cab Nets and Storage
side of the vehicle. Loosely install the four bolts and Bag installation procedure.
washers.

2. Position the front cab frame onto the front cab mounting
87 rt

posts. Align the two frames at the top joints and install the
Allen bolts using a 6 mm Allen wrench.
a

3. Install the front cab frame mounting hardware with the bolt
and cam to the outside of the frame and the nut and washer
to the inside.
P

4. Install the side bars (LH or RH frame) to the mounting

brackets at the rear frame and hip bars. Install the side nets
according to the procedure listed in the Owners Manual.

5. Attach the basket frame to the rear frame if removed.

6. Torque all cab frame fasteners to specification.

=T
Cab Frame Fasteners:
20 ft. lbs. (27 Nm)

5.10
 BODY / SUSPENSION / STEERING
MAIN FRAME
Exploded View

36 ft. lbs.
(49 Nm)

86 m
56 co
5
9- k.
r
36 ft. lbs.
(49 Nm)
99 a
7- Sh

17 ft. lbs.
87 rt

(23 Nm)
a
P

5.11
BODY / SUSPENSION / STEERING
FRONT A-ARMS
Exploded View

30 ft. lbs.
(41 Nm)

86 m
56 co
9- k.
r
99 a
7- Sh
87 rt

30 ft. lbs.
(41 Nm)
a
P

5.12
 BODY / SUSPENSION / STEERING
A-arm Replacement 4. Remove the lower shock mounting bolt.

1. Elevate the front end of the vehicle far enough off the
ground to remove the wheel.

CAUTION

Severe injury could occur if machine tips or falls.

2. Loosen and remove the (4) wheel nuts.

86 m
56 co
5. Remove the cotter pin, castle nut and washer from the bolt
attaching the A-arm to the spindle.

5
9- k.
r
99 a
3. Remove the (2) screws from the brake line retainer attached
to the front A-arm.
7- Sh
87 rt

6. Carefully remove the spindle assembly from the A-arm.

7. Remove the front and rear A-arm mounting fasteners (refer

to the Exploded View) and remove the A-arm from the
a

vehicle.
P

8. To reinstall, reverse steps 1-7. Torque fasteners to

Brake Line specification.
Retainer
=T
A-arm to Spindle Castle Nut: 30 ft. lbs. (41 Nm)

=T
Front Shock Mounting Bolt: 36 ft. lbs. (49 Nm)

=T
Wheel Nuts: 27 ft. lbs. (37 Nm)

5.13
BODY / SUSPENSION / STEERING
FRONT HUB 4. Remove the (2) bolts retaining the brake caliper and remove
the caliper from the disc. CAUTION: Do not hang the
Hub Removal caliper by the brake line. Use a strap or mechanics wire
to hang caliper to prevent damage to the brake line.
1. Elevate the front end of the vehicle far enough off the
ground to remove the wheel.

CAUTION

Severe injury could occur if machine tips or falls.

2. Loosen and remove the (4) wheel nuts and remove the black
rubber dust boot.

86 m
56 co
5. Remove the hub assembly from the spindle.

9- k.
r
Remove
99 a

3. Remove the cotter pin, castle nut and washers.

7- Sh
87 rt

Nut
Hub Seal and Bearing Replacement
a

1. Remove the (6) bolts retaining the brake disc to the hub.
P

Cotter Pin Washers

5.14
 BODY / SUSPENSION / STEERING
2. Remove the outer spacer from the hub. Hub Installation
1. Grease the spindle and reinstall the front hub assembly.

Grease

86 m
3. Remove the seals from each end of the hub and press the

56 co
bearings and spacer tube out.
2. Install the brake caliper and torque the mounting bolts to
specification.

=T
5
9- k.
r
Brake Caliper Bolts: 18 ft. lbs. (24 Nm)

3. Install the washers and torque the castle nut to specification.

Install a new cotter pin into the castle nut.
99 a

4. Using an arbor press, install new bearings along with the

7- Sh

spacer tube back into the hub.

5. Install new seals on each end of the hub. Press the seals into
the hub until the top of the seal is just past the chamfer. 40 ft. lbs.
(55 Nm)
87 rt

Chamfer
a
P

Replace Washers

=T
Front Hub Nut: 40 ft. lbs. (55 Nm)

4. Install the wheel, wheel nuts and rubber dust boot. Torque
6. Reinstall the brake disc with new mounting bolts. Torque the wheel nuts to specification.
the bolts to specification.

=T
=T
Wheel Nuts: 27 ft. lbs. (37 Nm)
Front Brake Disc Bolts: 7 ft. lbs. (10 Nm)

7. Reinstall outer spacer into the outer hub seal.

5.15
BODY / SUSPENSION / STEERING
SHOCKS Shock Replacement
1. Using a spring compressor, compress the shock spring far
Shock Exploded View
enough to remove the spring retainer.

Shock Spring
Compressor Tool
2870623

86 m
56 co
2. Remove the spring and adjustment collar from the existing
shock and install the components onto the new shock.

3. Compress the shock spring and install the spring retainer.

9- k.
r
Shock Installation
1. Install the shock assembly and torque the mounting bolts
to specification.
99 a

=T
7- Sh

Front Shock Mounting Bolt:

36 ft. lbs. (49 Nm)
87 rt

=T
Rear Shock Mounting Bolt:
a

43 ft. lbs. (58 Nm)

Shock Removal
P

2. If the adjustment collar was moved or replaced, adjust the

spring preload evenly between both front or rear shocks
1. Elevate the front or rear end of the vehicle off the ground (refer to Chapter 2 Maintenance).
to remove shock spring tension.

CAUTION

Severe injury could occur if machine tips or falls.

2. Remove the shock mounting bolts and remove the shock

from the vehicle.

3. Replace the shock, compression spring or adjustment collar

as required (see Shock Replacement).

5.16
 BODY / SUSPENSION / STEERING
REAR SWING ARM
Exploded View
72 ft. lbs.
(98 Nm)
7 ft. lbs.
(10 Nm) 72 ft. lbs. Replace if Removed
(98 Nm) 22 ft. lbs.
(30 Nm)

86 m
84 in. lbs. 7 ft. lbs.
(10 Nm) 16 ft. lbs. 72 ft. lbs.

56 co
(22 Nm) (10 Nm)
(98 Nm)

36 ft. lbs. 5
9- k.
(49 Nm)
r 16 ft. lbs.
(22 Nm)
16 ft. lbs.
84 in. lbs.
(22 Nm)
(10 Nm)
72 ft. lbs.
99 a
(98 Nm)

36 ft. lbs.
7- Sh

(49 Nm)

72 ft. lbs.
(98 Nm)
16 ft. lbs.
87 rt

(22 Nm)
72 ft. lbs.
(98 Nm)
a
P

5.17
BODY / SUSPENSION / STEERING
Swing Arm Removal 4. Loosen all (4) axle housing bolts.

1. Remove the plastic tie strap retaining the brake lines to the 5. Loosen the outer jam nut and back off the inner adjustment
swing arm. nut on each chain adjuster to remove tension.

Loosen

86 m
Remove Loosen

56 co
2. Slightly elevate the rear end of the vehicle off the ground. 6. Using mechanics wire or a long Panduit strap, tie the chain
tensioner back out of the way.

9- k. CAUTION

Severe injury could occur if machine tips or falls.

r
Chain
99 a
3. Remove the (2) bolts retaining the rear brake caliper and Tensioner
remove the caliper from the disc. CAUTION: Do not hang
7- Sh

the caliper by the brake line. Use a strap or mechanics wire

to hang caliper to prevent damage to the brake line.
87 rt

7. Remove the upper shock mounting bolts.

a

Remove
P

Remove

5.18
 BODY / SUSPENSION / STEERING
8. Remove the (2) swing arm through-bolts. 3. Install a new tie strap to retain the brake lines.

Tie Strap

86 m
56 co
NOTE: Lower the vehicle slightly to ease removal. 4. Line up the upper shock eyelets with the frame mounting
holes and install the mounting bolts. Torque the rear shock
9. Remove the drive chain from the front drive sprocket mounting bolts to specification.

10. Roll the swing arm assembly out from the vehicle.
=T
5
9- k.
r
Rear Shock Mounting Bolts: 43 ft. lbs. (58 Nm)

5. Install the rear brake caliper and torque the mounting bolts
99 a
to specification.
7- Sh

=T
Brake Caliper Bolts: 18 ft. lbs. (24 Nm)

6. Remove the wire or strap retaining the chain tensioner and

87 rt

allow it to return to its normal position.

11. Refer to the Axle Housing Removal procedure, if 7. Lower the rear end of the vehicle and perform the chain
a

replacing the swing arm. adjustment procedure (see Chapter 2 Maintenance).

P

8. Be sure the rear axle housing fasteners are torqued to

Swing Arm Installation specification.

1. Roll the swing arm assembly back into place and install the
drive chain over the front sprocket. =T
2. Line up the swing arm with the frame and install the Rear Axle Housing Bolts: 72 ft. lbs. (98 Nm)
through-bolts. Torque the swing arm bolts to specification.

=T
Swing Arm Mounting Bolts: 72 ft. lbs. (98 Nm)

5.19
BODY / SUSPENSION / STEERING
REAR AXLE 6. Remove the (2) fasteners retaining the LH axle housing to
the swing arm.
Axle Housing Removal
1. Elevate the rear end of the vehicle far enough off the
ground to remove the wheel(s).

Remove
CAUTION

Severe injury could occur if machine tips or falls.

2. Loosen and remove the (4) wheel nuts

86 m
Loosen

56 co
7. Remove the LH axle housing and spacer from the axle (see
Axle Housing Service if replacing the bearing or seal).

Spacer
9- k.
r
99 a
7- Sh

3. Remove the dust boot to access the rear hub retaining nut.

4. Remove the cotter pin, castle nut and dome washer.

Axle Housing
Nut
87 rt

8. Remove the (2) bolts retaining the rear brake caliper and
remove the caliper from the disc. CAUTION: Do not hang
a

the caliper by the brake line. Use a strap or mechanics wire

to hang caliper to prevent damage to the brake line.
P

Washer
Cotter Pin

Remove
5. Loosen the outer jam nut and back off the inner adjustment
nut on each chain adjuster to remove tension.

5.20
 BODY / SUSPENSION / STEERING
9. Remove the (2) axle retaining nuts and the (2) fasteners Axle Housing Installation
retaining the RH axle housing to the swing arm (see Axle
Housing Service if replacing the bearing or seal). 1. Install each axle housing and fasteners. Do not torque the
fasteners at this time

NOTE: Remember to install the chain adjusters onto

Remove
the lower axle housing fasteners and install the
spacer behind the LH axle housing.

Spacer

86 m
56 co
Axle Housing Service
Axle Housing 5
1.

2.
9- k.
Remove the seal from the housing.

Remove the circlip using a snap ring pliers.

r
2. Install the axle retaining nuts onto the RH side of the axle.
Torque the inner retaining nut to 7 ft. lbs. (10 Nm), then
3. Press the bearing out of the axle housing. torque the outer jam nut to 72 ft. lbs. (98 Nm).
99 a

6HDO 7 ft. lbs.

&LUFOLS (10 Nm)
7- Sh
87 rt
a

%HDULQJ 72 ft. lbs.

(98 Nm)
P

$[OH+RXVLQJ
/+6KRZQ
=T
4. Press a new bearing into the axle housing and install a new RH Axle Housing Retaining Nuts:
circlip. Inner Nut: 7 ft. lbs. (10 Nm)
Outer Nut: 72 ft. lbs. (98 Nm)
5. Press the new seal into the axle housing until it is flush with
the housing. 3. Install the rear brake caliper and torque the mounting bolts
to specification.

=T
Brake Caliper Bolts: 18 ft. lbs. (24 Nm)

5.21
BODY / SUSPENSION / STEERING
4. Install the rear hub, dome washer, and nut on each side. 2. Remove the axle clamp bolts from each side and remove
the clamp brackets to allow for axle removal.
NOTE: Be sure the dome on the washer is facing
out, away from the rear hub.
Clamp
Bracket
40 ft. lbs.
(55 Nm)

Remove

86 m
RH Side
Washer Shown
Replace

56 co
3. Remove the rear fastener and front lower fastener retaining
the chain guard.
5. Torque the rear hub retaining nut to specification and install
a new cotter pin on each side. 4. Pull the chain tensioner back to allow enough slack in the
chain to remove it from the front drive sprocket.
9- k.
r
=T 5. Rotate the RH axle housing to allow the axle assembly to
be removed.
Rear Hub Castle Nut: 40 ft. lbs. (55 Nm)
6. Carefully remove the axle assembly from the swing arm.
99 a
6. Install the rear wheels, wheel nuts and dust boots. Torque
the wheel nuts to specification.
7- Sh

=T
Wheel Nuts: 27 ft. lbs. (37 Nm)
87 rt

7. Lower the rear end of the vehicle and perform the chain
adjustment procedure (see Chapter 2 Maintenance).
a

8. Be sure the rear axle housing fasteners are torqued to

specification.
P

=T
Rear Axle Housing Bolts: 72 ft. lbs. (98 Nm) Axle Installation
1. Reverse the Axle Removal procedure.
Axle Removal 2. Torque the axle clamp bolts to specification.
1. Remove the axle housing fasteners (see Axle Housing
Removal). =T
NOTE: There is no need to remove the large axle
Axle Clamp Bolts:
nuts retaining the RH axle housing if removing the
36 ft. lbs. (49 Nm)
rear axle assembly from the swing arm.
3. Install the rear axle housing fasteners (see Axle Housing
Installation).

5.22
 BODY / SUSPENSION / STEERING
STEERING
Steering Wheel / Steering Shaft / Steering Gearbox Assembly Exploded View
11 ft. lbs.
(15 Nm)

86 m
10 ft. lbs.

56 co
(13.5 Nm)

5
9- k.
r
16-17 ft. lbs.
99 a
(22-23 Nm)
16-17 ft. lbs.
7- Sh

(22-23 Nm)
87 rt
a
P

29-37 ft. lbs.

(39-50 Nm)

17 ft. lbs.
(23 Nm)

21 ft. lbs.
(28 Nm)

5.23
BODY / SUSPENSION / STEERING
Steering Shaft Removal 4. Slide the pivot tube assembly off the steering shaft and
remove the shaft out of the vehicle from under the dash.
1. Remove the upper pinch bolt located under the steering
pivot tube assembly.
Steering Shaft Installation
1. Reinstall the steering shaft.

2. Install the shaft to the steering gearbox assembly and install

the pinch bolt. Torque the pinch bolt to specification.

=T

86 m
Steering Shaft Pinch Bolt:
29-37 ft. lbs. (39-50 Nm)

56 co
3. Ensure the wheels are pointing straight ahead. Install the
pivot tube stub shaft into the upper portion of the steering
shaft with the steering wheel properly aligned.
2. Remove the lower pinch bolt located at the steering gearbox
assembly. 4. Install the pivot tube bolts and steering wheel adjustment
9- k.
r bolt. Torque the bolts to specification.

=T
99 a
Steering Pivot Tube Bolts:
16-17 ft. lbs. (22-23 Nm)
7- Sh

=T
Steering Wheel Adjustment Bolt:
10 ft. lbs. (13.5 Nm)
87 rt

5. Install the upper pinch bolt and torque to specification.

3. Remove the adjustment bolt and pivot bolts retaining the
a

steering pivot tube assembly to the frame.

=T
P

Steering Shaft Pinch Bolt:

29-37 ft. lbs. (39-50 Nm)

5.24
 BODY / SUSPENSION / STEERING
Steering Gearbox Removal 6. Remove the (3) bolts retaining the steering gearbox to the
frame and remove the gearbox from the vehicle.
1. Remove the steering shaft (see Steering Shaft Removal).
2. Remove the front bumper to ease gearbox removal (see
Front Bumper Removal / Installation).
3. Remove the pinch bolt from the tie rod plate.

86 m
56 co
Steering Gearbox Installation
1. Install the steering gearbox and torque the (3) mounting
bolts to specification.
5
4. 9- k.
Carefully pry up on the tie rod plate and remove it from the
steering gearbox.
r =T
Steering Gearbox Mounting Bolts:
21 ft. lbs. (28 Nm)
99 a
2. Install the brake line under the retainer and securely tighten
the retaining bolt.
7- Sh

3. Align the boss splines on the gearbox stub shaft and the tie
rod plate.

Boss
87 rt

Spline

Boss
Spline
a
P

5. Loosen the brake line retainer and remove the brake line
from the gearbox assembly.

4. Install the tie rod plate. Torque pinch bolt to specification.

=T
Tie Rod Plate Pinch Bolt: 17 ft. lbs. (23 Nm)

5. Install the front bumper if previously removed (see Front

Bumper Removal / Installation).

6. Install the steering shaft (see Steering Shaft Installation).

5.25
BODY / SUSPENSION / STEERING
TIE ROD
Tie Rod End / Tie Rod / Steering Knuckle Assembly Exploded View

86 m
30 ft. lbs.
(41 Nm)

56 co
9- k.
r
99 a
7- Sh
87 rt
a
P

25 ft. lbs.
(34 Nm)

5.26
 BODY / SUSPENSION / STEERING
Tie Rod Removal / Installation 6. After performing the steering toe adjustment, torque the
jam nuts to specification.
Steering tie rods can be replaced by removing the rod-end castle
nut at the tie rod plate and spindle.

1. Elevate the front end of the vehicle.

CAUTION

Severe injury could occur if machine tips or falls.

2. Remove the cotter pin from each rod end castle nut.

86 m
3. Loosen and remove the (2) tie rod end castle nuts and Jam Nut
remove the tie rod from the vehicle.

56 co
4. If replacing the tie rod ends, loosen the jam nut(s) and
replace the end(s). =T
5. Install the tie rod and torque the castle nuts to specification.
Install a new cotter pin in each castle nut.
Tie Rod End Jam Nuts:
5
9- k.
r 12-14 ft. lbs. (17-19 Nm)
99 a
7- Sh

Cotter Pin
87 rt
a

=T
P

Tie Rod End Castle Nuts:

25 ft. lbs. (34 Nm)

NOTE: Refer to Chapter 2 Maintenance for the

steering toe alignment procedure.

5.27
BODY / SUSPENSION / STEERING
WHEELS
Front Wheel Exploded View

86 m
56 co
9- k.
r
99 a
7- Sh

Rear Wheel Exploded View

87 rt
a
P

5.28
 BODY / SUSPENSION / STEERING
Wheel Removal Wheel Installation
1. Position the vehicle on a level surface. 1. Verify the parking brake is still engaged.

2. Set the parking brake and stop the engine.
3. Loosen the wheel nuts slightly. If wheel hub removal is
required, remove the cotter pin and loosen the castle nut
slightly.
4. Elevate the front or rear end of the vehicle off the ground
placing a suitable stand or floor jack under the frame.
2. Install the wheel hub, washer(s), and castle nut, if
previously removed.
3. Place the wheel in the correct position on the wheel hub.
Be sure the valve stem is toward the outside and rotation
arrows on the tire point toward forward rotation.
4. Attach the wheel nuts and finger tighten them.

5. Carefully lower the vehicle to the ground.

CAUTION

86 m
6. Torque the wheel nuts and/or hub nut to the proper torque
specification.
Severe injury could occur if machine tips or falls.

56 co
5. Remove the wheel nuts and remove the wheel. =T
6. If removing the hub, remove the castle nut and washers(s). Wheel Nuts: 27 ft. lbs. (37 Nm)
5
9- k. =T
Front Hub Castle Nut: 40 ft. lbs. (55 Nm)
r
99 a

=T
7- Sh

Rear Hub Castle Nut: 40 ft. lbs. (55 Nm)

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

CAUTION
a

If wheels are improperly installed it could affect

vehicle handling and tire wear. On vehicles with
P

tapered rear wheel nuts, make sure tapered end

of nut goes into taper on wheel.

5.29
BODY / SUSPENSION / STEERING

NOTES

86 m
56 co
9- k.
r
99 a
7- Sh
87 rt
a
P

5.30
 BRAKES
CHAPTER 6
BRAKES
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
BRAKE SYSTEM SERVICE NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
BRAKE NOISE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
HYDRAULIC BRAKE SYSTEM - OVERVIEW OF OPERATION . . . . . . . . . . . . . . . . . . . 6.4

86 m
BRAKE SYSTEM - HYDRAULIC COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
BRAKE BLEEDING / FLUID CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7

56 co
BRAKE PEDAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
PEDAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
BRAKE PEDAL INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
9- k.
PARKING BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
PARKING BRAKE CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
FRONT BRAKE PADS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
r
FRONT PAD REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
FRONT BRAKE PAD ASSEMBLY / CALIPER INSTALLATION. . . . . . . . . . . . . . . . . . . 6.12
99 a
FRONT BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
7- Sh

DISC REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13

FRONT CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
FRONT CALIPER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
REAR BRAKE PAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
87 rt

REAR BRAKE PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15

REAR BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
REAR BRAKE PAD ASSEMBLY / CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . 6.17
BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
a

REAR BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18

DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18
6
P

REAR BRAKE DISC REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.18

REAR CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
REAR CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
REAR BRAKE CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.20
MASTER CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22
BRAKES SQUEAL / POOR BRAKE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . 6.22
PEDAL VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22
CALIPER OVERHEATS (BRAKES DRAG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22
BRAKES LOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.22

6.1
BRAKES
GENERAL SPECIFICATIONS
FRONT BRAKE SYSTEM
Item Standard Service Limit
Front Brake Pad Thickness .300 .007" (7.62 .178 mm) .180" (4.6 mm)
Front Brake Disc Thickness .160" (4.05 mm) .138" (3.50 mm)
Front Brake Disc Runout - .010" (.254mm)

REAR BRAKE SYSTEM

Item Standard Service Limit

86 m
Rear Brake Pad Thickness .300 .007" (7.62 .178 mm) .180" (4.6 mm)
Rear Brake Disc Thickness .160" (4.05 mm) .138" (3.50 mm)

56 co
Rear Brake Disc Runout - .010" (.254 mm)

TORQUE SPECIFICATIONS SPECIAL TOOLS

9- k.
Item
r Torque
ft. lbs.
Torque
Nm
Part Number
2870975
Tool Description
Mity Vac Pressure Test Tool
Brake Disc to Hub (Front) 7.0 9.5
99 a
Brake Disc to Hub (Rear) 21.0 28.5
7- Sh

Brake Line Banjo Bolts

14.5 19.6
(Caliper and master cylinder)

Brake Pad Guide Pins (All) 10.0 13.5

87 rt

Brake Pedal Mounting Bracket

15.0 20.0
to Frame

Caliper Mounting Bolts

a

18.0 24.5
(Front and Rear)
P

Master Cylinder to Frame 17.0 23.0

Master Cylinder Reservoir

15 in-lb 1.7
Hose Clamps

Master Cylinder Reservoir

60 in-lb 6.8
Hose Adaptor Clamp

Parking Brake Adjuster Jam

12.0 16.0
Nut

Wheel Nuts, Front 27.0 37.0

Wheel Nuts, Rear 27.0 37.0

6.2
 BRAKES
BRAKE SYSTEM SERVICE NOTES
Disc brake systems are light weight, low maintenance, and perform well in the conditions this vehicle will routinely encounter. There
are a few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function
and maximum pad service life.

Use only genuine Pure Polaris parts.

Do not over-fill the master cylinder fluid reservoir.

Make sure the brake pedal returns freely and completely.

Check and adjust master cylinder reservoir fluid level after pad service.

Clean the master cylinder reservoir cap and the area above and around the reservoir before you remove the cap. Cover the

86 m
reservoir immediately after filling to prevent contamination. Make sure atmospheric vent on reservoir is unobstructed.

Elevate front wheels or rear axle after any brake system service and test for brake drag. Investigate cause if brake drag is

56 co
evident.

Make sure floating caliper move freely on guide pins.

Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely; check for leakage.

9- k.
Perform a brake burnishing procedure after installing new pads to maximize service life.

DO NOT clean brake system components with petroleum based products. Use only approved brake cleaning products.
r
BRAKE NOISE TROUBLESHOOTING
99 a
Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise (squeal caused by vibration). If cleaning
does not reduce the occurrence of brake noise, Permatex Disc Brake Quiet (PN 2872113) can be applied to the back of the pads.
7- Sh

Follow directions on the package. This will keep pads in contact with caliper piston(s) to reduce the chance of squeaks caused by
dirt or dust.

Brake Noise Troubleshooting

87 rt

Possible Cause Remedy

Spray disc and pads with CRC Brakeleen or an equivalent
Dirt, dust, or imbedded material on pads or disc non-flammable aerosol brake cleaner. Remove pads and/or disc
a

hub to clean imbedded material from disc or pads.

Pad(s) dragging on disc (noise or premature pad wear) Adjust (where applicable). Investigate / correct the condition
6
P

Parking brake misadjusted Adjust. See Maintenance chapter.

Master cylinder reservoir overfilled Set to proper level
Master cylinder compensating port restricted Clean compensating port
Master cylinder piston not returning completely Inspect. Repair as necessary
Caliper piston(s) not returning Clean piston(s) seal
Operator error (riding the brake) Educate operator
Loose wheel hub, wheel bearings, brake disc Check wheel, hub, and disc for abnormal movement.
Brake disc warped or excessively worn Replace disc
Brake disc misaligned or loose Inspect and repair as necessary
If noise does not change when brake is applied check other
Noise is from other source (axle, hub, disc or wheel)
sources. Inspect and repair as necessary
Use only Pure Polaris replacement pads. Optional softer or
Wrong pad for conditions
harder pads may be available

6.3
BRAKES
HYDRAULIC BRAKE SYSTEM - OVERVIEW OF OPERATION
The Polaris brake system consists of the following components or assemblies: brake pedal, master cylinder, master cylinder fluid
reservoir, hydraulic brake lines, brake calipers, brake pads, and brake discs, which are secured to the drive line.
When the brake pedal is applied, the master cylinder piston is forced inward. As piston moves inward, pressure is created in the
separate and sealed front and rear brake chambers inside the master cylinder. Pressure travels through the front and rear brake lines
and then to the pistons inside the brake calipers. The caliper pistons are forced outward against the moveable brake pad. When the
pad contacts the brake disc, the floating caliper bracket moves to force the stationary brake pad against the disc, and the resulting
friction reduces brake disc and vehicle speed.
As brake pads wear normally from friction, the caliper pistons move outward to compensate. Fluid from the master cylinder reservoir
fills the additional volume created in the caliper body as the pistons move outward (self adjusting feature).
Fluid level in the reservoir is a critical maintenance item. If fluid level gets too low, air could enter the system and cause poor brake

86 m
performance or even brake system failure. If the fluid level is too high, pressure could build in the brake system causing the brake
pads to drag due to fluid expansion.
Brake fluid and brake system parts expand and contract due to the heating and cooling during normal operation. A very small hole

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called the compensating port, located inside the master cylinder, is opened and closed by the master cylinder piston. When the brake
pedal is released, the piston returns to its rest position and the compensating port is open. This allows expanding or contracting fluid
to move back and forth between master cylinder and fluid reservoir, preventing a buildup of pressure in the system.
It is very important that the master cylinder reservoir have adequate space to allow for fluid expansion. Never overfill the reservoir.
9- k.
Do not fill it beyond the MAX LEVEL line!
When servicing Polaris brake systems use only Polaris DOT 4 Brake Fluid (PN 2872189). WARNING: Once a bottle is opened,
use what is necessary and discard the rest in accordance with local laws. Do not store or use a partial bottle of brake fluid. Brake
r
fluid is hygroscopic, meaning it rapidly absorbs moisture. This property is desirable in order to reduce the chance of corrosion (due
to moisture) in the brake system. But an open container of fluid will absorb moisture from the environment. When brake fluid contains
99 a
moisture the boiling point is reduced, which can lead to early brake fade and the possibility of serious injury. Brake fluid must be
changed with fresh fluid from a sealed container at recommended intervals or if contaminated.
7- Sh

BRAKE SYSTEM - MECHANICAL COMPONENTS

Brake System - Mechanical Components
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12 ft-lb
(16 Nm)
a
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Brake Light Switch Spring

Pedal Return Spring Parking Brake Cable Parking Brake Switch

6.4
 BRAKES
BRAKE SYSTEM - HYDRAULIC COMPONENTS

1 Banjo Bolts (All):

14.5 ft. lbs. (19.6 Nm).
2 Bleed Screws (All):
47 in. lbs. (5.3 Nm)
3 Caliper Mounting Bolts (All):
18.0 ft. lbs. (24.5 Nm).
4 Brake Pad Guide Pins:
12.0 ft. lbs. (16.2 Nm).

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2
60 in-lbs. 4
(6.8 Nm)
3

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15 in-lbs.
(1.7 Nm)
17.0 ft-lbs.
(23.0 Nm)
1

1
9- k.
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LH Front Caliper
Adaptor Clamps
60 in-lbs. (6.8 Nm)
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2 2
7- Sh

Master Cylinder
4

3 1
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a

RH Front Caliper
1 (All Banjo Bolts)
6
P

52 in-lbs.
(5.8 Nm) 3

60 in-lbs.
(6.8 Nm)

Rear Caliper

6.5
BRAKES
BRAKE BLEEDING / FLUID CHANGE Master Cylinder Bleeding (If Required)
4. Remove protective cap from bleed screw and install a box
NOTE: If system is dry (such as if a brake line was
end wrench on front or rear screw. Attach one end of a
replaced) or if a large amount of air is in the system,
clean, clear hose on bleed screw and place the other end in
start by bleeding the master cylinder (both front and
a clean container. Be sure hose fits tightly.
rear bleed screws) then bleed the calipers.

CAUTION

Always wear safety glasses.

CAUTION

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Brake fluid will damage finished surfaces. Do not
allow brake fluid to come in contact with finished

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F
surfaces. This procedure should be used to R
change fluid or bleed brakes during
regular maintenance.
5. Have an assistant slowly pump the brake pedal until
1.
9- k.
Clean master cylinder reservoir cover and surrounding
area under front left cab thoroughly to prevent debris from
entering the reservoir. Remove the cover. 6.
pressure builds, then hold light pressure on the pedal.

While assistant is holding light pressure, open bleed screw

until brake pedal travels to the end of its stroke and no more
r
fluid moves into the clear hose attached to the bleed screw.
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Close bleed screw, then have assistant release brake pedal.

NOTE: Do not release brake pedal before bleed

7- Sh

screw is tight, or air may be drawn into the system.

7. Repeat Steps 5 and 6 until only clean fluid appears in the

hose and all air has been purged. Add fluid to reservoir if
necessary to keep fluid at the MAX level.
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CAUTION
a

Maintain at least 1/2"(1.27 cm) of brake fluid in

P

2. If changing brake fluid, remove as much old fluid from the reservoir at all times to prevent air from
reservoir as possible with a Mity Vac pump or similar entering the master cylinder.
tool. Do not actuate the brake pedal when reservoir is low.
8. Tighten bleed screw securely and remove hose. Torque
bleed screw to 47 in. lbs. (5.3 Nm). Install protective cap.
Mity Vac (PN 2870975)
9. Repeat Steps 4 - 8 for remaining master cylinder bleed
screw, then proceed to caliper bleeding procedure.
3. Add clean brake fluid from a sealed container to the
indicated MAX level of reservoir. Set reservoir cover
loosely in place to keep debris out, but do not secure it.

Polaris DOT 4 Brake Fluid

(P/N 2872189)

6.6
 BRAKES
Caliper Bleeding BRAKE PEDAL
10. The bleeding process is the same for the calipers as for the
master cylinder, using the bleed screw on each caliper. Brake Pedal Removal
Perform Steps 4-8 for each front caliper.
1. Refer to Fig. 2 for pedal removal.
2. Disconnect both springs (A).

C
F
D

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G

CAUTION A B E

9- k.
Maintain at least 1/2"(1.27 cm) of brake fluid in
the reservoir at all times to prevent air from
r
entering the master cylinder. 3.
4.
Remove cotter pin (B) and clevis pin (C).
Remove E-clip (D) and washer (E) from pedal mount.
11. Perform Steps 4-8 for the rear caliper.
5. Remove pedal assembly with bushings (F) and sleeve (G).
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Visually inspect pedal, bushings, and sleeve for wear and
replace as required.
7- Sh

Open
Pedal Installation
1. Apply Polaris Premium All Season grease to pivot post
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and install pedal with bushings and sleeve.

Close
2. Install washer and a new retaining E-clip.
a

3. Align pedal with master cylinder clevis and install pin.

4. Install washer and a new cotter pin.
6
P

12. Add brake fluid to MAX level inside reservoir. 5. Connect brake light switch spring and pedal return spring.
6. Push and release brake pedal to be sure linkage rod and
Master Cylinder Fluid Level pedal mechanism returns fully when pedal is released.
7. Inspect brake pedal travel. See Brake Pedal Inspection /
Between the MIN and MAX line shown Adjustment on page 6.8.
on the reservoir.
Brake Pedal Travel:
13. Install master cylinder reservoir cover securely. 1/2-3/4 (12-18mm)
14. Field test the vehicle at low speed before putting into
service. Check for proper braking action and inspect pedal
travel.
15. Perform brake pedal inspection. See Brake Pedal
Inspection / Adjustment on page 6.8.
16. Check brake system for fluid leaks.

6.7
BRAKES
Brake Pedal Inspection / Adjustment PARKING BRAKE
1. Push and release brake pedal. Verify master cylinder
actuator rod and pedal mechanism returns fully and pedal Parking Brake Adjustment
contacts pedal stop (on left side of pedal pivot bracket) 1. Place vehicle on a flat, level surface.
when released.
2. Shift transmission into Neutral.
2. If pedal does not return freely, remove pedal and lubricate.
parts. See Brake Pedal Removal on page 6.7. 3. Carefully lift rear tires off the ground with a stable platform
jack, or set vehicle on stable jack stands.
Pedal Free Play and Pedal Travel 4. Loosen jam nut (A) on parking brake adjustment bolt.
1. Place vehicle on a flat, level surface. 5. While rotating the rear wheels by hand, tighten the
adjustment bolt (B) until significant brake drag is detected.
2. Shift transmission into Neutral.

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6. Back the adjustment bolt out 1/4 turn.
3. Carefully lift rear tires off the ground with a stable platform 7. Hold adjustment bolt in place and tighten jam nut securely
jack, or set vehicle on stable jack stands. against lever arm.

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8. Check parking brake lever movement. Verify the rear
4. While rotating the rear wheels by hand, measure brake wheels rotate freely with the parking brake off (parking
pedal movement before any braking occurs (Free Play), and brake lever is in the DOWN position), and that the vehicle
record. will not move when the parking brake is applied (lever in
5. 9- k.
Measure the total brake pedal movement before brake is
firmly applied (Pedal Travel).
r 9.
the UP position).
Verify the park brake lever stays in the UP position when
brake is fully applied.
6. The pedal should move at least 1/4 inch before any braking
occurs, and no more than 1 - 1 1/2 inch before brakes are
99 a
firmly applied. See Fig.1.
7- Sh

Pedal Travel
1 - 1 1/2 in. (25-37mm)

A
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B
a
P

Fig. 1 1/4 in. (6mm) Minimum

7. If pedal travel is excessive, or if brake pedal feels spongy

and not firm, inspect brake fluid level in the reservoir,
inspect system for leaks, inspect caliper mounting bolts,
disc mounting bolts to be sure they are tight, and bleed the
brake system. See BRAKE BLEEDING / FLUID
CHANGE on page 6.6. Hold Adjuster Bolt While
Tightening Jam Nut

6.8
 BRAKES
Parking Brake Cable Replacement 7. Note location of tie strap for assembly. Strap (E) includes
parking brake cable and rear brake line. Strap (F) includes
1. Release parking brake. only park brake cable. Cut all tie straps.
2. Loosen jam nut (A) and back out adjuster bolt (B) a few 8. Cable routes on passenger side of shift cables (G) as shown.
turns (counterclockwise).
3. Pull cable casing forward and slide cable out of holder, then
remove cable from lever arm.

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E

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B
A

4. 9- k.
Cut tie strap (C). Release cable from guide (D).
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99 a

G
7- Sh

D
9. Hold cable adjuster nut (H) (10mm wrench). Loosen the
87 rt

C jam nut (I) (12mm wrench), and turn adjuster nut fully
inward to gain maximum cable slack.
NOTE: Step 9 is only necessary if more slack is
a

required for removal in Step 10 and Step 11.

WARNING
6
P

Use care when supporting vehicle so that it

does not tip or fall. Severe injury or death may occur
if the vehicle tips or falls.

NOTE: If you do not have the proper equipment to

safely lift and securely support the vehicle, refer to
Chapter 5 to remove the seats, rear access panel,
and battery tray panel to access the parking brake
cable and brake lever from the top.
H
5. Have an assistant help you tip the vehicle toward the
passenger side, or secure vehicle to a lift that will allow
access to the underside.
6. Secure the vehicle in position and place jack stands under I
the front and rear areas of the frame.

6.9
BRAKES
10. At caliper end of parking brake cable, have an assistant
push inner cable into the outer cable casing as far as
possible to maximize slack at the lever end.

1. Hold

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2. Push

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11. Remove cable from lever arm.

9- k.
12. Pull cable out of holder on frame.

Cable Installation
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99 a
1. On a new cable or if adjuster was loosened upon removal,
turn cable adjuster out until approximately 3/4 (20mm) of
thread is exposed. Screw jam nut against the adjuster nut.
7- Sh

Hold adjuster and tighten jam nut securely.

2. Route cable to passenger side of shift cables, and through

holder on park brake lever bracket.
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3. Pull inner cable and attach it to parking brake lever arm.

4. Refer to routing photos shown in the cable removal process

a

to route the cable along the frame rails and out the right side
near swingarm pivot.
P

5. Secure cable to frame with new tie straps.

6. Carefully remove supports and lower the vehicle.

7. Route cable through guide at front of swingarm and back

to rear caliper.

8. Secure cable to swingarm with rear brake line.

9. Connect caliper end of the cable.

10. Adjust parking brake. See Parking Brake Adjustment on

page 6.8.

6.10
 BRAKES
FRONT BRAKE PADS 6. Remove brake pad guide pin loosened in Step 3.

Front Pad Removal 7. Push mounting bracket (B) inward (toward piston side of
caliper).
1. Elevate and support front of vehicle. 8. Slide stationary pad out (away from bracket) and off the
threaded post, then rotate pad until it can be removed from
CAUTION remaining guide pin (C).

Use care when supporting vehicle so that it

does not tip or fall. B
Severe injury may occur if machine tips or falls.

2. Remove front wheel.

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3. Loosen one of two brake pad guide pins (A) on caliper one
full turn.

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C
A
9- k. 9. Remove inner pad.
10. Inspect caliper piston seals for leakage. Replace caliper
assembly if leaking.
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99 a

Pad Inspection
7- Sh

1. Measure thickness of each pad. Replace pads as a set if

4. Remove caliper mounting bolts slide caliper off disc. either is worn beyond the service limit.
NOTE: When removing caliper, use care not to
damage brake line. Support caliper to avoid kinking
87 rt

or bending brake line.

5. Slowly push caliper piston into caliper bore, using a
C-clamp or locking pliers with pads installed.
a

Measure
6
P

Thickness

Front Brake Pad Thickness

New: .300 .007 (7.6 mm .178 mm)
Service Limit: .180 (4.6 mm)

NOTE: Brake fluid will be forced through

compensating port into master cylinder fluid
reservoir when piston is pushed back into caliper.
Remove excess fluid from reservoir as required.

6.11
BRAKES
Front Brake Pad Assembly / Caliper 4. Install caliper onto front hub. Torque both mounting bolts.
Installation 30 ft. lbs.
(40 Nm)
1. Lubricate mounting bracket pins with a light film of
Polaris Premium All Season Grease (PN 2871423), and
install rubber dust boots. Be sure dust boots are fully
seated on caliper bracket and on caliper body.

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=T

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Caliper Mount Bolt Torque:
18 ft. lbs. (24.5 Nm)

5. Torque brake pad guide pin(s) that were loosened or

2. 9- k.
Push mounting bracket as far as possible toward the piston
side of the caliper. Install pads with friction material facing
each other.
r removed.

10 ft-lbs. (13.5 Nm)

WARNING
99 a

If brake pads are contaminated with grease, oil,

7- Sh

or liquid soaked do not use the pads.

Use only new, clean pads.

3. Screw guide pin (A) through both pads and on to threaded

87 rt

bracket post. Install pin until it stops against bracket (B).

Pads must slide freely on the pin. The guide pin will be fully
tightened after caliper is installed. Be sure boots (C) are
a

seated on caliper and on bracket.

6. Slowly pump brake pedal until pressure builds. Maintain at
least 1/2 inch (12.7 mm) of brake fluid in reservoir to
P

prevent air from entering the brake system.

B 7. Rotate wheel hub and verify the hub turns freely without
brake drag.
8. Verify fluid level in reservoir is up to MAX line inside
reservoir and install reservoir cap.
9. Install wheel and torque wheel nuts.

A =T
C

Front Wheel Nut Torque:

27 ft. lbs. (37 Nm)

10. Perform the Brake Burnishing Procedure to maximize pad

service life and minimize noise. See Brake Burnishing
Procedure on page 6.18.

6.12
 BRAKES
FRONT BRAKE DISC Disc Replacement
1. Remove front wheel and brake caliper. See Front Pad
Disc Inspection
Removal on page 6.11.
1. Visually inspect disc for scoring, scratches, or gouges.
Replace the disc if any deep scratches are evident. 2. Remove hub assembly. Refer to Chapter 5.

2. Use a 0-1 (0-25mm) micrometer to measure disc thickness 3. Remove (6) bolts and disc from hub.
at multiple locations around pad contact surface. Replace
disc if worn beyond service limit at any measurment point. 7 ft. lbs. (9.5 Nm)

X
X

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X X

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X X

X
X
4. Clean the wheel hub mating surface and install new disc on
9- k.
r
Brake Disc Thickness
5.
wheel hub.

Install new bolts and torque to 7 ft. lbs. (9.5 Nm).

New: .160 (4.05 mm)

CAUTION
99 a
Service Limit: .138 (3.50 mm)
7- Sh

Always use new brake disc mounting bolts. The

Brake Disc Thickness Variance bolts have a pre-applied locking agent which is
destroyed upon removal.
Service Limit .002 (.051 mm)
difference between measurements 6. Install wheel hub assembly. Refer to Chapter 5.
87 rt

7. Install front brake caliper (See Front Brake Pad Assembly

/ Caliper Installation on page 6.12.) and pump brake pedal
a

3. Mount a dial indicator and measure disc runout. Slowly to regain pressure and set pads against disc.
rotate the disc and read total runout on the dial indicator.
6
P

Replace the disc if runout exceeds service limit.
Brake Disc Runout
Service Limit .010 (.254 mm)
8. Field test unit for proper braking action before putting into
service. Inspect for fluid leaks and firm brakes. Make sure
the brake is not dragging when pedal is released. If the brake
drags, re-check assembly and installation.

6.13
BRAKES
FRONT CALIPER 4. Remove caliper mounting bolts and slide caliper off disc.

Front Caliper Removal

NOTE: The caliper is not serviceable. Each caliper
can be replaced as an assembly.

1. Elevate and safely support front of vehicle.

2. Remove (4) wheel nuts and front wheel.

CAUTION

Use care when supporting vehicle so that it does not

86 m
tip or fall. Severe injury may occur.

3. Clean caliper, brake line, and banjo bolt before removal,

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and note how front brake lines are routed and secured. 5. Place a container below caliper to catch brake fluid and
remove brake line from caliper. Immediately cover and seal
end of brake line to prevent contamination.
6. Remove two caliper mounting bolts and caliper assembly
from front hub.
9- k. Caliper Installation
1. Separate brake pads and slide over brake disc. Align
r
caliper mounting holes and install bolts. Torque mounting
99 a
bolts to specification.
2. Place new sealing washers on each side of brake line banjo
Line Guides
7- Sh

fitting and install banjo bolt.

3. Orient brake line to proper angle and torque to
specification.

18 ft-lb. (24.5 Nm)

87 rt
a
P

Driver Side Shown

14.5 ft-lb. (19.6 Nm)

=T
Caliper Mount Bolt Torque:
18 ft. lbs. (24.5 Nm)

Brake Line Banjo Bolt Torque:

Passenger Side Driver Side
14.5 ft. lbs. (19.6 Nm)

6.14
 BRAKES
4. Bleed the brake system. See BRAKE BLEEDING / 4. Remove caliper mounting bolts (A). Lift caliper off disc.
FLUID CHANGE on page 6.6.
NOTE: When removing caliper, be careful not to
5. Install wheel and torque wheel nuts to specification. damage brake line. Support caliper so as not to kink
or bend brake line.

=T
Front Wheel Nut Torque: A
27 ft. lbs. (37 Nm)

NOTE: If new brake pads are installed, brake

burnishing is recommended. See Brake Burnishing

86 m
Procedure on page 6.18.

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REAR BRAKE PAD
Rear Brake Pad Removal
5. Push caliper piston into the caliper bore slowly using a C-
1. 9- k.
Elevate and support rear of vehicle. clamp or locking pliers with pads installed.
NOTE: NOTE: It may be necessary to back the
CAUTION parking brake adjuster screw out a few turns.
r
99 a
Use care when supporting vehicle so that it
does not tip or fall.
7- Sh

Severe injury may occur if machine tips or falls.

2. Remove rear wheel.

3. Loosen the upper brake pad guide pin about 1 turn before
removing caliper.
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a

6
P

NOTE: Brake fluid will be forced through

compensating port into master cylinder fluid
reservoir when piston is pushed back into caliper.
Remove excess fluid from reservoir as required.

6.15
BRAKES
6. Remove brake pad guide pin (B) loosened in Step 3. Rear Brake Pad Inspection
1. Measure the thickness of the pad material. Replace pads if
worn beyond the service limit.

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Measure
Thickness

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7. Slide outer pad toward outside of caliper body until it clears
the threaded stud. Rotate pad and remove. Rear Brake Pad Thickness
New .300 .007 (7.6 mm .178 mm)
Service Limit .180 (4.6 mm)
9- k.
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99 a
7- Sh
87 rt

8. Slide inner pad toward outside of caliper body until it clears

the threaded stud. Rotate pad and remove.
a
P

9. Inspect caliper piston seals for signs of brake fluid leakage.

Replace caliper if leaking.

6.16
 BRAKES
Rear Brake Pad Assembly / Caliper 4. Install caliper and torque mounting bolts to specification.
Installation
1. Lubricate mounting bracket pins with a light film of
Polaris Premium All Season Grease (PN 2871423), and
install rubber dust boots. Be sure dust boots are fully
seated on caliper bracket and on caliper body.

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=T
Rear Caliper Mount Bolt Torque:
18 ft. lbs. (24.5 Nm)

2. 9- k.
Push mounting bracket as far as possible toward the piston
side of the caliper. Install pads with friction material facing
each other.
r
5. Torque brake pad guide pin(s) that were loosened or
removed.
99 a
WARNING 10 ft-lbs. (13.5 Nm)
7- Sh

If brake pads are contaminated with grease,

oil, or liquid soaked do not use the pads.
Use only new clean pads.

3. Screw guide pin (A) through both pads and on to threaded

87 rt

bracket post. Install pin until it stops against bracket (B).

Pads must slide freely on the pin. The guide pin will be fully
tightened after caliper is installed. Be sure boots (C) are
a

seated on caliper and on bracket.

6
P

=T
B
Brake Pad Guide Pin Torque:
10 ft. lbs. (13.5 Nm)

6. Slowly pump the brake pedal until pressure builds.

A C Maintain at least 1/2 inch (12.7 mm) of brake fluid in the
reservoir to prevent air from entering the brake system.

7. Adjust parking brake. See Parking Brake Adjustment on

page 6.8.

6.17
BRAKES
8. Verify fluid level in reservoir is up to the MAX line inside
reservoir and install reservoir cap. Brake Disc Thickness Variance

Master Cylinder Fluid Service Limit .002 (.051 mm)

difference between measurements
Up to MAX line inside reservoir
3. Mount a dial indicator and measure disc runout. Slowly
9. Install wheel and torque wheel nuts.
rotate the disc and read total runout on the dial indicator.
Replace the disc if runout exceeds specifications.
=T
Rear Wheel Nut Torque: Brake Disc Runout
Service Limit .010 (.254 mm)

86 m
27 ft. lbs. (37 Nm)

Rear Brake Disc Replacement

Brake Burnishing Procedure

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1. Remove rear brake caliper. See Rear Brake Pad
It is required that a burnishing procedure be performed after Removal on page 6.15.
installation of new brake pads to extend service life and reduce
2. Refer to Rear Axle Removal (Chapter 5) to replace the rear
noise.
brake disc.
9- k.
Start machine and slowly increase speed to 25 mph. Gradually
apply brakes to stop machine. Allow pads and disc to cool
sufficiently during the procedure. Do not allow pads or disc to
r
=T
become hot or warping may result. Repeat this procedure 10
Rear Brake Disc:
times.
21 ft. lbs. (28.5 Nm)
99 a

REAR BRAKE DISC

7- Sh

Disc Inspection CAUTION

1. Visually inspect disc for scoring, scratches, or gouges. Always use new brake disc mounting bolts. The
Replace the disc if any deep scratches are evident. bolts have a pre-applied locking agent which is
87 rt

destroyed upon removal.

2. Use a 0-1 micrometer and measure the disc thickness at
eight different points around the pad contact surface.
3. Install rear brake caliper. See Rear Brake Pad Assembly /
Replace disc if worn beyond service limit.
a

Caliper Installation on page 6.17.

X
X 4. Field test unit for proper braking action before putting into
P

service. Inspect for fluid leaks and firm brakes. Make sure
the brake is not dragging when pedal is released. If the brake
X X drags, re-check assembly and installation.
X X
Side
X View
X
Measure
Thickness

Brake Disc Thickness

New: .160 (4.05 mm)
Service Limit: .138 (3.50 mm)

6.18
 BRAKES
REAR CALIPER SERVICE 5. Front routing and clamp shown below.

Rear Caliper Removal

NOTE: The caliper is not serviceable. The caliper
must be replaced as an assembly.
1. Elevate and safely support rear of vehicle.
2. Remove right wheel.

CAUTION

Use care when supporting vehicle so that it does not

86 m
tip or fall. Severe injury may occur.

3. Clean caliper, brake line, and banjo bolt before removal,

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and note how rear brake line fitting is oriented on caliper.
If brake line is being replaced, note how brake line is routed
and secured.

9- k.
r 6. Remove two bolts and separate parking brake lever arm
assembly from caliper or see NOTE below.
99 a
7- Sh

Brake line with park

brake cable.
87 rt

4. Tie straps - secure brake line with throttle cable in areas (A).
a

Secure with parking brake cable to frame in area (B).

NOTE: The parking brake cable can be

6
P

disconnected by loosening jam nut (C) and backing

out adjuster bolt (D) a few turns.

C
A B

6.19
BRAKES
7. Remove two caliper mounting bolts and caliper assembly.
8. Place a container below caliper to catch brake fluid and
remove brake line from caliper. Immediately cover and seal
end of brake line to prevent contamination.
2. Bleed rear brake system. See BRAKE BLEEDING /
FLUID CHANGE on page 6.6.
3. Attach parking brake cable to lever arm with one washer
(A) on each ends of spring. If lever arm plate was removed,
install plate and torque bolts (B) to 12 ft-lbs. (16 Nm).

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B

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Rear Brake Caliper Installation
1.
9- k.
Install caliper and torque mounting bolts to specification.
r
18 ft-lb. (24.5 Nm)
4.

5.
Adjust parking brake. See Parking Brake Adjustment on
page 6.8.

Verify fluid level in reservoir is up to the MAX line inside

reservoir and install reservoir cap.
99 a

Master Cylinder Fluid

7- Sh

Up to MAX line inside reservoir

6. Install wheel and torque wheel nuts.

87 rt

=T
14.5 ft-lb. (19.6 Nm)
Rear Wheel Nut Torque:
a

27 ft. lbs. (37 Nm)

=T 7. Field test unit for proper braking action before putting into
P

service. Inspect for fluid leaks and firm brakes. Make sure
Rear Caliper Mount Bolt Torque: the brake is not dragging when pedal is released. If the brake
18 ft. lbs. (24.5 Nm) drags, re-check assembly and installation.

=T
Brake Line Banjo Bolt Torque:
14.5 ft. lbs. (19.6 Nm)

6.20
 BRAKES
MASTER CYLINDER 5. Remove clip (C) and disconnect brake actuator rod clevis
from brake pedal.
Removal
NOTE: The master cylinder is not serviceable but can be 6. Remove the two mounting fasteners (D) that secure the
replaced as an assembly. master cylinder to the frame.
1. Clean master cylinder reservoir cover and surrounding
area under front left cab thoroughly to prevent debris from
entering the reservoir. Remove the cover.

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D 17.5 ft-lb. (23.0 Nm)

2.
9- k.
Draw as much fluid as possible from the reservoir to
minimize spillage.
r Installation
1. Reverse Steps 1-5 for master cylinder installation.
Refer to the torque specifications in the removal steps.
CAUTION Install new sealing washers on brake lines.
99 a
2. After installing the master cylinder, perform the following:
Brake fluid will damage finished surfaces.
Do not allow brake fluid to come in contact Fill the reservoir with Polaris Dot 4 Brake Fluid (PN
7- Sh

with finished surfaces. 2872189) from a new, sealed container.

3. Place a container under the master cylinder to catch brake
Bleed the master cylinder and both front and rear brake
fluid. Loosen hose clamps (A) and remove hoses from hose
lines and calipers. See BRAKE BLEEDING / FLUID
adaptors. Drain remaining fluid from reservoir and hoses.
CHANGE on page 6.6.
87 rt

Immediately cover and seal ends of supply hoses to prevent

contamination. Inspect pedal free play and pedal travel. See Brake
4. Remove front and rear brake line banjo bolts (B). Pedal Inspection / Adjustment on page 6.8.
a

Immediately cover and seal ends of brake lines to prevent

contamination. Test brake system for proper function before returning
the vehicle to service.
6
P

NOTE: Note brake line locations on master cylinder.

NOTE: Dispose of fluid properly. Do not re-use.

A 15 in-lb. (1.7 Nm)

B 14.5 ft-lb. (19.6 Nm)

6.21
BRAKES
TROUBLESHOOTING

Brakes Squeal / Poor Brake Performance Parking Brake Drags or Ineffective Brake
Air in system Improper adjustment

Water in system (brake fluid contaminated) Rear brake pads worn

Caliper or disc misaligned or loose Rear caliper misaligned, damaged, or improperly

assembled
Caliper dirty or damaged
Rear caliper bracket loose
Brake line damaged or lining ruptured
Parking brake cable not returning freely

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Worn disc or bent disc
Parking brake cam arm not returning
Worn friction pads
Broken, missing, or damaged return spring for parking

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Incorrectly adjusted parking brake brake lever or parking brake cam (on rear caliper)
Worn or damaged master cylinder or components Loose or broken caliper mounting bracket,
Brake pads dragging
9- k.
Caliper piston seized

Pedal Vibration
r
Disc damaged, loose, or worn (runout or thickness
99 a
variance exceeds service limit)
7- Sh

Brake pads worn

Loose caliper

Caliper Overheats (Brakes Drag)

87 rt

Compensating port plugged in front or rear chamber of

master cylinder
a

Parking brake applied or misadjusted

Brake pedal binding or unable to return fully

P

Caliper piston(s) not returning properly / binding

Operator riding brakes

Brakes Lock
Mechanical parts sticking (brake pedal, parking brake
lever, etc.)

Caliper pistons sticking

Master cylinder piston sticking

Improper assembly of brake system components

6.22
 CVT / TRANSMISSION
CHAPTER 7
CVT / TRANSMISSION
SPECIFICATIONS / TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
CVT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
CVT MAINTENANCE / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
DRIVE CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
DRIVEN CLUTCH OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
CVT SYSTEM DRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

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CVT OVERHEATING / WATER INGESTION DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . 7.4
CLUTCH (CVT) COVER REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
CLUTCH (CVT) COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
DRIVE BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6

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DRIVE BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
DRIVE BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
DRIVE CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
DRIVE CLUTCH REMOVAL, DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . . 7.7
DRIVE CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
9- k.
DRIVEN CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
rDRIVEN CLUTCH REMOVAL, DISASSEMBLY, INSPECTION. . . . . . . . . . . . . . . . . . . . 7.9
DRIVEN CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
DRIVEN CLUTCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
TRANSMISSION SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
99 a
TRANSMISSION DISASSEMBLY AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
INPUT SHAFT REMOVAL / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
TRANSMISSION MAIN SHAFT ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
7- Sh

TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17

OUTPUT GEAR PINION DEPTH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
OUTPUT SHAFT HOUSING DISASSEMBLY / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . 7.20
7
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7.1
CVT / TRANSMISSION
SPECIFICATIONS / TOOLS
Torque Specifications

TRANSMISSION TORQUE SPECIFICATIONS

Fastener Thread Size Ft. Lbs. (Nm)
CVT Cover Bolts 6mm 6-8 (8-11 Nm)
CVT Drain Plug 6mm 6-8 (8-11 Nm)
Drive Clutch Nut 7/16 - 20 29 (39 Nm)
Driven Clutch Nut 7/16 - 20 40 (55 Nm)

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Output Shaft Cover 6mm 6-8 (8-11 Nm)
Output Shaft
8mm 12 (16 Nm)
Housing Screws

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Oil Drain Bolt
14mm 18 (18-23 Nm)
(Crankcase)
72 (98 Nm)
Output Shaft Collar
- Shimming
Nut 9- k.
Shift Detent Bolt
r
10mm
Required
14 (19 Nm)
Transmission
6mm 6-8 (8-11 Nm)
Cover Bolts
99 a

Special Tools
7- Sh

Output Shaft Collar Nut Socket

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7.2

CVT SYSTEM
WARNING
All CVT maintenance or repairs should be performed
only by a certified Polaris Master Service Dealer (MSD)
technician who has received the proper training and
understands the procedures outlined in this manual.
Because of the critical nature and precision balance
incorporated into the CVT components, it is
absolutely essential that no disassembly or repair be
made without factory authorized special tools and
86 m
service procedures.
The Continuously Variable Transmission (CVT) consists of
three major assemblies: 1) The Drive Clutch; 2) The Driven
56 co
Clutch; and 3) The Drive Belt. The internal components of the
drive clutch and driven clutch control engagement (initial
vehicle movement), clutch upshift and backshift. During the
development of a Polaris RZR, the CVT system is matched first
9- k.
to the engine power curve; then to average riding conditions and
the vehicles intended usage. Therefore, modifications or
variations of components at random are never recommended.
Proper clutch setup and careful inspection of existing
r CVT driven clutches primarily sense torque, but also react to
components must be the primary objective when
99 a
troubleshooting and tuning.
CVT Maintenance / Inspection
7- Sh
Under normal operation the CVT system will provide years of
trouble free operation. Periodic inspection and maintenance is
required to keep the system operating at peak performance. The
following list of items should be inspected and maintained to
87 rt
ensure maximum performance and service life of CVT
components. See CVT Overheating / Water Ingestion
Diagnostics on page 7.4 for more information.
a
1. Drive clutch rollers and sheave bushing.
P
2. Driven clutch rollers, pins, spring, centrifugal friction
shoes, and transmission drive hub.
3. Clutch sheave faces. Clean and inspect for wear.
4. CVT system sealing. The CVT system is air cooled by fins
on the drive clutch. The fins create a low pressure area
around the drive clutch, drawing fresh air in through the
intake duct. The opening for this intake duct is located at a
high point on the vehicle. All connecting air ducts, as well
as the clutch cover, must be sealed to ensure clean air is
being used for cooling the CVT system. This also reduces
the chance of water and other contaminants entering the
CVT area.
CVT / TRANSMISSION
Drive Clutch Operation
Drive clutches primarily sense engine RPM. The major
component which controls shifting function are the shift
centrifugal weights (rollers) inside the moveable sheave.
Whenever engine RPM is increased, centrifugal force is created,
causing the rollers to push against the cam plate and force the
moveable sheave toward the drive belt. This motion pinches the
drive belt between the spinning sheaves and causes it to rotate,
which in turn rotates the driven clutch. If belt speed is sufficient,
centrifugal friction shoes on the driven clutch overcome their
return spring pressure and swing outward against the
transmission drive hub, and the vehicle (if in gear) begins to
move.
At lower RPM, the drive belt rotates low in the drive clutch
sheaves. As engine RPM increases, centrifugal force causes the
drive belt to be forced upward on drive clutch sheaves, changing
the ratio of the drive to driven clutch from low to high.
Driven Clutch Operation
RPM, applying and retracting the friction shoes according to the
forces applied to it from the drive belt, while at the same time
reacting to the torque at the transmission input shaft. If the
torque resistance at the transmission input shaft is greater than
the load from the drive belt, the drive belt is kept at the outer
diameter of the driven clutch sheaves (low ratio).
As engine RPM and horsepower increase, the load from the
drive belt increases, resulting in the belt rotating up toward the
7
outer diameter of the drive clutch sheaves and downward into
the sheaves of the driven clutch. This action, which increases the
driven clutch speed, is called upshifting.
Should the throttle setting remain the same and the vehicle is
subjected to a heavier load, the torque sensing driven clutch will
close, forcing the drive belt back up toward the outer diameter
of the driven clutch. This also forces the belt downward into the
sheaves of the drive clutch. This action, which decreases the
driven clutch speed, is called backshifting.
In situations where loads vary and throttle settings are constant,
the drive and driven clutches are continually shifting to maintain
optimum engine RPM. At full throttle a perfectly matched CVT
system should hold engine RPM at the peak of the power curve.
This RPM should be maintained during clutch upshift and
backshift. In this respect, the CVT system is similar to a power
governor. Rather than vary throttle position, as a conventional
governor does, the CVT system reacts to engine load
requirements by either upshifting or backshifting.
7.3
CVT / TRANSMISSION
CVT System Drying 3. Allow engine RPM to settle to idle speed, shift transmission
to lowest available range and test for belt slippage. Repeat
NOTE: If operating the RZR in wet conditions, be as needed.
sure to check the CVT cover and both air ducts for
proper sealing to reduce the chance of water FRONT CVT Drain Plug
ingestion. Refer to Owners Manual for Safe Riding
Tips and operational guidelines for wet conditions.

1. To drain any water that may be trapped inside the CVT

area, remove the CVT drain plug and O-ring located on the Transmission
bottom of the crankcase and let the water drain out. The Drain Plug
CVT drain plug is shown at right.
Shift Detent
2. To further expel water from the CVT area cover and to dry

86 m
out the CVT system, shift the transmission to neutral and
rev the engine slightly to expel the moisture. This will also Engine Oil
air-dry the belt and clutches. Drain Plug

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CVT Overheating / Water Ingestion Diagnostics
During routine maintenance or whenever CVT system overheating is evident, check the inlet and outlet ducts for obstructions.
9- k.
Obstructions to air flow through the ducts will significantly increase CVT system operating temperatures. Be sure all air ducts and
connecting boots are in good condition and tightly sealed (clamps are in place and tight).
r
CVT Air Duct System
99 a

Air Outlet Duct

7- Sh
87 rt

36 in-lb. (4.0 Nm)

a

Air Inlet Duct Clamps 25 in-lb. (2.8 Nm)

36 in-lb. (4.0 Nm)
P

Clamps 25 in-lb. (2.8 Nm)

Boot

Boot

7.4
 CVT / TRANSMISSION
Clutch (CVT) Cover Removal / Inspection Clutch (CVT) Cover Installation
1. Refer to Chapter 5 to remove the seats, rear access panel, 1. Clean gasket surfaces and install a new gasket with cover
and battery tray panel to access the CVT cover. alignment dowels (E) in place.
2. Remove duct mounting screws (A). Loosen duct clamps 2. Install drive and driven clutch with belt. Refer to clutch
(B) and slide both ducts off cover. installation this chapter.

36 in-lb.
(4.0 Nm) A E

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25 in-lb.
(2.8 Nm) B E

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3. Remove (8) cover screws. Tap cover to loosen.
4. Pull cover out until disengaged from dowel pins. Tip
3. Guide cover through cables and tip in same manner as for

5.
9- k.
bottom of cover up to clear fuel tank.
Carefully guide cover to clear shift cables and tank.
r removal in order to clear fuel tank.
99 a
7- Sh

7
87 rt
a

4. Install cover and tighten all screws to specified torque.

6. Inspect bearing (C). It should rotate freely without binding.
5. Connect inlet and exhaust air ducts (F) with clamps.
P

Replace if rough, if inner race is loose, or if bearing is loose

in the cover. Be sure screws for air duct plate (D) are tight. 6. Install battery tray panel, rear access panel, and seats.

F
F

7.5
CVT / TRANSMISSION
Drive Belt Removal Drive Belt Installation
1. Remove CVT cover. See Clutch (CVT) Cover Removal / 1. Do not attempt to install drive belt with drive clutch
Inspection on page 7.5 stationary sheave installed.
2. Pull moveable (outer) sheave of driven out and push belt
2. Push moveable sheave and spacer sleeve of drive clutch
as far down as possible to create belt slack.
fully inward and measure the amount of exposed splines on
the shaft. Be sure at least 5/16 (mm) of spline is exposed.
If less than 5/16 is exposed, remove clutch and sleeve and
check assembly of components.

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3. Remove drive clutch nut (A). Use a strap wrench to hold
stationary sheave.
9- k.
r
3. Loop belt around driven clutch. Install belt so numbers can
99 a
be read from front of vehicle looking rearward.
7- Sh

B
87 rt

4. Hold inner (moveable) sheave (B) inward when removing

a

belt from drive clutch to prevent rollers from falling out of

the clutch ramps. Remove belt from driven clutch.
P

Drive Belt Inspection

1. Inspect surface of drive belt for uneven wear or grease
deposits. Measure width. Replace belt if worn or glazed.

4. Compress moveable sheave of driven clutch and force belt

as far down as possible. Hold belt down in driven sheaves
and loop front of belt over drive clutch shaft.

CVT Drive Belt Width

Service Limit: .626 (15.9mm)

7.6
 CVT / TRANSMISSION
5. Hold belt as high as possible on sheaves. Install stationary DRIVE CLUTCH SERVICE
sheave over shaft splines. Start nut and tighten finger tight
while moving belt and sheave to ensure FULL engagement Drive Clutch Removal, Disassembly and
of stationary sheave splines with shaft splines. Inspection
1. Remove drive belt. See Drive Belt Removal on page 7.6.

2. Remove stationary sheave from splines of shaft, holding

moveable sheave and spacer inward.

3. Hold moveable sheave, spacer sleeve, and cam plate

together. Slide off crankshaft as an assembly to prevent
rollers from falling out of cam plate.

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6. Hold stationary sheave with a strap wrench.

7. 9- k.
Tighten nut to specification.
r
99 a

4. Inspect surface of sleeve (A) and bushing (B) for wear,

7- Sh

pitting, or damage.

5. Inspect cam plate guides and both sides of guide posts on

7
moveable sheave for wear. Replace guides as a set.
87 rt

A B
a
P

Drive Clutch Nut Torque

29 ft. lbs. (39 Nm)

7.7
CVT / TRANSMISSION
Refer to Fig. 1. Drive Clutch Assembly
6. Inspect cam plate for wear on all roller track surfaces (D). 1. Do not grease clutch components.
7. Clean any belt material from sheaves with isopropyl 2. Install rollers in moveable sheave.
alcohol or brake parts cleaner.
3. Install cam plate guides (H, Fig. 1) in cam plate and
8. Inspect both sheave faces (E) for grooves, wear, or damage. assemble cam plate to moveable sheave, aligning guides
with guide posts.
9. Inspect splines of stationary sheave (F) for wear.
Temporarily install stationary sheave on crankshaft to 4. Install sleeve in bushing.
verify splines fit tightly on splines of crankshaft.
5. Install assembly on crankshaft.
10. Remove and inspect each roller (G). Replace as a set if any
NOTE: When installing moveable sheave / cam plate

86 m
have flat spots or if worn (they should be cylindrical).
assembly onto the crankshaft, hold assembly
11. If rollers are worn, inspect roller tracks in moveable sheave together to prevent rollers from dislodging.
for wear also.

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12. Replace drive clutch assembly if either sheave guide posts
or roller tracks are worn.

9- k.
r D E

F
99 a
7- Sh

H
G

6. See Drive Belt Installation on page 7.6 to install belt and

29 ft. lbs. (39 nm) complete the installation of drive clutch stationary sheave.
87 rt

Fig. 1
a
P

7.8
 CVT / TRANSMISSION
DRIVEN CLUTCH SERVICE 5. Measure inside diameter of drive hub.

Driven Clutch Removal, Disassembly,

Inspection
1. Remove belt. See Drive Belt Removal on page 7.6.

2. Use a strap wrench to hold drive hub and remove driven

clutch retaining nut.

3. Pull outward on driven clutch and tap shaft with a soft faced
hammer to release drive hub from splines.

Drive Hub I. D.

86 m
Service Limit: 4.43 (112.5 mm)

56 co
6. Secure driven clutch assembly in a soft jaw vise or clamp.
Loosen retaining nut (counterclockwise) about 1 turn. Hold
downward pressure on friction shoe plate (C), then remove
nut. Release pressure on plate and remove friction shoe
assembly and driven spring.
9- k.
r
CAUTION

Components are under spring pressure. Wear eye

99 a
and face protection and use care during removal.
4. Visually inspect friction surface of drive hub (A) for deep
7- Sh

scoring or damage. Visually inspect splines (B) for wear.

7
87 rt

A B

C
a
P

7. Rotate and pull upward on roller pin cover to remove.

7.9
CVT / TRANSMISSION
8. Remove (3) rollers and pins (D). Inspect roller tracks (E) 13. Measure thickness of friction shoe material. Replace shoes
in moveable sheave. as a set if worn beyond service limit.

86 m
Refer to Fig. 2. Driven Clutch Friction Shoe Thickness

56 co
Service Limit: .039 (1.0mm)
9. Separate moveable and fixed sheave. Clean all parts and
sheave faces with isopropyl alcohol or brake parts cleaner.
14. To replace friction shoes, remove E-clips that retain the
10. Inspect both sheave faces (F) for grooves, wear, or damage.
9- k.
11. Replace seals (G) and O-rings (H) upon assembly.
r backing plate. Use a suitable tool to remove and install the
return springs, using care not to stretch springs more than
required for installation.

F
99 a

H
7- Sh

G
87 rt

Fig. 2
a

12. Inspect spring free length. Replace if less than service limit.
P

Driven Compression Spring Length

Service Limit: 2.74 (69.7mm)

7.10
 CVT / TRANSMISSION
Driven Clutch Assembly 7. Secure clutch in a clamping device and torque nut.
1. Press new seals (A) into moveable sheave with seal lips
facing inward. Press seals flush with edge of seal bore.
2. Fill outer cavity between seals (roller area) with grease and
slide moveable sheave onto post of stationary sheave (B).
3. Align and insert (3) roller/pin assemblies (C).

86 m
B
Driven Assembly Nut Torque

56 co
50-54 ft. lbs. (68-73 Nm)
C

4. Lubricate and install new O-rings in grooves of driven Driven Clutch Installation
9- k.
sheave, then install outer roller pin cover (D) until flange
is firmly seated against sheave.
r 1. Install belt on driven clutch with numbers readable from
centrifugal hub side of clutch.
2. Compress driven clutch and force belt into the sheaves as
far as possible, and hold belt in position.
99 a

3. Loop the belt over drive clutch and install driven clutch on
transmission shaft.
7- Sh

D 4. Install drive hub and engage splines of drive hub to splines

of transmission input shaft.
7
5. Install driven clutch nut. Tighten nut to specified torque.
87 rt

6. Install drive clutch stationary sheave. See Drive Belt

Installation on page 7.6.
5. Clean threads (E) to remove all oil, grease, or old locking
a

agent then apply a few drops of Loctite 272.

6. Have an assistant available for final assembly. Install
P

spring. Place centrifugal hub (F) over spring and compress

assembly together with both hands, aligning flats of hub
with flats on threaded shaft. With assembly compressed and
threads exposed, have assistant thread a new nut onto shaft.

Driven Clutch Nut Torque

New 40 ft. lbs. (55 Nm)

7.11
CVT / TRANSMISSION
TRANSMISSION SERVICE 4. Remove angle drive inspection / oil fill cover.

Transmission Disassembly and Inspection NOTE: Angle drive removal is not required for
transmission cover removal or access to internal
IMPORTANT: To ensure proper shifting, verify shift
cables are in good condition, routed properly, and transmission components. Drive pinion gear (D) and
adjusted properly after transmission is assembled shaft will stay with cover when removed.
and engine is installed.
1. Remove drain plug (A) and drain oil from case.

86 m
D

56 co
A

2.
9- k.
Remove shift cable bracket (B) and shift arm screw (C).
r 5. Remove (3) angle drive output housing screws. Remove
housing.

B
99 a
7- Sh
87 rt

C
a
P

3. Mark shift shaft and shift cable arm orientation before 6. Note number of shims for assembly.
removing the arm.

7.12
 CVT / TRANSMISSION
7. Turn output shaft by hand to check for smooth rotation. 10. Remove retaining ring from drive pinion.
Push on splined end and gear end of shaft. There should be
no detectable up and down or side to side movement. Check
splines and gear teeth for wear or damage.

86 m
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11. Remove spacer and gear.

8. If damage or wear is evident, or if seal is leaking, replace

output housing assembly or replace parts as required. See
9- k.
Output Shaft Housing Disassembly / Assembly on
page 7.20.

If parts are replaced refer to

r
output gear depth adjustment
99 a
in this chapter.
7- Sh

7
12. Push shaft out of cover housing.
87 rt
a

9. Remove all transmission cover screws. Tap lightly with a

P

soft faced hammer. Pry points (E) can be used carefully to

help release cover and gasket.

13. Inspect gear teeth and bearing. If components are replaced,

inspect output gear pinion depth and adjust with shims as
required. See Output Gear Pinion Depth Adjustment on
page 7.19 for procedure.
E

7.13
CVT / TRANSMISSION
14. Remove detent bolt with ball and spring. 17. Remove shift fork shaft. Pull fork out of shift drum track.

86 m
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15. Pull shift shaft from case. 18. Remove shift drum.

9- k.
r
99 a
7- Sh
87 rt

16. Push and release the spring loaded gear position switch 19. Remove shift fork.
a

plunger (F). Be sure it moves freely inward and extends

under spring pressure when released.
P

7.14

20. Inspect shift drum track (G), paying close attention to
corner areas where track changes direction. Inspect shift
fork guide (H) for wear or damage.
21. Inspect gear position detent track (I) of shift drum. Replace
drum if deeply grooved from detent ball travel.
22. Inspect pad area of shift fork (J) and replace if bent, worn,
discolored, scored, or damaged.
CVT / TRANSMISSION
25. Inspect input pinion gear for tooth damage. Push on shaft
to check for play in bearing. Rotate the shaft to check for
smooth bearing rotation.
26. Inspect all bearings in case. They should rotate freely
without binding. Bearing inner race should have no
detectable radial (up and down) movement of inner race.

86 m
I H

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J

9- k.
23. Pull main shaft from case with thrust washer on inside end.
r
27. Inspect mainshaft components. See Transmission Main
Shaft Assembly View on page 7.16
99 a

Input Shaft Removal / Inspection

7- Sh

1. Remove bearing stop screw and washer (A). 7

2. Tap input shaft from CVT side to remove shaft with
bearing.
87 rt
a

87 in-lbs (9.8 Nm)

P

24. Remove countershaft. A

7.15
CVT / TRANSMISSION
Transmission Main Shaft Assembly View
1. Refer to Fig. 3 for assembly view. Replace all retaining rings if removed.

2. Remove flat washer (A), circlip (B), shaft collar (C), washers (D) (one washer on each side of gear E), sliding dog gear (F),
snap ring retainer (G), splined washer (H), gear with needle bearing (I), and thrust washer (J).

3. Inspect forward / reverse dog gear. Closely inspect outer corners of dogs for rounding or damage (K).

4. Inspect edges of slots (L) in forward and reverse gears for severe rounding that would reduce contact area of sliding gear dog.
Compare leading and trailing edges of slots to determine level of wear. Inspect needle bearing (M).

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J
9- k.
r G
F
C
99 a
I B
H
7- Sh

D
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a

E
D
P

Fig. 3

L
K
M

7.16
 CVT / TRANSMISSION
Transmission Assembly Install gear position switch plunger (E) with spring in
end of shift shaft. Use light grease to hold parts in place
1. To assemble transmission, reverse disassembly procedure,
and carefully install shaft in gear case.
and read the following assembly notes.
After installing countershaft (A), install mainshaft as an
assembly. Hold washer (B) in place with a small
amount of grease. E

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B Align center teeth of shift shaft and drum (F).

9- k.
Assemble shift fork and drum in the Neutral position.
Rotate shift drum to align Neutral detent notch (C) with
center of detent bolt hole (D).
r
F
99 a

D
C
7- Sh

7
2. Torque detent bolt to specification.
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=T
a

Detent Bolt:
Assemble shift detent ball, spring, and bolt into bottom 14 ft. lbs. (19 Nm)
P

of transmission case, but do not fully tighten the bolt. 3. Verify (two) cover alignment dowel pins are in place.
Leave just enough tension on detent ball to keep shift Install cover with a new gasket. Torque cover screws
drum from rotating out of Neutral. evenly in a criss-cross pattern to specification.

=T
Transmission Cover Screws:
6-8 ft. lbs. (8-11 Nm)

4. Install and torque drain plug.

=T
Oil Drain Plug:
18 ft. lbs. (24.5 Nm)

7.17
CVT / TRANSMISSION
5. Assemble output shaft housing to case with existing shims. 9. After installation in the frame, adjust shift cables in the
If components were replaced you must inspect output gear following manner:
pinion depth. See Output Gear Pinion Depth Adjustment
on page 7.19. Place gear selector in NEUTRAL

Verify transmission shift arm is in NEUTRAL

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=T Shift Arm - Neutral Position

9- k.
r Output Housing:
14 ft. lbs. (19 Nm)
Attach cables to bracket and to shift arm.

Adjust each cable until slack is removed from each

6. Install outer cover (oil fill cover). cable and tighten cable adjusters securely.
99 a
7. Add 27 fl. oz. (800ml) of oil. Check for proper shift operation
7- Sh

LUBRICANT CAPACITY

AGL - Synthetic ATV

27 fl. oz. (800 ml)
Gearcase Lubricant
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8. Verify vent hose is clear. After installing engine in frame,

route and secure hose lightly as shown with open end (G)
pointing down.
a

G
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7.18

Output Gear Pinion Depth Adjustment
NOTE: This procedure sets pinion depth only. There
are no provisions for backlash adjustment.
CVT / TRANSMISSION
5. The specified pinion depth is .012 - .016 inch (0.3mm-
0.4mm) from the bottomed position. Therefore, you will
need to install a shim pack with a thickness of .012 - .016
inch (0.3mm-0.4mm) plus the gap measured in Step 4.

1. Remove O-ring from output shaft housing (re-install for Example: Gap between housing and case is .020 inch (0.50
final assembly). mm) with no shims installed and gears bottomed.
2. Remove any existing shims from housing.
To obtain correct pinion depth, a shim pack with a thickness
3. Install housing in transmission case. The pinion gear and totaling .032 - .036 inch (.8-.9mm) must be installed.
output gear should bottom against each other, leaving a gap
between housing and transmission case that can be
measured with a feeler gauge at (A). .020 Measured Gap .020 Measured Gap
+ .012 Minimum Clearance +.016 Maximum Clearance

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.032 in. .038 in.

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A Minimum shim Maximum shim
pack thickness (inch) pack thickness (inch)

9- k.
r
99 a

4. Hold gears in bottomed position by applying light pressure

7- Sh

to the center of the output shaft. Measure the gap with a

feeler gauge and record. 7
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a

= In. / mm.
P

Output Pinion Shaft Shim Pack Requirement:

Measured Distance
plus
.012-.016 / 0.3mm-0.4mm

7.19
CVT / TRANSMISSION
Output Shaft Housing Disassembly / Assembly
1. If housing is removed from transmission case, temporarily re-install with all 3 screws (A).

2. Remove collar nut (B) using special socket PA-49959.

3. Push shaft out of bearings.

4. Inspect shaft and housing for wear.

5. Clean housing and inspect for wear in the bearing bore areas.

6. Install new bearing (C) on shaft.

7. Install new seal (D) in housing with spring side of seal facing pinion gear.

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8. Apply grease to shaft oil seal then carefully slide shaft assembly through seal and into housing until bottomed in bearing bore.

9. Install bearing (E) over splined end of shaft and push into housing until seated.

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10. Install collar nut hand tight.

11. Temporarily install housing to transmission case with all 3 screws (A) and fully tighten collar nut to specified torque. Remove
housing from case.
9- k.
12. Perform pinion depth inspection / adjustment to determine the thickness of shim pack (F) required. See Output Gear Pinion
Depth Adjustment on page 7.19.
r
13. Install new O-ring (G) on housing after Step 12 is completed.
99 a

A
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B
a

72ft. lbs. (98Nm)

P

7.20
 ELECTRICAL
CHAPTER 8
ELECTRICAL
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
ELECTRICAL SYSTEM SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
SWITCHES AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
KEY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
BRAKE PEDAL / PARKING BRAKE SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
ELECTRONIC THROTTLE CONTROL (ETC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
ETC OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4

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ETC SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
DAYTIME RUNNING LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
DRL TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
DRL LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5

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TAIL LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
TAIL LIGHT LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
INDICATOR LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
INDICATOR LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
TRANSMISSION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
9- k.
rTRANSMISSION SWITCH - CIRCUIT BREAKOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
99 a
OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
IGNITION SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
7- Sh

IGNITION SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9

RPM IGNITION LIMITER FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.10
RPM LIMITER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
IGNITION COIL TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
CDI OUTPUT TEST
USING PEAK READING ADAPTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
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PULSER COIL OUTPUT / RESISTANCE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11

CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
CHARGING SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
a

MAIN FUSE / FUSE HOLDER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13

VOLTAGE REGULATOR / RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
STATOR / ALTERNATOR TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
8
P

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.14
STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16
STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16
STARTER MOTOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
STARTER DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
STARTER BRUSH INSPECTION / REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18
ARMATURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.18
STARTER REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
STARTER SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
STARTER SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.20

8.1
ELECTRICAL
GENERAL INFORMATION SWITCHES AND CONTROLS
Special Tools Key Switch
The key switch can be tested with an ohm meter.
PART NUMBER TOOL DESCRIPTION
When the key is turned to the OFF position, there should no
Fluke77 Digital
PV-43568 continuity between any of the wires.
Multimeter
2870836 Peak Reading Adaptor When the key switch is turned to the ON position, there should
be continuity between the red (RD) and brown (BN) wires.
2870630 Timing Light There should also be continuity between the black (BK) and
8712100 or 8712500 Tachometer dark green (DG) wires.

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When the key is turned to the START position, there should
Electrical System Service Notes
be continuity between the red (RD) and brown (BN) wires.
Reference the following notes when diagnosing electrical There should also be continuity between the black (BK), dark

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problems. green (DG), and dark green/red (DG/RD) wires.

The ignition system timing is non-adjustable. The

KEY SWITCH CONTINUITY CHART
specifications in Chapter 1 are intended for reference
only.
9- k.
Refer to wiring diagram for stator and electrical
component resistance specifications.
r Switch
Position
Color
RD BN BK DG DG/RD

When measuring resistance of a component that has a OFF

low resistance value (under 10 Ohms), remember to
99 a
subtract meter lead resistance from the reading. ON
Connect the leads together and record the resistance. START
7- Sh

The resistance of the component is equal to tested value

minus the lead resistance.

Become familiar with the operation of the meter. Be

sure leads are in the proper jack for the test being
87 rt

performed (i.e. 10A jack for current readings). Refer to

the owners manual included with the meter for more
information.
a

Voltage, amperage, and resistance values included in

this manual are obtained with a Fluke 77 Digital
P

Multimeter (PV-43568). This meter is acceptable for

use when diagnosing electrical problems. Readings
obtained with other meters may differ.

Pay attention to the prefix on the multimeter reading (K,

M, etc.) and the position of the decimal point.

For resistance readings, isolate the component to be

tested. Disconnect it from the wiring harness or power
supply.

8.2
 ELECTRICAL
Brake Pedal / Parking Brake Switches 1. Locate the parking brake and brake pedal switches.

The brake pedal switch when closed, illuminates the rear brake 2. Disconnect wire harness from each switch and connect an
lamp and completes the START command circuit. The brake ohmmeter across the two switch wires.
pedal must be depressed to start the engine. The reading should be infinite ().

The parking brake switch is closed when the parking brake lever 3. Apply either the brake pedal or parking brake and check for
is pulled. When pulled, the switch closes, which signals the CDI continuity between switch contacts. Replace switch if there
to limit engine RPM. is no continuity, or if the resistance is greater than .5 ohms
when the brake is applied with slight pressure.

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8
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8.3
ELECTRICAL
Electronic Throttle Control (ETC) ETC Switch Adjustment
Always check the throttle pedal for smooth operation before 1. Slide the boot off the throttle cable adjuster and jam nut.
riding. Periodically check the throttle free play. It should be kept
between 1/16 and 1/8 (1.5mm 3.2mm).

If adjustment is required, turn the throttle cable adjuster until the

free play falls within the acceptable limit. Adjuster

ETC Operation
When the throttle is closed (idle), the throttle pedal arm
depresses a small micro switch that limits engine rpm. This
action opens the circuit. Boot

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Throttle Arm

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2. Set parking brake.

3. Start engine and set idle to specified RPM.

9- k.
Micro Switch
r NOTE: Be sure the engine is at operating
temperature.
Chapter 2.
See Idle Speed Adjustment in

4. Loosen the adjustment nut on inline cable adjuster.

99 a

5. Turn cable adjuster out until engine RPM begins to

increase.
7- Sh

When the throttle pedal is pushed forward, the throttle arm

moves off the micro switch and allows the engine rpm to 6. Turn cable adjuster back in until throttle lever has 1/16
increase with lever movement. This action closes the circuit. (.16 cm) of travel before engine RPM increases.

7. Tighten lock nut securely and slide boot completely in

87 rt

If the throttle cable would become hung up or stuck while the

vehicle is being operated, the spring loaded throttle arm will place to ensure a watertight seal.
return back and depress the micro switch, limiting engine rpm.
NOTE: Verify ETC switch plunger is held inward at
a

The ETC switch and throttle arm are located in a sealed throttle idle position.
pedal assembly. Switch or throttle cable replacement requires
P

removing the assembly cover. Always replace the cover gasket

with a new one during assembly.

8.4
 ELECTRICAL
DAYTIME RUNNING LIGHTS DRL Lamp Replacement
If the daytime running lights do not operate, lamp replacement
DRL Test
may be required. Install only the recommended replacement
The daytime running lights are powered by an AC current from lamps.
the Generator / Stator.

If running lights are not working, perform the following:

1. Disconnect the harness from the faulty light.

2. Using a Volt Ohm Meter, measure the AC voltage between

the (YELLOW) and (BLACK) wires. Voltage above 5
VAC should be present when unit is running.

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If voltage is present:
1. Replace the faulty bulb.

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If voltage is not present:
1. Remove cover from back of light housing
1. The black wire should have continuity to ground. If no
continuity is present, check for an short or break in the 2. Press in and rotate the lamp socket counter-clockwise and

2.
9- k.
wiring harness or a poor connection.

If black wire has good continuity to ground, check the

wiring harness from the stator to the running lights. There
r 3.
should be continuity between the (YELLOW) wire at the
light connector and the (YELLOW) wire at the Generator
99 a
/ Stator.
7- Sh
remove it from the housing.
Apply Dielectric Grease PN 2871329 to the new bulb
contacts and install.
4. Verify the new lamp filament is horizontal, and then
reinstall the socket into the housing and rotate clockwise
about 1/4 turn. Replace the cover.
5. Start the engine to make sure the lights come on. If the lights

3. If continuity is good. Perform stator resistance tests by do not operate, check the charging system and related
using the resistance chart located in the wiring diagram. wiring for possible malfunction.
4. Replace Generator / Stator if resistance is not within
specification.
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8
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8.5
ELECTRICAL
TAIL LIGHT INDICATOR LAMPS
Tail Light Lamp Replacement Indicator Lamp Replacement
If the tail light lamp does not work, the lamp may need to be 1. The indicator lamps are located on the dash.
replaced.
2. Disconnect the indicator light wire connections from the
harness.

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1. Remove the two screws securing the lens cover. Remove
the lens cover.
2. Remove the lamp and replace it with a new recommended

3.
9- k.
lamp. Apply Dielectric Grease (PN 2871329) to the lamp
terminals.
Test the light for proper operation.
r
3. Remove the nut from the backside of the indicator lamp.
4. Remove the lamp.
4. Reinstall the lens cover.
99 a
5. Install new lamp(s) into the dash and secure with retaining
nut.
7- Sh

6. Apply dielectric grease to the wire connections of the new

lamp.
7. Turn ignition key to the ON position and shift the
transmission into Neutral or Reverse to verify light
operation.
87 rt

8. If the lights do not operate, check battery voltage at the light

harness and check related wiring for possible malfunction.
a
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8.6
 ELECTRICAL
TRANSMISSION SWITCH
Transmission Switch - Circuit Breakout

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9- k.
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99 a
7- Sh

Testing
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1. With the switch installed, use an ohmmeter to test

continuity between the switch leads and engine ground.
a

2. First, shift the transmission into neutral and test for

continuity between the DG/WH wire and ground.
8
P

3. Then shift the transmission into reverse and test for

continuity between the DB wire and ground. In both tests
you should have continuity to ground.

8.7
ELECTRICAL
Removal IGNITION SYSTEM
1. Remove the CVT cover. The indicator switch will be
Overview
visible between the drive and driven clutch. Refer to CVT
Chapter for CVT cover removal and installation. The ignition system consists of a simple magneto-driven system
that includes a stator pulser coil, CDI Box, ignition coil and
2. Remove the (2) screws and pull on switch to release from related wiring / connectors.
crankcase. Timing is non-adjustable on this ignition system.
3. Inspect the shift indicator contacts, shift drum, pin and
spring. Verify the pin is not sticking in the drum or is Ignition System Troubleshooting
damaged. Replace any worn or damaged components. No Spark, Weak or Intermittent Spark
INSPECT No 12 volt power on brown (BN) wire at CDI box or no

86 m
CDI box ground path from the black/white (BK/WH)
wire

Spark plug gap incorrect

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Fouled spark plug

Faulty spark plug cap or poor connection to high

tension lead
9- k.
r Related wiring loose, disconnected, shorted, or
corroded

Engine Stop switch or ignition switch faulty

99 a
Installation ETC switch faulty
1. Install spring and pin into shift drum.
7- Sh

Poor ignition coil ground

2. Install switch with new O-ring. Route wires through Faulty stator (measure resistance of all ignition related
crankcase. windings)
3. Install retaining screws. Incorrect wiring (inspect color coding in connectors
87 rt

etc)
4. Torque screws to specification.
Faulty ignition coil winding (measure resistance of
a

primary and secondary)

Sheared flywheel key

P

Pin
Flywheel loose or damaged

Excessive crankshaft runout on magneto. (RH) end

should not exceed .005

Faulty CDI module

=T
Indicator Switch Screw Torque:
39-52 in. lbs. (4.5-6 Nm)

8.8
 ELECTRICAL
Ignition System Testing
Whenever troubleshooting an electrical problem, first check all terminal connections to be sure they are clean and tight. Use the
following flow chart as a guide for troubleshooting. NOTE: The brown (BN) wire on youth models carries 12V key-on power.

Condition: No spark or intermittent spark.

Turn key switch to

ON.
Disconnect 2-wire
connector from
CDI

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Measure between
engine ground and
BROWN wire.

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Battery voltage on
Battery voltage on RED Replace key
Battery Voltage? NO YES BROWN wire at key NO
circuit at key switch? switch.
switch at ON position?

9- k.
r
NO YES
YES
99 a
Check wiring
Check 15A fuse
between switch
and battery.
and CDI.
Disconnect 4-wire
7- Sh

plug from CDI.

Check the BLACK
wire for continuity
to ground.
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Continuity? NO Check wiring.

a

YES

Disconnect DG
8
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wire from ignition

coil.
Check for Check wiring and/
Continuity? NO
continuity between or key switch.
plug and key
switch in ON
position.
YES

Perform CDI
output test, pulser
coil output test and Replace suspect
Components
ignition coil NO components and
pass tests?
resistance test recheck.
detailed within this
chapter.
YES

If vehicle still has no spark,

repeat troubleshooting steps.
Pay close attention to
condition of wires and
connections.

8.9
ELECTRICAL
RPM Ignition Limiter Functions
NOTE: The CDI box reads the RPM signal from the stator. The CDI box acts as a limiter by retarding the
ignition timing if RPM reaches the specified limit. In reverse gear, the CDI box retards ignition timing and
limits RPM once it receives a ground path from the transmission switch dark blue (DB) wire indicating the
vehicle is in reverse. The CDI box can also receive a ground path from the ETC switch causing the CDI box to
retard timing and limit RPM if the throttle cable becomes slack or stuck.

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8.10
 ELECTRICAL
RPM Limiter Specifications Pulser Coil Output / Resistance Tests
Disconnect the 4-wire connector at the CDI box. Install the Peak
Ignition
Model Max RPM Reading Adaptor (PV-39991) to your meter and connect one
Timing
meter lead to the dark blue / black wire (DB/YEL) and the other
170cc 8000 N/A to engine ground. Set meter to read DC Volts. Crank engine and
verify pulser coil output.
NOTE: There are no timing advance marks stamped
on the flywheel to read with a timing light. Connect
Voltage Reading
Meter Leads
Test (With Peak Reading Adapter)
Between:
Ignition Coil Test
DB/YEL to 5 DC Volts minimum @
Pulser Coil
Engine Ground cranking RPM

86 m
Measure between
the two wire tabs for
If readings are within specifications, test the resistance value of
primary reading.
the pulser coil. When finished, reconnect the 4-wire connector

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to CDI box.

Connect
Ohm Test Reading
Meter Leads To:
Pulser Coil DB/YEL to Black 151 20%
9- k.
r
99 a

Test Description Resistance

7- Sh

Ignition Coil Primary Winding 0.2 20%

Ignition Coil Secondary Winding
(With Cap Installed) 8 K 20%
(Without Cap Installed) 3 K 20%
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Spark Plug Resistor Cap 5K

a

CDI Output Test

Using Peak Reading Adaptor
8
P

Re-connect all wires to the CDI box. Disconnect the (BLACK/

YEL) CDI output wire from ignition coil primary terminal.
Install the Peak Reading Adaptor (PV-39991) to your meter and
connect one meter lead to engine ground and the other to the
(BLACK/YEL) CDI output wire at the ignition coil. Set meter
to read DC Volts. Crank engine and verify CDI output to the
ignition coil. When finished, reconnect CDI output wire to
ignition coil.

Connect Meter
Output Test Reading
Leads To:
BLK/YEL to
CDI Output 180 DC Volts 20%
Engine Ground

8.11
ELECTRICAL
CHARGING SYSTEM
Charging System Testing
Whenever charging system problems are suspected, proceed with the following system checks:

Using a volt meter, set it to read D.C. volts, Remove the battery and properly
measure the battery open circuit voltage No service. Reinstall the fully charged
(across the positive and negative posts). battery or a fully charged shop battery.
Is the reading 12.8 volts or more? Verify condition of 15A fuse.

Yes

86 m
Meter Setting: DC Volts
With the transmission in neutral, start the
engine and increase RPM to between 3000

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and 4000. Read battery voltage with the Yes Check for a system current draw.
a voltmeter. Voltage readings should start
to increase towards 13.0 V D.C.
Was an increase noticed?
No
9- k.
r
Meter Setting: AC Volts
Disconnect the wire connector between the Perform the resistance tests detailed
regulator / rectifier and stator. Using a volt in this chapter under the
99 a
meter perform a stator output test.
See the test procedure detailed in this chapter Stator / Alternator Tests. If stator
No tests good, inspect the flywheel
under Stator / Alternator Tests.
7- Sh

magnets, stator coils and stator

Does stator AC output meet specification? wire harness for damage. Repair or
Yes replace any damaged components.
87 rt

Meter Setting: DC Volts

Reconnect the alternator wires. Note: Red
wire must be connected to harness. Battery Check regulator / rectifier connections
a

voltage must be present on red wire terminal and ground, battery connections,
on harness side of voltage regulator connector. No main fuse and connecting wires.
P

Is it? Repair or replace faulty wiring or

components.
Yes

If all of the previous tests indicate a

good condition, but the charging voltage does
not rise above battery voltage at the
connector or terminal board, replace the
voltage regulator.

8.12
 ELECTRICAL
Main Fuse / Fuse Holder Location Stator / Alternator Tests
A 15 Amp fuse protects the main electrical system. The fuse is Two tests can be performed using a multimeter to determine the
located in the battery compartment. condition of the stator:

86 m
15 Amp Fuse Take Measurements on
Stator Side of Harness

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NOTE: Use only the recommended fuse capacity, as TEST 1: Measure resistance value of each stator leg.
use of a higher amperage fuse to correct blown-fuse
1. Measure the resistance value of the stator legs. Use the
damage.9- k.
situations could lead to electrical component

Voltage Regulator / Rectifier

following chart as a reference when testing.

Connect
Ohm Test Reading
r
Meter Leads To:
The voltage regulator / rectifier is located near the front of the 0.1 20%
99 a
BK to Ground
engine.
Battery Charge Coil BK to YEL 0.9 20%
7- Sh

The regulator diodes can be tested with an ohm meter. Attach the BK to RED 1.1 20%
positive + lead to the BK pin and the negative - lead to the
WHT pin. There should be measurable resistance. Reverse the
TEST 2: Measure AC voltage output of each stator leg. Test at
leads and test. There should be no continuity. The YEL and RED
cranking rpm with a voltmeter set to read AC volts.
pins should be tested the same and achieve the same results.
87 rt

1. Turn over the engine with the starter motor.

2. First measure from the red wire (RD) to engine ground.

a

Compare readings to specifications.

3. Next measure from the yellow wire (YE) to engine ground.

8
P

Compare readings to specifications.

Connect
AC Output Test AC Reading
Meter Leads To:
YEL to Ground 8 Vac
Battery Charge Coil
RED to Ground 5 Vac

NOTE: To check the charging system output further,

start the engine and perform the same tests. Voltage
should increase with increased RPM.

Maximum Stator Output

6.5 Amps @ W.O.T.

8.13
ELECTRICAL
BATTERY New Battery Activation

Battery Maintenance Service Notes

WARNING

WARNING Battery electrolyte is poisonous. It contains sul-

furic acid. Serious burns can result from contact
Battery electrolyte is poisonous. It contains with skin, eyes or clothing. Antidote:
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.
External: Flush with water. Eyes: Flush with water for 15 minutes and get
prompt medical attention.

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Internal: Drink large quantities of water or milk.
Batteries produce explosive gases. Keep
Follow with milk of magnesia, beaten egg, or
sparks, cigarettes, etc. away. Ventilate when
vegetable oil. Call physician immediately. charging or using in an enclosed space. Always

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Eyes: Flush with water for 15 minutes and get
prompt medical attention.
Batteries produce explosive gases. Keep
shield eyes when working near batteries.
KEEP OUT OF REACH OF CHILDREN
To ensure maximum service life and performance from a new
battery, perform the following steps.

9- k.
sparks, flame, cigarettes, etc. away. Ventilate
when charging or using in an enclosed space.
Always shield eyes when
working near batteries.
1. Remove the battery (1), battery acid (2), funnel (3) and cap
(4) from the box.
1 2
r
KEEP OUT OF REACH OF CHILDREN.
99 a

CAUTION
7- Sh

Always wear safety glasses, rubber protective

gloves and appropriate clothing when
working with batteries.
87 rt

IMPORTANT: DO NOT activate Youth RZR batteries

unless they will be put into service within 30 days of
activation. 4 3
a

Youth RZR vehicles use a low maintenance battery. Do not

2. Remove the protective strip from the top of the battery.
remove the battery cap strip to check acid level or add water
P

Insert the battery electrolyte funnel into the filler holes.

once the battery have been activated. Perform the proper battery
tests and charge or replace the battery as required. 3. Carefully press the battery electrolyte pack onto the funnel.
The funnel will puncture the pack seals, releasing
New batteries must be fully charged before use or battery life
electrolyte into the battery. Allow the pack to drain for 20
will be significantly reduced (10-30% of the batterys full
minutes, periodically tapping the sides to release any air-
potential).
lock or bubbles that may be present.
NOTE: DO NOT use a constant high-amperage
4. Properly dispose of the battery electrolyte pack. Let battery
battery charger to charge this style of battery. Use a
set with the vent cap strip off for 30 minutes to allow full
low-amperage charger capable of charging voltage
absorption of the electrolyte. After 30 minutes, install the
that is 1/10 of the battery amp-hour rating.
battery seal strip onto the battery.

5. Charge the battery initially for 3 to 5 hours using Christie

Charger (PA-37453) or a charger with an output capable of
1/10th the batterys amp-hour rating.

8.14

Battery Removal
WARNING
Improperly connecting or disconnecting battery
cables can result in an explosion and cause
serious injury or death. When removing the
battery, always disconnect the negative (black)
cable first.
When reinstalling the battery, always connect
the negative (black) cable last.
ELECTRICAL
Battery Installation
1. Place the fully charged battery in its holder.
2. Attach the hold-down strap(s).
3. Connect and tighten the red positive (+) cable first.
4. Connect and tighten the black negative (-) cable last.
5. Torque the battery terminal bolts to 3.5 ft. lbs. (4.7 Nm)
6. Verify that the cables are properly routed.
NOTE: When installing a new battery, make sure it's
fully charged prior to its initial use. 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. If charging is

86 m
To remove the battery:
necessary, use a .5 amp battery charger.
1. Remove the drivers seat to access the battery.
Battery Voltage Test

56 co
Battery voltage should be checked with a digital multi-tester.
Readings of 12.8 or less require further battery testing and
charging. See Load Test.

9- k.
r NOTE: Batteries should be kept at or near a full
charge as possible. If the battery is stored or used in
a partially charged condition, crystal sulfation will
form on the plates, reducing the efficiency and
Battery Location
service life of the battery.
99 a

Battery Load Test

7- Sh

2. Disconnect the hold-down strap securing the battery in CAUTION

position.
Remove the spark plug high tension lead and connect
3. Disconnect the black negative (-) battery cable first.
87 rt

securely to engine ground before proceeding.

4. Disconnect the red positive (+) battery cable last.
A battery may indicate a full charge condition in the battery
5. Lift the battery out of the compartment. voltage test and the specific gravity test, but still may not have
a

the storage capacity necessary to properly function in the

CAUTION electrical system.
8
P

For this reason, a battery capacity or load test should be

To reduce the chance of sparks:
Whenever removing the battery, disconnect the
negative (black) cable first. When reinstalling the
battery, install the negative cable last.
Battery Cleaning
Keep the 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.
conducted whenever poor battery performance is suspected. To
perform this test:
1. Connect a multi-tester to the battery in the same manner as
was done in the battery voltage test. The reading should be
12.8 volts or greater.
2. Engage the electric starter and view the registered battery
voltage while cranking the engine. Continue the test for 15
seconds. During this cranking period, the observed voltage
should not drop below 9.5 volts.
3. If the beginning voltage is 12.8 or higher and the cranking
voltage drops below 9.5 volts during the test, replace the
battery.

8.15
ELECTRICAL
Battery Charging Procedure
Charge the battery using a charger capable of producing voltage
1/10th of the batterys amp/hr rating. Example: Youth batteries
have an amp/hr rating of 12 amps. Do not exceed 1.2 amps
charging voltage or damage to the battery will result.
Fully charged, the battery should read 12.8-13.0 Volts. After
charging is complete, let the battery stand 1-2 hours and re-test
the voltage. Do not overcharge the battery!
There is no need to remove the cell cap strip or add water for the
life of the battery.
STARTER SYSTEM
Starter Relay
The starter relay consists of a simple 2-way circuit. Power is
present at the (RD) wire from the battery. Once the switching
side of the relay receives power from the brake switch and a
ground path when the key is turned to the START position,
battery power is sent to the starter motor to crank the engine.
The relay assembly is attached to a cross member located above
the engine.

86 m
BATTERY CHARGING CHART

State

56 co
of VOLTAGE ACTION CHARGE TIME
Charge

100% 12.8-13.0 None FULL None Required

75%

50%
9- k.
12.5-12.8

12.0-12.5
r Slight
Charge

Charge
3-6 Hours @ 0.5 A

5-11 Hours @ 0.5 A

13+ Hours @ 0.5 A Use the illustration below when troubleshooting a No Start
25% 11.5-12.0 Charge
99 a
Check Charging condition.
Less than 20 Hours @ 0.5 A
7- Sh

0% Charge
11.5 Battery may be dead

Because of the characteristics of a sealed battery, overcharging

decreases the volume of electrolyte. The longer the overcharge
87 rt

time, the greater the drop in electrolyte, and subsequently

starting power. Water cannot be added to a sealed battery. If a
sealed battery is overcharged, it will have to self-discharge
before it can be used. Overcharging can also warp plates,
a

making future charging difficult. Watch charging times

carefully, or use a charger with limited charging time/current
P

capabilities. Polaris recommends using the Christie Multi

Battery Charger (PV-67030), available from tool provider SPX
for charging batteries. Always stop charging if the battery
becomes warm to the touch. Let it cool sufficiently before
resuming charging.

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

8.16
 ELECTRICAL
Starter Motor Service 2. Remove the three screws and washers.

The starter motor is a complete service part. If it is determined

that the starter motor is the failed part, replace as needed. See the
parts manual for correct part number.

Although the starter motor is not serviceable, it can be

disassembled, tested and cleaned.

O-ring

O-ring

86 m
3. Remove magnet housing while holding the armature and

56 co
brush holder section together.

9- k.
Starter Disassembly
r
NOTE: Use only electrical contact cleaner to clean
starter motor parts. Other solvents may leave a
99 a
residue or damage internal parts and insulation.
7- Sh

NOTE: Some starter motors may not be serviceable.

Replacement of entire assembly may be required.
Check the parts manual for replacement part
information.

1. Disconnect the negative battery cable and starter motor

87 rt

harness. Remove the (2) bolts from the starter and pull it
from the engine.
a

8
P

8.17
ELECTRICAL
Starter Brush Inspection / Replacement 2. Using a digital multi-tester, measure the resistance between
each of the commutator segments. The reading should be
1. Using an Ohm meter, measure the resistance between the .3 ohms or less.
cable terminal and the insulated brush. The reading should
be .3 ohms or less. Measure the resistance between the
cable terminal and brush housing. Make sure the brush is
not touching the case. The reading should be infinite (no
reading).

2. Remove the brush plate and brushes. Measure the brush

length and replace if worn past the service limit.

86 m
56 co
0.20 (5 mm) 3. Measure the resistance between each commutator segment
and the armature shaft. The reading should be infinite. (no

9- k.
r continuity)

Brush Length Service Limit

99 a
0.20 (5 mm)
7- Sh

3. Inspect the surface of the commutator for wear or

discoloration. See Armature Test.

4. Be sure that the terminal bolt insulation washer is properly

seated in the housing and the tab on the brush plate engages
87 rt

the notch in the brush plate housing.

a

Armature Test
4. Check commutator bars for discoloration. Bars discolored
1. Inspect surface of commutator. Replace if excessively in pairs indicate shorted coils, requiring replacement of the
P

worn or damaged. starter motor.

5. Place armature in a growler. Turn growler on and position
a hacksaw blade or feeler gauge lengthwise 1/8 (.3 cm)
above armature coil laminates. Rotate armature 360. If
hacksaw blade is drawn to armature on any pole, the
armature is shorted and must be replaced.

8.18
 ELECTRICAL
6. Inspect the permanent magnets in starter housing. Make Starter System Troubleshooting
sure they are not cracked or separated from housing.
Starter Motor Does Not Turn

CAUTION Battery discharged - low specific gravity

Use care when handling the starter housing.
Do not drop or strike the housing, as magnet
damage is possible. If the magnets are damaged,
the starter must be replaced.
Starter Reassembly
Loose or faulty battery cables or corroded connections
(see Voltage Drop Tests)
Related wiring loose, disconnected, or corroded
Poor ground connections at battery cable, starter motor
or starter solenoid (see Voltage Drop Tests)
Faulty starter button

86 m
1. Place armature in field magnet casing.
Faulty ignition switch (Do other systems function?)
2. Inspect and replace the O-rings if damaged.
Faulty starter solenoid or starter motor

56 co
3. Install case sealing O-ring. Make sure O-ring is in good
condition and not twisted on the case. Lubricate the ends Engine problem - seized or binding (Can engine be
of the armature shaft and oil seal with a light film of grease, rotated easily with recoil starter?).
and install housing.
4. Install brush housing onto the armature, pushing back Starter Motor Turns Over Slowly

5.
9- k.
brushes while installing armature shaft.
Reinstall starter motor housing screws and washers. Make
Battery discharged - low specific gravity

Excessive circuit resistance - poor connections (see

sure O-rings are in good condition and seated in groove.
r
Tighten sufficiently. Voltage Drop Test below)
99 a
6. Reinstall the starter motor to the engine. Engine problem - seized or binding (Can engine be
rotated easily with recoil starter?)
7- Sh

Voltage Drop Test

Faulty or worn brushes in starter motor
The Voltage Drop Test is used to test for bad connections. When
performing the test, you are testing the amount of voltage drop Automatic compression release inoperative
through the connection. A poor or corroded connection will
Starter Motor Turns - Engine Does Not Rotate
87 rt

appear as a high voltage reading.

To perform the test, place the meter on DC volts and place the Faulty starter drive
a

meter leads across the connection to be tested. Refer to the chart
on next page to perform voltage drop tests on the starter system.
P
Faulty starter drive gears or starter motor gear
Faulty flywheel gear or loose flywheel
8

Voltage should not exceed

.1 DC volts per connection

8.19
ELECTRICAL
Starter System Testing
Condition: Starter motor fails to turn engine. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic
testing of starter system. A digital multitester must be used for this test.

Locate the starter relay.

See Starter Relay
earlier in this chapter for
location reference

86 m
Disconnect the 2-wire connector at
Connect meter Disassemble starter
the starter relay. Set volt meter to
leads to RED lug to motor to test and
read DC voltage and connect meter

56 co
YES starter motor and clean internal
leads between the DG/YEL and DG/
engine ground and YES components.
RED wires. Turn the key switch to
retest. If tests fail, or motor
the START position, and push in
Is battery voltage still does not work,
the brake pedal.
present? replace assembly.
Is battery voltage present?

9- k.
r
NO
NO

Replace starter
relay.
99 a
Check battery condition,
Recharge and test
RED battery connections
battery, replace 15A
at relay and 15A fuse. NO
fuse, or repair
7- Sh

connections.
Condition Good?

YES
87 rt

Check the key switch for

proper function. Turn key to
a

START. NO
Replace key switch and/or
Is there continuity between
check wiring circuits.
DG/RED and BLACK?
P

Is there continuity between

RED and BROWN?

YES

Set the meter to read Ohms.

Check the function of the foot
NO
brake switch. Replace foot brake
Is there continuity between the DG/ pedal switch.
YEL and BROWN wires when the
foot brake pedal is pressed?

8.20
 WIRE DIAGRAM

2009 RANGER RZR 170

86 m
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9- k.
r
99 a
7- Sh
87 rt
a
P

WD-1