Polaris RZR XP 900 2014

GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
1
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL NUMBER DESIGNATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE INDENTIFICATION NUMBER (VIN) DESIGNATION. . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE AND ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
GENERAL: 2013 RANGER RZR XP 900 / EPS / INT’L . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
DETAILED: 2013 RANGER RZR XP 900 / EPS / INT’L . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
GENERAL: 2013 RANGER RZR XP 4 900 / EPS / INT’L . . . . . . . . . . . . . . . . . . . . . . . . 1.8
DETAILED: 2013 RANGER RZR XP 4 900 / EPS / INT’L . . . . . . . . . . . . . . . . . . . . . . . . 1.9
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
STANDARD BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
METRIC BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
1.1
9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual
© Copyright 2012 Polaris Sales Inc.
GENERAL INFORMATION
VEHICLE IDENTIFICATION
Model Number Designation
Example: R13XT9EAK
MODEL
GROUP CHASSIS DRIVELINE ENGINE CATEGORY OPTION REGION
YEAR
1st digit 2/3rd digit 4th digit* 5th digit* 6th digit* 7th digit* 8th digit 9th digit** 10th digit
C = Sportsman 6x6
D = Sportsman Tour Displacement in cc divided
E = Trail Boss by 10 and rounded to two
F = Sportsman Youth A = 2x4 Chain digits
G = Sport B = 2x4 Shaft (i.e. 50 = 498cc)
H = RANGER 6x6 C = 4x4 AC Drive ------------ A = ORV
J = RZR XP E = 4x4 Shaft / IRS For electric vehicles D = Diesel
K = Sport Youth G = 4x4 Chain rear /  08 = 48 Volt E = EU On-road
11 M = Sportsman shaft front 12 = 72 Volt F = INT’L
A = ATV
12 N = Trail Blazer H = 4x4 Shaft / IRS G = EV C = Calif.
R = RANGER
13 P = Phoenix J = 2x4 Swing arm Manual L = LSV
R = RANGER Midsize N = 4x4 Shaft ADC - - OR - - M = Military
S = RZR P = 2x4 / IRS Manual S = Scandinavian
T = Sportsman X2 R = 6x6 Shaft / IRS 5 = 550 V = EU On-road
U = RANGER Fullsize T = 4x4 Shaft / Trailing Arm 6 = 570 E = EPS
V = RZR X = 4x4 Shaft EBS 7 = 760 D = Diesel
W = Multi-pass RGR 8 = 850 F=D+E
X = Multi-pass RZR 9 = 875
Z = Sportsman XP
* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively
** = 9th digit will be used on color/featured versions of models (not including the base)
First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN.
Engine Designation Number

1204573 RZRXP 875-13 .................................................... 4-Stroke DOHC Twin Cylinder, Liquid Cooled, Electric Start
Vehicle Identification Number (VIN) Designation

Example: 4XAXT9EAXDB000000
Vehicle Descriptors Vehicle Identifiers

Engine Modifier
Mfg. Location
Model Year *
Engine Size
Check Digit
World Mfg. ID
Category
Individual Serial No.

Driveline
Chassis
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4 X A X T 9 E A X D B 0 0 0 0 0 0
* Model Year: A = 2010; B = 2011; C = 2012; D = 2013
1.2
GENERAL INFORMATION
Vehicle and Engine Serial Number Location
Whenever corresponding about a Polaris ORV, refer to the vehicle identification number (VIN) and the engine serial 1
number.
The VIN can be found stamped on a portion of the left rear frame, behind the lower shock mounting location. Refer to
Figure 1-1.
The engine serial number can be found on a decal applied to the front of the engine crankcase (A) or stamped into the
crankcase on the PTO side of the engine (B). Refer to Figure 1-2.
Figure 1-1 Figure 1-2

B
VIN A
1.3
GENERAL INFORMATION
VEHICLE INFORMATION
Publication Numbers
Model Model No. Owner’s Manual Parts Manual

2013 RANGER RZR XP 900 R13JT87AD, AL, AT 9924093 9924094
2013 RANGER RZR XP 900 EPS R13JT9EAK, AO 9924093 9924094
2013 RANGER RZR XP 900 INT’L R13JT9EFX 9924093 9924094
2013 RANGER RZR XP 4 900 R13XT87AA 9924107 9924108
2013 RANGER RZR XP 4 900 EPS R13XT9EAK 9924107 9924108
2013 RANGER RZR XP 4 900 INT’L R13XT9EFX 9924107 9924109
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.
Replacement Keys
Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the
original key and refer to the chart to the right for the proper part number.
Series# Part Number

KEY COVER
20 4010278
P/N 5533534
21 4010278
22 4010321
23 4010321
27 4010321
Key Series
28 4010321
Number
31 4110141
32 4110148
67 4010278
68 4010278
1.4
GENERAL INFORMATION
SPECIAL TOOLS
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other
tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when
1
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/
Select “SPX Website - Tools, diagnostics” from

the “Service and Warranty” drop down menu
1.5
GENERAL INFORMATION
GENERAL SPECIFICATIONS
MODEL: 2013 RANGER RZR XP 900
MODEL NUMBER: R13JT87AD, AL, AT
ENGINE NUMBER: 1204573
Category Dimension / Capacity
Length 108.4 in. / 275 cm
Width 64 in. / 162.5 cm
Height 73 in. / 185 cm
Wheel Base 81.4 in. / 207 cm
Ground Clearance 13 in. / 33 cm
Dry Weight 1190 lbs. / 540 kg
Gross Vehicle Weight 1930 lbs. / 875 kg
Cargo Box Capacity 300 lbs. / 136 kg
740 lbs. / 335.6 kg
Maximum Weight
(Includes driver, passenger, cargo
Capacity (Payload)
and accessories)
Hitch Towing Capacity This vehicle is not equipped with a

hitch for towing loads. Do not use
this vehicle for towing. Do not modify
Hitch Tongue Capacity the vehicle by adding a hitch.
MODEL: 2013 RANGER RZR XP 900 EPS / INT’L

MODEL NUMBER: R13JT9EAK, AO / R13JT9EFX
Length 108.4 in. / 275 cm
Width 64 in. / 162.5 cm
Height 73 in. / 185 cm
Wheel Base 81.4 in. / 207 cm
Ground Clearance 13 in. / 33 cm
740 lbs. / 335.6 kg
Maximum Weight
(Includes driver, passenger, cargo
Capacity (Payload)
and accessories)

1.6
GENERAL INFORMATION
2013 RANGER RZR XP 900 / EPS / INT’L Drivetrain
MODEL NUMBER: 87AD, AL, AT / 9EAK, AO / 9EFX Transmission Type Polaris Automatic PVT 1
ENGINE NUMBER: 1204573 Drive Ratio - Front 3.82:1
Engine Drive Ratio - Final 3.53:1
4-Stroke DOHC Twin Cylinder, Shift Type In Line Shift - H / L / N / R / P
Platform
Liquid Cooled, Electric Start Front Gearcase Polaris Demand Drive Plus
Engine Number 1204573 Fluid Type / Capacity 6.75 oz. (200 ml)
Engine Displacement 875cc Polaris AGL Plus
Transmission
XP 900: 44 oz. (1300 ml)
Number of Cylinders 2 Fluid Type / Capacity
XP INT’L: 41 oz. (1200 ml)
Bore & Stroke (mm) 93 x 64.4 mm
Drive: Polaris, Basic,
Compression Ratio 10.5:1 Non-Braking Bearing
Clutching (PVT) Type
Engine Idle Speed 1250 ± 100 RPM
Driven: Team Roller Dampened
Engine Max Operating RPM 8750 RPM
Clutching (PVT)
Lubrication Wet Sump 10.5 in. (26.7 cm)
Center-to-Center Distance
Oil Requirements PS-4 Plus or Extreme Duty PVT Drive Belt 3211148
Oil Capacity 2.5 qts. / 2.4 liters Steering / Suspension
Coolant Capacity 4.9 qts. / 4.6 liters Independent Dual A-arm
Front Suspension / Shock
Overheat Warning Instrument Cluster Indicator FOX™ 2.0 Piggyback
Exhaust System Dual Headpipe / Single Silencer Front Travel 13.5 in. / 34.3 cm
Fuel System Independent Trailing Arm
Rear Suspension / Shock
Fuel System Type Bosch M17 EFI FOX™ 2.0 Piggyback
Fuel Delivery Electronic Fuel Pump (in tank) Rear Travel 14 in. / 35.6 cm
Fuel Pressure 43.5 ± 2 psi (300 ± 14 kPa) Shock Preload Adjustment Threaded Spanner Wrench
Front / Rear Adjustment
Fuel Filters See Chapter 4
Toe Out 1/8 - 3/16 in. (3.2 - 4.8 mm)
7.25 gal. (27.4 liters)
Fuel Capacity / Requirement Wheels / Brakes
87 Octane (minimum)
Electrical 12 x 6 / Cast Aluminum
Front Wheel Size Maxxis Bighorn / 26 x 9 R12
Alternator Rated Output 570 Watts @ 3000 RPM Front Tire Type / Size ITP Baja Cross XD / 26 x 9 R12
2 - Dual Beam LED: ITP 900XCT / 27 x 9 R12
Headlights
Low 27 Watts; High 27 Watts 12 x 8 / Cast Aluminum
Tail / Brake 2 - 6 Watts / 2 - 27 Watts Rear Wheel Size Maxxis Bighorn / 26 x 12 R12
Starting System Electric Start Rear Tire Type / Size ITP Baja Cross XD / 26 x 11 R12
ITP 900XCT / 27 x 11 R12
Ignition System Bosch M17 (ECU Controlled)
Front: 12 psi (82.7 kPa)
Spark Plug / Gap RG4YCX / 0.03 in. (0.75 mm) Tire Air Pressure
Rear: 14 psi (96.5 kPa)
Deka ETX30L / 30 AH
Battery Foot Actuated - 4 Wheel
365 CCA / 12 Volt Brakes - Front / Rear
Hydraulic Disc
Instrument Type Multifunction Instrument Cluster
Brake Fluid DOT 4
DC Outlet Standard 12 Volt
Parking Brake Hand Actuated
Chassis / EFI / Fan (INT’L Model Only) (located in center console)
Relays
Fuel Pump / EPS (OPT)
Circuit Breaker 20 Amp: Fan Motor CLUTCH CHART
10 Amp: Drive Shift Drive Driven
Altitude
10 Amp: Fuel Pump Weight Spring Spring
Fuses (Fuse/Relay Box) 20 Amp: Lights
20 Amp: EFI 0-1500 26-59 Blue / Yellow Red
20 Amp: Accessory Meters (0-5000) (1322981) (7043766) (3234452)
30 Amp: EFI (Feet) 1500-3700 26-55 Blue / Yellow Red

Fuses (Power Fuse Holder) 30 Amp: Chassis (5000 - 12000) (1322982) (7043766) (3234452)
30 Amp: EPS (OPT)
1.7
GENERAL INFORMATION
MODEL: 2013 RANGER RZR XP 4 900
MODEL NUMBER: R13XT87AA
Length 134.4 in. / 341.4 cm
Width 64 in. / 162.5 cm
Height 77 in. / 195.6 cm
Wheel Base 107.4 in. / 272.8 cm
Ground Clearance 12.5 in. / 31.8 cm
Dry Weight 1390 lbs. / 630.5 kg
900 lbs. / 408 kg
Maximum Weight
(Includes driver, passengers, cargo
Capacity (Payload)
and accessories)

MODEL: 2013 RANGER RZR XP 4 900 EPS / INT’L

MODEL NUMBER: R13XT9EAK / R13XT9EFX
Length 134.4 in. / 341.4 cm
Width 64 in. / 162.5 cm
Height 77 in. / 195.6 cm
Wheel Base 107.4 in. / 272.8 cm
Ground Clearance 12.5 in. / 31.8 cm
900 lbs. / 408 kg
Maximum Weight
(Includes driver, passengers, cargo
Capacity (Payload)
and accessories)

1.8
GENERAL INFORMATION
2013 RANGER RZR XP 4 900 / EPS / INT’L Drivetrain
MODEL NUMBER: R13XT87AA / R13XT9EAK, FX Transmission Type Polaris Automatic PVT 1
ENGINE NUMBER: 1204573 Drive Ratio - Front 3.82:1
Engine Drive Ratio - Final 3.53:1
4-Stroke DOHC Twin Cylinder, Shift Type In Line Shift - H / L / N / R / P
Platform
Liquid Cooled, Electric Start Front Gearcase Polaris Demand Drive Plus
Engine Number 1204573 Fluid Type / Capacity 6.75 oz. (200 ml)
Engine Displacement 875cc Polaris AGL Plus
Transmission
XP 4 900: 44 oz. (1300 ml)
Number of Cylinders 2 Fluid Type / Capacity
XP 4 INT’L: 41 oz. (1200 ml)
Bore & Stroke (mm) 93 x 64.4 mm
Drive: Polaris, Basic,
Compression Ratio 10.5:1 Non-Braking Bearing
Engine Idle Speed 1250 ± 100 RPM Clutching (PVT) Type
Driven: Team Roller
Engine Max Operating RPM 8750 RPM Dampened
Lubrication Wet Sump Clutching (PVT)
10.5 in. (26.7 cm)
Oil Requirements PS-4 Plus or Extreme Duty Center-to-Center Distance
Oil Capacity 2.5 qts. / 2.4 liters PVT Drive Belt 3211148
Coolant Capacity 9.7 qts. / 9.2 liters Steering / Suspension
Overheat Warning Instrument Cluster Indicator Independent Dual A-arm
Exhaust System Dual Headpipe / Single Silencer Front Suspension / Shock Walker Evans™ 2.0"
Piggyback
Fuel System
Front Travel 13.5 in. / 34.3 cm
Fuel System Type Bosch M17 EFI
Independent Trailing Arm
Fuel Delivery Electronic Fuel Pump (in tank) Rear Suspension / Shock Walker Evans™ 2.5"
Fuel Pressure 43.5 ± 2 psi (300 ± 14 kPa) Piggyback
Fuel Filters See Chapter 4 Rear Travel 14 in. / 35.6 cm
7.25 gal. (27.4 liters) Shock Preload Adjustment Threaded Spanner Wrench
Fuel Capacity / Requirement
87 Octane (minimum) Front / Rear Adjustment
Electrical Toe Out 1/8 - 3/16 in. (3.2 - 4.8 mm)
Alternator Rated Output 570 Watts @ 3000 RPM Wheels / Brakes
2 - Dual Beam LED: 12 x 6 / Cast Aluminum
Headlights Front Wheel Size
Low 27 Watts; High 27 Watts Maxxis Bighorn / 26 x 9 R12
Front Tire Type / Size
Tail / Brake 2 - 6 Watts / 2 - 27 Watts ITP 900XCT / 27 x 9 R12
Starting System Electric Start 12 x 8 / Cast Aluminum
Rear Wheel Size
Maxxis Bighorn / 26 x 12 R12
Ignition System Bosch M17 (ECU Controlled) Rear Tire Type / Size
ITP 900XCT / 27 x 11 R12
Spark Plug / Gap RG4YCX / 0.03 in. (0.75 mm)
Front: 14 psi (96.5 kPa)
Deka ETX30L / 30 AH Tire Air Pressure
Battery Rear: 16 psi (110.3 kPa)
365 CCA / 12 Volt
Foot Actuated - 4 Wheel
Instrument Type Multifunction Instrument Cluster Brakes - Front / Rear
Hydraulic Disc
DC Outlet 2- Standard 12 Volt Brake Fluid DOT 4
Chassis / EFI / Fan
Relays CLUTCH CHART
Fuel Pump / EPS (OPT)
Circuit Breaker 20 Amp: Fan Motor Shift Drive Driven
Altitude
10 Amp: Drive Weight Spring Spring
10 Amp: Fuel Pump 0-1500 26-59 Purple Red
Fuses (Fuse/Relay Box) 20 Amp: Lights (0-5000) (1322981) (7043805) (3234452)
Meters
20 Amp: EFI
(Feet) 1500-3700 26-55 Purple Red
20 Amp: Accessory
(5000 - 12000) (1322982) (7043805) (3234452)
30 Amp: EFI
Fuses (Power Fuse Holder) 30 Amp: Chassis
30 Amp: EPS (OPT)
1.9
GENERAL INFORMATION
MISC. SPECIFICATIONS AND CHARTS

Conversion Table
°C to °F: °C x 9/5 + 32 = °F °F to °C: °F - 32 x 5/9 = °C
1.10
GENERAL INFORMATION
Standard Bolt Torque Specification
1
Grade 2 Grade 5 Grade 8
Grade 2 Grade 5 Grade 8

Bolt Size
Ft. Lbs. (Nm) Ft. Lbs. (Nm) Ft. Lbs. (Nm)
1/4-20 5 (7) 8 (11) 12 (16)

1/4-28 6 (8) 10 (14) 14 (19)
5/16-18 11 (15) 17 (23) 25 (35)
5/16-24 12 (16) 19 (26) 29 (40)
3/8-16 20 (27) 30 (40) 45 (62)
3/8-24 23 (32) 35 (48) 50 (69)
7/16-14 30 (40) 50 (69) 70 (97)
7/16-20 35 (48) 55 (76) 80 (110)
1/2-13 50 (69) 75 (104) 110 (152)
1/2-20 55 (76) 90 (124) 120 (166)
Metric Bolt Torque Specification
Grade
Bolt Size 4.6 4.8 8.8 / 8.9 10.9 12.9
Ft. Lbs. (Nm) Dry Threads
M3 .3 (.5) .5 (.7) 1 (1.3) 1.5 (2) 1.5 (2)

M4 .8 (1.1) 1 (1.5) 2 (3) 3 (4.5) 4 (5)
M5 1.5 (2.5) 2 (3) 4.5 (6) 6.5 (9) 7.5 (10)
M6 3 (4) 4 (5.5) 7.5 (10) 11 (15) 13 (18)
M8 7 (9.5) 10 (13) 18 (25) 26 (35) 33 (45)
M10 14 (19) 18 (25) 37 (50) 55 (75) 63 (85)
M12 26 (35) 33 (45) 63 (85) 97 (130) 11 (150)
M14 37 (50) 55 (75) 103 (140) 151 (205) 177 (240)
M16 59 (80) 85 (115) 159 (215) 232 (315) 273 (370)
M18 81 (110) 118 (160) 225 (305) 321 (435) 376 (510)
1.11
GENERAL INFORMATION
SAE Tap / Drill Sizes Decimal Equivalents
Metric Tap / Drill Sizes
1.12
MAINTENANCE
CHAPTER 2
MAINTENANCE
PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
BREAK-IN PERIOD / MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PRE-RIDE - 50 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
50 - 500 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
2
MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
MAINTENANCE QUICK REFERENCE, CONTINUED..... . . . . . . . . . . . . . . . . . . . . . . . . 2.7
GREASE LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
LUBRICANTS / SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 2.10
PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
SHIFT CABLE INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FUEL TANK VENT LINE AND FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
FUEL PUMP / FUEL FILTERS / FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
THROTTLE PEDAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
THROTTLE FREEPLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
ENGINE INTAKE PRE-FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
INTAKE BAFFLE BOX DRAIN INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
AIR BOX / AIR FILTER EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
ENGINE OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
ENGINE CRANKCASE BREATHER HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . 2.20
ENGINE CYLINDER LEAKDOWN TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
VALVE CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
EXHAUST - SPARK ARRESTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
TRANSMISSION AND FRONT GEARCASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
FRONT GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
COOLANT STRENGTH / LEVEL INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
COOLING SYSTEM PRESSURE TEST / HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
RADIATOR INSPECTION / CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
COOLANT DRAIN / FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
PVT / FINAL DRIVE / WHEEL AND TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
DRIVE CLUTCH / DRIVEN CLUTCH / BELT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . 2.31
PVT INTAKE PRE-FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
PVT DRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
DRIVE SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
WHEEL AND HUB TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
WHEEL REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
BATTERY CHARGING / OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35
ENGINE / CHASSIS ELECTRICAL GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36
SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36
2.1
MAINTENANCE
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37
STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37
STEERING WHEEL FREEPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37
TIE ROD END / WHEEL HUB INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38
WHEEL TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38
WHEEL TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39
SUSPENSION (FOX™). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.40
SPRING PRELOAD ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.40
SHOCK COMPRESSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.41
SUSPENSION (WALKER EVANS™) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.42
SPRING PRELOAD ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.42
SHOCK COMPRESSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.43
BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.44
BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.44
BRAKE PAD / DISC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.44
BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.44
PARKING BRAKE CABLE ADJUSTMENT (INT’L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.45
PARKING BRAKE PAD INSPECTION (INT’L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.45
2.2
MAINTENANCE
PERIODIC MAINTENANCE CHART
Periodic Maintenance Overview
Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts,
use genuine Pure Polaris parts available from your Polaris dealer. 2
NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment
procedures, have a qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of
approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.
Severe Use Definition

• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the
oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to
rise, discontinue use and determine the cause or see your dealer.
Break-In Period
The break-in period consists of the first 25 hours of operation. Careful treatment of a new engine and drive components
will result in more efficient performance and longer life for these components.
• Drive vehicle slowly at first while varying the throttle position. Do not operate at sustained idle.
• Perform regular checks on fluid levels and other areas outlined on the daily pre-ride inspection checklist.
• Change both the engine oil and filter after 25 hours or one month.
• See “Owner’s Manual” for additional break-in information.
Maintenance Chart Key

The following symbols denote potential items to be aware of during maintenance:
 = CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an
authorized Polaris dealer.

= SEVERE USE ITEM: See information provided above.

E = Emission Control System Service (California).
NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.
WARNING
Improperly performing the procedures markedcould result in component failure and lead to serious injury or death.
Have an authorized Polaris dealer perform these services.
2.3
MAINTENANCE
Pre-Ride - 50 Hour Maintenance Interval
Maintenance Interval
(whichever comes first)
Item Remarks
Miles
Hours Calendar
(KM)
Steering - -
Front / Rear Suspension - -
Tires - -
Brake Fluid Level - -
Inspect or adjust as needed.
Brake Pedal Travel - Pre-Ride - See Pre-Ride Checklist on Page 2.10.
Brake System - -
Wheels / Fasteners - -
Frame Fasteners - -
E Engine Oil Level - -
E Engine Intake Pre-Filter - Daily - Inspect and clean often
PVT Intake Pre-Filter - Daily - Inspect and clean often
 Intake Baffle Box Drain - Daily -
Inspect drain at the bottom of the air intake
E baffle box for obstructions
Coolant Level - Daily - Check level daily
Head Lights / Tail Lights - Daily - Check operation
 Brake Pad Wear / Inspect 10 H Monthly 100 (160) Inspect periodically
 Parking Brake Pads (INT’L)
 Parking Brake Cable 25 H - - Inspect; adjust tension after first 25 hours
 Adjustment (INT’L)
 Air Filter 25 H Monthly 250 (400) Inspect; replace as needed
E
Battery 25 H Monthly 250 (400) Check terminals; clean; test
Perform a break-in oil and filter change at
 Engine Oil & Filter Change 25 H 1M 250 (400) 25 hours or one month; perform every 50
E (Break-In Period) hours or 6 months thereafter
Front Gearcase Lubricant Initial fluid level inspection; add lubricant if
 25 H 1M 250 (400)
(Demand Drive Plus) needed
Transmission Lubricant Initial fluid level inspection; add lubricant if
 25 H 1M 250 (400)
(AGL Gearcase Lubricant) needed
 General Lubrication 50 H 3M 500 (800) Lubricate all fittings, pivots, cables, etc.
 Throttle Cable / Throttle
50 H 6M 500 (800) Inspect; adjust; replace if necessary
E Pedal
E Throttle Body Intake Boots 50 H 6M 500 (800) Inspect ducts for proper sealing / air leaks
Shift Cable / Linkage 50 H 6M 500 (800) Inspect; adjust as needed
 Steering 50 H 6M 500 (800) Lubricate (if applicable)
 Front / Rear Suspension 50 H 6M 500 (800) Lubricate (if applicable)
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
50 - 500 Hour Maintenance Interval
Maintenance Interval
(whichever comes first)
Item Remarks
Miles
Hours Calendar
(KM)
 Cooling System 50 H 6M 500 (800)

Inspect coolant strength seasonally;
pressure test system yearly
2
Perform a break-in oil change at 25 hours
 Engine Oil Change 50 H 6M 1000 (1600)
or one month
 Engine Oil Filter Change 50 H 6M 1000 (1600) Replace oil filter during engine oil change
 Parking Brake Cable 100 H 6M 1000 (1600) Inspect; adjust tension as needed
 Adjustment (INT’L)
Front Gearcase Lubricant
 100 H 12 M 1000 (1600) Change lubricant
(Demand Drive Plus)
Transmission Lubricant
 100 H 12 M 1000 (1600) Change lubricant
(AGL Gearcase Lubricant)
 Check for leaks at fill cap, fuel line / rail, and
Fuel System 100 H 12 M 1000 (1600)
E fuel pump.
 Inspect; replace as needed; torque to
Spark Plug Inspection 100 H 12 M 1000 (1600)
E specification
 Radiator 100 H 12 M 1000 (1600) Inspect; clean external surfaces
 Cooling Hoses 100 H 12 M 1000 (1600) Inspect for leaks; pressure test system
 Engine Mounts 100 H 12 M 1000 (1600) Inspect, torque to specification
Exhaust Silencer / Pipe 100 H 12 M 1000 (1600) Inspect
Inspect for wear, routing, security; apply
 Wiring 100 H 12 M 1000 (1600) dielectric grease to connectors subjected
to water, mud, etc.
 Clutches (Drive and Driven) 100 H 12 M 1000 (1600) Inspect; clean; replace worn parts
 Drive Belt 100 H 12 M 1000 (1600) Inspect; replace as needed
 Front Wheel Bearings 100 H 12 M 1000 (1600) Inspect; replace as needed
 Shocks 100 H - - Visually inspect shock seals
 Shocks - 12 M 1500 (2400) Change shock oil and inspect seals

 Coolant - 24 M - Replace coolant
 Brake Fluid 200 H 24 M 2000 (3200) Change every two years (DOT 4)
Spark Arrestor 200 H 24 M 2000 (3200) Clean out

Valve Clearance 200 H - 2000 (3200) Inspect; adjust as needed
E

Spark Plug Replacement 500 H 36 M 5000 (8000) Replace; torque to specification
E
Inspect periodically; adjust when parts are
 Toe Adjustment -
replaced
Headlight Aim - 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 Quick Reference
III. # Item Lube Rec. Method Frequency*

Polaris PS-4 Plus or Perform a break-in oil and filter
Add oil to proper level on
1 Engine Oil Polaris PS-4 Extreme Duty change at 25 hrs or one month;
dipstick
4-Cycle Engine Oil perform every 50 hrs thereafter
Maintain coolant level in Check level daily; change
2 Engine Coolant Polaris 60/40 Coolant
coolant reservoir bottle. coolant every two years
* More often under severe use, such as operated in water or under severe loads.
2.6
MAINTENANCE
Maintenance Quick Reference, Continued.....
III. # Item Lube Rec. Method Frequency*

Maintain fluid level between Check level during pre-ride
3 Brake Fluid Polaris DOT 4 Brake Fluid “MAX and “MIN” lines on the inspection; change fluid every
master cylinder reservoir
Add lubricant until it is
two years
2
4 Front Gearcase Polaris Demand Drive Plus Initial level check at 25 hours or
visible at the fill hole threads 1 month; Change lubricant at
Polaris AGL Plus Add lubricant until it is 100 hours or every 12 months,
5 Transmission
Gearcase Lubricant visible at the fill hole threads whichever comes first
* More often under severe use, such as operated in water or under severe loads.
2.7
MAINTENANCE
Grease Lubrication Points
There are grease fittings at each front A-arm pivot point, each rear torsion bar bushing and on the front propshaft yokes.
Apply grease until all traces of water have been purged out at each of these areas.
Item Method Recommended Lube Frequency

Front A-arm Grease 3 fittings on each
Polaris All Season Grease
Pivot Bushings side of the vehicle
Grease middle and rear Grease fittings every 500 miles
Propshaft Yokes Polaris Premium U-Joint Grease
fittings (800 km); Grease before long
Front Stabilizer Bar Grease the fitting on each periods of storage, and after
Polaris All Season Grease thoroughly washing or
Bushings (INT’L) side of the vehicle
Grease 2 fittings through submerging the vehicle
Rear Torsion Bar
the skid plate access holes Polaris All Season Grease
Bushings
on each side of the vehicle
2.8
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
Engine Lubricant
2871950
Loctite™ Threadlock 242 
(6 ml.) (12 count) 2
2870791 Fogging Oil (12 oz. Aerosol) Premium Carbon Clean 
2871326
(12 oz.) (12 count)
PS-4 Plus Synthetic 4-Cycle Engine Oil
2876244
(Quart) 2870652 Fuel Stabilizer (16 oz.) (12 count)
PS-4 Plus Synthetic 4-Cycle Engine Oil 2872189 DOT 4 Brake Fluid (12 count)
2876245
(Gallon)
2871557 Crankcase Sealant, 3-Bond 1215 (5 oz.)
PS-4 Extreme Duty Synthetic 4-Cycle Engine
2878920
Oil (Quart) NOTE: The number count indicated by each part
PS-4 Extreme Duty Synthetic 4-Cycle Engine number in the table above indicates the number of
2878919 units that are shipped with each order.
Oil (Gallon)
2540086 Engine Oil Filter (2013 ONLY)
2879723 Engine Oil Change Kit (PS-4 Plus)
2879324 Engine Oil Change Kit (PS-4 Extreme Duty)
Gearcase / Transmission Lubricants
AGL Plus Gearcase Lubricant
2878068
(1 Qt.) (12 Count)
2878069
(1 Gal.) (4 Count)
2878070
(2.5 Gal.) (2 Count)
Demand Drive Plus 
2877922
(Quart)
Demand Drive Plus
2877923
(2.5 Gallon)
2870465 Oil Pump for 1 Gallon Jug
Grease / Specialized Lubricants
2871312 Grease Gun Kit
Premium All Season Grease 
2871322
(3 oz. cartridge) (24 Count)
Premium All Season Grease 
2871423
(14 oz. cartridge) (10 Count)
2871460 Starter Drive Grease (12 Count)
2871515 Premium U-Joint Lube (3 oz.) (24 Count)
2871551 Premium U-Joint Lube (14 oz.) (10 Count)
2871329 Dielectric Grease (Nyogel™)
Coolant
2871323 60/40 Coolant (Gallon) (6 Count)
2871534 60/40 Coolant (Quart) (12 Count)
2.9
MAINTENANCE
GENERAL VEHICLE INSPECTION Shift Cable Inspection / Adjustment

AND MAINTENANCE Shift cable adjustment may be necessary if symptoms
include:
Pre-Ride / Daily Inspection • No gear position or AWD display on instrument
Perform the following pre-ride inspection daily, and when cluster
servicing the vehicle at each scheduled maintenance. • Ratcheting noise on deceleration
• Engine Oil - Check for proper level on dipstick • Inability to engage into a gear
(refer to “Engine Oil Level” procedure)
• Excessive gear lash (noise)
• Tires - check condition and pressures
• Gear selector moving out of desired range
• Fuel tank - fill to proper level
1. Locate the shift cable attached to the transmission
• All brakes - check operation and fluid leveL and
case in the right rear wheel well area.
adjustment (includes parking brake on INT’L
Model) 2. Inspect shift cable, clevis pin, pivot bushings, and dust
• Throttle - check for free operation and closing boot. Replace if worn or damaged.
• Headlights/Taillights/Brakelights - also check

operation of all indicator lights, instrument cluster Shift Cable
and switches Mount
• Ignition switch - check for proper function

• Wheels - check for tightness of wheel nuts and Shift Cable
axle nuts; check to be sure axle nuts are secured
by cotter pins
• Engine Intake Pre-Filter - Inspect pre-filter and
clean with soapy water and low pressure
compressed air if necessary Pin and
Bushings Dust Boot
• PVT Intake Pre-Filter - Inspect pre-filter and clean
with soapy water and low pressure compressed air
if necessary
3. If adjustment is required, loosen the lower jam nut and
• Steering - check for free operation noting any pull the cable out of the mount to move the upper jam
unusual looseness in any area nut.
• Loose parts - visually inspect vehicle for any
damaged or loose nuts, bolts or fasteners Upper
Jam Nut
• Engine coolant - check for proper level at the
recovery bottle
• Drive Shaft Boots - Inspect inner and outer boots
for tears or damage on both front and rear drive
shafts
• Check all front and rear suspension components
for wear or damage.
Lower
Jam Nut
Frame, Nuts, Bolts, and Fasteners
Periodically inspect the torque of all fasteners in
accordance with the maintenance schedule. Check that all 4. Adjust the shift cable so there is the same amount of
cotter pins are in place. Refer to specific fastener torques cable travel when shifting slightly past HIGH gear and
listed in each chapter. PARK.
2.10
MAINTENANCE
5. Thread the upper or lower jam nut as required to FUEL SYSTEM AND AIR INTAKE
obtain proper cable adjustment.
Fuel System
NOTE: This procedure may require a few attempts to
obtain the proper adjustment.
WARNING
6. Once the proper adjustment is obtained, place the
shift cable and upper jam nut into the mount. Tighten
Gasoline is extremely flammable and explosive
2
the lower jam nut against the mount.
under certain conditions.
7. Start engine and shift through all gears to ensure the Always stop the engine and refuel outdoors or in
shift cable is properly adjusted. If transmission still a well ventilated area.
ratchets after cable adjustment, the transmission will Do not smoke or allow open flames or sparks in
require service. or near the area where refueling is performed or
where gasoline is stored.
Do not overfill the tank. Do not fill the tank neck.
If you get gasoline in your eyes or if you swallow
gasoline, seek medical attention immediately.
If you spill gasoline on your skin or clothing,
immediately wash it off with soap and water
and change clothing.
Never start the engine or let it run in an enclosed
area. Engine exhaust fumes are poisonous and
can result in loss of consciousness or
death in a short time.
Never drain the fuel when the engine is hot.
Severe burns may result.
Fuel Tank Vent Line and Filter

Symptoms of a restricted fuel tank vent include the
following: collapsing fuel tank, engine miss or hesitation,
loss of engine performance or high exhaust temperatures.
1. Remove the seats and the engine service panel.
2. Locate and inspect the in-line filter (A). Note the

direction of the arrow on the filter if removed.
NOTE: Be sure to install the filter in the orientation

shown in the previous photo.
2.11
MAINTENANCE
3. If there is debris visible in the filter, replace it. NOTE: Refer to Chapter 4 for fuel pump replacement
and all other information related to the EFI System.
4. Check the fuel tank vent line for signs of wear,
deterioration or damage. Replace vent line if Fuel Lines
necessary.
1. Check both quick-connect fuel lines at the fuel tank
5. Be sure the vent line is routed properly and secured for signs of wear, deterioration, damage or leakage.
with cable tie(s). Replace line(s) if necessary.
IMPORTANT: Make sure vent line is not kinked or

Supply Line
pinched.
Fuel Pump / Fuel Filters

The fuel pump assembly is located in the fuel tank under
the passenger seat.
The RZR XP 900 EFI engine uses a serviceable, high-
volume, high-pressure, fuel pump that includes a
preliminary filter and an internal fine filter located before
the pump regulator.
RZR XP
Shown Return Line
Fuel Pump Asm
2. Locate the fuel supply fitting (C) through the right rear
wheel well on the upper right side of the engine. Check
the line and quick-connect fitting for signs of wear,
deterioration, damage or leakage. Replace line if
necessary.
C
RZR XP
Shown
NOTE: Neither filter is servicable individually. Must

replace the fuel pump as an assembly.
2.12
MAINTENANCE
3. Locate the fuel return fitting (D) through the left rear Throttle Pedal Inspection
wheel well on the upper left side of the engine. Check
the line and quick-connect fitting for signs of wear, This vehicle is equipped with a Throttle Release Switch
deterioration, damage or leakage. Replace line if (TRS) used to detect when the throttle pedal has returned
necessary. to the rest position.
NOTE: The throttle pedal lever is designed to have a

D few degrees of freeplay prior to engaging the throttle 2
arm that pulls the throttle cable.
Always check that the throttle pedal moves independently

of the cable pull lever at the start of throttle pedal travel and
that the throttle pedal returns normally before starting the
engine.
There should be minimal freeplay between the throttle

cable and the cable pull lever. If there is excessive play
due to cable stretch or misadjustment, it will cause a delay
in throttle response, especially at low engine speed. The
throttle may also not open fully. If the throttle cable has no
freeplay, the throttle may be hard to control, and the idle
4. Be sure fuel lines are routed and retained properly. speed may be erratic.
IMPORTANT: Make sure lines are not kinked or

pinched. TRS
Throttle Pedal
Throttle Cable
Check throttle pedal freeplay periodically in accordance

with the Periodic Maintenance Chart. Adjust the freeplay
if necessary (see “Throttle Freeplay Adjustment”).
2.13
MAINTENANCE
Throttle Freeplay Adjustment Adjustment
Inspection 1. Allow the engine and exhaust system to cool before

attempting to perform this procedure.
1. Place the transmission in PARK.
2. Start the engine, and warm it up thoroughly. CAUTION

3. Measure the distance the throttle arm (A) moves Use caution when performing this procedure.
before the engine begins to pick up speed. Throttle Engine and exhaust components may be hot and
cable freeplay should be 1/16” - 1/8” (1.5 - 3 mm). may cause severe injury or burns.
2. Locate the throttle freeplay adjustment through the

right rear wheel well, behind the exhaust header pipe.
A 3. Slide back the cable adjuster boot (C).
C E
D
NOTE: The throttle pedal lever (B) is designed to
have a few degrees of freeplay prior to engaging the
throttle arm (A) that pulls the throttle cable.
4. Using a 14 mm open-end wrench, loosen the

adjustment jam nut (D). Using a 12 mm open-end
wrench, move the cable adjuster (E) until 1/16” to 1/
8” (1.5 - 3 mm) of freeplay is achieved at the throttle
arm (A).
NOTE: While adjusting, lightly move the throttle

pedal in and out.
5. Apply Thread Sealant with Teflon® to the adjuster

threads.
6. Re-tighten the jam nut after final adjustment is made.
7. Slide the cable adjuster boot over the cable adjuster

to its original position.
2.14
MAINTENANCE
Engine Intake Pre-Filter Service Air Filter Service
It is recommended that the engine intake pre-filter be Inspect the air filter at the intervals outlined in the Periodic
inspected daily. The filter should be inspected using the Maintenance Chart. In extremely dusty conditions, air filter
following procedure: replacement will be required more often.
1. The engine intake pre-filter is located just above the 1. Remove the cargo box access panel (A).
left rear wheel fender. 2
A
2. Press in on intake grill cover tab to access pre-filter.
Press In Tab
2. Loosen the (5) air box cover retaining knobs (B) and
rotate them away from the cover. Release the (2)
cover latches (C).
3. Inspect the pre-filter. If necessary, clean with soapy
water and dry with low pressure compressed air.
C
B
Pre-Filter
3. Pull cover rearward far enough to remove air filter (D).
2.15
MAINTENANCE
NOTE: Leave the lower portion of the air box cover Intake Baffle Box Drain Inspection
in the hinges. It is not necessary to remove the cover
when servicing the air filter. It is recommended that the intake baffle box drain be
inspected daily.
4. Inspect the air box for oil or water deposits. Wipe away
any deposits with a clean shop towel. 1. Access the intake baffle box drain through the left
rear wheel well.
NOTE: If the filter has been soaked with fuel or oil it
must be replaced.
Baffle Box
5. Inspect the air filter and replace if necessary.
IMPORTANT: DO NOT attempt to clean the air filter.

6. Place the air filter into the air box and reinstall the air
box cover.
NOTE: Be sure the lower tabs on the air box cover

are properly engaged into the airbox.
7. Engage the cover latches and tighten the retaining Drain

knobs.
8. Reinstall the cargo box access panel.

2. Check the drain to ensure it is not plugged with debris
so it can drain properly. If needed, remove the drain
from the baffle box during inspection.
2.16
MAINTENANCE
Air Box / Air Filter Exploded View
Intake Pre-Filter 2
Intake Baffle Box
Seal
Air Box Cover
Clamps
Air Filter
Bolts
Flange
Bushing (2)
Intake Hose
Air Box
Base Clamp
Snap Bushing
Grommet (2) Drain Cap

Dual Round
Throttle Body Boot
Knob (5)
Pivot Nut (5)
Intake Tubes
Clamp
Clamps
2.17
MAINTENANCE
ENGINE 5. Reinstall the dipstick and push it into place. Do not

lock the dipstick
Engine Oil Level
NOTE: Make certain the dipstick is inserted all the
The 2013 RZR XP 900 engine has a wet-sump design, way into the dipstick tube to keep the depth of the
meaning the engine oil is contained in the bottom of the dipstick consistent.
crankcase. To check the oil level, follow the procedure
listed below: 6. Remove the dipstick and check the oil level.
Access the oil dipstick through the engine service panel. 7. Add the recommended oil as necessary to bring the
oil level within the SAFE range on dipstick. Do not
Access the oil fill cap through the cargo box access panel. overfill (see NOTE below).
Polaris recommends the use of PS-4 Plus Synthetic or

PS-4 Extreme Duty Synthetic 4-Cycle Engine Oil.
= Maintain Oil Level In SAFE Range
Recommended Engine Oil: DO NOT Overfill the Engine
PS-4 Plus Synthetic (PN 2876244)

Ambient Temp Range: -35° F to 100° F NOTE: A rising oil level between checks during cold
weather operation can indicate contaminants such
PS-4 Extreme Duty Synthetic (PN 2878920) as gas or moisture collecting in the crankcase. If the
Ambient Temp Range: 0° F to 120° F oil level is over the upper mark, change the oil
immediately.
Capacity: 2.5 Quarts (2.4 L)
8. Add engine oil through the oil fill cap (B) located on
top of the valve cover, under the cargo box access
1. Position vehicle on a level surface and place the
panel.
transmission in PARK.
2. Stop the engine and allow it to cool down before B

removing the dipstick.
3. Remove the seats and engine service panel to access

the dipstick.
4. Unlock the dipstick lever (A). Remove the dipstick and

wipe it dry with a clean cloth.
9. When finished, reinstall dipstick and lock the lever.
2.18
MAINTENANCE
Engine Oil and Filter Change 6. Using the Oil Filter Wrench (PU-50105), turn the oil
filter (D) counter-clockwise to remove it.
Always change engine oil and filter at the intervals outlined
in the Periodic Maintenance Chart. Always change the oil
filter whenever changing the engine oil.
The engine oil dipstick is located on the front side of the

engine. Access the dipstick through the engine service 2
panel.
The engine oil fill cap is located on top of the valve cover.
Access the oil fill cap through the cargo box access panel.
The crankcase drain plug is located on the bottom of the

crankcase. Access the drain plug through the skid plate
access hole located directly under the crankcase. D
1. Position vehicle on a level surface and place the

transmission in PARK.
Oil Filter Wrench:
2. Stop the engine and allow it to cool down. PU-50105: 2.5” (64 mm)
3. Clean the area around the crankcase drain plug.

7. Using a clean dry cloth, clean the filter sealing surface
on the engine crankcase.
CAUTION
8. Lubricate the O-ring on the new oil filter with a film of
Use caution when performing this procedure. fresh engine oil. Check to make sure the O-ring is in
Do not allow hot engine oil to come into contact good condition. Install it by hand until the O-ring
with skin, as serious burns may result. contacts the sealing surface, then turn an additional
1/2 turn.
4. Place a drain pan under the engine crankcase and
remove the drain plug (C). Allow the oil to drain =T
completely.
Oil Filter Torque:
Turn by hand until filter O-ring contacts sealing
surface, then turn an additional 1/2 turn.
9. Replace the sealing washer on drain plug.
NOTE: The sealing surface on the drain plug should

be clean and free of burrs, nicks or scratches.
10. Reinstall the engine crankcase drain plug. Torque

drain plug to specification.
Access through
skid plate hole C
=T
5. Remove the seats and engine service panel to access Crankcase Drain Plug:
the oil filter and dipstick. 12 ft-lbs (16 Nm)
2.19
MAINTENANCE
11. Remove oil fill cap (see “Engine Oil Level”). Fill engine Engine Crankcase Breather Hose Inspection
with 2.5 quarts (2.4 L) of recommended engine oil.
The engine crankcase is equipped with a breather hose.
Inspect the breather hose for possible kinks or wear. The
hose is form fitted for proper fit.
=
Follow the breather hose (A) from the crankcase to the
Recommended Engine Oil: engine intake baffle box.
PS-4 Plus Synthetic (PN 2876244)

A
Ambient Temp Range: -35° F to 100° F
PS-4 Extreme Duty Synthetic (PN 2878920)

Ambient Temp Range: 0° F to 120° F
Capacity: 2.5 Quarts (2.4 L)
12. Verify the transmission is still in PARK.
13. Start the engine and allow it to idle for 30 seconds.
14. Stop the engine and inspect for oil leaks. Wait at least
15 seconds before removing the dipstick.
15. Unlock the dipstick lever. Remove the dipstick and NOTE: Make sure hoses are not kinked or pinched.
wipe it dry with a clean cloth (see “Engine Oil Level”).
16. Reinstall the dipstick and push it into place. Do not Engine Cylinder Leakdown Test
lock the dipstick
A cylinder leak-down test is the best indication of engine
NOTE: Make certain the dipstick is inserted all the condition. Follow tester manufacturer’s instructions to
way into the dipstick tube to keep the depth of the perform a cylinder leak-down test. Never use high
dipstick consistent. pressure leakage testers as crankshaft seals may
dislodge and leak.
17. Remove the dipstick and check the oil level.
Cylinder Leakage Service Limit: 20%
18. Add the recommended oil as necessary to bring the
oil level within the SAFE range on dipstick. Do not
If leakage exceeds service limit, inspect the
overfill.
engine for the cause.
Maintain Oil Level In SAFE Range
DO NOT Overfill the Engine
19. When finished, reinstall the oil fill cap, oil dipstick and
lock the lever.
20. Reinstall the cargo box access panel, engine service

panel and seats.
21. Dispose of used oil and filter properly.
2.20
MAINTENANCE
Valve Clearance Inspection 8. Remove the (2) screws (D) that mount the air box to
the upper frame cross member.
IMPORTANT: Valve clearance inspection should be
performed on a cold engine, at room temperature. 9. Remove the (2) tie-straps (E) retaining the harness to
the rear cross member.
1. Remove the seats and engine service panel.
2. Disconnect the negative (-) battery cable.

10. Remove the screw (F) retaining the throttle cable to
the IAC valve. 2
3. Remove the cargo box assembly (see Chapter 5 11. Disconnect the fuel injector leads (G) and remove the
“Cargo Box Assembly Removal”). (2) tie-straps (H) retaining the injector leads to the rear
cross member.
4. Remove the (8) screws that retain the outer clutch
cover.
5. Maneuver the outer clutch cover to allow access to the

drive clutch, in order to rotate the engine.
H
G
12. Remove the spark plug wires from the engine.
13. Remove the push rivet (I) that retains the heat shield
to the frame cross member.
NOTE: Removal of left rear wheel or left rear shock
I K J
is NOT necessary to perform this procedure.
6. Loosen the hose clamp and remove the PVT outlet J L

duct (A).
7. Remove the harness (B) and hoses (C) from the IAC L
motor and valve.
A C
14. Remove the (4) bolts (J) that attach the rear cross
member (K) and box support brackets (L) to the
F
vehicle frame.
E D
2.21
MAINTENANCE
15. Remove the cross member from the vehicle to gain 18. Rotate the drive clutch counter-clockwise until the
access to valve cover as shown below. cam lobes above the valves you are inspecting are
facing up.
Cam Lobe Up
Measure
Here
16. Remove the (4) T40 bolts retaining the valve cover.
19. Measure the valve clearance using a feeler gauge.
Cam Lobe Up
20. If the valve clearance is out of specification, proceed

to “Valve Clearance Adjustment” (see Chapter 3).
17. The engine will need to be rotated (4) times to inspect
all (8) valve clearances. Two valves can be measured
at each camshaft lobe position.
= In. / mm.
MAG PTO
Intake Intake Intake Valve Clearance (cold):
.006 ± .002 in. (0.15 ± 0.05 mm)
= In. / mm.
Exhaust Valve Clearance (cold):

.012 ± .002 in. (0.30 ± 0.05 mm)
MAG PTO
Exhaust Exhaust 21. Repeat steps 18-20 until all (8) valves have been
inspected.
NOTE: Remove spark plugs to aid engine rotation.

2.22
MAINTENANCE
22. If previously removed, apply anti-seize compound to 28. Route the injector leads and vent hoses through the
the spark plug threads and reinstall the spark plugs. rear cross member. Connect the injector leads to the
Torque spark plugs to specification. main harness.
29. Install (4) new tie-straps as shown to secure the

=T harness to the rear cross member.
Spark Plug Torque: 2

7 ft-lbs (10 Nm)
23. Inspect the valve cover seal and replace if necessary.
24. Install valve cover and the (4) T40 bolts. Torque bolts
to specification.
=T
Valve Cover Bolts:
7 ft-lbs (10 Nm)
25. Install the rear cross member (K) and box support 30. Install the PVT outlet duct (A) and tighten the hose
brackets (L) back into position. Install the (4) self clamp.
tapping mounting bolts (J) and torque to specification.
31. Install the harness (B) and hoses (C) on to the IAC
I K J motor and valve.
J L A C
L B
D
=T
32. Install the (2) screws (D) that mount the air box to the
Rear Cross Member Bolts:
upper frame cross member.
17 ft-lbs (23 Nm)
33. Install the screw (F) retaining the throttle cable to the
26. Install the push rivet (I) that retains the heat shield to IAC valve.
the frame cross member.
34. Install outer clutch cover and (8) retaining screws.
27. Install the spark plug wires. Ensure wires are pushed Torque screws to specification.
down all the way so they engage onto the spark plugs.
IMPORTANT: The engine will misfire if the spark plug =T

wires are installed incorrectly. The spark plug wires
are marked with PTO and MAG and should be installed Outer Clutch Cover Screws:
to the corresponding cylinder. 45-50 in-lbs (5 Nm)
2.23
MAINTENANCE
35. Connect the negative (-) battery cable to the battery. Exhaust - Spark Arrestor
36. Start the engine to ensure proper operation.
WARNING
37. Install the cargo box assembly (see Chapter 5).
38. Install the seats and engine service panel. Do not clean spark arrestor immediately after
the engine has been run, as the exhaust system
becomes very hot. Serious burns could result
from contact with the exhaust components.
Allow components to cool sufficiently before
proceeding. Wear eye protection and gloves.
Never run the engine in an enclosed area.
Exhaust contains poisonous carbon monoxide
gas that can cause loss of consciousness
or death in a very short time.
Periodically clean spark arrestor to remove accumulated

carbon.
1. Remove the retaining screw and nut.
2. Remove the spark arrestor from the end of the

silencer.
3. Use a non-synthetic brush to clean the arrestor

screen. A synthetic brush may melt if components are
warm. If necessary, blow debris from screen with
compressed air.
4. Inspect the screen for wear and damage. Replace if

needed.
5. Reinstall the arrestor and torque the retaining screw

to 8 ft-lbs (11 Nm).
Silencer
Screen
Arrestor
Screw
8 ft-lbs (11 Nm) Nut
2.24
MAINTENANCE
TRANSMISSION AND FRONT GEARCASE
Specification Chart
Gearcase Lubricant Capacity Fill / Drain Plug Torque
Transmission
Transmission (INT’L)
AGL Plus Gearcase Lubricant
44 oz. (1300 ml)
41 oz. (1200 ml)
10-14 ft-lbs (14-19 Nm)
10-14 ft-lbs (14-19 Nm)
2
Front Gearcase Demand Drive Plus 6.75 oz. (200 ml) 8-10 ft-lbs (11-14 Nm)
Transmission Lubrication
NOTE: It is important to follow the transmission 4. Reinstall the fill plug and torque to specification.
maintenance intervals described in the Periodic
Maintenance Chart. Regular lubricant level
=T
inspections should be performed as well.
The transmission lubricant level should be checked and Fill / Drain Plug Torque:
changed in accordance with the maintenance schedule. 10-14 ft-lbs (14-19 Nm)
• Be sure vehicle is positioned on a level surface

when checking or changing the lubricant. Transmission Lubricant Change
• Check vent hose to be sure it is routed properly The drain plug is located on the bottom of the transmission
and unobstructed. gearcase. Access the drain plug through the drain hole in
the skid plate.
Transmission Lubricant Level Check
1. Remove the fill plug (refer to “Transmission Lubricant
The fill plug is located on the rear portion of the Level Check”).
transmission gearcase. Access the fill plug at the rear of
2. Place a drain pan under the transmission drain plug.
the vehicle. Maintain lubricant level even with the bottom
of the fill plug hole. 3. Remove drain plug and allow lubricant to drain
completely.
1. Position vehicle on a level surface.
2. Remove the fill plug and check the lubricant level.
3. If lubricant level is not even with bottom threads, add

recommended lubricant as needed. Do not overfill.
2.25
MAINTENANCE
4. Clean the drain plug magnetic surface. Front Gearcase Lubrication
5. Reinstall drain plug with a new O-ring and torque to NOTE: It is important to follow the front gearcase
specification. maintenance intervals described in the Periodic
Maintenance Chart. Regular fluid level inspections
6. Add the recommended amount of lubricant through should be performed as well.
the fill plug hole. Maintain the lubricant level at the
bottom of the fill plug hole when filling the The front gearcase fluid level should be checked and
transmission. Do not overfill. changed in accordance with the maintenance schedule.
• Be sure vehicle is positioned on a level surface
when checking or changing the fluid.
=
• Check vent hose to be sure it is routed properly
and unobstructed.
Recommended Transmission Lubricant:
(PN 2878068) (Quart) Front Gearcase Fluid Level Check
The fill plug is located on the bottom right side of the front
Capacity: 44 oz. (1300 ml) gearcase. Access the fill plug through the right front wheel
well. Maintain fluid level even with the bottom of the fill plug
Capacity (INT’L): 41 oz. (1200 ml) hole.
7. Reinstall fill plug with a new O-ring and torque to 1. Position vehicle on a level surface.
specification.
2. Remove the fill plug and check the fluid level.
=T
Fill / Drain Plug Torque:
10-14 ft-lbs (14-19 Nm)
8. Check for leaks. Dispose of used lubricant properly.
3. If fluid level is not even with the bottom threads, add

the recommended fluid as needed. Do not overfill.
2.26
MAINTENANCE
4. Reinstall the fill plug and torque to specification. 6. Add the recommended amount of fluid through the fill
hole. Maintain the fluid level even with the bottom
threads of the fill plug hole.
=T
Fill / Drain Plug Torque:
=
8-10 ft-lbs (11-14 Nm)
2
Recommended Front Gearcase Fluid:
Front Gearcase Fluid Change: Polaris Demand Drive Plus
(PN 2877922) (Quart)
The drain plug is located on the bottom of the front
gearcase. Access the drain plug through the access hole
Capacity: 6.75 oz. (200 ml)
in the frame underneath the front gearcase.
1. Remove the fill plug (refer to “Front Gearcase Fluid 7. Reinstall fill plug with a new O-ring and torque to
Level Check”). specification.
2. Place a drain pan under the front gearcase drain plug.

=T
3. Remove the drain plug and allow fluid to drain
completely. Fill / Drain Plug Torque:
8-10 ft-lbs (11-14 Nm)
8. Check for leaks. Dispose of used fluid properly.
4. Clean the drain plug magnetic surface.
5. Reinstall drain plug with a new O-ring and torque to

specification.
2.27
MAINTENANCE
COOLING SYSTEM Coolant Level Inspection

The pressure cap (A) and recovery bottle (B) are located
Cooling System Overview
under the front hood of the vehicle. The coolant level must
The engine coolant level is controlled, or maintained, by be maintained between the minimum and maximum levels
the recovery system. The recovery system components indicated on the recovery bottle.
are the recovery bottle, radiator filler neck, radiator
pressure cap and connecting hose. A B
As coolant operating temperature increases, the

expanding (heated) excess coolant is forced out of the
radiator past the pressure cap and into the recovery bottle.
As engine coolant temperature decreases the contracting
(cooled) coolant is drawn back up from the tank past the
pressure cap and into the radiator.
NOTE: Some coolant level drop on new machines is

normal as the system is purging itself of trapped air.
Observe coolant levels often during break-in period.
NOTE: Overheating of engine could occur if air is

not fully purged from system.
With the engine at operating temperature, the coolant
IMPORTANT: Polaris Premium 60/40 Antifreeze is level should be between the upper and lower marks on the
premixed and ready to use. Do not dilute with water. coolant recovery bottle. If not, perform the following
procedure:
Coolant Strength
1. Position the vehicle on a level surface.
Test the strength of the coolant using an antifreeze
hydrometer. 2. Remove the front hood.
3. View the coolant level in the recovery bottle.
4. If the coolant level is below the MIN line, inspect the

coolant level in the radiator.
NOTE: If overheating is evident, allow system to

Antifreeze Hydrometer cool completely and check coolant level in the
radiator and inspect for signs of trapped air in
system.
• A 50/50 or 60/40 mixture of antifreeze and distilled
water will provide the optimum cooling, corrosion
WARNING
protection, and antifreeze protection.
• Do not use tap water, straight antifreeze or straight Never remove the pressure cap when the
water in the system. Tap water contains minerals engine is warm or hot. Escaping steam can
and impurities which build up in the system. cause severe burns. The engine must be cool
• Straight water or antifreeze may cause the system before removing the pressure cap.
to freeze, corrode, or overheat.
5. Remove the pressure cap. Using a funnel, add
coolant to the top of the filler neck.
=
6. Reinstall the pressure cap.
Recommended Coolant:
NOTE: Use of a non-standard pressure cap will not
Polaris Premium Pre-Mixed Antifreeze
allow the recovery system to function properly.
(PN 2871534) (Quart)
(PN 2871323) (Gallon)
2.28
MAINTENANCE
7. Remove recovery bottle cap and add coolant using a Cooling System Hoses
funnel.
1. Inspect all vehicle hoses for cracks, deterioration,
8. Fill recovery bottle to MAX level with recommended abrasion or leaks. Replace if necessary.
coolant or 50/50 or 60/40 mixture of antifreeze and
distilled water as required for freeze protection in your
area.
2
=
(PN 2871534) (Quart)
(PN 2871323) (Gallon)
9. Reinstall the recovery bottle cap.
10. If coolant was required, start engine and check for

leaks. Make sure radiator fins are clean to prevent
overheating.
Cooling System Pressure Test

Refer to cooling system pressure test procedures
provided in Chapter 3 “Engine / Cooling”.
2. Inspect all engine hoses for cracks, deterioration,

abrasion or leaks. Replace if necessary.
3. Check tightness and condition of all hose spring

clamps. Replace if necessary.
2.29
MAINTENANCE
Radiator Inspection / Cleaning Coolant Drain / Fill
1. Check radiator air passages for restrictions or 1. Remove the front hood.
damage.
WARNING
Never drain the coolant when the engine and

radiator are warm or hot. Hot coolant can cause
severe burns. Allow engine and radiator to cool.
2. Slowly remove the pressure cap to relieve any cooling

system pressure.
3. Place a suitable drain pan underneath the radiator

fitting on the front right side of the vehicle.
4. Drain the coolant from the radiator by removing the

lower coolant hose from the radiator as shown.
2. Carefully straighten any bent radiator fins.
Drain Here
3. Remove any obstructions with low pressure
compressed air or low pressure water.
CAUTION
Washing the vehicle with a high-pressure

washer could damage the radiator fins and
impair the radiators effectiveness. Use of a high-
pressure washer is not recommended.
5. Allow coolant to drain completely. Properly dispose of

the used coolant.
6. Reinstall coolant hose and reposition the spring

clamp.
7. Remove the pressure cap. Using a funnel, add the

recommended coolant to the top of the filler neck and
fill the recovery bottle to the MAX level.
8. Refer to “Cooling System Bleeding Procedure”

provided in Chapter 3.
(PN 2871534) (Quart)
(PN 2871323) (Gallon)
2.30
MAINTENANCE
PVT / FINAL DRIVE / WHEEL AND TIRE PVT Drying
NOTE: After operating in water, the vehicle’s PVT
Drive Clutch / Driven Clutch / Belt Service
system should be checked immediately. Use the
Refer to Chapter 6 “Clutching (PVT)” for service and following instructions to dry it out before operating.
removal procedures.
The PVT drain plug is located at the bottom of the outer
PVT Intake Pre-Filter Service clutch cover. Access the drain plug through the left rear 2
wheel well.
It is recommended that the PVT intake pre-filter be
inspected daily. The filter should be inspected using the 1. Using a flat blade screwdriver, remove the PVT drain
following procedure: plug and O-ring from the outer clutch cover.
1. The PVT intake pre-filter is located just above the

right rear wheel fender.
2. Press in on the intake grill cover tab to access the pre-

filter.
PVT Drain
Press In Tab 2. Allow the water to drain out completely.
3. Reinstall the drain plug and O-ring.
4. Place the transmission in PARK, apply the brake and

start the engine.
3. Inspect the pre-filter. If necessary, clean with soapy
water and dry with low pressure compressed air. 5. Apply varying throttle for 10-15 seconds to expel the
moisture and air-dry the belt and clutches.
NOTE: Do not hold the throttle pedal wide open for

more than 5 seconds.
6. Allow the engine RPM to return to idle, then shift the

transmission into low gear.
7. Test the PVT system for belt slippage. If the belt slips,
repeat the process or remove the outer clutch cover
to inspect the PVT system (see Chapter 6 “Clutching
(PVT)” for service and removal procedures).
Pre-Filter
IMPORTANT: If the vehicle has ingested a large
amount of water into the PVT system and has not been
operated for a period of time, be sure to check the PVT
system components for water damage.
2.31
MAINTENANCE
Drive Shaft Boot Inspection Wheel Installation
Inspect the front and rear drive shaft boots for damage, 1. Verify the transmission is still in PARK.
tears, wear or leaking grease. If the boots exhibit any of
these symptoms, they should be replaced. Check to see 2. Place the wheel in the correct position on the wheel
the boot clamps are properly positioned. Refer to Chapter hub. Be sure the valve stem is toward the outside and
7 for drive shaft boot replacement. rotation arrows on the tire point toward forward
rotation.
3. Attach the wheel nuts and finger tighten them.
4. Carefully lower the vehicle to the ground.
5. Torque the wheel nuts and/or hub nut to the proper

torque specification (see “Wheel and Hub Torque
Table”).
6. If hub nut was removed, install a new cotter pin after

the hub nut has been tightened. If the holes do not line
up, turn the hub nut counter-clockwise until the cotter
pin can be installed.
Use a new Wheel Hub

Note cotter pin
Tire Rotation
Wheel and Hub Torque Table

Washers
Item Specification Hub Nut

Wheel Nuts 30 ft-lbs (41 Nm)
(Cast Aluminum Wheels) + 90° (1/4 turn)
Hub Retaining Nuts
80 ft-lbs (108 Nm) Valve stem
(Front and Rear) Wheel Nuts (4) facing outward
NOTE: Do not lubricate the stud or the lug nut.

CAUTION
Wheel Removal If wheels are improperly installed it could affect
1. Position the vehicle on a level surface. vehicle handling and tire wear. On vehicles with
tapered wheel nuts, make sure tapered end of
2. Place the transmission in PARK and stop the engine. nut goes into taper on wheel.
3. Loosen the wheel nuts slightly. If wheel hub removal

is required, remove the wheel cap, cotter pin and
loosen the hub nut slightly.
4. Elevate the appropriate side of the vehicle by placing

a suitable stand under the frame.
5. Remove the wheel nuts and remove the wheel.
2.32
MAINTENANCE
Tire Inspection
• Improper tire inflation may affect vehicle
maneuverability.
• When replacing a tire always use original
equipment size and type.
• The use of non-standard size or type tires may 2
affect vehicle handling.
WARNING
Operating with worn tires will increase the

possibility of the vehicle skidding easily with
possible loss of control.
Worn tires can cause an accident.
Always replace tires when the useable tread

depth has worn out.
Tire Pressure
Remove the valve stem cap and check tire pressure using
the tire pressure gauge included in the vehicle’s tool kit.
CAUTION
Maintain proper tire pressure.

Refer to the warning tire pressure decal
applied to the vehicle.
RZR XP
Tire Pressure Inspection (Cold)
Front Rear
12 psi (82.7 kPa) 14 psi (96.5 kPa)
RZR XP 4
Tire Pressure Inspection (Cold)
Front Rear
14 psi (96.5 kPa) 16 psi (110.3 kPa)
2.33
MAINTENANCE
ELECTRICAL AND IGNITION SYSTEM Battery Removal

1. Remove the driver’s seat to access the battery.
Battery Maintenance
Keep battery terminals and connections free of corrosion. Battery
If cleaning is necessary, remove the corrosion with a stiff
wire brush. Wash with a solution of one tablespoon baking
soda and one cup water. Rinse well with tap water and dry
off with clean shop towels. Coat the terminals with
dielectric grease or petroleum jelly.
WARNING
CALIFORNIA PROPOSITION 65 WARNING:

Batteries, battery posts, terminals and related RZR XP
accessories contain lead and lead compounds,
and other chemicals known to the State of
California to cause cancer and birth defects or Battery
other reproductive harm.
WASH HANDS AFTER HANDLING.
WARNING
Battery electrolyte is poisonous. It contains

sulfuric acid. Serious burns can result from
contact with skin, eyes or clothing. Antidote:
External: Flush with water.

RZR XP 4
Internal: Drink large quantities of water or milk.
Follow with milk of magnesia, beaten egg, or
2. Disconnect the black (negative) battery cable(s).
vegetable oil. Call physician immediately.
3. Disconnect the red (positive) battery cable(s).
Eyes: Flush with water for 15 minutes and get
prompt medical attention.
CAUTION
Batteries produce explosive gases.
Keep sparks, flame, cigarettes, etc. away. To reduce the chance of sparks: Whenever
Ventilate when charging or using in an enclosed removing the battery, disconnect the black
space. Always shield eyes when (negative) cable first. When reinstalling the
working near batteries. battery, install the black (negative) cable last.
KEEP OUT OF REACH OF CHILDREN.
NOTE: Batteries must be fully charged before use or

battery life will be reduced by 10-30% of full
potential. Charge battery according to “Charging
Procedure” provided in Chapter 10. Do not use the
vehicle’s stator/alternator to charge a new battery.
Battery Charging / Off Season Storage

Refer to Chapter 10 “Electrical” for charging and off
season storage procedures.
2.34
MAINTENANCE
4. Remove the battery hold-down strap. Battery Installation
IMPORTANT: Using a new battery that has not been
Remove
fully charged can damage the battery and result in a
shorter life. It can also hinder vehicle performance.
Follow the battery charging procedure in Chapter 10
“Electrical” before installing the battery.
2
1. Ensure the battery is fully charged.
2. Place the battery in the battery holder and secure with

hold-down strap.
3. Coat the terminals with dielectric grease or petroleum

RZR XP jelly.
4. Connect and tighten the red (positive) cable(s) first.
Remove 5. Connect and tighten the black (negative) cable(s) last.
RZR XP 4
RZR XP
5. Lift the battery out of the vehicle.
RZR XP 4
6. Verify that cables are properly routed and reinstall the

driver’s seat.
2.35
MAINTENANCE
Engine / Chassis Electrical Ground Spark Plug Service
Inspect the ground cable connections. Remove ground Inspect and replace the spark plugs at the intervals
terminals and clean if necessary. outlined in the Periodic Maintenance Chart.
RZR XP 1. Remove the cargo box access panel (A).
1. Remove the driver’s seat and locate the start

solenoid (A) behind the battery box. A
2. Inspect the ground terminals (B) located below the

solenoid. Be sure they are clean and tight.
WARNING
B A hot engine can cause serious burns. Allow

engine to cool or wear protective gloves when
removing the spark plugs.
RZR XP 4
2. Remove both spark plug caps (B).
1. Remove the left rear passenger seat and the engine
service panel to access the ground terminals (B).
B
2. Inspect the ground terminals. Be sure they are clean
and tight.
IMPORTANT: Note MAG and PTO reference decals (C)

B on spark plug wires for reassembly.
3. Clean out plug wells with compressed air to remove

any loose dirt or debris.
4. Rinse plug wells with water and dry with compressed

air.
NOTE: Spark plug wells have drain holes built into

the cylinder head to allow water to drain out.
2.36
MAINTENANCE
5. Remove spark plugs using a 5/8” spark plug socket STEERING
with an extension.
Steering Inspection
6. Inspect electrodes for wear and carbon buildup. Look
for a sharp outer edge with no rounding or erosion of The steering components should be checked periodically
the electrodes. 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 be replaced. 2
Inspect electrode for wear and buildup
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.
NOTE: Check front end alignment whenever

steering components are replaced.
Spark Plug Gap:
0.03" (0.75 mm)
WARNING
Due to the critical nature of the procedures

7. Clean with electrical contact cleaner or a glass bead outlined in this chapter, Polaris recommends
spark plug cleaner only. CAUTION: A wire brush or steering component repair and adjustment be
coated abrasive should not be used. performed by an authorized Polaris MSD
certified technician.
8. Measure gap with a wire gauge. Adjust gap if
necessary by carefully bending the side electrode.
Steering Wheel Freeplay
9. If necessary, replace spark plug with proper type.
CAUTION: Severe engine damage may occur if the Check steering wheel for specified freeplay and operation.
incorrect spark plug is used.
1. Position the vehicle on level ground.
2. Lightly turn the steering wheel left and right.
Recommended Spark Plug:
Champion RG4YCX 3. There should be 0.8”-1.0” (20-25 mm) of freeplay.
4. If there is excessive freeplay or the steering feels
10. Apply anti-seize compound to the spark plug threads. rough, inspect the following components.
• Tie Rod Ends
11. Install spark plugs and torque to specification.
• Steering Shaft U-Joints
• Steering Gearbox
=T
Spark Plug Torque:
7 ft-lbs (10 Nm)
U-Joints
12. Install the plug caps to the appropriate cylinder by Tie Rod
referencing the MAG and PTO spark plug wire decals.
Ensure wires are pushed down all the way so they
engage onto the spark plugs.

Tie Rod
Gearbox
2.37
MAINTENANCE
Tie Rod End / Wheel Hub Inspection Wheel Toe Alignment Inspection
• To check for play in the tie rod end, grasp the 1. Place machine on a smooth level surface and set
steering tie rod, pull in all directions feeling for steering wheel in a straight ahead position. Secure
movement. the steering wheel in this position.
2. Place a chalk mark on the center line of the front tires

approximately 10” (25.4 cm) from the floor or as close
to the hub/axle center line as possible.
Vehicle shown is
for reference only
• Replace any worn steering components. Steering

should move freely through entire range of travel
without binding.
• Elevate front end of machine so front wheels are
off the ground. Check for any looseness in front
wheel/hub assembly by grasping the tire firmly at
top and bottom first, and then at front and rear. Try
to move the wheel and hub by pushing inward and
pulling outward. NOTE: It is important the height of both marks be
equally positioned to get an accurate measurement.
Check for Loose Wheel or Hub
3. Measure the distance between the marks and record
the measurement. Call this measurement “A”.
4. Rotate the tires 180° by moving the vehicle forward.

Position chalk marks facing rearward, even with the
hub/axle center line.
5. Again measure the distance between the marks and

record. Call this measurement “B”. Subtract
measurement “B” from measurement “A”. The
difference between measurements “A” and “B” is the
vehicle toe alignment. The recommended vehicle toe
tolerance is 1/8” to 3/16” (3.2 to 4.8 mm) toe out. This
• If abnormal movement is detected, inspect the hub means the measurement at the front of the tire (A) is
and wheel assembly to determine the cause 1/8” to 3/16” (3.2 to 4.8 mm) wider than the
(loose wheel nuts or loose front hub nut). measurement at the rear (B).
• Refer to Chapter 7 “Final Drive” for front hub

service procedures.
= In. / mm.
Wheel Toe-Out:
(A) - (B) = 1/8" to 3/16" (3.2 to 4.8 mm)
2.38
MAINTENANCE
Wheel Toe Adjustment • IMPORTANT: When tightening the tie rod end jam
nuts, the rod ends must be held parallel to prevent
If toe alignment is incorrect, repeat steps 3-5 of “Wheel rod end damage and premature wear. Damage
Toe Alignment Inspection”, but instead measure the may not be immediately apparent if done
distance between each wheel and the vehicle center. This incorrectly.
will tell you which tie rod needs adjusting.
• After alignment is complete, torque jam nuts to
specification. 2
=T
Tie Rod Jam Nut:
Vehicle shown is
for reference only 12-14 ft-lbs (16-19 Nm)
NOTE: Be sure steering wheel is straight ahead

before determining which tie rod needs adjustment.
CAUTION
During tie rod adjustment, it is very important that

the following precautions be taken when
tightening tie rod end jam nuts.
If the rod end is positioned incorrectly it will not
pivot, and may break.
To adjust toe alignment:

• Hold tie rod end to keep it from rotating.
• Loosen jam nuts at both end of the tie rod.
• Shorten or lengthen the tie rod until alignment is as
required to achieve the proper toe setting as
specified in “Wheel Toe Alignment”.
2.39
MAINTENANCE
SUSPENSION (FOX™) 3. Turn the lower adjustment ring (1) clockwise to

increase preload or counter-clockwise to decrease
Spring Preload Adjustment preload.
The front and rear shocks have a spring preload Factory Preload Setting
7.625 in. (19.37 cm)
adjustment. Suspension spring preload may be adjusted
to suit different riding conditions or vehicle payloads.
Decrease Increase
WARNING Preload Preload
Uneven adjustment may cause poor handling of

the vehicle, which could result in an accident 1
and serious injury or death. Always adjust both
the left and right spring preloads equally.
Spring Preload Adjustment - Factory Setting
Front Rear
7.625 in. (19.37 cm) 3.625 in. (9.21 cm) 2.0 Piggyback
Front Shock
NOTE: Refer to the shock illustrations within this
Factory Preload Setting
procedure for spring preload measurement location. 3.625 in. (9.21 cm)
The factory preload setting is appropriate for nearly all

riding conditions. Since this vehicle is equipped with full Decrease Increase
skid plates, adjustment is not necessary. Preload Preload
If desired, the spring preload setting may be adjusted to

maintain vehicle clearance height when carrying loads.
1
1. Raise and safely support the front or rear of the

vehicle off the ground to allow the suspension to fully
extend. Ride-In Spring
Not Shown
2. Loosen the upper jam nut adjustment ring using the
spanner wrench (PN 2877408) included in the
vehicle’s tool kit. 2.0 Piggyback
Rear Shock
IMPORTANT: DO NOT increase the spring preload by

more than one inch (25.4 mm) over the factory setting.
4. Once you have obtained the correct preload, hold the

lower adjustment ring while tightening the upper
adjustment ring to lock them in place.
IMPORTANT: Always return the spring preload to the

factory setting after the load is removed from the
vehicle. The increased suspension height will
negatively impact vehicle stability when operating
PN 2877408 without a load.
Shock Spanner Wrench:

PN 2877408
2.40
MAINTENANCE
Shock Compression Adjustment
The compression damping adjustment is located on top of
the shock ‘Piggyback’ reservoir of each shock.
Turn the clicker adjuster knob to make damping

adjustments.
2
NOTE: When clicker adjuster is turned clockwise
until it stops, damping is in the fully closed position.
Turn the clicker clockwise to increase compression

damping. Turn the clicker counter-clockwise to decrease
compression damping.
NOTE: The factory setting is 10 clicks from closed.

Refer to the “Compression Adjustment Table”.
Increase Decrease
Damping Damping
Clicker
Adjuster
Compression Adjustment Table
Setting Compression Damping

Softest Full counter-clockwise position
Factory 10 clicks from closed
Firmest 2 clicks from closed
2.41
MAINTENANCE
SUSPENSION (WALKER EVANS™) IMPORTANT: DO NOT increase the spring preload by

more than one inch (25.4 mm) over the factory setting.
Spring Preload Adjustment
Factory Setting
The front and rear shocks have a spring preload 6.560 in. (16.66 cm)
adjustment. Suspension spring preload may be adjusted
to suit different riding conditions or vehicle payloads.
WARNING
Uneven adjustment may cause poor handling of Decrease Increase

the vehicle, which could result in an accident Preload Preload
and serious injury or death. Always adjust both
the left and right spring preloads equally.
1
Spring Preload Adjustment - Factory Setting
Front Rear
6.560 in. (16.66 cm) 0.940 in. (2.39 cm)
NOTE: Refer to the shock illustrations within this

procedure for spring preload measurement location.
2.0" Piggyback
The factory preload setting is appropriate for nearly all
Front Shock
riding conditions. Since this vehicle is equipped with full
skid plates, adjustment is not necessary.
Factory Setting
If desired, the spring preload setting may be adjusted to 0.940 in. (2.39 cm)
maintain vehicle clearance height when carrying loads.
1. Raise and safely support the front or rear of the Decrease Increase
vehicle off the ground to allow the suspension to fully Preload Preload
extend.
2. Using the shock spanner/spreader tool (PN 2878925)

included in the vehicle’s tool kit, turn the adjustment
collar (1) to increase or decrease preload.
Ride-In Spring
1
Spring Spacer
2.5" Piggyback
Rear Shock
PN 2878925
IMPORTANT: Always return the spring preload to the
factory setting after the load is removed from the
vehicle. The increased suspension height will
Shock Spanner / Clutch Spreader Tool: negatively impact vehicle stability when operating
PN 2878925 without a load.
2.42
MAINTENANCE
Shock Compression Adjustment Walker Evans™ 2.5" Rear Shock:
The compression damping adjustment is located on the
shock ‘Piggyback’ reservoir of each shock. Damping Setting Compression Damping
adjustments can be made without using any tools. Softest Full counter-clockwise position
NOTE: When the adjuster knob is turned counter-
clockwise until it stops, the damping is in the fully
Factory
Firmest
7 clicks from softest position
Full clockwise position
2
open position (softest).
Turn the adjuster knob clockwise to increase compression

damping. Turn the adjuster knob counter-clockwise to Adjuster
decrease compression damping. Knob
NOTE: The recommended factory setting for the

front and rear shocks are provided in the following
compression adjustment tables.
Walker Evans™ 2.0" Front Shock:

Increase Decrease
Setting Compression Damping Damping Damping
Softest Full counter-clockwise position
Factory 6 clicks from softest position
Firmest Full clockwise position
Decrease Increase
Damping Damping
Adjuster
Knob
Rear
Shock
Front
Shock
2.43
MAINTENANCE
BRAKE SYSTEM Brake Pad / Disc Inspection

1. Check the brake pads for wear, damage, or
Brake Fluid Inspection
looseness.
Always check the brake pedal travel and inspect the brake
fluid reservoir level before each operation. If the fluid level 2. Inspect the brake pad surface for excessive wear.
is low, add DOT 4 brake fluid only.
3. Pads should be changed when the friction material is
Brake fluid should be changed every two years. The fluid worn to .040” (1 mm).
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

through the left front wheel well.
1. Position the vehicle on a level surface.

Measure Pad Material
Thickness Service Limit:
2. Place the transmission in PARK.
.040" (1 mm)
3. View the brake fluid level in the reservoir. The level
should be between the MAX and MIN level lines.
4. Check surface condition of the brake discs.
5. Measure the thickness of the front and rear brake

discs.
Maximum
Minimum 6. The disc(s) should be replaced if thickness is less than
Master Cylinder .170” (4.32 mm).
Service Limit:
.170" (4.32 mm)
Front Rear
Disc Disc
4. If the fluid level is lower than the MIN level line, add
brake fluid until it reaches the MAX level line.
5. Install the reservoir cap and apply the brake pedal

forcefully for a few seconds and check for fluid Measure Brake Disc Thickness
leakage around the master cylinder fittings and the
brake caliper fittings.
Brake Hose and Fitting Inspection

Check brake system hoses and fittings for cracks,
deterioration, abrasion, and leaks. Tighten any loose
fittings and replace any worn or damaged parts.
2.44
MAINTENANCE
Parking Brake Cable Adjustment (INT’L) Parking Brake Pad Inspection (INT’L)
When the parking brake is fully engaged and “BRAKE” is Inspect the parking brake caliper brake pad thickness.
displayed on the instrument cluster, engine speed is Replace brake pads if damaged or worn beyond service
limited to 1500 RPM while in gear. If throttle is applied, this limit. Replace caliper assembly if damage or excessive
limiting feature prevents operation, which protects the wear is found. Refer to the following image for brake pad
parking brake pads from excessive wear. specifications.
2
NOTE: Inspect the parking brake cable tension after
the first 25 hours of operation and every 100 hours Outboard Inboard
of operation afterwards to ensure proper cable Pad Pad
tension.
Loss of tension in the parking brake cable will cause

illumination of the parking brake indicator and activation of
the limiting feature. If this occurs, inspect and adjust
parking brake cable tension. If performing this service is
difficult due to conditions or location, temporarily
disconnect the parking brake switch electrical connector.
Reconnect the connector as soon as practicable and
adjust the parking brake cable to proper tension.
1. Pull back on the parking brake lever (located in dash).
2. After 3 to 4 clicks “BRAKE” should display on the

instrument cluster and the wheels of the vehicle Outboard Pad Thickness Inboard Pad Thickness
should not rotate when turning by hand. After 8 full New 0.250” (6.35 mm) New 0.300” (7.62 mm)
clicks of lever travel, the vehicle should not roll while Limit: 0.190” (4.83 mm) Limit: 0.240” (6.10 mm)
parked.
3. If the vehicle moves, adjustment is necessary.
4. Adjust the parking brake cable where the cable

attaches to the caliper mount / shift cable bracket. The
mount bracket is located on the right-hand side of the
transmission.
Adjustment Procedure: Refer to Chapter 9 “Brakes”

for complete adjustment procedure.
2.45
MAINTENANCE
NOTES
2.46
ENGINE / COOLING
CHAPTER 3
ENGINE / COOLING
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
SPECIAL TOOLS / ENGINE LUBRICATION SPECIFICATIONS. . . . . . . . . . . . . . . . . . . 3.3
OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
ENGINE OIL FLOW CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
ENGINE SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
ENGINE DETAIL - TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES . . . . . . . . 3.8
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
COOLING SYSTEM SPECIFICATIONS / PRESSURE TEST . . . . . . . . . . . . . . . . . . . . 3.13
PRESSURE CAP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
3
RADIATOR REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
THERMOSTAT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
COOLING SYSTEM EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17
COOLING SYSTEM BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
WATER PUMP REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
WATER PUMP SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
ACCESSIBLE ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
TOP-END SERVICE (ENGINE IN CHASSIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27
ENGINE MOUNTING AND TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
ENGINE BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
ENGINE DISASSEMBLY / INSPECTION - TOP END. . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
VALVE COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32
CAMSHAFT SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
CAMSHAFT / CAMSHAFT BORE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
CYLINDER HEAD WARP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.37
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38
COMBUSTION CHAMBER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39
ENGINE DISASSEMBLY / INSPECTION - LOWER END. . . . . . . . . . . . . . . . . . . . . . . . 3.42
STATOR COVER REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
WATER PUMP HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
FLYWHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43
STARTER ONE-WAY CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
STARTER ONE-WAY CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44
STARTER ONE-WAY CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45
CRANKCASE DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46
BALANCE SHAFT REMOVAL / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48
CRANKSHAFT REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.49
CRANKCASE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.52
CYLINDER / PISTON REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53
CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.53
PISTON DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.54
PISTON RING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.55
PISTON RING TO GROOVE CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . 3.56
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.56
PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.57
CONNECTING ROD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.57
3.1
ENGINE / COOLING
ENGINE ASSEMBLY - LOWER END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59
BEARING SELECTION IDENTIFICATION LETTERS AND NUMBERS . . . . . . . . . . . . 3.59
CONNECTING ROD BEARING SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.60
CRANKSHAFT MAIN BEARING SELECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.60
UPPER CRANKCASE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.61
PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.61
PISTON / CONNECTING ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.62
CYLINDER / PISTON INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.63
CRANKSHAFT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.64
BALANCE SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.66
LOWER CRANKCASE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.67
CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.67
FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.71
STATOR COVER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.72
ENGINE ASSEMBLY - TOP END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.73
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.73
VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.74
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.74
CAMSHAFT INSTALLATION / TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.75
CAMSHAFT TIMING - QUICK REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.79
VALVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.80
INTAKE VALVE LASH - SHIM SELECTION MATRIX . . . . . . . . . . . . . . . . . . . . . . . . . . 3.82
EXHAUST VALVE LASH - SHIM SELECTION MATRIX . . . . . . . . . . . . . . . . . . . . . . . . 3.83
VALVE COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.84
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.85
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.85
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.86
3.2
ENGINE / COOLING
GENERAL INFORMATION
Special Tools
Tool Description Part Number
Bench Mount Engine Stand Adapter PW-47053
Clutch Center Distance Tool PU-50658
Cylinder Holding & Camshaft Timing Plate PU-50563
Engine Stand (2” Bore) PU-50624
Engine Stand Adapter (Mounts To The Engine) PU-50562 3
Engine Stand Sleeve Adapter (Use With 2” Bore Stand) PU-50625
Engine Stand Sleeve Adapter (Use With 2.375” Bore Stand) PW-47054
Flywheel Puller PA-49316
Mity Vac™ Pressure Test Tool 2870975
Oil Filter Wrench PU-50105
Oil Pressure Gauge PV-43531
Oil Pressure Gauge Adapter PU-50565
Piston Ring Compressor Pliers PV-43570-1
Valve Spring Compressor PV-1253 or PV-4019 (Quick Release)
Valve Spring Compressor Adapter PV-43513-A
Water Pump Mechanical Seal Installer PU-50564
SPX Corp: 1-800-328-6657 or http://polaris.spx.com/
Engine Lubrication Specifications
=
Oil Capacity * Approx. 2.5 Quarts (2.4 L)
Oil Filter Wrench PU-50105 or 2.5” (64 mm)
Oil Filter PN 2540086
Oil Type PS-4 Plus
Ambient Temp Range: Synthetic Engine oil
-35° F to 100° F (PN 2876244) (Quart)
Oil Type PS-4 Extreme Duty
Ambient Temp Range: Synthetic Engine Oil
0° F to 120° F (PN 2878920) (Quart)
Oil Pressure
Minimum Specification 10 PSI @ 1200 RPM
(using Polaris engine oil
at operating temperature) 40 PSI @ 7000 RPM
*Additional oil may be required after complete engine

disassembly. Check level after filling and add oil as
needed.
3.3
ENGINE / COOLING
Oil Pressure Test
1. Attach the Oil Pressure Gauge Adapter (PU-50565) Oil Pressure Specification (Engine Hot):
to the Oil Pressure Gauge (PV-43531). Minimum @ 1200 RPM: 10 PSI
Minimum @ 7000 RPM: 40 PSI
PU-50565
6. Upon assembly, torque the crankcase gallery plug to
specification.
=T
Crankcase Gallery Plug:
11 ft-lbs (15 Nm)
PV-43531
Oil Pressure Gauge Adapter: PU-50565

Oil Pressure Gauge: PV-43531
2. Remove the seats, engine service panel, and divider

panel heat shield.
3. Clean the area around the main oil gallery plug (A),
located in the upper crankcase on the MAG side of the
engine.
4. Remove the crankcase gallery plug (A) and insert the

oil pressure adapter.
5. Start engine and allow it to reach operating

temperature, monitoring gauge indication.
NOTE: Test results are based on the use of the

recommended engine oil (Polaris PS-4 Plus or PS-4
Extreme Duty) at operating temperature, and may
vary considerably if any other oil is used or if engine
is not up to temperature.
3.4
ENGINE / COOLING
Engine Oil Flow Chart
Pump
Inlet
Air Box
Water Pump shaft
Pressure bearing (splash)
Pump
Pressure Oil Pump
Regulating
Valve
Assembly
Breather
Assembly
3
Oil Filter Internal

Bypass
Cylinder Head
Cam Cyl. head

Heat Coolant in bearings drains
Exchanger Coolant out
Cylinder
unit
Chain Cam chain
tensioner chest
Balancer
bearing
Starter gear bearing
S
Main U
Stator (bolt jet feed)
(MAG) M
bearing 1 P
Main Oil
Main
Gallery
(CENTER)
Piston spray jet 1 Piston & small
bearing 2
end bearings 1
Main Crank big end 1

(PTO1)
bearing 3 Piston & small
Piston spray jet 2 end bearings 2
Crank big end 2
Balancer bearing
Main
(PTO2)
bearing 4
3.5
ENGINE / COOLING
ENGINE SERVICE SPECIFICATIONS
Engine Specifications
CAMSHAFT / CYLINDER HEAD / CYLINDER
Cam Lobe Height - Intake (Standard) 1.5390" - 1.5429" (39.09 - 39.19 mm)
Cam Lobe Height - Intake (Service Limit) 1.5370" (39.04 mm)
Cam Lobe Height - Exhaust (Standard) 1.5142" - 1.5181" (38.46 - 38.56 mm)
Cam Lobe Height - Exhaust (Service Limit) 1.5122" (38.41 mm)
Camshaft Journal O.D. - All (Standard) 0.9036" - 0.9055" (22.954 - 22.999 mm)
Camshaft Journal O.D. - All (Service Limit) 0.9033" (22.944 mm)
Camshaft
Camshaft Journal Bore I.D. - All (Standard) 0.9055" - 0.9063" (23.000 - 23.021 mm)
Camshaft Journal Bore I.D. - All (Service Limit) 0.9072" (23.044 mm)
Camshaft Oil Clearance (Standard) 0.0000" - 0.0026" (0.001 - 0.067 mm)
Camshaft Oil Clearance (Service Limit) 0.0039" (0.1 mm)
Camshaft End Play (Standard) 0.0040" - 0.0100" (0.101 - 0.254 mm)
Camshaft End Play (Service Limit) 0.0157" (0.4 mm)
Cylinder Head - Surface Warp Limit 0.0039" (0.1 mm)
Cylinder Head
Cylinder Head - Standard Height 4.682" ± 0.0019" (118.93 ± 0.05 mm)
Valve Seat - Contacting Width - Intake (Standard) 0.0393" ± 0.0039" (1.0 ± 0.10 mm)
Valve Seat - Contacting Width - Intake (Service Limit) 0.0551" (1.4 mm)
Valve Seat Valve Seat - Contacting Width - Exhaust (Standard) 0.0590" ± 0.0039" (1.5 ± 0.10 mm)
Valve Seat - Contacting Width - Exhaust (Service Limit) 0.0748" (1.9 mm)
Valve Seat Angles 30.0° ± 1.5° / 45.0° ± 0.5° / 60.0° ± 1.5°
Valve Guide Valve Guide Inner Diameter 0.2165" - 0.2171" (5.500 - 5.515 mm)
Valve Lash (Cold) - Intake 0.006" ± 0.002" (0.15 ± 0.5 mm)
Valve Lash (Cold) - Exhaust 0.012" ± 0.002" (0.30 ± 0.5 mm)
Valve Stem Diameter - Intake 0.2155" - 0.2161" (5.475 - 5.490 mm)
Valve Stem Diameter - Exhaust 0.2147" - 0.2153" (5.455 - 5.470 mm)
Valve
Valve Stem Oil Clearance - Intake 0.0003" - 0.0015" (0.010 - 0.040 mm)
Valve Stem Oil Clearance - Exhaust 0.0011" - 0.0023" (0.030 - 0.060 mm)
Valve Stem Overall Length - Intake 3.7704" (95.77 mm)
Valve Stem Overall Length - Exhaust 3.8023" (96.58 mm)
Valve Spring Free Length (Standard) 1.7263" (43.85 mm)
Valve Spring
Valve Spring Free Length (Service Limit) 1.6830" (42.75 mm)
Cylinder - Surface Warp Limit
0.002" (0.05 mm)
(mating with cylinder head)
Cylinder Bore - Standard 3.6614" ± 0.0003" (93 mm ± 0.008 mm)
Cylinder
Cylinder Out of Round Limit 0.001" (0.025 mm)
Cylinder Taper Limit 0.001" (0.025 mm)
Cylinder to Piston Clearance 0.0009" - 0.0019" (0.025 - 0.050 mm)
3.6
ENGINE / COOLING
PISTON / RINGS / CONNECTING ROD / CRANKSHAFT / BALANCE SHAFT
Piston - Standard O.D. - Measured 90 degrees to pin,

3.6597 ± 0.0003" (92.959 ± 0.008 mm)
0.39 in. (10 mm) up from piston skirt. See text.
Piston
Piston Pin Bore I.D. (Standard) 0.7877" - 0.7881" (20.009 - 20.018 mm)
Piston Pin Bore I.D. (Service Limit) 0.7893" (20.05 mm)
Piston Pin O.D. (Standard) 0.7873" - 0.7875" (20.000 - 20.005 mm)
Piston Pin
Piston Pin O.D. (Service Limit) 0.7866" (19.98 mm)
Top Ring (Standard) 0.010" - 0.014" (0.25 - 0.35 mm)
Top Ring (Service Limit) 0.0196" (0.5 mm) 3
Second Ring (Standard) 0.015" - 0.025" (0.37 - 0.63 mm)
Installed
Gap Second Ring (Service Limit) 0.028" (0.70 mm)
Piston Ring Oil Control Rails (Standard) 0.008" - 0.028" (0.20 - 0.70 mm)
Oil Control Rails (Service Limit) 0.0354" (0.9 mm)
Top Ring (Standard)
Ring to Groove 0.0007" - 0.0023" (0.020 - 0.060 mm)
Second Ring (Standard)
Clearance
Service Limit 0.0047" (0.12 mm)
Connecting Rod Small End I.D. (Standard) 0.7879" - 0.7885" (20.015 - 20.030 mm)
Connecting Rod Small End I.D. (Service Limit) 0.7897" (20.06 mm)
Connecting Rod 1 - Marking Connecting Rod Big End Bore I.D. 1.7318" - 1.7321" (43.989 - 43.996 mm)
2 - Marking Connecting Rod Big End Bore I.D. 1.7321" - 1.7323" (43.996 - 44.003 mm)
3 - Marking Connecting Rod Big End Bore I.D. 1.7323" - 1.7326" (44.003 - 44.010 mm)
B - Marking Main Journal O.D. (Standard) 1.6140" - 1.6143" (40.996 - 41.004 mm)
G - Marking Main Journal O.D. (Standard) 1.6137" - 1.6140" (40.988 - 40.995 mm)
Y - Marking Main Journal O.D. (Standard) 1.6134" - 1.6137" (40.980 - 40.987 mm)
Main Journal O.D. (Service Limit) 1.6129" (40.970 mm)
Crankshaft B - Marking Rod Journal O.D. (Standard) 1.6118" - 1.6122" (40.942 - 40.950 mm)
G - Marking Rod Journal O.D. (Standard) 1.6115" - 1.6118" (40.934 - 40.941 mm)
Y - Marking Rod Journal O.D. (Standard) 1.6112" - 1.6115" (40.926 - 40.933 mm)
Rod Journal O.D. (Service Limit) 1.6104" (40.906 mm)
Crankshaft Runout Limit (PTO and MAG) Less than 0.001" (0.025 mm)
Bearing Journal O.D. (Standard) 1.4939" - 1.4946" (37.946 - 37.962 mm)
Balance Shaft
Bearing Journal O.D. (Service Limit) 1.4921" (37.900 mm)
3.7
ENGINE / COOLING
ENGINE DETAIL - TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES
Main Engine Components - Torque Specification and Sequence
7 ft-lbs
(10 Nm)
7 ft-lbs
(10 Nm)
26 ft-lbs
(35 Nm)
CAM CARRIER
TORQUE SEQUENCE
7 ft-lbs
(10 Nm)
CRANKCASE SPLIT-LINE
TORQUE SEQUENCE
26 ft-lbs
(35 Nm)
CYLINDER HEAD
TORQUE SEQUENCE
Step 1: 9 ft-lbs (12 Nm)
Step 1: 9 ft-lbs (12 Nm) Step 2: 26 ft-lbs (35 Nm)
9 ft-lbs Step 2: 21 ft-lbs (28 Nm) Step 3: 180° (1/2 turn)
(12 Nm) Step 3: 90° (1/4 turn)
9 ft-lbs
(12 Nm)
9 ft-lbs
(12 Nm)
26 ft-lbs SUMP COVER STATOR COVER
(35 Nm) TORQUE SEQUENCE TORQUE SEQUENCE
3.8
ENGINE / COOLING
Balance Shaft / Connecting Rods / Crankcase / Crankshaft / Pistons
3.9
ENGINE / COOLING
Cylinder / Oil Cooler / Oil Filter / Oil Pump / Oil Sump / Water Pump
3.10
ENGINE / COOLING
Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
3.11
ENGINE / COOLING
Spark Plugs / Starter / Thermostat Housing / Throttle Body / Valve Cover
3.12
ENGINE / COOLING
ENGINE COOLING SYSTEM Cooling System Pressure Test
Cooling System Specifications 1. Remove the hood from the front cab.
Condition Coolant Temperature °F (°C) WARNING

Room Temperature 68° F (20° C)
Never remove pressure cap when engine is
Thermostat Open 180° F (82° C) warm or hot. The cooling system is under
pressure and serious burns may result.
Fan Off 192° F (89° C)
Allow the engine to cool before servicing.
Fan On 198° F (92° C)
2. Remove pressure cap and pressure test the cooling
3
Thermostat
203° F (95° C) system using a commercially available pressure
Full Open Lift
tester.
Engine Temperature
233° F (112° C)
Overheat Indicator
Engine Protection
236° F (113° C)
Ignition Misfire
Engine Protection
257° F (125° C)
Shutdown
Item Specification
Test Here
RZR XP:
4.9 qts. (4.6 L)
Cooling System Capacity
RZR XP 4:
9.7 qts. (9.2 L)
Pressure Cap Relief 13 PSI
Polaris Premium Antifreeze

2871534 - Quart
2871323 - Gallon
Recommended Coolant
3. The system must maintain 10 psi for five minutes or
Use only high quality antifreeze/coolant mixed with
longer. If pressure loss is evident within five minutes,
distilled water in a 50/50 or 60/40 ratio, depending on
check the filler neck, radiator, hoses, clamps and
freeze protection required in your area.
water pump weep hole for leakage.
CAUTION: Using tap water in the cooling system will lead
to a buildup of deposits which may restrict coolant flow and
reduce heat dissipation, resulting in possible engine
damage. Polaris Premium 60/40 Antifreeze/Coolant is
recommended for use in all cooling systems and comes
pre-mixed, ready to use.
3.13
ENGINE / COOLING
Pressure Cap Test 3. Remove the (5) fasteners (B) that secure the upper
radiator cover (C) to the front cab. Remove the upper
1. Remove the hood from the front cab (see radiator cover (C) from the vehicle.
“WARNING” under “Cooling System Pressure Test”).
2. Remove pressure cap (A) and test using a pressure

cap tester (commercially available).
C
B
WARNING
The cooling system is under pressure and

3. The pressure cap relief pressure is 13 psi. Replace serious burns may result.
cap if it does not meet this specification. Allow the engine to cool before servicing.
4. Drain radiator by removing lower radiator hose (D). Be

Radiator Removal / Installation sure to catch and dispose of coolant properly.
1. Remove the hood and front bumper (see Chapter 5).
D
2. Remove the (4) fasteners that secure the front
bumper support to the main frame.
17 ft-lbs
(20 Nm)
5. Disconnect cooling fan electrical connector.
6. Remove the upper radiator hose from the radiator.
3.14
ENGINE / COOLING
7. Remove the (2) upper radiator support bolts (E) and
disconnect the small radiator bypass hose (F).
E F
3
8. Lift radiator up to disengage it from its lower mounting

points. Tilt top of radiator outward and remove the
radiator from the vehicle.
9. Separate the fan motor assembly from the radiator.

Inspect fan blades for damage.
10. Reverse this procedure for installation. Be sure to

properly fill and bleed cooling system as outlined in
this chapter.
3.15
ENGINE / COOLING
Thermostat Replacement 8. Lift the cover from the housing and remove the
thermostat.
1. Remove the hood from the front cab.
NOTE: Thermostat has a pop-off relief to allow the
bypass system to operate until thermostat opens.
WARNING
9. Install a new thermostat with the bleed hole (D)
The cooling system is under pressure and positioned closest to the engine.
serious burns may result.
Allow the engine to cool before servicing.
2. Remove the pressure cap to relieve any system

pressure (see “Pressure Cap Test”).
3. Drain coolant to a level below the thermostat housing. D
4. Remove upper coolant hose from thermostat housing

(A).
5. Remove the rear bolt (B) retaining the thermostat

cover.
NOTE: Image shown above is with engine removed

for clarity.
B
10. Reverse this procedure for installation. Torque
thermostat cover bolts to specification.
=T
A
Thermostat Cover Bolts:
89 ± 9 in-lbs (10 ± 1 Nm)
11. Be sure to properly fill and bleed cooling system as

6. Remove the cargo box access panel. outlined in this chapter.
7. Using an 8 mm swivel socket and long extension,

remove the front bolt (C) retaining the thermostat
cover.
3.16
ENGINE / COOLING
Cooling System Exploded View
Coolant Flow Diagram
Engine
Water Pump Housing Filler Neck
Engine
Cylinder Fitting
Recovery Bottle
Radiator
Engine
Engine Oil Cooler
Thermostat Housing
Bypass (active when thermostat closed)
Outlet (active when thermostat open)
3.17
ENGINE / COOLING
Cooling System Bleeding Procedure 6. Open the bleed screw (C) to allow any trapped air to
escape. Close the bleed screw once a steady stream
of coolant begins to drain out.
WARNING
C
Always wear safety glasses and proper shop
clothing when performing the procedures in this
manual. Failing to do so may lead to possible
injury or death.
CAUTION
Use caution when performing these procedures.

Coolant may be hot and may cause
severe injury or burns.
NOTE: If the coolant level is LOW in the radiator, or

if there are leaks in the system, the coolant system
7. Tighten the bleed screw to specification, top off
will not draw coolant from the reservoir tank.
coolant and properly install the pressure cap.
1. Allow engine and cooling system to cool down.
=T
CAUTION
Coolant Bleed Screw:
89 ± 9 in-lbs (10 ± 1 Nm)
Be sure the engine has cooled and no pressure
is built up in the cooling system before removing
the pressure cap. The coolant may be hot and 8. Start the engine and allow it to idle until the coolant
could cause severe injury or burns. fan has cycled two times.
9. Allow engine and cooling system to completely cool

2. Remove the hood. down (see CAUTION).
3. Remove the recovery bottle cap (A) and fill the bottle 10. Remove the pressure cap. Add the necessary amount
to the MAX line. of Polaris Premium Antifreeze to the radiator filler
neck.
B A
11. Open the bleed screw to allow any trapped air to
escape. Close the bleed screw once a steady stream
of coolant begins to drain out.
12. Tighten the bleed screw to specification, top off

coolant and properly install the pressure cap.
=T
Coolant Bleed Screw:
89 ± 9 in-lbs (10 ± 1 Nm)
4. Remove the pressure cap (B) and add the necessary 13. Fill the recovery bottle to the MAX line.
amount of Polaris Premium Antifreeze to the radiator
14. Reinstall the hood.
filler neck.
15. Reinstall the seats and engine service panel.
5. Remove the seats, engine service panel and divider
panel heat shield to access the coolant bleed screw.
3.18
ENGINE / COOLING
Water Pump Removal 13. Maneuver water pump downward and remove it
through the access hole in the skid plate.
1. Allow engine and cooling system to cool down.
14. Plug the water pump drive access hole in the engine
block with a clean shop towel.
CAUTION
Be sure the engine has cooled and no pressure Water Pump Installation
is built up in the cooling system before removing
the pressure cap. The coolant may be hot and 1. Replace the (2) sealing O-rings on the water pump
could cause severe injury or burns. housing.
2. Remove both seats and the engine service panel.

NOTE: Do not reuse the water pump O-rings. Always 3
use NEW O-rings each time the water pump is
3. Disconnect the (-) negative battery cable. removed.
4. Remove all debris and thoroughly clean water pump 2. Lubricate new O-rings with fresh engine oil.
area and RH side of engine block.
Use New O-rings
5. Remove the hood.
6. Remove the pressure cap from the filler neck.
7. Drain cooling system as outlined in this chapter.
8. Elevate the rear of the vehicle off the ground using a

suitable ATV lift and remove the right rear wheel.
9. Remove the right rear shock lower mounting bolt.

Discard the nut. Swing and support right rear shock
rearward to gain access to water pump area.
10. Remove the (5) coolant hoses that are attached to the
3. Remove the shop towel from the water pump drive
water pump. Note location and routing for installation.
access hole in the engine block.
Be sure to catch and dispose of coolant properly.
4. Clean the O-ring sealing surface in the engine block
11. Remove the (3) bolts retaining water pump to engine
using a clean shop towel.
block. Note different bolt lengths for installation.
5. Use a shop light to illuminate the water pump drive
access hole in engine crankcase.
6. Note orientation of the water pump drive slot.
Note Orientation of Drive Slot
25 mm
35 mm
12. Remove water pump from engine by gently twisting

and rocking the water pump housing while pulling
Clean Surface
outward.
3.19
ENGINE / COOLING
7. Rotate water pump drive tab so it matches the angle 12. Install the (5) coolant hoses that attach to the water
of the drive slot in the engine. pump. Be sure orientation and routing are correct.
Rotate Drive Tab
CAUTION
The water pump drive tab and slot must be aligned

properly during installation. Severe engine or water
pump damage will occur if the tab and slot are not in 13. Install the right rear lower shock bolt and new nut.
alignment during water pump installation. Torque mounting bolt to specification.
8. Maneuver water pump up through the access hole in

the skid plate on the RH side of the vehicle. =T
9. Slide water pump into engine crankcase. Rear Shock Mounting Bolt:
10. Be sure water pump is fully seated and the drive tab Lower: 70 ft-lbs (95 Nm)
and slot are properly engaged.
14. Install the right rear wheel. Torque wheel nuts to
11. Install the (3) water pump mounting bolts and torque specification.
to specification.
=T
Wheel Nuts:
30 ft-lbs (41 Nm) + 90° (1/4 turn)
15. Connect the (-) negative battery cable.
16. Fill and bleed cooling system as outlined in this

chapter.
25 mm
17. Install the hood, engine service panel and seats
(Chapter 5).
35 mm
NOTE: Install different bolt lengths as shown.
=T
Water Pump Mounting Bolts:
89 ± 9 in-lbs (10 ± 1 Nm)
3.20
ENGINE / COOLING
Water Pump Service NOTE: A 5/32" (4 mm) diameter punch will fit in the
lubrication slot to aid in the removal of the oil seal.
NOTE: The water pump cover gasket can be Be sure not to damage the water pump shaft bearing
replaced while the water pump housing is still surface.
installed in the engine.
1. Remove water pump assembly as outlined in this 5/32" Punch

chapter.
2. Remove the (3) bolts retaining water pump cover (A)
to water pump housing (B). Discard cover gasket (C).
A C B 3
8. Inspect the water pump shaft bore for excessive wear

or damage. Replace water pump housing assembly if
necessary.
D 9. Clean and inspect water pump shaft for excessive

wear or damage. Replace water pump housing
assembly if necessary, as shaft can not be purchased
3. Place the water pump drive tab (D) vertically into a soft separately.
jaw vice.
10. Thoroughly clean mechanical seal and oil seal bores.
4. Remove the bolt and washer retaining the water pump
impeller to the shaft. Inspect the impeller veins and 11. Install a NEW oil seal into the water pump housing
water pump housing for damage. Replace if needed. until fully seated.
NOTE: The water pump impeller bolt is left hand 12. Fully install the water pump shaft and (2) washers into
thread (reverse thread). the housing.
13. Place water pump drive tab vertically into soft jaw vice
LH Thread as previously shown in this procedure.
14. Install a NEW mechanical seal into the water pump
housing using special tool PU-50564. Press the new
mechanical seal in until it is flush with the water pump
housing.
PU-50564
Soft Jaw Vice
5. Remove impeller from water pump shaft.

6. Using an appropriate arbor press, properly support
the water pump housing and press out the water pump
shaft from the impeller side.
7. Extract the mechanical seal and the oil seal from the
water pump housing.
3.21
ENGINE / COOLING
15. Rotate water pump shaft after seal installation to verify
free movement.
16. Place impeller onto the water pump shaft.
17. Apply Loctite® 204™ to the threads of the impeller bolt.
Install washer and impeller bolt and torque to
specification.
=T 1
Water Pump Impeller Bolt:

89 ± 18 in-lbs (10 ± 2 Nm)
(Apply Loctite® 204™ to bolt threads)
3
18. Clean cover (A) and housing gasket surfaces (B).
19. Install a new water pump cover gasket (C).
A C B
=T
Water Pump Cover Bolts:
89 ± 18 in-lbs (10 ± 2 Nm)
(Apply Loctite® 204™ to bolt threads)
21. Install (2) new water pump (O-rings) and lubricate

them with fresh engine oil.
20. Install the water pump cover and (3) retaining bolts. 22. Install water pump assembly into engine as shown in
Torque bolts in sequence to specification. the “Water Pump Installation” procedure.
Bolt (LH Thread)
Loctite® 204™
O-Rings
Mechanical Washers
Seal
PU-50564
Water Pump Drive Tab

Oil Seal Shaft
Impeller Water Pump Housing
Washer
3.22
ENGINE / COOLING
ENGINE SERVICE Engine Removal
IMPORTANT: Some engine repair procedures can be
Accessible Engine Components
performed without removing the engine assembly
The following components can be serviced or removed from the vehicle. Refer to “Accessible Engine
with the engine installed: Components” for further information.
• Camshaft(s) NOTE: The use of an overhead or portable engine

hoist is the only recommended method for removing
• Camshaft Sprocket(s) and installing the engine.
• Cylinder Head
• Flywheel
NOTE: Have an assistant help guide the engine in
and out of the vehicle while using an engine hoist to 3
• Oil Cooler prevent personal injury or damage to vehicle
components.
• Starter Motor / Idler Gear Asm
• Stator (Alternator)
WARNING
• Thermostat
• Valve Cover Always wear safety glasses and proper shop
clothing when performing the procedures in
• Water Pump this Service Manual.
Failing to do so may lead to possible injury.
The following components require engine removal for
service: 1. If vehicle was recently operated, allow it to cool down
before attempting to perform any work.
• Camshaft Timing Chain
• Connecting Rod(s) 2. Thoroughly clean the engine and chassis.
• Counterbalance Shaft / Bearings 3. Drain the engine oil and coolant prior to engine
• Crankcase removal (see Chapter 2).
• Crankshaft / Main Bearings 4. RZR XP: Remove the seats, console cover, engine
service panel and divider panel heat shield (see
• Crankshaft Seal (PTO)
Chapter 5).
• Cylinder RZR XP 4: Remove the rear passenger seats, engine
service panel and divider panel heat shield (see
• Oil Pump / Oil Pump Sprocket or Chain
Chapter 5).
• Piston / Rings
5. Disconnect the (-) negative battery cable from the
battery.
Top-End Service (Engine in Chassis)
6. Remove the rear bumper and cargo box as an
Some top-end engine components can be serviced while assembly (see Chapter 5).
the engine is mounted in the chassis.
7. Remove the air box assembly (see Chapter 4 “ECT
To service the top-end of the engine refer to the “Valve Sensor Replacement”).
Clearance Inspection” procedure in Chapter 2, which
provides detailed steps to access the valve cover. 8. Elevate the rear of the vehicle off the ground using a
suitable lift and remove the left rear wheel.
WARNING
Use care when supporting vehicle so that it does not

tip or fall.
Serious injury may occur if vehicle tips or falls.
3.23
ENGINE / COOLING
9. Remove lower mounting bolt (A) from the left rear 12. Disconnect the IAC valve (C), MAQS (D), ECT sensor
shock and discard the nut. Install a new nut upon (E), and CPS sensor (F) connectors, fuel injector
assembly. harness leads (G) and ignition coil harness lead.
Remove wire ties retaining harness to the fuel rail and
10. Remove the outer clutch cover screws (B) and remove rear cross member.
the cover from the vehicle.
C G
D E
A F
13. Disconnect the stator harness (H).

11. Remove drive belt, drive clutch, driven clutch, inner
clutch cover and clutch outlet duct (see Chapter 6).
CAUTION
Correct Drive Clutch Puller P/N 2872085
14. Remove (+) positive cable from the starter motor.
15. Remove (-) negative cable from the starter mounting

bolt.
IMPORTANT: Be sure to use the correct Drive Clutch

Puller (PN 2872085) to prevent damage to crankshaft.
3.24
ENGINE / COOLING
16. Remove wire tie retaining harness to rear cross 20. Remove the breather hose from the crankcase.
member.
21. Remove the (6) fasteners that attach the exhaust

17. Remove screw retaining throttle cable guide. head pipe to the engine. Remove the (2) exhaust
springs that attach the head pipe to the muffler.
Remove exhaust head pipe towards the front of the
vehicle. Discard exhaust gaskets.
Exhaust
Head Pipe
Discard
18. Disconnect fuel lines and remove throttle body Springs

assembly (see Chapter 4). Make note of line routing
for installation.
22. Remove heat shield mounting screw, and remove
19. Remove spark plug wires from the engine. heat shield from vehicle.
IMPORTANT: The spark plug wires are marked with

MAG and PTO. Note during installation procedure.
3.25
ENGINE / COOLING
23. Remove the push rivet that attaches the heat shield 26. Remove the (4) rear mounting bolts (J) that attach the
to the rear cross member. Remove the (8) bolts and rear of the engine to the transmission.
(4) nuts that attach the front and rear cross member
to the vehicle frame and remove both cross members. J
Rear
Cross Member
J
Front
Cross Member
K
24. Place a suitable drain pan under the vehicle and
remove the (2) coolant hoses from the engine.
Dispose of engine coolant properly.
NOTE: It is not necessary to remove the bolts that

retain the bracket (K) to the transmission.
27. Remove the (4) front engine mounting bolts (L) and
Remove nuts (M).
L
M
25. Use an overhead or portable engine hoist and suitable
engine straps to secure engine in its current position.
28. With the help of an assistant and the engine hoist,

raise the engine vertically out of the vehicle frame.
3.26
ENGINE / COOLING
NOTE: Have an assistant help guide the engine in Engine Installation
and out of the vehicle while using an engine hoist to
prevent personal injury or damage to vehicle Use the following procedure to reinstall the engine
components. assembly.
29. Remove the starter motor bolts and starter motor from 1. Attach engine with suitable lifting straps to an
the engine. overhead or portable engine hoist.
30. Remove the (6) transmission joint bracket bolts and 2. Remove the engine stand adapter plate and install the
transmission joint bracket from the engine. starter motor back onto engine. Torque starter motor
bolts to specification.
3. Install transmission joint bracket onto engine and 3

torque fasteners to specification in sequence.
31. Install the engine stand adapter (PU-50562) onto the

engine where the starter motor was located.
32. Select the proper engine stand sleeve adapter and

install it onto the engine stand adapter.
• Sleeve adapter for a 2” bore engine stand: 

(PU-50625)
• Sleeve adapter for a 2.375” bore engine stand: 
(PW-47054)
33. Place engine onto the engine stand (PU- 50624) for
service.
PU-50562
=T
PU-50625
or Starter Motor Bolts: 7 ft-lbs (10 Nm)
PW-47054 Trans Joint Bracket Bolts: 44 ft-lbs (60 Nm)
PU-50624
3.27
ENGINE / COOLING
4. Use the overhead or portable engine hoist and
suitable engine straps to lower the engine into the
vehicle frame.
NOTE: Have an assistant help guide the engine in

and out of the vehicle while using an engine hoist to
prevent personal injury or damage to vehicle
components.
5. Align both the front and rear engine mounting

locations. Install the (4) front engine mounting bolts
(L) and nuts (M) and hand tighten. Tool Fully Seated Inward
8. Loosen the (2) bolts (N) retaining transmission joint

bracket to the transmission on the right side.
L
M
9. Align the front transmission mounting holes with

IMPORTANT: DO NOT torque fasteners at this time. transmission joint bracket mounting holes on engine.
6. Align transmission joint mounting holes with the
transmission front mounting holes. 10. Install the (2) bolts (P) retaining the transmission joint
bracket to the engine on the right side. Hand tighten
7. Install the Clutch Center Distance Tool (PU-50658) the bolts so they remain loose at this time.
onto the crankshaft and transmission input shaft to
properly position the clutch center distance. The IMPORTANT: DO NOT torque fasteners at this time.
pictures below show the tool (PU-50658) properly
installed.
Drive Clutch Bolt Installed
3.28
ENGINE / COOLING
11. Install the (2) longer bolts into left side mounting holes. 15. Remove the lifting straps and overhead or portable
Torque left side mounting bolts to specification using engine hoist.
the numbered sequence shown.
16. Install the (2) coolant hoses onto the engine.
17. Install both front and rear cross members onto the
vehicle frame. Torque fasteners to specification.
1 17 ft-lbs
40 ft-lbs
(23 Nm)
(54 Nm)
2 3
12. Torque right side mounting bolts to specification using

5 18. Install push rivet through heat shield into rear cross
member.
19. Install the exhaust heat shield and retaining screw.

6
3, 7
=T
Engine / Transmission Mounting Bolts:
Step 1-2: 64 ft-lbs (87 Nm)

20. Replace exhaust gaskets (seals). Install exhaust
13. Remove the clutch center distance tool.
head pipe. Install the (6) fasteners that attach the
14. Torque the (4) front engine mount fasteners to exhaust head pipe to the engine and torque to
specification. specification.
=T =T
Front Engine Mount Fasteners: Exhaust Head Pipe Bolts:

40 ft-lbs (54 Nm) 18 ft-lbs (24 Nm)
3.29
ENGINE / COOLING
21. Install the (2) exhaust springs that attach the head NOTE: Be sure to connect the engine intake hose
pipe to the muffler. and clutch air intake hose to the rear cargo box asm
upon installation.
22. Install the breather hose to the crankcase.
23. Install the spark plug wires to the appropriate cylinder
by referencing the MAG and PTO spark plug wire 35. Remove the pressure cap and fill the cooling system
decals. through the filler neck with properly mixed anti-freeze
/ coolant.
IMPORTANT: Ensure plug wires caps are pushed
down all the way so they engage onto the spark plugs. 36. Install a new oil filter. Lubricate the seal with engine
oil prior to installation (see Chapter 2 “Maintenance”).
24. Install the throttle body assembly and connect fuel
lines as outlined in the EFI Chapter (see Chapter 4). 37. Add approximately 2.5 quarts (3.3 L) of Polaris PS-4
Install throttle cable retaining clip. Plus or PS-4 Extreme Duty Synthetic Engine Oil to the
engine. Additional oil may be required after complete
25. Secure wire harness in the routing clip on the rear engine disassembly. Check level after filling and add
cross member. oil as needed.
26. Install (+) positive cable to the starter motor. 38. Follow the “Cooling System Bleeding Procedure” as
outlined in this chapter.
27. Install (-) negative cable to the starter motor mounting
bolt. 39. RZR XP: Install the divider panel heat shield, engine
service panel, console cover and seats (see Chapter
28. Properly route and connect the harness leads for the 5).
stator, CPS, IAC valve, MAQS, ECT sensor, fuel RZR XP 4: Install the divider panel heat shield, engine
injectors and ignition coil. service panel, and rear passenger seats (see Chapter
5).
29. Install the air box assembly as outlined in the EFI
Chapter (see Chapter 4 “ECT Sensor Replacement”). 40. Start engine and check for any oil or coolant leaks.
30. Install the inner clutch cover, drive clutch, driven 41. Check the engine oil level (see Chapter 2).
clutch, drive belt, outer clutch cover and clutch outlet
duct (see Chapter 6). 42. Refer customer to “Engine Break-In Period” upon
returning vehicle to customer.
31. Install the left rear shock lower mounting bolt and new
nut. Torque to specification.
=T
Rear Shock Mounting Bolt:
Lower: 70 ft-lbs (95 Nm)
32. Install the left rear wheel and torque wheel nuts to
specification.
=T
Wheel Nuts:
30 ft-lbs (41 Nm) + 90° (1/4 turn)
33. Install the rear bumper and cargo box as an assembly

(see Chapter 5).
3.30
ENGINE / COOLING
Engine Mounting and Torque Values
64 ft-lbs 18 ft-lbs
44 ft-lbs (87 Nm)* (24 Nm)
(60 Nm)*
40 ft-lbs
(54 Nm)* 3
44 ft-lbs
(60 Nm)*
44 ft-lbs 40 ft-lbs
(60 Nm)* (54 Nm)
17 ft-lbs * Reference “Engine Installation”

(23 Nm) procedure for torque sequence.
Engine Break-In Period 5. Perform regular checks on fluid levels, controls and all
important bolt torques.
The break-in period consists of the first 25 hours of
operation, or the time it takes to use 15 gallons (57 liters) 6. Change oil and oil filter after 25 hour break-in period.
of fuel. Careful treatment of a new engine and drive
components will result in more efficient performance and Engine Lubrication Specifications
longer life for these components.
CAUTION =
Use only Polaris PS-4 Plus or PS-4 Extreme Oil Capacity * Approx. 2.5 Quarts (2.4 L)
Duty Synthetic 4-Cycle Engine Oil. Oil Filter Wrench PU-50105 or 2.5” (64 mm)
Never substitute or mix oil brands.
Serious engine damage and voiding of Oil Filter PN 2540086
warranty can result. Oil Type PS-4 Plus
Do not operate at full throttle or high speeds for Ambient Temp Range: Synthetic Engine oil
extended periods during the first three hours of -35° F to 100° F (PN 2876244) (Quart)
use. Excessive heat can build up and cause
damage to close fitted engine parts. Oil Type PS-4 Extreme Duty
Ambient Temp Range: Synthetic Engine Oil
1. Fill fuel tank with unleaded fuel which has a minimum 0° F to 120° F (PN 2878920) (Quart)
pump octane number of 87 = (R + M)/2.
Oil Pressure
2. Refer to Chapter 2, “Engine Oil Level”. Check oil level Minimum Specification 10 PSI @ 1200 RPM
indicated on dipstick. Add oil if necessary. (using Polaris engine oil
at operating temperature) 40 PSI @ 7000 RPM
3. Drive slowly at first to gradually bring engine up to
operating temperature.
* Additional oil may be required after complete engine
4. Vary throttle positions. Do not operate at sustained disassembly. Check level after filling and add oil as
idle or sustained high speed. needed.
3.31
ENGINE / COOLING
ENGINE DISASSEMBLY / INSPECTION - TOP END
Valve Cover Removal Camshaft Removal
NOTE: The valve cover can be removed with the NOTE: The camshafts can be removed with the
engine installed in the chassis. engine installed in the chassis.
1. Remove the (4) valve cover shoulder bolts (A) and 1. Rotate the engine so the PTO cylinder is at Top Dead
isolators (B) using a T40 driver. Center (TDC) to relieve most of the valve spring
pressure. The camshaft lobes should face out and
the slots on the end of the camshafts should line up.
D
Lobes should face out

A
2. Remove the hydraulic cam chain tensioner (E) from

the cylinder. Replace the sealing washer (F) upon
C
reassembly.
2. Replace isolators (B) and valve cover seal (C) if oil

leaks are evident.
3. Remove the spark plugs (D). Stuff spark plug holes

with shop towels to prevent anything from falling into
the combustion chamber.
3.32
ENGINE / COOLING
3. Remove the (2) bolts retaining the fixed cam chain 7. Lift the chain and sprockets off the camshafts to allow
guide (G) and remove the assembly from the engine. each sprocket to be removed.
4. Remove the remaining (2) bolts that retain the front 8. Using a paperclip (J) or other tool, hold cam chain up.
camshaft carrier (H) and carefully lift the carrier off the
camshafts. J
NOTE: The crankcase has a built-in lower guide to

prevent the chain from falling off the crankshaft.
5. Hold camshafts with an open-end wrench, and 9. Evenly loosen the (4) bolts retaining each rear
remove the top bolt from the camshaft sprockets (I). camshaft carrier (K) and carefully lift the carriers off
the camshafts.
Hold shafts
here
K K
I I
L M
Remove
6. Rotate the engine using the flywheel and remove the

remaining bolt from each camshaft sprocket (I).
3.33
ENGINE / COOLING
10. Mark the intake (L) and exhaust (M) camshafts to NOTE: Replace camshafts if damaged or if any part
ensure proper assembly. is worn past the service limit.
11. Carefully remove camshafts from the cylinder head.

= In. / mm.
Camshaft Sprocket Inspection
Inspect cam sprocket teeth for wear or damage. Replace Camshaft Lobe Height:
timing chain and sprockets if worn or damaged. Intake: 1.5390" - 1.5429" (39.09 - 39.19 mm)
Service Limit: 1.5370" (39.04 mm)
Inspect
Sprocket Teeth Exhaust: 1.5142" - 1.5181" (38.46 - 38.56 mm)
3. Visually inspect each camshaft journal for scoring,

wear or damage.
4. Measure the diameter of the camshaft journals using
a micrometer. Compare to specification.
Replace if
Worn or Damaged
Camshaft / Camshaft Bore Inspection

Inspect all main journals and cam lobes as described
below and compare to specifications. Replace
camshaft(s) or cylinder head if worn beyond service limit NOTE: Replace camshafts if damaged or if any part
or if any surface is pitted or damaged. is worn past the service limit.
1. Visually inspect each cam lobe for wear or damage.
2. Measure the height of each cam lobe from the base = In. / mm.
circle to highest point on the lobe using a micrometer.
Compare to specification.
Camshaft Journal O.D.:
0.9036" - 0.9055" (22.954 - 22.999 mm)
3.34
ENGINE / COOLING
5. Temporarily install the camshaft carriers to measure 7. Calculate oil clearance by subtracting camshaft
the camshaft bore. Torque bolts in sequence to journal O.D.s from camshaft carrier bore I.D.s.
specification. Replace cylinder head if worn. Compare to specification.
= In. / mm.
Calculated Camshaft Oil Clearance:

0.0000" - 0.0026" (.025 - 0.067 mm)
Service Limit: 0.0039" (.10 mm) 3
=T
Camshaft Carrier Bolts:
89 in-lbs (10 Nm)
6. Measure camshaft bore and compare to

specifications.
NOTE: Replace cylinder head if camshaft journal

bores are damaged or if worn past the service limit.
= In. / mm.
Camshaft Carrier Bore I.D.:

0.9055" - 0.9063" (23.000 - 23.021 mm)
3.35
ENGINE / COOLING
Cylinder Head Removal IMPORTANT: Once the cylinder head is removed,
nothing retains the cylinder to the engine. DO NOT
NOTE: The cylinder head can be serviced with the rotate the engine without using the Cylinder Holding
engine installed in the chassis. & Camshaft Timing Plate (PU-50563). Refer to
“Cylinder / Piston Removal”.
1. Remove the (2) outer M6 bolts (A) that retain the
cylinder head (B) to the cylinder.
2. Loosen the (6) cylinder head bolts (C) evenly 1/8 turn
Cylinder Head Warp Inspection
at a time until all are loose. Thoroughly clean cylinder head surface to remove all
traces of gasket material and carbon.
3. Remove and discard the cylinder head bolts (C).
4. Tap cylinder head lightly with a soft faced hammer CAUTION

until loose.
5. Tap only in reinforced areas or on thick parts of the Use care not to damage gasket sealing surface.
cylinder head casting. All gasket surfaces must be clean, dry and free
of any oil or grease upon assembly. Clean
6. Remove the cylinder head (B) and head gasket (D). sealing surfaces with rubbing alcohol or
electrical contact cleaner. Do not touch sealing
surfaces of the new head gasket.
1. Lay a straight edge (E) across the surface of the

C cylinder head at several different points and measure
A warp by inserting a feeler gauge between the straight
edge and the cylinder head surface. If warp exceeds
the service limit, replace the cylinder head.
= In. / mm.
Cylinder Head Warp Limit:

0.0039" (0.10 mm)
D
3.36
ENGINE / COOLING
Cylinder Head Disassembly 2. Compress the valve spring by hand using valve spring
compressor adapter (PV-43513-A).
WARNING PV-43513-A
Wear eye protection during cylinder head

disassembly and reassembly or when working
with the valve springs.
IMPORTANT: Keep mated parts together and in order

with respect to their location in the cylinder head for
assembly purposes. It is important to install cylinder
head components back in the same location. Mark
3
each component or place them in an organized rack
as you remove them.
1. Remove the valve bucket (F) and adjustment shim

(G) from the cylinder head.
3. Push down on spring and remove split keepers (H).
H
I
K
L
F
M
G
4. Slowly release valve spring pressure and remove the

compressor adapter.
5. Remove the valve retainer (I), valve spring (J), valve

stem seal (K) and valve spring seat (L). Discard the
valve seal.
NOTE: Replace valve seals whenever cylinder head

is disassembled. Hardened, cracked or worn seals
will cause excessive oil consumption.
6. Lift up the cylinder head and push the valve (M) out,
keeping it in order for reassembly in the same valve
guide.
3.37
ENGINE / COOLING
7. Repeat the previous steps to remove the remaining 3. Check the end of the valve stem for flaring, pitting,
valves. wear or damage.
8. Clean the combustion chamber and head gasket

surface.
9. Measure the free length of each valve spring with a

Vernier caliper and compare to specification.
Top
4. Inspect split keeper groove for wear or flaring in the

keeper seat area.
Bottom
NOTE: The valves can be re-faced or end ground, if
necessary. They must be replaced if extensively
worn, burnt, bent or damaged.
5. Measure diameter of valve stem with a micrometer in

three places, then rotate 90° and measure again (take
= In. / mm. six measurements total). Compare to specifications.
Valve Spring Free Length:

Standard: 1.7263" (43.85 mm)
Valve Inspection
1. Remove all carbon from valves with a soft wire wheel
or brush.
2. Check valve face for runout, pitting, and burnt spots.

To check for bent valve stems, mount valve in a drill
or use “V” blocks and a dial indicator.
= In. / mm.
Valve Stem Diameter:

Intake: 0.2155" - 0.2161" (5.475 - 5.490 mm)
Exhaust: 0.2147" - 0.2153" (5.455 - 5.470 mm)
3.38
ENGINE / COOLING
6. Measure valve guide inside diameter at the top, NOTE: Carbon Clean Fuel Treatment (2871326) can
middle and end of the guide using a small hole gauge be used to help remove carbon deposits.
and a micrometer. Measure in two directions.
IMPORTANT: Do not use a metal scraper, a coarse
wire brush or abrasive cleaners to clean the cylinder
head. Damage may result.
2. Visually inspect cylinder head gasket surface and

combustion chamber for cracks or damage. Pay close
attention to areas around spark plug and valve seats.
Valve Seat Reconditioning 3

Valve seat reconditioning should be performed by a
technician proficient in cylinder head reconditioning
techniques. Reconditioning techniques vary, so follow the
instructions provided by the valve reconditioning
equipment manufacturer. Do not grind seats more than
necessary to provide proper seat surface, width, and
contact point on valve face.
= In. / mm.
WARNING
Valve Guide I.D.:
0.2165" - 0.2171" (5.500 - 5.515 mm) Wear eye protection or a face shield during
cylinder head disassembly and reassembly.
7. Be sure to measure each guide and valve
combination individually. Valve Seat Inspection
NOTE: The valve guides cannot be replaced. 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
Combustion Chamber Cleaning the valve seat is cracked the cylinder head must be
replaced.
WARNING Valve seat width and point of contact on the valve face is
very important for proper sealing. The valve must contact
Wear eye protection during combustion the valve seat over the entire circumference of the seat,
chamber cleaning. and the seat must be the proper width all the way around.
If seat is uneven, compression leakage will result. If seat
1. Clean all accumulated carbon deposits from is too wide, seat pressure is reduced, causing carbon
combustion chambers and valve seat area. accumulation and possible compression loss. If seat is too
narrow, heat transfer from valve to seat is reduced. The
Combustion Area valve may overheat and warp, resulting in burnt valves.
3.39
ENGINE / COOLING
Renewing Valve Seats * If too low, use the 60° cutter to raise the seat. When
contact area is centered on the valve face, measure seat
1. Install pilot into valve guide.
width.
2. Apply cutting oil to valve seat and cutter.
* If the seat is too wide or uneven, use both top and bottom
cutters to narrow the seat.
3. Place 46° cutter on the pilot and make a light cut.
* If the seat is too narrow, widen using the 45° cutter and
4. Inspect the cut area of the seat:
re-check contact point on the valve face and seat width
* If the contact area is less than 75% of the circumference after each cut.
of the seat, rotate the pilot 180° and make another light cut. NOTE: When using an interference angle, the seat
* If the cutter now contacts the uncut portion of the seat, contact point on the valve will be very narrow, and is
check the pilot. Look for burrs, nicks, or runout. If the pilot a normal condition. Look for an even and continuous
is bent it must be replaced. contact point all the way around the valve face (A).
* If the contact area of the cutter is in the same place, the B

valve guide is distorted from improper installation.
* If the contact area of the initial cut is greater than 75%,
continue to cut the seat until all pits are removed and a new
seat surface is evident.
A
NOTE: Remove only the amount of material
necessary to repair the seat surface.
5. To check contact area of the seat on the valve face, Proper Seat Contact
apply a thin coating of Prussian Blue™ paste to the on Valve Face
valve seat. If using an interference angle (46°) apply
black permanent marker to the entire valve face (A).
Intake Seat Cutter Diameter: 1.567 in. (39.80 mm)
INTAKE
30°
6. Insert valve into guide and tap valve lightly into place
45°
a few times. Seat Width
60° .039” (1.00 mm)
7. Remove valve and check where the Prussian Blue™
indicates seat contact on the valve face. The valve
seat should contact the middle of the valve face or
slightly above, and must be the proper width.
* If the indicated seat contact is at the top edge of the valve

face and contacts the margin area (B) it is too high on the
valve face. Use the 30° cutter to lower the valve seat.
3.40
ENGINE / COOLING
Exhaust Seat Cutter Diameter: 1.364 in. (34.65 mm)
EXHAUST
3
30°
45°
Seat Width 60°
.059” (1.50 mm)
= In. / mm.
Valve Seat Width:

Intake: 0.039" (1.00 mm)
Exhaust: 0.059” (1.50 mm)

8. Clean all filings from the area with hot soapy water.
Rinse and dry with compressed air.
9. Lubricate valve guides with clean engine oil and apply

oil or water based lapping compound to the face of the
valve.
NOTE: Lapping is not required if an interference

angle reconditioning method is used.
10. Insert the valve into its respective guide and lap using
a lapping tool or a section of fuel line connected to the
valve stem.
11. Rotate the valve rapidly back and forth until the cut
sounds smooth. Lift the valve slightly off of the seat,
rotate 1/4 turn, and repeat the lapping process. Do this
four to five times until the valve is fully seated, and
repeat process for the other valve(s).
12. Thoroughly clean cylinder head and valves.
3.41
ENGINE / COOLING
ENGINE DISASSEMBLY / INSPECTION - LOWER END
Stator Cover Removal / Inspection
NOTE: The stator cover can be removed with the
engine installed in the chassis.
1. Remove the (13) screws retaining the stator cover.
3. Inspect the condition of the stator windings (A) and

output wires (B). If replacement is required, refer to
Chapter 10.
CAUTION A
C
The flywheel contains powerful magnets. Use
caution when removing and installing the stator
cover. DO NOT place fingers between cover and
crankcase at any time during the removal /
installation process or injury could result.
2. Carefully pry the stator cover off the engine using the
two pry areas as shown below. B
4. Inspect the ball bearing (C) that supports the starter

motor shaft.
5. If bearing replacement is required, remove the

retaining ring and heat the stator cover around the
bearing evenly with a heat gun. Tap cover on a soft
work surface to remove the bearing from the housing.
A blind bearing puller can also be used. Replace
bearing if removed.
3.42
ENGINE / COOLING
Water Pump Housing Removal 3. Remove the water pump assembly from the engine by
using a twisting motion as you pull out on the housing.
NOTE: The water pump housing can be serviced
with the engine installed in the chassis (see ENGINE
COOLING SYSTEM - Water Pump Removal).
1. Remove the coolant lines from the thermostat

housing, cylinder inlet and oil cooler. Leave them all
attached to the water pump housing.
4. If water pump service is required (impeller or

mechanical seal), refer to “ENGINE COOLING
SYSTEM”.
Flywheel Removal
2. Remove the (3) long gold colored bolts retaining the NOTE: The flywheel can be serviced with the engine
water pump housing to the engine. installed in the chassis.
1. Remove the stator cover assembly.
2. Remove the starter torque limit gear as an assembly.
3. Inspect gear teeth for damage. Inspect fit of shaft

inside gear and replace gear assembly is clearance
is excessive. Inspect the shaft and bearing surfaces
in the crankcase and stator cover for excessive wear.
3.43
ENGINE / COOLING
4. Using a commercially available strap wrench (D), hold Starter One-Way Clutch Inspection
the flywheel and remove the flywheel retaining bolt
(E). NOTE: The starter one-way clutch can be serviced
with the engine installed in the chassis.
D 1. Remove the stator cover and flywheel (see “Stator

E Cover Removal / Inspection” and “Flywheel
Removal”).
2. Place flywheel on a work bench with the one-way

clutch facing up. Grasp clutch gear and rotate
clockwise. It should turn smoothly without binding.
3. Rotate one-way gear counterclockwise. The gear

should immediately lock in position and not slip.
4. Inspect the one-way gear bushing (A) for wear or

galling. If service is required, refer to “Starter One-
Way Clutch Disassembly”.
5. Fully install Flywheel Puller (PA-49316) on the
threads of the flywheel (left hand thread - turn flywheel
puller counterclockwise to install). Gear
Rotation
6. Hold puller body and tighten the center bolt to remove
the flywheel.
Starter One-Way Clutch Disassembly

PA-49316
1. Lift up to remove starter one-way gear.
3.44
ENGINE / COOLING
2. Remove the (3) one-way clutch retaining screws. Starter One-Way Clutch Assembly
1. Install one-way clutch in clutch hub with flange of
clutch (F) engaged in recess.
3. Remove the one-way clutch and inspect both sides of

drive rollers (B). Inspect the roller contact surface (C) 2. Clean screw threads in flywheel to remove all oil or
inside the hub for wear, damage or uneven surface. grease.
3. Place one-way clutch on flywheel and install the (3)

screws. Torque screws to specification.
B
=T
C
One-Way Clutch Retaining Screws:
106 in-lbs (12 Nm)
4. Reassemble starter one-way clutch and gear using

the following illustration.
4. Inspect drive surface of starter gear (D) and bushing Torque Limit
(E) for wear, damage or uneven surface. If any starter Gear Pin
one-way clutch component is worn or damaged,
replace the clutch and starter gear as an assembly. Torque Limit
Gear Asm.
D E
Screws
106 in-lbs
(12 Nm)
Starter
Gear
One-Way
Clutch Asm
Bolt Flywheel
133 ft-lbs
(180 Nm)
3.45
ENGINE / COOLING
5. If starter gear was replaced, inspect the torque limit 4. Install the Cylinder Holding & Camshaft Timing Plate
gear. (PU-50563) onto the cylinder. The cylinder holding
tool retains the cylinder and pistons when the engine
6. After assembly, be sure the starter gear rotates in the is rotated.
clockwise direction only.
PU-50563
Gear
Rotation
5. Rotate engine to access the crankcase sump cover.

Crankcase Disassembly / Inspection 6. Remove the (13) M6 and (3) M8 bolts retaining the
1. Remove the oil cooler (A) from the crankcase. sump cover (C) to the crankcase.
M6
A
M8
2. Remove the crankcase drain plug (B) to drain any oil 7. Remove the sump cover (D) from the crankcase.
remaining in the engine.
D
3. Remove the oil filter.
3.46
ENGINE / COOLING
8. Remove and clean oil pump pick-up (E). 11. Lift the oil pump drive chain and remove the oil pump.
9. Remove the (3) bolts (F) that retain the oil pump (G)
to the crankcase.
3
E
12. Visually inspect the oil pump and drive sprocket (I) for
10. Use one of the oil pump retaining bolts or a pen wear or damage. Replace oil pump drive chain and
magnet to extract the dowel pins (H) from the oil sprocket if worn or damaged. If any part of the oil pump
pump. Doing so allows for oil pump removal without is damaged, the entire assembly must be replaced.
having to remove the pump drive sprocket. Replace the oil pump seal (J) during crankcase
assembly.
J I
NOTE: Oil pump assembly is non-serviceable
13. Rotate the engine so the cylinder is facing up.

NOTE: If unable to extract the dowel pins from the
oil pump, the oil pump sprocket must be removed. 14. Remove the (11) M6 and (2) M8 upper crankcase
Access the sprocket bolt by removing the case plug. bolts.
M8
M6
3.47
ENGINE / COOLING
15. Rotate the engine so the cylinder is facing down. Balance Shaft Removal / Inspection
16. Remove the (8) M10, (2) M8 and (1) M6 lower 1. Perform “Crankcase Disassembly / Inspection”
crankcase bolts. Discard the (8) M10 bolts. procedure.
2. Note timing marks (K) on balance shaft and
M10
crankshaft drive gears. Shafts must be properly timed
upon assembly.
M6
K
M8
17. Tap on the lower crankcase in reinforced areas with 3. Carefully rotate the balance shaft (L) and remove it
a soft faced hammer to loosen. Carefully lift up and from the crankcase.
remove the lower crankcase half.
4. Inspect the balance shaft gear teeth for damage.
3.48
ENGINE / COOLING
5. Measure each bearing journal in two locations, 90 5. Carefully lift the crankshaft (N) out of the crankcase.
degrees apart. Replace balance shaft if either journal
is worn below the service limit specification. If worn N
past the service limit, replace the balance shaft
assembly.
6. Remove the cam chain (P), oil pump drive chain (Q)
and PTO main seal (R) from the crankshaft.
= In. / mm.
P
Balance Shaft Diameter (MAG & PTO)
Standard: 1.4939” - 1.4946” (37.946 - 37.962 mm)
Service Limit: 1.4921 in. (37.900 mm)
Crankshaft Removal / Inspection

1. Perform “Crankcase Disassembly / Inspection” R
procedure.
2. Perform “Balance Shaft Removal / Inspection”

procedure.
3. For ease of assembly, mark each connecting rod and

end cap.
4. Loosen, remove and discard the (4) connecting rod

Q
bolts (M). Remove the end caps from the crankshaft.
M 7. Inspect the crankshaft gear (S) and auxiliary sprocket

(T) for broken or worn teeth.
3.49
ENGINE / COOLING
8. If the crankshaft gear (S) is damaged, the crankshaft 11. Support crankshaft on V-blocks or on-centers in a
assembly must be replaced. crankshaft stand or lathe. Measure crankshaft runout
and replace if runout exceeds maximum listed below.
9. If the auxiliary sprocket (T) is damaged, remove the
sprocket with a 3-jaw puller.
= In. / mm.
10. Using an arbor press, install new sprocket in any
orientation to the depth shown in the following
illustration. Crankshaft Maximum Runout:
.001 in. (0.025 mm)
12. Visually inspect surface of crankshaft main and

connecting rod journals. Replace crankshaft if any
journal is scratched or pitted.
1.0551 ± .0039 in.

(26.8 ± 0.1 mm)
= In. / mm.
Auxiliary Sprocket Installed Depth:

1.0551 ± .0039 in. (26.8 ± 0.1 mm)
3.50
ENGINE / COOLING
13. Measure each main journal and connecting rod 14. Refer to the six letters stamped onto the PTO end of
journal in two locations, 90 degrees apart. Replace the crankshaft.
crankshaft if any journal is worn below the service limit
specification. 1 2 3 4 5 6
XXXXXX
MAG Journal Numbers
Journal 1
(Main Bearing)
Journal 2
15. Use the table below to see if the crankshaft bearing
(Rod Bearing)
journals are within specification. If worn past the
service limit, replace the crankshaft assembly.
Crankshaft Bearing Journal Diameters
B
Journal 3 1.6140 - 1.6143 in.
(Main Bearing) Main Standard
(40.996 - 41.004 mm)
Bearing
Service Limit 1.6129 in. (40.970 mm)
1.6118 - 1.6122 in.
Conn Rod Standard
(40.942 - 40.950 mm)
Bearing
Journal 4 Service Limit 1.6104 in. (40.906 mm)
(Rod Bearing) G
1.6137 - 1.6140 in.
Main Standard
(40.988 - 40.995 mm)
Bearing
Journal 5 1.6115 - 1.6118 in.
Conn Rod Standard
(Main Bearing) (40.934 - 40.941 mm)
Bearing
Y
Journal 6 1.6134 - 1.6137 in.
Main Standard
(Main Bearing) (40.980 - 40.987 mm)
Bearing
1.6112 - 1.6115 in.
Conn Rod Standard
(40.926 - 40.933 mm)
Bearing
PTO 16. Whether installing a new crankshaft or re-installing

the original, refer to the bearing selection chart
provided in the “Crankshaft Main Bearing Selection”
and “Connecting Rod Bearing Selection” procedures.
3.51
ENGINE / COOLING
Crankcase Inspection 5. Remove and discard the plain bearings located in the
upper crankcase (B), lower crankcase (C) and
1. Remove the oil drain diverter (A) from the upper connecting rods (D). Replace the crankcase
crankcase. assembly if a bearing bore is galled or if bearing
inserts have rotated in the case.Refer to bearing
A selection procedures upon assembly.
2. Remove all traces of crankcase sealer from the B

crankcase mating surfaces. Inspect the surfaces
closely for nicks, burrs or damage.
D
3. Be sure alignment pins are in place where used.
4. Be sure oil passages are clean and free of any

cleaning solvent (see “Engine Oil Flow Chart”).
IMPORTANT: Always replace plain bearings when the

crankcase or connecting rods have been
disassembled. Refer to “Bearing Selection Chart”.
3.52
ENGINE / COOLING
Cylinder / Piston Removal 5. Remove the piston / connecting rod assemblies from
the cylinder.
CAUTION
Pistons must be removed from the cylinders

with the connecting rods attached.
DO NOT attempt to service the cylinder or
pistons without disassembling the crankcase.
Although you can remove the cylinder and
pistons without disassembly, you will not be able
to reassemble the engine because of the unique
cylinder skirt and crankcase design.
3
1. Perform “ENGINE DISASSEMBLY / INSPECTION -
TOP END” and the “ENGINE DISASSEMBLY /
INSPECTION - LOWER END” procedures.
3. Remove the Cylinder Holding & Camshaft Timing NOTE: If the pistons are to be reused, mark the
Plate (PU-50563) from the cylinder. pistons so they are reassembled in the same
cylinder bore and direction from which they were
removed (MAG / PTO).
PU-50563
Cylinder Inspection
1. Lay a straight edge (E) across the top surface of the
cylinder at several different points and measure warp
by inserting a feeler gauge between the straight edge
and the cylinder surface. If warp exceeds the service
limit, replace the cylinder.
4. Carefully lift the cylinder and pistons from the upper

crankcase.
= In. / mm.
Cylinder Warp Limit:

.002" (0.05 mm)
2. Inspect cylinder for wear, scratches, or damage.
3.53
ENGINE / COOLING
IMPORTANT: DO NOT hone the cylinders or attempt Piston Disassembly / Inspection
to repair a damaged cylinder by honing.
NOTE: New pistons are directional (intake vs.
3. Inspect cylinder for taper and out of round with a dial exhaust), but can be placed in either cylinder.
bore gauge. Measure in two different directions (front
to back and side to side), on three levels (0.59 in. 1. Note location of the piston circlip gap (A) at the top
down from top, the middle, and 1.54 in. up from (12:00 position) or bottom (6:00 position).
bottom). Record measurements. If cylinder is tapered
or out of round beyond 0.001", the cylinder must be A
replaced.
0.59 in. (15 mm) Down From Top
2. Remove piston circlip and push piston pin out of

piston. If necessary, heat the crown of the piston
slightly with a heat gun if pin cannot be removed by
hand. Discard circlips.
1.54 in. (39.3 mm) Up From Bottom
= In. / mm.
Cylinder Taper:
Service Limit: 0.001" (.025 mm)
Cylinder Out of Round:

Service Limit: 0.001" (.025 mm)
= In. / mm. CAUTION
DO NOT apply heat to piston rings or a loss of

Standard Bore Size:
radial tension could result.
3.6614" ± .0003" (93 mm ± .008 mm)
3.54
ENGINE / COOLING
3. Measure piston pin bore I.D. in two directions (90° Piston Ring Removal
apart). Replace piston and piston pin if out of
specification. 1. Carefully remove top compression ring (B) by hand or
using a ring removal pliers.
CAUTION
DO NOT expand the ring more than necessary

to remove it from the piston or the ring may
break or lose radial tension.
• Piston ring pliers: Carefully expand ring and lift it

3
off the piston.
• By hand: Placing both thumbs on the ring ends,
spread the ring open and push up on opposite
side. Do not scratch ring lands.
= In. / mm.
B
Piston Pin Bore I.D.:
C
0.7877" - 0.7881" (20.009 - 20.018 mm)
Service Limit: 0.7893" (20.05 mm) D
4. Measure piston pin O.D. in two directions (90° apart)

at three locations on the length. Replace piston and
piston pin if out of specification.
2. Repeat procedure for second compression ring (C).
3. The oil control ring (D) is a three piece design

consisting of a top and bottom steel rail and a center
expander section. Remove top rail first, then bottom
rail, then the expander.
Piston Pin Measurement Locations
= In. / mm.
Piston Pin O.D.:

0.7873" - 0.7875" (20.000 - 20.005 mm)
3.55
ENGINE / COOLING
Piston Ring to Groove Clearance Inspection Piston Ring Installed Gap
1. Measure piston ring to groove clearance by placing 1. Place each piston ring (A) inside the cylinder (B). Use
the ring in the ring land and measuring with a the piston to push the ring squarely into cylinder, as
thickness (feeler) gauge. Replace piston and rings if shown below.
ring-to-groove clearance exceeds service limits.
2. Measure installed gap with a feeler gauge (C) at both
the top and bottom of the cylinder.
IMPORTANT: A difference between top and bottom

end gap measurements is a general indication of
cylinder taper (wear). The cylinder should be
Measure measured for taper and out of round.
Here
Head Gasket
Surface
Measure
Here B A C
0.59 in.
(15mm)
= In. / mm.
3. If the installed gap measurement exceeds the service
limit, replace the rings.
Piston Ring to Groove Clearance:
Top / Second Ring:

0.0007" - 0.0023" (0.020 - 0.060 mm) = In. / mm.
Piston Ring Installed Gap:
Top Ring: .010" - .014" (.25 - .35 mm)

Service Limit: .020" (.50 mm)
Second Ring: .015" - .025" (.37 - .63 mm)

Oil Control Rails: .008" - .028" (.20 - .70 mm)

NOTE: Always check piston ring installed gap when

installing new rings and/or a new cylinder.
3.56
ENGINE / COOLING
Piston-to-Cylinder Clearance Connecting Rod Inspection
Measure piston outside diameter at a point 10 mm up from 1. The 5 digit numbers stamped onto the intake side of
the bottom of the piston, at a right angle to piston pin bore. the connecting rod are serial numbers used to match
the rod stem with the rod cap.
Subtract measurement from maximum measurement
obtained in Step 4 of “Cylinder Inspection” procedure. INTAKE
Side of Rod
XXXXX XXXXX
Matching 5 Digit
0.39 in. Serial Numbers
(10mm)
= In. / mm.
2. The number and letter stamped onto the exhaust side
Piston O.D. (Standard): of the connecting rod represent the bore diameter and
3.6597 ± .0003" (92.959 ± .008 mm) weight grading of the connecting rod.
EXHAUST
Side of Rod
= In. / mm.
Piston to Cylinder Clearance: Number

(Bore Diameter)
.0009" - .0019" (.025 - .050 mm)
X
X
Letter
(Weight Grading)
3. Inspect the small end and big end of connecting rod

(and matching rod cap) for damage, galling of surface
or pitting.
3.57
ENGINE / COOLING
4. Measure small end I.D. in two directions as shown. 8. Refer to the number stamped onto the exhaust side
Record measurements and compare to of the connecting rod. This number represents the
specifications. Replace connecting rod if worn past bore diameter.
the service limit specification.
EXHAUST
Side of Rod
Number
(Bore Diameter)
X
X
= In. / mm.
9. The table below lists the big end bore diameter
Connecting Rod Small End I.D.: specifications.
0.7879" - 0.7885" (20.015 - 20.030 mm)
Service Limit: 0.7897" (20.06 mm) Connecting Rod Big End Bore Diameters
1 2 3
5. Install matching rod cap on connecting rod (without
bearings) and install the bolts. 1.7318-1.7321 in. 1.7321-1.7323 in. 1.7323-1.7326 in.
(43.989-43.996 mm) (43.996-44.003 mm) (44.003-44.010 mm)
6. Tighten bolts snug, then torque to 13 ft-lbs (18 Nm).
10. Whether using new connecting rods or re-installing
7. Using a dial bore gauge, measure big end I.D. in two the original ones, refer to the bearing selection chart
directions shown. Record measurements and provided in the “Connecting Rod Bearing Selection”
compare to specifications. procedure in this chapter.
Remove bearings when
taking measurements
3.58
ENGINE / COOLING
ENGINE ASSEMBLY - LOWER END
Bearing Selection Identification Letters and Numbers
Connecting Rod
Bearing Identification Number
Crankcase
3
Bearing Identification Numbers
X
X
1-Number
XXXXXX
6-Numbers
XXXXXX
6-Letters
Crankshaft
Bearing Identification Letters
3.59
ENGINE / COOLING
Connecting Rod Bearing Selection Crankshaft Main Bearing Selection
In order to select the proper bearing for the connecting In order to select the proper main bearings for the
rods, you must reference the number on each connecting crankshaft, you must reference the six numbers on the
rod and match that up with the rod journal letters on the crankcase and match that up with the main journal letters
crankshaft. on the crankshaft.
MAG End MAG End 1 5
Reference number
1 1
1 on conn rod cap.
This Example: 2
2 2
3 3
2 2
4 3
5 5
3
6 6
4 6
4 4
PTO End Reference numbers
stamped on crankcase.
This Example: 2 2 2 2 2 2
Reference number
5 on conn rod cap.
Journals: 1 2 3 4 5 6
This Example: 2 Reference letters
stamped on crankshaft.
6 Reference letters This Example: G G Y G G Y
stamped on crankshaft. Journals: 1 2 3 4 5 6
This Example: G G Y G G Y
Journals: 1 2 3 4 5 6 In this example, you would use the number 2 as the
crankcase codes (case journals 1, 2, 3, 4). You would use
PTO End
letters G, Y, G, Y as the crankshaft codes (crank journals
1, 3, 5 and 6). Based off the bearing selection chart, you
In this example, you would use the number 2 as the would use:
connecting rod code. You would use letters G and G as the Green bearing for Main #1
crankshaft codes (crank journals 2 and 4). Based off the Yellow bearing for Main #2
bearing selection chart, you would use a Green bearing Green bearing for Main #3
for each connecting rod Yellow bearing for Main #4
Bearing Selection Chart - Rod Bearings Bearing Selection Chart - Main Bearings
Crankshaft Crankshaft
Code B G Y Code B G Y
1 Blue Blue Green 1 Blue Blue Green
Rod Case
2 Blue Green Yellow 2 Blue Green Yellow
3 Green Yellow Yellow 3 Green Yellow Yellow
3.60
ENGINE / COOLING
Upper Crankcase Preparation Piston Ring Installation
IMPORTANT: Always replace plain bearings when the NOTE: Apply clean engine oil to all ring surfaces
crankcase or connecting rods have been and ring lands upon installation. Always check
disassembled. Refer to bearing selection procedures. piston ring installed gap before rings are installed on
piston (see “Piston Ring Installed Gap”). Clean
1. Remove all traces of crankcase sealer from the accumulated carbon from piston ring grooves and
crankcase mating surfaces. Inspect the surfaces oil ring lube holes if piston has been in service.
2. Clean bolt hole threads to remove any oil or crankcase

Marking
sealant. Top Ring Up 3
3. Inspect crankcase bearing bores. Replace the
crankcase assembly if a bearing bore is galled or if
bearing inserts have rotated in the case. Marking
Up
Second Ring
5. Refer to “Oil Flow Chart” at the beginning of this

chapter and trace the oil paths through the crankcase Upper Rail
and cylinder.
6. Flush all oil passages with solvent and then warm Spring Expander
soapy water. Rinse with clear, warm water and dry
with compressed air.
Lower Rail
7. Be sure passages are clean and dry before
assembling the upper crankcase.
1. Place oil control ring expander in oil ring groove.
Rotate expander in groove until butt ends are on PTO
side of piston (see illustration below).
IMPORTANT: Ends must butt squarely together and

must not overlap.
2. Install lower rail with end gap positioned on the intake

side of piston.
3.61
ENGINE / COOLING
3. Install upper rail with end gap positioned on the 5. Install top ring with mark facing top of piston. Rotate
exhaust side of piston. ring to position the end gap toward exhaust side of
piston as shown below.
Upper Rail Lower Rail
Gap Position Gap Position Top Ring
Gap Position
6. Be sure top and second rings rotate freely in their

grooves and do not bind when compressed by hand.
Spring Expander
Gap Position
Piston / Connecting Rod Assembly
1. Lubricate connecting rod small end, piston pin bore
4. Install second ring with marking facing top of piston. and piston pin with engine oil.
Rotate ring to position the end gap toward intake side
of piston as shown below.
CAUTION
Second Ring
Gap Position 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.
2. Install a new circlip on one side of piston with gap at

the top (12:00 position) or bottom (6:00 position).
12:00
6:00
3.62
ENGINE / COOLING
IMPORTANT: Never re-use a piston pin circlip. Cylinder / Piston Installation
NOTE: If reinstalling the original connecting rods,
orientate the rods the same as when removed. If new
CAUTION
connecting rods are being installed, they can be
installed either way (there is no piston pin offset in
the rod), however it is recommended they be Pistons must be installed into the cylinders with
installed with rods facing the same direction. the connecting rods attached.
DO NOT attempt to service the cylinder or
3. Place piston (A) on connecting rod (B). Push piston pistons without disassembling the crankcase.
pin (C) through rod and piston until it seats against the Although you can remove the cylinder and
installed circlip. pistons without disassembly, you will not be able
IMPORTANT: Do not tap on pin or cause any sideways to reassemble the engine because of the unique
cylinder skirt and crankcase design.
3
force to connecting rod. Warm piston crown with a
heat gun if pin cannot be installed by hand, or use a
NOTE: If the pistons are being reused, reassemble
piston pin installation tool.
in the same cylinder bore and direction from which
they were removed (MAG / PTO).
CAUTION
NOTE: New pistons are directional (intake vs.
DO NOT apply heat to piston rings or a loss of exhaust), but can be placed in either cylinder.
radial tension could result.
1. Apply clean engine oil to each piston assembly,
cylinder bore and bottom tapered portion of each
cylinder sleeve.
A
2. Verify that all ring end gaps are correctly located on
B each piston (see “Piston Ring Installation”).
3. Note the piston orientation mark (arrow) located on

top of the piston. Arrow should point toward the
exhaust side.
4. Install the remaining circlip (D) with gap at the top

(12:00 position) or bottom (6:00 position). Push the
piston pin in both directions to make sure the clips are
properly seated in the groove.
Arrow to Point
Toward Exhaust Side
NOTE: Orientation arrow is also located on the

bottom side of piston as an additional reference.
3.63
ENGINE / COOLING
4. Carefully compress the piston rings with your fingers 10. Carefully place the cylinder and pistons into the upper
and install the piston / connecting rod assemblies into crankcase.
the cylinder from the bottom side.
Install pistons
past the cylinder
sleeve opening
11. Install the Cylinder Holding & Camshaft Timing Plate

(PU-50563) onto the cylinder. The cylinder holding
tool retains the cylinder and pistons when the engine
NOTE: Use a slight front to back rocking motion is rotated.
until all rings are captive in cylinder and past the
cylinder sleeve opening. PU-50563
5. Rotate the engine so the crankcase to cylinder

mounting surface is facing up.
6. Clean base gasket sealing surface on cylinder and

crankcase to remove all oil and grease.
NOTE: Base gasket and surfaces must be DRY and

oil free. Use care upon assembly to keep oil away.
7. Reinstall dowel pins in crankcase if previously

removed.
8. Install a new cylinder base gasket.

Crankshaft Installation
9. Verify piston orientation (arrow pointing toward
exhaust) one last time prior to installation. IMPORTANT: Whether installing a new crankshaft or
re-installing the original, refer to the bearing selection
charts (see “Crankshaft Main Bearing Selection” and
“Connecting Rod Bearing Selection” procedures in
this chapter).
1. Rotate the engine so the cylinder is facing down.
2. Clean the bearing bore surfaces of upper crankcase

(main bearings), connecting rods and connecting rod
caps.
3. Align tab of new main bearing (A) with the slot in main
bearing bore of crankcase. Press bearing insert firmly
into place. Repeat for all main bearings.
3.64
ENGINE / COOLING
4. Align tab of new connecting rod bearings (B) with the 7. Loop cam chain (D) and oil pump drive chain (E) over
slot in the connecting rod stem and connecting rod crankshaft sprockets.
end cap. Press bearing insert firmly into place. Repeat
for the other connecting rod. 8. Apply Polaris PS-4 engine oil to the new crankshaft
oil seal (F) and install the seal on the PTO end of the
B crankshaft.
3
F
5. Install oil drain diverter (C) into the upper crankcase.

E
C
9. Carefully lower the crankshaft into upper crankcase.

Guide connecting rods onto the rod journals of
crankshaft as necessary.
6. Apply Polaris PS-4 engine oil to each main and rod

bearing journal of crankshaft.
Apply
Engine Oil
10. Adjust the PTO crankshaft seal so it rests properly in

the upper crankcase.
11. Clean bolt hole threads in connecting rod to remove

all oil.
Apply
Engine Oil
3.65
ENGINE / COOLING
12. Install matching rod cap on connecting rod with 5 digit Balance Shaft Installation
serial number stampings aligned.
IMPORTANT: Whether installing a new balance shaft
INTAKE or re-installing the original, refer to bearing selection
Side of Rod chart (see “Balance Shaft Bearing Selection”
procedure in this chapter).
1. Clean the upper crankcase balance shaft bearing

bore surfaces.
XXXXX XXXXX
2. Align tab of new balance shaft bearings (A) with the

slot in each bearing bore of crankcase. Press bearing
Matching 5 Digit
Serial Numbers insert firmly into place.
13. Install new bolts and tighten evenly until snug.
NEW Bolts
3. Rotate the crankshaft until the alignment dot (B) on

the crankshaft MAG end gear is visible.
4. Apply Polaris PS-4 engine oil to both balance shaft

journals.
Apply
Engine Oil
14. Torque connecting rod bolts to specification.
=T
Connecting Rod Bolts: Apply
Engine Oil
Step 1: Torque to 9 ft-lbs (12 Nm)
Step 1: Torque to 13 ft-lbs (18 Nm)
Step 2: Tighten an additional 105°
3.66
ENGINE / COOLING
5. Install the balance shaft, placing the tooth with the Lower Crankcase Preparation
alignment dot (C) in-line with the dot (B) on the
crankshaft gear (see reference images below). IMPORTANT: Always replace plain bearings when the
crankcase or connecting rods have been
disassembled. Refer to bearing selection procedures.
1. Remove all traces of crankcase sealant from the

crankcase mating surfaces. Inspect the surfaces
2. Clean bolt hole threads to remove any oil or crankcase

sealant.
3. Inspect crankcase bearing bores. Replace the

3
crankcase assembly if a bearing bore is galled or if
bearing inserts have rotated in the case.
5. Refer to “Oil Flow Chart” at the beginning of this

chapter and trace the oil paths through the crankcase
B C and cylinder.
6. Flush all oil passages with solvent and then warm

soapy water. Rinse with clear, warm water and dry
with compressed air.
7. Be sure passages are clean and dry before

assembling the crankcase.
Crankcase Assembly
1. Check to be sure the PTO crankshaft seal is resting
properly in the upper crankcase.
2. Align tab of new main bearings (A) and new balance

shaft bearings (B) with the slot in each bearing bore
of the lower crankcase. Press bearing inserts firmly
into place.
3.67
ENGINE / COOLING
3. Apply Polaris PS-4 engine oil to the new bearings 8. Inspect crankcase mating surfaces to be sure they are
installed in the lower crankcase half. joined properly. Investigate the cause of any gaps.
4. Clean crankcase mating surfaces to remove any oil. 9. Install the (8) M10, (2) M8 and (1) M6 lower crankcase
bolts. Tighten all bolts lightly by hand.
5. Apply a thin, continuous film of Crankcase Sealant
(PN 2871557) to upper crankcase mating surface as M10
shown. Do not allow sealant to dry before assembly. M6
Sealant Path DO NOT Block

Oil Passages
M8
IMPORTANT: Install new M10 lower crankcase bolts.

10. Torque lower crankcase bolts in sequence to
specification. Repeat sequence to verify final torque.
Sealant Path
IMPORTANT: DO NOT block oil passages with

crankcase sealant.
6. Carefully place lower crankcase on upper case,

making sure the oil pump drive chain is fed through
the lower crankcase.
=T
Lower Crankcase Bolts:
M10 Bolts:
Step 1: 9 ± 2 ft-lbs (12 ± 3 Nm)
Step 2: 21 ± 2 ft-lbs (28 ± 3 Nm)
Step 3: Tighten an additional 90° (1/4 turn)
M8 Bolts: 26 ft-lbs (35 Nm)

M6 Bolts: 9 ft-lbs (12 Nm)
7. Tap lower crankcase with a rubber hammer to seat the
case halves together.
3.68
ENGINE / COOLING
12. Install the (11) M6 and (2) M8 upper crankcase bolts. 16. Lift the oil pump drive chain and install the oil pump.
Tighten all bolts lightly by hand.
M8
M6
17. Install dowel pins (C) into oil pump mounting holes.
13. Torque the upper crankcase bolts in sequence to

specification (start with #12). Repeat the sequence to
verify final torque.
18. Install the (3) bolts (D) that retain oil pump (E) to the
crankcase. Torque mounting bolts to specification.
=T
Upper Crankcase Bolts:
M8 Bolts: 26 ± 1 ft-lbs (35 ± 2 Nm)
M6 Bolts: 89 ± 9 in-lbs (10 ± 1 Nm) D
14. Rotate the engine so the cylinder is facing down.
15. Install a new seal on the oil pump.

=T
Oil Pump Mounting Bolts:
89 in-lbs (10 Nm)
3.69
ENGINE / COOLING
19. Reinstall oil pump pick-up (F) if previously removed. 23. Install the (13) M6 and (3) M8 bolts that retain the oil
Torque mounting screws to specification. sump cover (H) to the crankcase.
=T
M6
Oil Pump Pick-Up Retaining Screws:
89 ± 9 in-lbs (10 ± 1 Nm)
20. Clean the gasket sealing surfaces on oil sump cover

and crankcase to remove old gasket material and any
oil.
NOTE: Gasket surfaces must be DRY and oil free.

Use care upon assembly to keep oil away.
H
21. Apply a thin, continuous film of Crankcase Sealant
(PN 2871557) to sump cover mating surface as
shown. Do not allow sealant to dry before assembly. 24. Torque the oil sump cover bolts in sequence to
specification. Repeat the sequence to verify final
torque.
Sealant Path
22. Install the oil sump cover (G) onto the crankcase.
G =T
Oil Sump Cover Bolts:
M6 Bolts:
106 in-lbs (12 Nm)
M8 Bolts:
26 ft-lbs (35 Nm)
3.70
ENGINE / COOLING
25. Reinstall the crankcase drain plug if previously Flywheel Installation
removed. Torque drain plug to specification.
1. If previously removed, reinstall the flywheel key.
=T 2. Clean taper of crankshaft to remove all oil or grease.
Crankcase Drain Plug: 3. Clean flywheel taper to remove all oil or grease.
12 ft-lbs (16 Nm)
4. Align flywheel key-way with key and install the
flywheel, seating it fully on taper.
26. Reinstall the oil cooler (J), if previously removed. Use
new O-rings upon installation. 5. Install flywheel retaining bolt. Using a commercially
available strap wrench (A), hold the flywheel and
torque the flywheel retaining bolt (B) to specification.
3
IMPORTANT: If the Cylinder Holding & Camshaft
Timing Plate (PU-50563) is installed, remove it before
tightening the flywheel.
D
B
27. Proceed to “Flywheel Installation” and then “Cylinder

Head Installation”.
=T
Flywheel Retaining Bolt:
133 ft-lbs (180 Nm)
6. Install the starter torque limit gear as an assembly.
3.71
ENGINE / COOLING
Stator Cover Installation
1. Apply gasket tack adhesive to help hold gasket in
place during assembly.
2. Install a new stator cover gasket over alignment pins.
CAUTION
The flywheel contains powerful magnets. Use

caution when removing and installing the stator
cover. DO NOT place fingers between cover and
crankcase at any time during the removal /
installation process or injury could result.
3. Install stator cover and (13) screws. Torque screws in

sequence to specification.
=T
Stator Cover Screws:
106 ± 18 in-lbs (12 ± 2 Nm)
3.72
ENGINE / COOLING
ENGINE ASSEMBLY - TOP END
Cylinder Head Assembly 7. Install the valve spring (D) with tightly spaced coils
facing down toward the cylinder head.
NOTE: Assemble the valves one at a time to
maintain proper order.
WARNING Top
Wear eye protection during cylinder head

disassembly and reassembly or when working
with the valve springs.
Paint Mark 3
Bottom
1. Apply engine oil to valve guides and seats.
2. Coat valve stem with Premium Starter Grease

(2871460).
NOTE: Valve springs to be installed with paint mark
3. Install the valve (A) in the cylinder head, through the facing up.
guide.
8. Place the valve retainer (E) on the spring.
F
9. Compress the valve spring by hand using valve spring
E
compressor adapter (PV-43513-A). Compress spring
D only enough to allow split keeper installation.
B PV-43513-A
C
NOTE: To prevent damage to the valve seals, do not

compress the valve spring more than necessary to
install the keepers.
4. Carefully install a new valve seal (B) on the valve 10. Install split keepers (F) with gap even on both sides.
guide with a rotating motion. Push firmly until seated
in retaining groove and square with the guide 11. Repeat this procedure for remaining valves.
IMPORTANT: Valve seals should be installed AFTER

the valves are in the head to avoid valve seal damage.
5. Dip the seat (C), valve spring (D) and retainer (E) in
clean engine oil.
6. Install the valve spring seat (C).
3.73
ENGINE / COOLING
12. Install the valve adjustment shim (G) and valve bucket Valve Sealing Test
(H) for each valve in the order they were removed.
1. Clean and dry the combustion chamber area (A).
2. Pour a small amount of clean solvent into each intake

port (B) and check for leakage around the valves. The
valve seats should hold fluid with no seepage.
G 3. Repeat for exhaust valves by pouring fluid into each

exhaust port (C).
C
NOTE: Shim 240 is shown for reference only. Refer
to “Valve Clearance Adjustment” procedure for
proper shim selection.
Cylinder Head Installation

H
2. Remove the Cylinder Holding & Camshaft Timing
Plate (PU-50563) from the cylinder.
PU-50563
IMPORTANT: If any valve train components were

replaced, refer to “Valve Clearance Adjustment”
procedure prior to “Camshaft Installation / Timing”
procedure.
IMPORTANT: Once the cylinder head is removed,

nothing retains the cylinder to the engine. DO NOT
rotate the engine without using the Cylinder Holding
& Camshaft Timing Plate (PU-50563).
3. Prepare cylinder head gasket sealing surfaces by

cleaning thoroughly to remove all residue. The head
gasket must be installed clean and dry, free from oil
or grease.
3.74
ENGINE / COOLING
NOTE: Do not touch sealing surfaces of gasket. 8. Torque cylinder head bolts in sequence to
specification.
4. Guide cam chain (D) through a new head gasket (E)
and install the gasket on the cylinder, locating it on the
alignment pins.
5. Carefully set the cylinder head (F) in place on

alignment pins.
6. Install new bolts and finger tighten the (6) cylinder

head bolts (G) evenly.
7. Install and finger tighten the (2) outer M6 bolts (H) 3

evenly.
G
H
=T
Cylinder Head Torque Procedure:
Step 1: In Sequence to 9 ft-lbs (12 Nm)
Step 2: In Sequence to 26 ft-lbs (35 Nm)
Step 3: In Sequence Additional 180° (1/2 turn)
Step 4: Outer M6 Head Bolts 89 in-lbs (10 Nm)
Camshaft Installation / Timing

IMPORTANT: If any valve train components were
replaced, refer to “Valve Clearance Adjustment”
procedure prior to “Camshaft Installation / Timing”.
1. Rotate the engine until the flywheel Top Dead Center

(TDC) mark (A) is aligned or centered in the
Crankshaft Position Sensor (CPS) mounting hole (B).
F This places the PTO cylinder at TDC for camshaft
installation.
D
A
E
B
IMPORTANT: Install new cylinder head bolts.
3.75
ENGINE / COOLING
IMPORTANT: DO NOT use the “V” mark located on the 6. Install the (4) bolts that retain each rear camshaft
flywheel opposite of the “I” mark. Only the “I” mark carrier (C) and tighten the bolts evenly until snug.
should be used as a TDC reference.
2. Reference the intake and exhaust markings made C

C
during disassembly. If installing new camshafts or if
camshafts were not marked, you can reference the
part number stamped on the end of the shafts.
INTAKE EXHAUST
Part Number Part Number
7. Install the Cylinder Holding & Camshaft Timing Plate

(PU-50563) into the end of camshafts as shown. Use
a 13/16” open-end wrench to rotate camshafts slightly
if needed.
Intake Camshaft - PN 1204052
Exhaust Camshaft - PN 1204053

PU-50563
3. Lubricate all camshaft lobes and bearing journal
surfaces with Polaris PS-4 engine oil prior to
installation.
4. Carefully install the camshafts into the cylinder head.

The PTO camshaft lobes should face out as shown.
8. Verify the TDC mark on the flywheel is still properly

aligned (see Step 1).
9. Pull cam chain upward, making sure it is engaged with

the drive sprocket on the crankshaft.
10. While lifting the cam chain up, engage the cam
sprockets into the chain with the “I” and “E” marks
facing out.
5. Carefully install the rear camshaft carriers onto the

camshafts. Carrier openings should face each other
when installed properly.
3.76
ENGINE / COOLING
11. Install the sprockets onto the camshafts and align the 13. Verify cam timing is correct. Flywheel TDC mark
sprocket marks with the valve cover gasket surface should still be aligned (see Step 1) and cam sprocket
(see sprocket timing illustration). markings should line up as shown.
IMPORTANT: Intake cam sprocket should have “I”

marks aligned with gasket surface and the exhaust
cam sprocket should have “E” marks aligned with
gasket surface.
IMPORTANT: Install the exhaust cam sprocket first

(opposite the cam chain tensioner) to ensure proper
cam timing.
12. Use new camshaft sprocket retaining bolts upon

assembly. Install the top bolt in each camshaft
sprocket (D). Do not torque the bolts at this time.
D D
Install
IMPORTANT: Use new sprocket retaining bolts upon

assembly.
3.77
ENGINE / COOLING
14. If timing marks are not aligned, remove sprockets and 20. Torque the camshaft carriers bolts in sequence to
correct alignment. specification.
15. Remove the Cylinder Holding & Camshaft Timing

Plate (PU-50563) from the end of the camshafts.
16. Rotate the engine using the flywheel and install the
remaining bolt in each camshaft sprocket. Torque the
sprocket bolts to specification.
=T
Camshaft Sprocket Bolts:
14 ft-lbs (19 Nm)
17. Rotate the engine using the flywheel and torque the
remaining sprocket bolts to specification.
18. Install the front camshaft carrier (E) and (2) outer
retaining bolts. =T
89 ± 9 in-lbs (10 ± 1 Nm)
21. Apply Polaris PS-4 engine oil to the cam chain

E tensioner bore prior to assembly. Use a new tensioner
sealing washer (G).
22. Install the hydraulic cam chain tensioner (H) into the
cylinder and torque to specification.
19. Install the fixed cam chain guide (F) and (2) retaining
bolts.
G
F
=T
Cam Chain Tensioner:
29.5 ± 3 ft-lbs (40 ± 4 Nm)
23. Rotate crankshaft through two revolutions and verify

camshaft timing is correct.
3.78
ENGINE / COOLING
Camshaft Timing - Quick Reference
Intake Cam Exhaust Cam
3
Align Marks Align Marks
with Surface with Surface
CPS
Mounting Hole
Align Flywheel Mark

IMPORTANT: DO NOT
in Mounting Hole
use the “V” mark located
on the flywheel opposite
of the “I” mark. Only the
“I” mark should be used
as a TDC reference.
3.79
ENGINE / COOLING
Valve Clearance Adjustment 5. Install the (4) bolts that retain each rear camshaft
carrier (A) and tighten the bolts evenly to specification.
IMPORTANT: Always inspect valve clearance prior to
camshaft installation or final engine assembly.
A
1. Reference the camshaft intake and exhaust markings A
made during disassembly. If installing new camshafts
or if camshafts were not marked, you can reference
the part number stamped on the end of the shafts.
INTAKE EXHAUST
Part Number Part Number
=T
89 ± 9 in-lbs (10 ± 1 Nm)
Intake Camshaft - PN 1204052
6. Rotate the camshaft until the cam lobes above the
Exhaust Camshaft - PN 1204053 valves you are inspecting are facing up.
2. Lubricate the camshaft bearing journal surfaces with Cam Lobe Up

Polaris PS-4 engine oil prior to installation.
3. Carefully install the camshafts into the cylinder head.

The PTO camshaft lobes should face out as shown. Measure
Here
7. Measure the valve clearance using a thickness

(feeler) gauge. Record the measurement if clearance
is out of specification.
8. Repeat steps 6 and 7 until all (8) valves have been

inspected.
4. Carefully install the rear camshaft carriers onto the

camshafts. Carrier openings should face each other = In. / mm.
when installed properly.
Intake Valve Clearance (cold):

.006 ± .002 in. (0.15 ± 0.05 mm)
3.80
ENGINE / COOLING
11. Record the 3 digit adjustment shim number (B).
= In. / mm.
Exhaust Valve Clearance (cold):

.012 ± .002 in. (0.30 ± 0.05 mm)
B
9. If any of the valve clearance measurements are out
of specification, remove the camshaft carriers and
camshafts and proceed with this procedure.
NOTE: If all valve clearance measurements are

within specification, remove the camshaft carriers
3
and proceed to “Camshaft Installation / Timing”.
10. Remove the valve bucket from a valve that was out of
specification.
NOTE: Shim 240 is shown for reference only.
12. Reference the valve clearance measurement

recorded for that valve, along with the 3-digit shim
number.
13. Refer to the appropriate shim selection matrix (Intake

or Exhaust) on the following pages and select the
proper shim.
14. Install the new adjustment shim and valve bucket.
NOTE: Lubricate the outer portion of the valve

bucket upon installation.
15. Repeat steps 10-14 until all necessary valves have

been adjusted.
IMPORTANT: Keep mated parts together and in order
with respect to their location in the cylinder head for 16. Reinstall the camshafts and camshaft carriers and
assembly purposes. Mark each component or place tighten the bolts evenly to specification.
them in an organized rack as you remove them.
=T
CAUTION
If performing this procedure with the cylinder 89 ± 9 in-lbs (10 ± 1 Nm)
head installed on the engine, cover the spark
plug holes and the cam chain opening to prevent 17. Measure and confirm that valve clearance is now
a valve adjustment shim from falling into the within specification for each valve.
cylinder or crankcase.
18. If valve clearance is not within specification, repeat
this procedure.
19. If all valve clearance measurements are now within

specification, remove the camshaft carriers and
proceed to “Camshaft Installation / Timing”.
3.81
ENGINE / COOLING
Intake Valve Lash - Shim Selection Matrix
Example:
• Installed shim is 240 = In. / mm.
• Measured clearance is 0.002 in. (0.05 mm)
• Replace 240 shim with 232 shim Intake Valve Clearance (cold):
.006 ± .002 in. (0.15 ± 0.05 mm)
Shim Thickness: Example 240 equals thickness of 2.40 mm
Part Number: 3022173-XXX (Xs represent 3 digits on shim)
Existing Valve Lash Shim Marking (3 digits on shim)

190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280
Correct Valve Lash Shim Marking (3 digits on shim)
0.000-0.024 178 180 182 185 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268
0.025-0.049 180 182 185 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270
0.050-0.074 182 185 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272
0.075-0.099 185 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275
0.100-0.200
(Standard)
0.201-0.225 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285
0.226-0.250 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288
0.251-0.275 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290
0.276-0.300 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292
0.301-0.325 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295
0.326-0.350 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298
0.351-0.375 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.376-0.400 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.401-0.425 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.426-0.450 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.451-0.475 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.476-0.500 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
Intake Valve Clearance Before Adjusting (mm)
0.501-0.525 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.526-0.550 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.551-0.575 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.576-0.600 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.601-0.625 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.626-0.650 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.651-0.675 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.676-0.700 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.701-0.725 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.726-0.750 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.751-0.775 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.776-0.800 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.801-0.825 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.826-0.850 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.851-0.875 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.876-0.900 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.901-0.925 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.926-0.950 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.951-0.975 270 272 275 278 280 282 285 288 290 292 295 298 300
0.976-1.000 272 275 278 280 282 285 288 290 292 295 298 300
1.001-1.025 275 278 280 282 285 288 290 292 295 298 300
1.026-1.050 278 280 282 285 288 290 292 295 298 300
1.051-1.075 280 282 285 288 290 292 295 298 300
1.076-1.100 282 285 288 290 292 295 298 300
1.101-1.125 285 288 290 292 295 298 300
1.126-1.150 288 290 292 295 298 300
1.151-1.175 290 292 295 298 300
1.176-1.200 292 295 298 300
1.201-1.225 295 298 300
1.226-1.250 298 300
1.251-1.275 300
3.82
ENGINE / COOLING
Exhaust Valve Lash - Shim Selection Matrix
Example:
• Installed shim is 240 = In. / mm.
• Measured clearance is 0.007 in. (0.18 mm)
• Replace 240 shim with 230 shim Exhaust Valve Clearance (cold):
.012 ± .002 in. (0.30 ± 0.05 mm)
Shim Thickness: Example 240 equals thickness of 2.40 mm
Part Number: 3022173-XXX (Xs represent 3 digits on shim)
Existing Valve Lash Shim Marking (3 digits on shim)

190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280
3
Correct Valve Lash Shim Marking (3 digits on shim)
0.000-0.024 170 172 175 178 180 182 185 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252
0.025-0.049 170 172 175 178 180 182 185 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255
0.050-0.074 170 172 175 178 180 182 185 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258
0.075-0.099 170 172 175 178 180 182 185 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260
0.100-0.124 172 175 178 180 182 185 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262
0.125-0.149 175 178 180 182 185 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265
0.150-0.174 178 180 182 185 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268
0.175-0.199 180 182 185 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270
0.200-0.224 182 185 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272
0.225-0.249 185 188 190 192 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275
0.250-0.350
(Standard)
0.351-0.375 195 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285
0.376-0.400 198 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288
0.401-0.425 200 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290
0.426-0.450 202 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292
0.451-0.475 205 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295
0.476-0.500 208 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298
0.501-0.525 210 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.526-0.550 212 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.551-0.575 215 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
Exhaust Valve Clearance Before Adjusting (mm)
0.576-0.600 218 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.601-0.625 220 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.626-0.650 222 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.651-0.675 225 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.676-0.700 228 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.701-0.725 230 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.726-0.750 232 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.751-0.775 235 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.776-0.800 238 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.801-0.825 240 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.826-0.850 242 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.851-0.875 245 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.876-0.900 248 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.901-0.925 250 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.926-0.950 252 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.951-0.975 255 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
0.976-1.000 258 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
1.001-1.025 260 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
1.026-1.050 262 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
1.051-1.075 265 268 270 272 275 278 280 282 285 288 290 292 295 298 300
1.076-1.100 268 270 272 275 278 280 282 285 288 290 292 295 298 300
1.101-1.125 270 272 275 278 280 282 285 288 290 292 295 298 300
1.126-1.150 272 275 278 280 282 285 288 290 292 295 298 300
1.151-1.175 275 278 280 282 285 288 290 292 295 298 300
1.176-1.200 278 280 282 285 288 290 292 295 298 300
1.201-1.225 280 282 285 288 290 292 295 298 300
1.226-1.250 282 285 288 290 292 295 298 300
1.251-1.275 285 288 290 292 295 298 300
1.276-1.300 288 290 292 295 298 300
1.301-1.325 290 292 295 298 300
1.326-1.350 292 295 298 300
1.351-1.375 295 298 300
1.376-1.400 298 300
1.401-1.425 300
3.83
ENGINE / COOLING
Valve Cover Installation
1. Apply anti-seize compound to spark plug threads.
2. Install spark plugs (A) and torque to specification.
3. Prepare valve cover sealing surfaces by cleaning

thoroughly to remove all residue.
4. Install a new valve cover seal (B).
5. Install the (4) valve cover shoulder bolts (C) and

isolators (D) using a T40 driver.
6. Torque valve cover bolts to specification.
=T
Spark Plugs: 7 ft-lbs (10 Nm)
Valve Cover Bolts: 89 in-lbs (10 Nm)
3.84
ENGINE / COOLING
TROUBLESHOOTING Engine Idles But Will Not Accelerate
• Spark plug fouled/weak spark
Engine
• Broken throttle cable
Spark Plug Fouling
• Obstruction in air intake
• Spark plug cap loose or faulty
• Air box removed (reinstall all intake components)
• Incorrect spark plug heat range or gap
• Incorrect ignition timing
• PVT system calibrated incorrectly/ components
worn or mis-adjusted • Restricted exhaust system
• Fuel quality poor (old) or octane too high • Cam worn excessively
3
• Low compression Engine Has Low Power
• Restricted exhaust • Spark plug fouled
• Weak ignition (loose coil ground, faulty coil, or • Cylinder, piston, ring, or valve wear or damage
stator) (check compression)
• Restricted air filter (main or pre-cleaner) or • PVT not operating properly
breather system
• Restricted exhaust muffler
• Improperly assembled air intake system
• Cam worn excessively
• Restricted engine breather system
Piston Failure - Scoring
• Oil contaminated with fuel
• Lack of lubrication
Engine Turns Over But Fails To Start
• Dirt entering engine through cracks in air filter or
• No fuel ducts
• Dirt in fuel line or filter • Engine oil dirty or contaminated
• Fuel will not pass through fuel valve
Excessive Smoke and Carbon Buildup
• Fuel pump inoperative/restricted
• Excessive piston-to-cylinder clearance
• Tank vent plugged or pinched
• Wet sumping
• Engine flooded
• Worn rings, piston, or cylinder
• Low compression (high cylinder leakage)
• Worn valve guides or seals
• No spark (Spark plug fouled) ignition component
• Restricted breather
failure
• Air filter dirty or contaminated
Engine Does Not Turn Over
Piston Failure - Scoring
• Dead battery
• Lack of lubrication
• Starter motor does not turn
• Dirt entering engine through cracks in air filter or
• Engine seized, rusted, or mechanical failure
ducts
Engine Runs But Will Not Idle • Engine oil dirty or contaminated
• Restricted fuel supply
• Low compression
• Crankcase breather restricted
3.85
ENGINE / COOLING
Excessive Smoke and Carbon Buildup Cooling System
• Excessive piston-to-cylinder clearance Overheating
• Wet sumping due to over-full crankcase • Low coolant level
• Worn rings, piston, or cylinder • Air in cooling system
• Worn valve guides or seals • Wrong type/mix of coolant
• Restricted breather • Faulty pressure cap or system leaks
• Air filter dirty or contaminated • Restricted system (mud or debris in radiator fins
causing restriction to air flow, passages blocked in
Low Compression radiator, lines, pump, or water jacket, accident
• Cylinder head gasket leak damage)
• No valve clearance (cam wear) • Lean mixture (vents, fuel pump or fuel valve)
• Cylinder or piston worn • Fuel pump output weak
• Piston rings worn, leaking, broken, or sticking • Electrical malfunction
• Bent valve or stuck valve • Water pump failure/ Loose impeller
• Valve spring broken or weak • Thermistor failure
• Valve not seating properly (bent or carbon • Cooling fan inoperative or turning too slowly
accumulated on sealing surface) (perform current draw test)
• Rocker arm sticking • Low oil level

• Spark plug incorrect heat range
Backfiring
• Faulty hot light circuit
• Fouled spark plug or incorrect plug or plug gap
• Thermostat stuck closed or not opening
• Intake system air leaks completely
• Exhaust system air leaks
• Radiator is missing its internal diverter plate not
• Valve sticking allowing coolant to flow through entire radiator
• Ignition system faulty:  Temperature Too Low
Spark plug cap cracked / broken
Ignition coil faulty • Thermostat stuck open
Ignition or kill switch circuit faulty
Poor connections in ignition system Leak at Water Pump Weep Hole
Ignition timing incorrect • Faulty water pump mechanical seal (coolant leak)
Sheared flywheel key
• Faulty pump shaft oil seal (oil leak)
3.86
ELECTRONIC FUEL INJECTION
CHAPTER 4
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
EFI SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
EFI SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
EFI SYSTEM COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
FUEL LINE REMOVAL / INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
FUEL TANK REMOVAL (RZR XP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
FUEL TANK INSTALLATION (RZR XP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
FUEL TANK REMOVAL (RZR XP 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
FUEL TANK INSTALLATION (RZR XP 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
ELECTRONIC FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
PRINCIPAL COMPONENTS / EFI OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . 4.15
4
INITIAL PRIMING / STARTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
ELECTRONIC CONTROL UNIT (ECU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
ECU SERVICE / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
MANIFOLD AIR QUALITY SENSOR (MAQS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
MAQS TEST / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
CRANKSHAFT POSITION SENSOR (CPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
CPS TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18
CPS REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
IDLE AIR CONTROL VALVE (IAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20
IAC TEST / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20
ENGINE COOLANT TEMPERATURE SENSOR (ECT) . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
ECT SENSOR TEST / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
DUAL THROTTLE BODY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23
THROTTLE BODY SERVICE / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25
FUEL INJECTOR TROUBLESHOOTING / TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.26
FUEL INJECTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.30
FUEL SENDER TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.30
FUEL PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.31
FUEL PUMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.32
IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.35
IGNITION COIL / HT LEAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.35
IGNITION COIL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.35
EFI DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.36
INSTRUMENT CLUSTER TROUBLE CODE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . 4.36
EFI TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.39
DIGITAL WRENCH® OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40
SPECIAL TOOLS / DIAGNOSTIC SOFTWARE VERSION . . . . . . . . . . . . . . . . . . . . . . 4.40
ECU REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40
GUIDED DIAGNOSTIC AVAILABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40
DIGITAL WRENCH® COMMUNICATION ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40
DIGITAL WRENCH® - DIAGNOSTIC CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 4.41
DIGITAL WRENCH® SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4.41
DIGITAL WRENCH® VERSION AND UPDATE ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.41
DIGITAL WRENCH® UPDATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.42
DIGITAL WRENCH® FEATURE MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.43
ENGINE CONTROLLER REPROGRAMMING (REFLASH). . . . . . . . . . . . . . . . . . . . . . 4.44
4.1
GENERAL INFORMATION Fuel Pressure Gauge Kit - PU-43506-A
IMPORTANT: The EFI fuel system remains under high
pressure, even when the engine is not running. Before
WARNING attempting to service any part of the fuel system,
pressure should be relieved. The Fuel Pressure
* Gasoline is extremely flammable and explosive Gauge Kit has an integrated pressure relief valve that
under certain conditions. can be used to bleed off pressure once you have
* EFI components are under high pressure. completed the fuel pressure test.
Verify system pressure has been
relieved before disassembly.
* Never drain the fuel system when the engine is hot.
Severe burns may result.
* Do not overfill the tank. The tank is at full capacity Relief Valve
when the fuel reaches the bottom of the filler neck.
Leave room for expansion of fuel.
* Never start the engine or let it run in an enclosed area.
Gasoline powered engine exhaust fumes are
poisonous and can cause loss of consciousness
and death in a short time.
* Do not smoke or allow open flames or sparks in or near
the area where refueling is performed or where Adapter shown is
gasoline is stored. included with kit.
* If you get gasoline in your eyes or if you should
swallow gasoline, seek medical attention immediately.
* If you spill gasoline on your skin or clothing,
Fuel Pressure Gauge Adapter - PV-48656
immediately wash with soap and water
and change clothing.
Adapter works with
* Always stop the engine and refuel outdoors PU-43506-A
or in a well ventilated area.
Special Tools
Disconnect here and connect
PART in-line w/fuel pump outlet
TOOL DESCRIPTION
NUMBER
PU-43506-A Fuel Pressure Gauge Kit

PV-48656 Fuel Pressure Gauge Adapter
Digital Wrench® Diagnostic Software
(Includes most recent version of software
PU-47063-B w/serial number, standard interface
cable, USB-Serial Adaptor cable and Digital Wrench® Diagnostic Software - PU-47063-B
SmartLink Module Kit)
This dealer-only software installs on laptop computers
Digital Wrench® SmartLink Module Kit
PU-47471 equipped with a CD drive and is designed to replace
(PU-47470, PU-47469, PU-47468)
multiple shop tools often used to test EFI components. It
Digital Wrench® also includes step-by-step diagnostic procedures to aid
PU-47470
PC Interface Cable technician repair and troubleshooting.
Digital Wrench® IMPORTANT: If the PC you are using is not equipped
PU-47469
Vehicle Interface Cable with a 9-pin serial port, a USB to serial port adapter will
Digital Wrench® be necessary. A USB to serial port adapter can be
PU-47468 purchased through SPX Corporation (PU-50621) or
SmartLink Module
DSA at: www.diagsys.com
4.2
Digital Wrench® SmartLink Module Kit - PU-47471 Digital Wrench® - Download Website
This module kit contains the necessary cables and Located at: www.polaris.diagsys.com
hardware to communicate between the vehicle ECU and
the Digital Wrench® diagnostic software. Polaris dealers
can also order the following kit components separately:
SmartLink Module PU-47468, Vehicle Interface Cable
PU-47469 and PC Interface Cable PU-47470. This
module kit is used on all 8 pin connector-based Polaris EFI
systems. This kit is available to Polaris dealers through our
tool supplier SPX at http://polaris.spx.com or (1-800-328-
6657).
PU-47469
4
Download Digital Wrench® Updates:
PU-47468
PU-47470
Digital Wrench® - Diagnostic Connector
Located under the dash connected to a sealed plug.
IMPORTANT: For the most recent information on

Digital Wrench® software and update downloads
please visit the website: www.polaris.diagsys.com
4.3
EFI Service Notes
• For more convenient and accurate testing of EFI • Always disconnect negative (-) battery cable lead
components, it is recommended dealers utilize the before charging battery.
Digital Wrench® Diagnostic Software (dealer
only). Some testing may be done manually using • Always unplug ECU from the wire harness before
the procedures provided in this chapter. performing any welding on the unit.
• 80% of all EFI problems are caused by wiring

harness connections.
• For the purpose of troubleshooting difficult running

issues, a known-good ECU from another
RANGER RZR XP 900 of the same model and
year may be used without damaging system or
engine components.
• Never attempt to service any fuel system

component while engine is running or ignition
switch is "on."
• Cleanliness is essential and must be maintained at

all times when servicing or working on the EFI
system. Dirt, even in small quantities, can cause
significant problems.
• Do not use compressed air if the system is open.

Cover any parts removed and wrap any open
joints with plastic if they will remain open for any
length of time. New parts should be removed from
their protective packaging just prior to installation.
• Clean any connector before opening to prevent dirt

from entering the system.
• Although every precaution has been taken to

prevent water intrusion failure, avoid direct water
or spray contact with system components.
• Do not disconnect or reconnect the wiring harness

connector to the control unit or any individual
components with the ignition "on." This can send a
damaging voltage spike through the ECU.
• Do not allow the battery cables to touch opposing

terminals. When connecting battery cables attach
the positive (red) cable to positive (+) battery
terminal first, followed by negative (black) cable to
negative (-) battery terminal.
• Never start the engine when the cables are loose

or poorly connected to the battery terminals.
• Never disconnect battery while engine is running.
• Never use a battery boost-pack to start the engine.
• Do not charge battery with key switch "on."
4.4
EFI System Exploded View
1. Electronic Control Unit (ECU) 9. Fuel Pump / Regulator
2. Manifold Air Quality Sensor (MAQS) 10. Fuel Level Sender
3. Crankshaft Position Sensor (CPS) 11. Fuel Filter
4. Idle Air Control Valve (IAC) 12. Fuel Supply Line
5. Engine Coolant Temperature Sensor (ECT) 13. Fuel Return Line
6. Dual Throttle Body Assembly 14. Ignition Coil
7. Fuel Injectors 15. Spark Plug Wires
8. Fuel Rail / Regulator 16. Spark Plugs
13
1
12 4
14
10
9
15 11
7
16
4 8
3
5
4.5
EFI System Component Locations 4. Idle Air Control Valve (IAC)
- Located above the engine, underneath the cargo box
1. Electronic Control Unit (ECU) access panel.
- RZR XP: Located behind driver’s seat.
- RZR XP 4: Located behind left rear passenger seat.
IAC
ECU
RZR XP Shown
5. Engine Coolant Temperature Sensor (ECT)
- Located on the left side of the thermostat housing.
2. Manifold Air Quality Sensor (MAQS) The sensor can be accessed with the air box
- Located on the PTO end of the throttle body assembly removed.
assembly.
ECT
MAQS
6. Dual Throttle Body Assembly

3. Crankshaft Position Sensor (CPS) - Located between the air box assembly and rubber
- Located on top of the stator cover. cylinder head adapters.
CPS
Throttle Body
4.6
7. Fuel Injectors
- Located on the top of the throttle body in the intake Located in Fuel Tank
track, retained on top by the fuel rail.
Fuel Line
Connection
Regulator
Pump / Sending Unit Fuel Pump

Electrical Connection
Fuel Injectors
Preliminary Filter
4
8. Fuel Rail / Regulator
- Located on the throttle body, on top of the fuel 10. Ignition Coil / High Tension Leads
injectors. - Located behind the engine service panel on the
driver’s side of the vehicle.
Regulator
Fuel Rail
Fuel Return
Ignition Coil
Fuel Supply
9. Fuel Pump / Regulator / Fuel Gauge Sender

Assembly
- RZR XP: Located under the passenger seat.
- RZR XP 4: Located under right rear passenger seat.
Fuel Pump Asm
RZR XP Shown
4.7
FUEL TANK
Exploded View
Fuel Flow
Fuel Return Line Pressure Regulator Fuel Rail Fuel Injectors
Fuel Tank
Pressure Regulator
Fuel Filters Fuel Pump Assembly Fuel Supply Line
4.8
Fuel Line Removal / Installation 3. Pull on the fuel line for removal.
4. To install the line, verify the connections are clean and

free of debris.
5. Place the fuel line back over the fitting and slide the
green connector locking mechanism back into place.
Verify the connector tabs snap back into place.
6. Be sure fuel line is routed and retained properly.
Fuel Return Line

1. Place a shop towel around the fuel line to catch any
dripping fuel.
2. If removing either end of return line (B), squeeze the

connector tabs (C) together and push the white
locking slide back to release the line. 4
B
Fuel Supply Line

1. Place a shop towel around the fuel line to catch any
dripping fuel.
C
2. If removing either end of supply line (A), pull open tabs
while moving green connector out to release the line.
A
Tank Fitting
B C
Tank Fitting
A
Rail Fitting
3. Pull on the fuel line for removal.
4. To install the line, verify the connections are clean and

free of debris.
5. Place the fuel line back over the fitting and slide the
white connector locking mechanism back into place.
Verify the connector tabs snap back into place.
Rail Fitting
6. Be sure fuel line is routed and retained properly.
4.9
Fuel Tank Removal (RZR XP) 6. Remove the push rivets and Torx screws retaining the
right-hand rocker panel using the multi-function pliers
IMPORTANT: Syphon as much fuel from the tank as and a T27 Torx driver. Remove the rocker panel from
possible before attempting to remove it from the the vehicle.
vehicle.
WARNING
Always wear safety goggles when working with

high pressure or flammable fluids. Failure to do so
could result in serious injury or complications.
1. Remove the driver and passenger seats along with

the engine service panel.
2. Disconnect the negative battery cable from the Remove
battery, located under the driver’s seat. Rocker Panel
3. While holding a shop towel over the fuel line

connectors, disconnect the fuel supply line (A) from 7. Remove the fastener retaining the seat belt
the pump and the fuel return line (B) from the tank (see mechanism to the frame near the right rear portion of
“Fuel Lines - Quick Connect Fittings” for specific the fuel tank. Once removed, place the mechanism in
removal procedures). the rear cargo box to keep it out of the way.
NOTE: A small amount of fuel may come out of the
fuel lines or pump fitting. Properly drain fuel into a
suitable container.
4. Remove the fuel tank vent line (C) from the tank fitting.
5. Disconnect the fuel pump electrical harness (D).
A D
8. Remove the (2) bolts retaining the rear seat base

assembly to the frame. Remove the rear seat base
assembly from the vehicle.
Remove
Seat Base Asm
4.10
9. Remove the shift knob using a flat blade screwdriver 12. Lift the rear of the fuel tank up first.
and T25 Torx driver. Remove the screws retaining the
center console using a T27 and T30 Torx driver. 13. Carefully pull the fuel tank out of the vehicle.
Remove the console from the vehicle.
Shift Knob
Center Console
4
Fuel Tank Installation (RZR XP)
10. Remove the Torx screws retaining the right rear
fender well using a T25 and T27 Torx driver. Remove 1. Carefully reinstall the fuel tank assembly. Install the
the fender well from the vehicle. inner tank bracket with the fuel tank to ensure the
bracket is inserted properly into the lower fuel tank
mount as shown.
T25
Screws
Tank Mount Tank Bracket
T27
Screw
11. Remove the (2) tank bracket fasteners that retain the
fuel tank in the chassis. Swing the tank brackets clear
of the fuel tank for removal. 2. Reinstall the (2) fuel tank brackets and fasteners.
3. Reinstall right rear fender well. Secure with screws.
4. Reinstall center console, shift knob and screws.
5. Reinstall rear seat base assembly. Secure with bolts.
6. Reinstall seat belt mechanism. Torque bolt to
specification.
=T
Seat Belt Mechanism Bolt:
40 ft-lbs (54 Nm)
7. Reinstall right-hand rocker panel and all previously

removed fasteners.
4.11
8. Install the fuel lines, vent line and clamp. Verify the line 6. Remove the push rivets and Torx screws retaining the
connections are secure. right-hand rocker panel using the multi-function pliers
and a T27 Torx driver.
9. Reconnect the fuel pump electrical harness.
7. Remove the fuel tank cap and carefully lift the rocker
10. Reconnect negative battery cable. Test the fuel pump panel up over the fuel tank filler neck. Remove the
by turning the ignition key on and listening for the rocker panel from the vehicle.
pump to activate. Check the fuel line fittings for leaks.
NOTE: Reinstall the fuel tank cap once the rocker
11. Finally, install engine service panel and both seats. panel is removed.
Fuel Tank Removal (RZR XP 4) 8. Remove the (2) fuel tank bracket fasteners that retain
the fuel tank in the chassis. Swing the tank brackets
IMPORTANT: Syphon as much fuel from the tank as clear of the fuel tank for removal.
possible before attempting to remove it from the
vehicle.
WARNING
Always wear safety goggles when working with

high pressure or flammable fluids. Failure to do so
could result in serious injury or complications.
1. Remove the driver’s seat, rear passenger seats and

the engine service panel.
2. Disconnect the negative battery cable from the

battery, located under the driver’s seat.

connectors, disconnect the fuel supply line (A) from
the pump and the fuel return line (B) from the tank (see
“Fuel Lines - Quick Connect Fittings” for specific
removal procedures).

suitable container.
4. Remove the fuel tank vent line (C) from the tank fitting.
5. Disconnect the fuel pump electrical harness (D).
A B
4.12
9. Remove the fastener retaining the seat belt 11. Remove the Torx screws and push rivets retaining the
mechanism to the frame near the right rear portion of rear right-hand divider panel. Remove the divider
the fuel tank. Once removed, place the mechanism in panel from the vehicle.
the rear cargo box to keep it out of the way.
Screws
Push Rivets
Screw
4
Rear RH
Divider Panel
10. Remove the (2) bolts (E) retaining the rear seat base
assembly (F) to the frame. Remove the rear seat base
assembly from the vehicle. Take note of the (2) 12. Remove the (2) fasteners retaining the frame support
spacers (G) located between the seat base and and remove the support from the vehicle.
frame.
Remove
Frame Support
G
F
13. Lift up on the rear of the fuel tank first. Then carefully
pull the fuel tank out the side of the vehicle.
4.13
Fuel Tank Installation (RZR XP 4) IMPORTANT: Be sure to install the (2) washer spacers
(G) between the seat base and frame as shown above.
1. Carefully reinstall the front portion of the fuel tank
assembly. Install the inner tank bracket with the fuel 6. Torque the seat base fasteners (E) to specification.
tank partially installed. This will ensure the bracket is
inserted properly into the lower tank mount as shown.
=T
Tank Mount
Seat Base Fasteners:
40 ft-lbs (54 Nm)
7. Reinstall seat belt mechanism. Torque retaining bolt

to specification.
Tank Bracket
=T
Retaining Bolt:
40 ft-lbs (54 Nm)
8. Reinstall right-hand rocker panel and all previously

2. Reinstall both fuel tank brackets and fasteners. removed Torx screws and push rivets.
3. Reinstall the frame support and torque the fasteners 9. Install the fuel lines, vent line and clamp. Verify the line
to specification. connections are secure.
10. Reconnect the fuel pump electrical harness.

=T
11. Reconnect negative battery cable. Test the fuel pump
by turning the ignition key on and listening for the
Fasteners:
pump to activate. Check the fuel line fittings for leaks.
40 ft-lbs (54 Nm)
12. Finally, install the engine service panel and the seats.
4. Reinstall the rear right-hand divider panel. Secure
with screws and push rivets.
5. Reinstall the rear seat base assembly (F) and spacers

(G).
G
F
4.14
ELECTRONIC FUEL INJECTION The ECU controls the amount of fuel being injected and
the ignition timing by monitoring the primary sensor
Principal Components signals for intake air temperature, manifold absolute
pressure (load), engine temperature, engine speed (RPM)
The Electronic Fuel Injection (EFI) system is a complete and throttle position. These primary signals are compared
engine fuel and ignition management design. This system to the programming in the ECU computer chip, and the
includes the following principal components: ECU adjusts the fuel delivery and ignition timing based on
• Check Engine Light these values.
• Crankshaft Position Sensor (CPS) During operation, the ECU has the ability to re-adjust
• Dual Throttle Body / lntake Adapter temporarily; providing compensation for changes in
overall engine condition and operating environment, so it
• Engine Control Unit (ECU) will be able to maintain the ideal air/fuel ratio.
• Engine Coolant Temperature Sensor (ECT)
During certain operating periods such as cold starts, warm
• Fuel Filter(s) up, acceleration, etc., a richer air / fuel ratio is
• Fuel Injectors automatically calculated by the ECU. 4
• Fuel Pressure Regulators
Initial Priming / Starting Procedure
• Fuel Pump
NOTE: The injection system must be purged of all
• Fuel Rail
air prior to the initial start up, and / or any time the
• Fuel Supply/Return Lines system has been disassembled.
• Idle Air Control Valve (IAC)
If the EFI system is completely empty of fuel or has been
• Ignition Coil disassembled and repaired:
• Manifold Air Quality Sensor (MAQS)
1. Cycle the key switch from “OFF” to “ON” 6 times,
• Wire Harness Assembly waiting for approximately 3 seconds at each “ON”
cycle to allow the fuel pump to cycle and shut down.
EFI Operation Overview
2. Once step 1 is completed, turn the key switch to
The EFI system is designed to provide peak engine “START” until the engine starts or 5 seconds has
performance with optimum fuel efficiency and lowest passed.
possible emissions. The ignition and injection functions
are electronically controlled, monitored and continually 3. If the engine failed to start, repeat step 1 for 2 more
corrected during operation to maintain peak performance. cycles and attempt to start the engine.
The central component of the system is the Bosch M17 If the engine fails to start, a problem may still exist, and
Electronic Control Unit (ECU) which manages system should be diagnosed.
operation, determining the best combination of fuel
mixture and ignition timing for the current operating NOTE: Accurate testing of EFI components is
conditions. recommended utilizing the Digital Wrench®
Diagnostic Software (dealer only).
An electric fuel pump is used to move fuel from the tank,
through the fuel supply line, to the fuel rail. Fuel pressure
regulators located in the tank and on the end of the fuel rail,
maintain system operating pressure and return excess
fuel back into the fuel tank. At the engine, fuel fed through
the fuel rail supplies fuel to the injectors, which inject into
the intake ports. The ECU controls the amount of fuel by
varying the length of time that the injectors are "on." This
range can vary depending on fuel requirements. The
controlled injection of the fuel occurs every other
crankshaft revolution, or once for each 4-stroke cycle.
When the intake valve opens, the fuel/air mixture is drawn
into the combustion chamber, ignited and burned.
4.15
ELECTRONIC CONTROL UNIT (ECU) ECU Service
Never attempt to disassemble the ECU. It is sealed to
Operation Overview
prevent damage to internal components. Warranty is void
The ECU is the brain or central processing computer of the if the case is opened or tampered with in any way.
entire EFI fuel/ignition management system. During
operation, sensors continuously gather data which is All operating and control functions within the ECU are pre-
relayed through the wiring harness to input circuits within set. No internal servicing or readjustment may be
the ECU. Signals to the ECU include: ignition power (on/ performed. If a problem is encountered, and you
off), intake air temperature, manifold absolute pressure determine the ECU to be faulty, contact the Polaris Service
(load), engine coolant temperature, crankshaft position Department for specific handling instructions. Do not
and engine speed (RPM), throttle position and battery replace the ECU without factory authorization.
voltage. The ECU compares the input signals to the
programmed maps in its memory and determines the For the purpose of troubleshooting, a known-good ECU
appropriate fuel and ignition requirements for the from another Polaris RANGER RZR XP 900 of the same
immediate operating conditions. The ECU then sends model may be used without system or engine component
output signals to set injector duration and ignition timing. damage.
ECU Replacement
ECU
Although the need for ECU replacement is unlikely, a
specific replacement procedure is required to ensure that
all essential data contained within the original ECU is
transferred to the replacement ECU.
IMPORTANT: Refer to this procedure and carefully

follow all instructions provided in Digital Wrench®.
1. Carefully follow the ECU replacement instructions

provided in Digital Wrench® to ensure that all
essential data contained within the original ECU is
During operation, the ECU continually performs a 2. Remove the black plastic cover by lifting up on the tab.
diagnostic check of itself, each of the sensors, and system Remove the retaining screw that attaches the ECU to
performance. If a fault is detected, the ECU turns on the the left rear fender well.
“Check Engine” light on the instrument cluster and stores
the fault code in its fault memory. Depending on the Lift Tab Remove
significance or severity of the fault, normal operation may
continue, or "Fail-Safe" operation (slowed speed, richer
running) may be initiated. A technician can determine the
cause of the “Check Engine” light by referencing the
“Instrument Cluster Trouble Code Display” and
“Diagnostic Trouble Code Table” or by using Digital
Wrench®. The ECU requires a minimum of 7.0 volts to
operate. The memory in the ECU is operational the
moment the battery cables are connected.
To prevent engine over-speed and possible failure, an Remove

RPM limiting feature is programmed into the ECU. If the
maximum RPM limit is exceeded, the ECU suppresses the
injection signals, cutting off the fuel flow and retards the
ignition timing. This process repeats it self in rapid
succession, limiting operation to the preset maximum.
Maximum RPM Limit: 8750
4.16
3. With the ignition turned off, disconnect the wire MANIFOLD AIR QUALITY SENSOR
harness from the ECU. Lift the connector locking lever
and rotate it up until the connector is free from the (MAQS)
ECU.
Operation Overview
NOTE: Upon removing the ECU connector, you
should hear a “click” when the connector is fully Mounted on the end of the dual throttle body assembly, the
open. MAQS performs three functions in one unit. The MAQS
detects intake air temperature, manifold absolute
pressure and throttle position.
MAQS
4. To install, reverse the procedure and tighten the

mounting screws to specification.
These sensor signals, comprised of separate intake air
NOTE: Upon installing the ECU connector, you temperature, manifold absolute pressure readings and
should hear a “click” when the connector is fully throttle plate position are processed by the ECU and
closed. compared to its programming for determining the fuel and
ignition requirements during engine operation. The MAQS
provides the ECU with engine load data.
=T
ECU Retaining Screws: MAQS Test / Replacement
10 in-lbs (1.1 Nm)
The MAQS is a non-serviceable item and can only be
tested using Digital Wrench®. If the sensor is faulty, the
dual throttle body assembly must be replaced. Refer to
“Throttle Body Removal” procedure.
IMPORTANT: This sensor should only be tested using

Digital Wrench® Diagnostic Software (dealer only).
4.17
CRANKSHAFT POSITION SENSOR CPS Test
(CPS) The CPS is a sealed, non-serviceable assembly. If fault
code diagnosis indicates a problem with this sensor, test
Operation Overview as follows:
Mounted on top of the stator cover, the crankshaft position 1. Locate the CPS harness connector above the
sensor is essential to engine operation, constantly transmission on the RH side of the vehicle and
monitoring the rotational speed (RPM) and position of the disconnect the harness.
crankshaft.
2. Connect an ohmmeter between the CPS pin terminals
shown below. A resistance value of 1000  10% at
CPS room temperature should be obtained.
CPS Connector
A ferromagnetic 35-tooth encoder ring with a missing tooth

is built onto the flywheel. The inductive speed sensor is 1000 ± 10%
mounted 1.0 ± 0.26 mm (0.059 ± 0.010 in.) away from the
encoder ring. During rotation, an AC pulse is created
within the sensor for each passing tooth. The ECU CPS Resistance Specification:
calculates engine speed from the time interval between 1000  10%
the consecutive pulses.
3. If the resistance is correct:
The encoder ring missing tooth creates an “interrupt” input
signal, corresponding to specific crankshaft position. This • Test the main harness circuit between the sensor
signal serves as a reference for the control of ignition connector terminals and the corresponding pin
timing by the ECU. Synchronization of the CPS and terminals at the ECU (see wiring diagram).
crankshaft position takes place during the first two
revolutions each time the engine is started. This sensor • Check the sensor mounting, air gap, flywheel
must be properly connected at all times. If the sensor fails encoder ring for damage or runout, and flywheel
or becomes disconnected for any reason, the engine will key. Follow the “CPS Replacement” procedure to
stop running. inspect CPS and flywheel encoder ring for
damage.
4. If the resistance is incorrect, follow the “CPS

Replacement” procedure.
4.18
CPS Replacement
1. If not done already; disconnect the CPS harness
connector (see “CPS Test”).
2. Using an 8mm socket, remove the CPS retaining bolt

(A) and remove the sensor (B) from the stator cover.
3. Unclip the wire harness retainer (C) and remove the

CPS harness from the retainer to allow replacement.
4. Install new sensor using a light coating of oil on the

O-ring to aid installation.
5. Torque the CPS retaining bolt to specification.
=T
CPS Retaining Bolt:
106 in-lbs (12 Nm)
4.19
IDLE AIR CONTROL VALVE (IAC) IAC Replacement
1. Remove the cargo box access panel (A).
Operation Overview
The Idle Air Control (IAC) is used to stabilize the idle A
quality of the engine at cold start-up and after warm-up
operations.
IAC
2. Locate the IAC valve above the engine and

disconnect the vehicle harness (C) from the IAC
motor.
The IAC contains 1 stepper motor which receives varying

B
voltage signal pulses from the ECU. These pulses
determine the IAC plunger setting, thereby controlling the
amount of air bypassing the closed throttle body plates for
idle control. If the IAC is disconnected or inoperative, it will
remain at it’s last operated position.
IAC Test
The IAC is a non-serviceable item. If it is faulty, it must be
replaced. It can be ‘bench tested’ using the following
method:
C
Set your meter to read Ohms. Check the resistance values
at each of the following pin locations of the IAC. If any of
the readings are out of specification, replace the IAC. 3. Remove the (3) Phillips-head mounting screws (C)
and remove the IAC motor from the IAC housing.
IAC Valve Connector
4. Install the new IAC motor and torque the mounting
screws to specification.
4 5 6 NOTE: Make sure not to twist or pinch the IAC lines
upon assembly.
1 2 3
=T
Pins Resistance Pins Resistance IAC Mounting Screw:
1-2 30  ± 1.2  4-5 30  ± 1.2  17.7 in-lbs (2 Nm)
2-3 30  ± 1.2  5-6 30  ± 1.2 
5. Reconnect the vehicle harness to the IAC motor.
1-3 60  ± 2.4  4-6 60  ± 2.4 
4.20
ENGINE COOLANT TEMPERATURE
Temperature °F (°C) Resistance
SENSOR (ECT)
68 °F (20 °C) 2.5k  ± 6%
Operation Overview 86 °F (30 °C) 1.7k  ± 6%
Mounted in the thermostat housing, the engine 104 °F (40 °C) 1.2k  ± 6%
temperature sensor measures coolant temperature. The
122 °F (50 °C) 834  ± 6%
engine temperature sensor is a Negative Temperature
Coefficient (NTC) type sensor, as the temperature 140 °F (60 °C) 596  ± 6%
increases the resistance decreases.
158 °F (70 °C) 435  ± 6%
176 °F (80 °C) 323  ± 6%
194 °F (90 °C) 243  ± 6%
212 °F (100 °C) 186  ± 6%
4
ECT Sensor Replacement
A
ECT
Coolant passes through the thermostat housing and by

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

2. Be sure the engine has cooled enough to work on.
To quickly rule out other components and wiring related to
the ECT, disconnect the harness from the ECT sensor and 3. Remove the breather hose (B) from the air box and
start the engine. After a few seconds, the fan should turn loosen the hose clamps (C) retaining the air box to the
on and the “Check Engine” indicator should display on the throttle body assembly.
instrument cluster. This indicates all other components are
working properly.
ECT Sensor B
C
Refer to Chapter 3 and 10 for additional ECT sensor
information. Polaris dealers can test the sensor by using
Digital Wrench® Diagnostic Software (dealer only).
4.21
4. Remove the (2) screws (D) retaining the air box and 8. Torque the new ECT sensor to specification and
loosen the hose clamp (E) retaining the intake hose connect the vehicle harness to the sensor.
to the air box. Remove air box assembly from vehicle.
=T
D
ECT Sensor:
17 ft-lbs (23 Nm)
9. Reinstall the air box assembly:

• Be sure the lower air box post in placed properly
into the rubber grommet (G).
5. Disconnect the vehicle harness (F) from ECT sensor.
• Be sure the air box boots fully seat onto the dual
throttle body before tightening the hose clamps.
6. Drain the coolant so the level is below the sensor (see

Chapter 2 “Coolant Drain / Fill”).
7. Using a wrench, remove and replace the sensor,

applying a light coating of thread sealant to aid
installation.
Verify
Apply Installation
Thread Sealant
10. Reinstall the breather into the air box and tighten the
hose clamps retaining the air box to the throttle body.
11. Reinstall the (2) screws that retain the air box.
12. Position the intake hose onto the air box and tighten
the hose clamp.
14. Add the required amount of coolant and bleed the
system (see Chapter 3 “Cooling System Bleeding
Procedure”).
4.22
DUAL THROTTLE BODY ASSEMBLY 2. Be sure the engine has cooled enough to work on.
Operation Overview 3. Remove the breather hose (B) from the air box and
loosen the hose clamps (C) retaining the air box to the
Mounted to the cylinder head, the dual throttle body throttle body assembly.
assembly provides the proper air/fuel ratio needed for
engine operation.
C 4
Throttle Body
4. Remove the (2) screws (D) retaining the air box and
loosen the hose clamp (E) retaining the intake hose
The throttle body assembly also includes the Manifold Air to the air box. Remove air box assembly from vehicle.
Quality Sensor (MAQS), which provides the ECU with
intake air temperature, manifold absolute pressure and D
throttle position.
Throttle Body Service

The throttle body assembly is a non-serviceable
component. However, the fuel rail and fuel injectors can be
serviced separately (see “Fuel Injectors”). The Manifold
Air Quality Sensor (MAQS) attached to the end of the
throttle body is non-serviceable. If the sensor is faulty, the E
entire throttle body assembly must be replaced. Refer to
“Throttle Body Removal” procedure.
Throttle Body Removal 5. Remove the (2) screws (F) that mount the fuel rail to
the throttle body using a 5 mm Allen wrench.
F
A
4.23
6. Remove the (2) IAC valve hoses (G) that are attached 10. Using a T20 Torx driver, remove the (4) screws
to the throttle body. retaining the throttle body cover plate. Remove the
cover plate.
7. Disconnect the wire harness from the MAQS located

on the end of the throttle body assembly. 11. Rotate the throttle plate arm and remove the throttle
cable end (H) to allow for throttle cable removal.
8. Loosen the (2) hose clamps that retain the dual
throttle body assembly to the intake adapters.
Carefully lift the throttle body assembly out of the
intake adapters.
Throttle Body
Assembly
Loosen 12. Slide back the cable adjuster boot (I). Using a 14 mm
Clamps wrench, loosen the jam nut (J). Using a 12 mm
wrench, turn the adjuster (K) in and count the number
of turns it take to fully seat it. Note the number of turns
9. Lift the fuel rail and injectors out of the throttle body so it can be set the same upon assembly.
assembly taking care not to damage the fuel injector
ends.
NOTE: It is not necessary to disconnect fuel lines or J

the injector harnesses to perform this procedure. I
K
4.24
13. Unscrew the throttle cable adjuster and jam nut from FUEL INJECTORS
the throttle body. Remove the throttle body from the
vehicle. Operation Overview
14. Reverse the previous steps to reinstall the throttle The fuel injectors are mounted into the dual throttle body
body. assembly, with the fuel rail retaining them from the top end.
O-rings on both ends of the injector prevent external fuel
15. Upon installation of the throttle cable, refer to Chapter leaks and also insulate the injectors from heat and
2 “Throttle Freeplay Adjustment”. Torque the throttle vibration.
body cover screws to specification.
Fuel Rail
=T
Throttle Body Cover Screws:
18 in-lbs (2 Nm)
16. Upon installation of the fuel rail and injectors, lightly

4
lubricate injector O-rings to aid installation. Torque the
fuel rail mounting screws to specification.
Fuel
=T Injectors
Fuel Rail Mounting Screws:

44 in-lbs (5 Nm) When the key switch is on, the fuel rail is pressurized, and
the EFI relay provides voltage to the injectors. During
engine operation, the ECU completes the ground circuit,
energizing the injectors. The valve needle in each injector
is opened electromagnetically, and the pressure in the fuel
rail forces fuel down through the inside. The “director
plate” at the tip of the injector contains a series of
calibrated openings which directs the fuel into the intake
port in a cone-shaped spray pattern.
The amount of fuel injected is controlled by the ECU and

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

Crankshaft Position Sensor (CPS) and the Manifold Air
Quality Sensor (MAQS) to allow for sequential fuel
injection.
4.25
Fuel Injector Troubleshooting Fuel Injector Test
Injector problems typically fall into three general IMPORTANT: Take note of PTO and MAG fuel injector
categories- electrical, dirty / clogged, or leakage. An harness connectors before disconnecting them. The
electrical problem usually causes one or both of the harness leads are marked with PTO and MAG
injectors to stop functioning. Several methods may be identifiers.
used to check if the injectors are operating.
Harness Leads
• With the engine running at idle, feel for operational PTO and MAG
vibration, indicating that they are opening and
closing.
• When temperatures prohibit touching, listen for a
buzzing or clicking sound with a screwdriver or
mechanic's stethoscope.
• Disconnect the electrical connector from an
injector and listen for a change in idle performance
(only running on one cylinder) or a change in
injector noise or vibration.
NOTE: Do not apply voltage directly to the fuel
injector(s). Excessive voltage will burn out the
injector(s). Do not ground the injector(s) with the The fuel injectors are non-serviceable. If diagnosis
ignition on. lnjector(s) will open/turn on if relay is indicates a problem with either injector, test the resistance
energized. of the fuel injector(s) by measuring between the two pin
terminals:
If an injector is not operating, it can indicate either a bad
injector, or a wiring/electrical connection problem. Check
as follows:
Injector leakage is very unlikely, but in rare instances it can

be internal (past the tip of the valve needle), or external
(weeping around the injector body). The loss of system
pressure from the leakage can cause hot restart problems
and longer cranking times.
Injector problems due to dirt or clogging are unlikely due

to the design of the injectors, the high fuel pressure, the
use of filters and the detergent additives in the gasoline. Disconnect
Symptoms that could be caused by dirty/clogged injectors and test here
include rough idle, hesitation/stumble during acceleration,
or triggering of fault codes related to fuel delivery. Injector
clogging is usually caused by a buildup of deposits on the Fuel Injector Resistance Specification:
director plate, restricting the flow of fuel, resulting in a poor 11.4  - 12.6 
spray pattern. Some contributing factors to injector
clogging include; dirty air filters, higher than normal
operating temperatures, short operating intervals and IMPORTANT: Be sure to connect the PTO harness
dirty, incorrect, or poor quality fuel. Cleaning of clogged lead to the PTO injector and the MAG harness lead to
injectors is not recommended; they should be replaced. the MAG injector to ensure proper engine operation.
Additives and higher grades of fuel can be used as a
preventative measure if clogging has been a problem.
4.26
Fuel Injector Replacement 5. Remove the driver’s seat and disconnect the negative
battery cable.
6. Disconnect the fuel injector harness leads.
A
Disconnect 4
2. Be sure the engine has cooled enough to work on.
7. Hold a shop towel over the fuel line fittings and remove
3. Remove the breather hose (B) from the air box and
the fuel return and supply lines from each end of the
loosen the hose clamps (C) retaining the air box to the
fuel rail. Remove the vent line from the fuel pressure
throttle body assembly.
regulator.
Regulator
Fuel Return
B
C
Fuel Supply
4. Remove the (2) screws (D) retaining the air box and
8. Remove tie strap retaining the injector harness leads
loosen the hose clamp (E) retaining the intake hose
to the fuel rail. Remove the (2) screws that mount the
to the air box. Remove air box assembly from vehicle.
fuel rail to the throttle body using a 5 mm Allen wrench.
D
Remove
Remove
4.27
9. Carefully pull up on the fuel rail and injectors and 12. Install the new injector(s) into the fuel rail and reinstall
remove them from the throttle body as an assembly. the retaining clip.
Take care not to damage the fuel injector ends during
removal. Retaining
Clip
Fuel Rail / Injectors
Located above
boss on injector
NOTE: Be sure the retaining clip is positioned on

the injector and fuel rail as shown above.
10. Pull out on the fuel injector retaining clip and pull the
injector out of the fuel rail. Repeat on the other injector 13. Thoroughly clean the area around the fuel injector
if removal is necessary. ports on the throttle body.
14. Lightly lubricate the injector O-rings and reinstall the

fuel rail / injector assembly into the throttle body.
Retaining
Clip 15. Install the fuel rail mounting screws and torque to
specification.
=T
Fuel Rail Mounting Screws:
44 in-lbs (5 Nm)
16. Reinstall the fuel lines and vent line to the fuel rail.
17. Connect the harness leads to the fuel injectors.
IMPORTANT: Be sure to connect the PTO harness

lead to the PTO injector and the MAG harness lead to
the MAG injector to ensure proper engine operation.
11. Upon installation of the new fuel injectors, lightly

lubricate the injector O-rings to aid installation.
4.28
18. Use a tie strap to retain the harness leads to the fuel • Be sure the air box boots fully seat onto the dual
rail. throttle body before tightening the hose clamps.
Harness Leads
PTO and MAG
Verify
Installation
4
19. Reconnect the negative battery cable and reinstall the 22. Reinstall the breather into the air box and tighten the
driver’s seat. hose clamps retaining the air box to the throttle body
assembly.
20. Start the engine briefly and inspect the fuel rail and
injectors for fuel leaks. 23. Reinstall the (2) screws retaining the air box
assembly.
21. Reinstall the air box assembly:
24. Position the intake hose onto the air box and tighten
• Be sure the lower air box post is placed properly the hose clamp.
into the rubber grommet.
Rubber
Grommet
4.29
FUEL PUMP The ECU switches off the pump preventing the continued
delivery of fuel in these instances:
Operation Overview • If the key switch is not promptly turned to the
An electric fuel pump assembly is used to transfer fuel to "start" position.
the EFI system from inside the fuel tank. This assembly • If the engine fails to start.
includes the fuel pump, fuel filters, regulator and fuel
gauge sender. The pump is rated for a minimum output of • If the engine is stopped with the key switch "on"
25 liters per hour at 43.5 ± 2 psi and has two non- (as in the case of an accident).
serviceable fuel filters.
In these situations, the “check engine” light will go on, but
will turn off after 4 cranking revolutions if system function
Fuel Pump Asm is OK. Once the engine is running, the fuel pump remains
on.
Fuel Sender Test

If the fuel gauge reading on the instrument cluster is not
working, or if the display reading differs in large
comparison to the fuel in the tank, perform a resistance
test on the fuel sender.
Disconnect the fuel pump / sending unit connection and

RZR XP Shown
measure the resistance. If out of specification, replace the
fuel pump assembly.
Located in Fuel Tank
Fuel Line
Connection
Pump / Sending Unit
Electrical Connection
Fuel Pump
Fuel Sender Resistance Specifications:
Regulator Full: 6 ± 1 
Empty: 90 ± 4.5 
Preliminary Filter
When the key switch is turned to "ON", the ECU activates

the fuel pump, which pressurizes the system for start-up.
4.30
Fuel Pump Test NOTE: If the fuel pressure is out of specification,
replace the fuel pump assembly.
If a fuel delivery problem is suspected, make certain the
fuel pump filters are not plugged, that the pump is being 6. If the pump did not activate (Step 5), disconnect the
activated through the ECU, all electrical connections are harness connector from the fuel pump. Connect a DC
properly secured, the fuses are good, and a minimum of voltmeter across terminals “3” and “4” in the plug on
7.0 volts is being supplied. If during starting the battery the vehicle fuel pump harness. Turn on the key switch
voltage drops below 7.0 volts, the ECU will fail to operate and observe voltage to ensure a minimum of 7 volts
the system. is present.
WARNING
Fuel is extremely flammable and may cause

severe burns, injury, or death.
Do not use any device that produces a flame or
electrical devices that may spark around
fuel or fuel vapors.
4
1. Remove the passenger seat from the vehicle.
2. Cover the fuel line connection at the fuel tank with a

shop towel and disconnect the line from the fuel pump
outlet.
3. Install the Fuel Pressure Gauge Adapter (PV-48656)

in-line between the fuel pump outlet and fuel line.
4. Connect the hose from the Fuel Pressure Gauge Kit NOTE: If the voltage was below 7 VDC, test the
(PU-43506-A) to the test valve on the Fuel Pressure battery, ignition switch, relay(s), wiring harness and
Gauge Adapter (PV-48656). Route clear hose into a ECU.
portable gasoline container or the vehicle’s fuel tank.
7. If the reading is between 7 and 14 volts, turn key
switch off and connect an ohmmeter between
PU-43506-A
terminals “3” and “4”' at the white fuel pump connector
to check for continuity within the fuel pump.
NOTE: If there was no continuity between the pump

terminals, replace the fuel pump assembly.
8. If voltage at the plug was within the specified range,

and there was continuity across the pump terminals,
reconnect the plug to the fuel pump, making sure you
have a clean connection. Turn on the key switch and
listen for the pump to activate.
PV-48656
NOTE: If the pump starts, repeat steps 3, 4 and 5 to
verify correct pressure.
5. Turn on key switch to activate the pump and check the
system pressure on the gauge. If system pressure of 9. If the pump still does not operate, check for correct
43.5 ± 2 psi is observed, the ignition switch, ECU, fuel ECU operation by plugging in a known-good ECU of
pump, and pressure regulator are working properly. the same model.
Turn the key switch off and depress the valve button
on the tester to relieve the system pressure. NOTE: If the pump still does not operate, replace the
fuel pump assembly.
Normal Fuel Pressure: 43.5 ± 2 psi.
4.31
Fuel Pump Replacement
NOTE: The photos used in this procedure depict the CAUTION
RZR XP model. Even though the fuel tank is located
differently, the replacement procedure is the same It is possible for pressurized fuel to be present
for the RZR XP 4 model. when disconnecting the fuel line.
It is recommended to allow the vehicle to sit for
1. Move the vehicle to a well ventilated area. Shift the a period of one hour after shutting off the engine
transmission into Park and turn the ignition key off. before servicing the fuel pump. This allows the
exhaust to cool and fuel pressure to drop.
2. Remove the passenger seat to access the fuel pump.
WARNING suitable container.
Always wear safety goggles when working with 6. Remove the fuel tank vent line (C) from the tank fitting.
high pressure or flammable fluids. Failure to do
so could result in serious injury or complications. 7. Disconnect the fuel pump electrical harness (D).
3. Be sure the top of the fuel tank is clean. If it requires A D

cleaning, hand wash the top of the tank to ensure no
debris will enter the fuel system when the fuel pump B
is removed.
Clean this area
8. Place the Fuel Pump Service Tool (PU-50326) over

the fuel pump PFA nut. Using a 1/2” drive ratchet or
breaker bar, loosen and remove the PFA nut. Discard
the PFA nut.
CAUTION
PFA Nut
Failure to clean area around fuel pump may lead

to debris entering the fuel tank during service.
Excessive debris in fuel tank may cause
premature wear of fuel pump and/or clogging
of internal fuel filters.
4. Ensure that static has been discharged by touching a

ground source such as the engine or frame.
PU-50326
connectors, disconnect the fuel supply line (A) from
the pump and the fuel return line (B) from the tank (see NOTE: Apply downward force on the fuel pump
“Fuel Lines - Quick Connect Fittings” for specific flange while removing the fuel pump PFA nut.
removal procedures).
4.32
9. Carefully lift the fuel pump out of the fuel tank. As the 14. Install new PFA gasket onto fuel pump assembly
fuel pump assembly is being removed, be aware of using care not to damage gasket or bend float arm.
float arm and pump pre-filter. Hold the float arm to the
pump body as you lift and tilt the pump to ensure that
the float arm is not bent when removed from the tank.
10. Transfer old fuel pump to a suitable container capable

of safely holding fuel. The fuel pump will retain some
fuel.
11. Inspect the inside of the fuel tank for debris (may
require flashlight and mirror). If debris like mud or sand
is present, fuel tank should be flushed and cleaned out
prior to installation of new fuel pump assembly.
IMPORTANT: It is recommended to remove the fuel

tank from the vehicle and rinse it with a small amount
of clean fuel. Do not use water or any other chemicals
to remove debris.
12. Remove new fuel pump assembly, gasket and PFA

nut from packaging. Use care not to bend float arm
during un-packaging. Do not lift or carry fuel pump
assembly by the float arm.
13. Use cleaning wipes provided to clean fuel tank

surface and threads. Remove all debris, grease and
oil. Allow surfaces to dry completely.
4.33
15. Install fuel pump into fuel tank, hold float arm to the 19. Torque PFA nut to specification using the Fuel Pump
pump body and tilt assembly to ensure float arm does Service Tool (PU-50326) and a calibrated torque
not get caught or bent during installation. wrench.
16. Gently push down on fuel pump flange ensuring

flange is centered. 70 ± 5 ft-lbs
(95 ± 7 Nm)
17. Roughly align orientation mark on fuel pump between

the orientation marks on fuel tank to ensure float arm
does not get bent or snagged.
=T
Fuel Pump PFA Nut:
70 ± 5 ft-lbs (95 ± 7 Nm)
20. Verify alignment of fuel pump and tank orientation

marks.
21. Connect the fuel supply line to the pump and the fuel
return line to the tank (see “Fuel Lines - Quick Connect
Fittings” for specific installation procedures).
CAUTION
IMPORTANT: Be sure to engage the retainers on each
fuel line until each snaps into place. Pull on fuel lines
Failure to align the orientation marks may lead
lightly to confirm connection.
to interferences with the fuel level float arm
and cause incorrect function. 22. Install the fuel tank vent line onto the tank fitting.
18. While maintaining downward pressure, thread new 23. Connect the fuel pump electrical harness.
PFA nut onto fuel tank and hand tighten. Use care
when starting PFA nut, ensuring threads are properly 24. Test the fuel pump by turning on the key and listening
aligned. Verify orientation marks are still aligned for the pump to activate. Cycle the key several times
between fuel pump and fuel tank. to prime the system.
25. Install the passenger seat.
4.34
IGNITION COIL Ignition Coil Tests
The ignition coil can be tested by using an ohm meter. Use
Operation Overview
the following illustration and specification table to test the
The ignition coil is used to provide high voltage to fire the ignition coil resistance.
spark plugs. When the ignition key is on, DC voltage is
present in the primary side of the ignition coil windings. Test Pin Connection Resistance
During engine rotation, an AC pulse is created within the
crankshaft position sensor for each passing tooth on the Between 1 & 2
Primary 0.4 
flywheel’s encoder ring. The encoder ring missing tooth Between 2 & 3
creates an “interrupt” input signal, corresponding to
Secondary Between High Tension
specific crankshaft position. This signal serves as a 7.0k  ± 5%
(PTO) Lead Caps
reference for the control of ignition timing. The ECU then
calculates the time interval between the consecutive Secondary Between High Tension
7.4k  ± 5%
pulses, and determines when to trigger the voltage spike (MAG) Lead Caps
that induces the voltage from the primary to the secondary
coil windings to fire the spark plugs. Primary Test 4
MAG Cap Measure Between
Connector Pins
0.4 
Ignition Coil
Ignition Coil / HT Lead Replacement

IMPORTANT: The engine will misfire if the spark plug
wires are installed incorrectly. The spark plug wires
are marked with PTO and MAG from the factory and Secondary Test
should be installed to the corresponding cylinder and
ignition coil post.
1. Remove the seats and engine service panel to

access the ignition coil.
2. Disconnect the ignition coil harness and remove the
high tension leads from the coil.
3. Remove the fastener retaining the ignition coil and
remove it from the vehicle. If replacing the high
tension lead(s), remove the other end of the lead(s)
from the spark plug.
4. Install the new ignition coil and/or high tension lead(s).
=T
Ignition Coil Retaining Bolt: 75 in-lbs (8.5 Nm)
4.35
EFI DIAGNOSTICS 3. A set of three numbers will appear in the information
area.
Instrument Cluster Trouble Code Display • The first number (located far left) can range from 0
NOTE: The diagnostic mode is accessible only to 9. This number represents the total number of
when the check engine MIL has been activated. trouble code present (example: 2 means there are
3 codes present).
Use the following procedure to display diagnostic trouble • The second number (located top right) can be 2 to
codes that were activated during current ignition cycle 6 digits in length. This number equates to the
causing the MIL to illuminate. Diagnostic trouble codes will suspected area of fault (SPN).
remain stored in the gauge (even if MIL turns off) until the
key is turned off. • The third number (located bottom right) can be 1 to
2 digits in length. This number equates to the fault
NOTE: If there is a diagnostic problem with the mode (FMI).
power steering system, the power steering MIL will
illuminate and blink in place of the check engine MIL.
1. If the trouble code(s) are not displayed, use the

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

to advance to the next trouble code.
2. Press and hold the MODE button to enter the 5. To exit the diagnostic mode, press and hold the
diagnostics code menu. MODE button or turn the ignition key OFF once the
codes are recorded.
Digital Wrench®
Component Condition SPN FMI
P-Code
Voltage Too High 3 P0123
Throttle Position Sensor 1 51
Voltage Too Low 4 P0122
Data Erratic or Intermittent (or missing) 2 P0503
Vehicle Speed Signal 84
Received Vehicle Speed Has Error 19 C1069
Manifold Absolute Pressure Voltage Too High 3 P0108

102
Sensor Voltage Too Low 4 P0107
Intake Air Temperature Sensor 105
Voltage Too Low 4 P0112
4.36
Digital Wrench®
P-Code
Engine Temperature Sensor Voltage Too Low 4 P0117

110
(ECT) Temperature Too High 16 P0217
Engine Overheat Shutdown 0 P1217
P0563
Voltage Too High 3
System Power C1063
168
(Battery Potential / Power Input) P0562
Voltage Too Low 4
C1064
Engine Speed (This is applicable Engine Speed Too High 0 C1059
when the EPS module gets the
engine speed from the ECM) Received Engine Speed Has Error
190
19 C1066 4
Gear Sensor Signal Voltage Too Low 523 4 P0916
ECU Memory EEPROM: Read/Write Failure 628 12 C1073
Calibration Checksum/CRC Error 630 13 C1074
Crankshaft Position Sensor (CPS) Plausibility Fault 636 2 P0335
Camshaft Phase Sensor Circuit Fault 637 8 P0340
Driver Circuit Open / Grounded 5 P0261
Injector 1 (MAG) Driver Circuit Short to B+ 651 3 P0262
Driver Circuit Grounded 4 P1262
Injector 2 (PTO) Driver Circuit Short to B+ 652 3 P0265
Rear Differential Output Driver Circuit Short to B+ 746 3 P1692
Fan Relay Driver Circuit Driver Circuit Short to B+ 1071 3 P1482
Ignition Coil Primary Driver 1
Driver Circuit Short to B+ 1268 3 P1353
(MAG)
Ignition Coil Primary Driver 2
(PTO)
Fuel Pump Driver Circuit Driver Circuit Short to B+ 1347 3 P0232
Voltage Too High 3 P16A2
ECU Output Supply Voltage 1 3597
Voltage Too Low 4 P16A1
4.37
Digital Wrench®
P-Code
Voltage Too High 3 P16A9
Voltage Too Low 4 P16A8
Voltage Too High 3 P17AA
Voltage Too Low 4 P17AB
Throttle Release Signal Signal Out of Range 520194 2 P1553
Throttle Stuck 7 P1552
All Wheel Drive Control Circuit
(AWD)
Steering Over Current Shut Down Current Above Normal or Grounded 520221 6 C1050
Steering Excessive Current Error Current Above Normal or Grounded 520222 6 C1051
Steering Torque Partial Failure Condition Exists 520223 31 C1052
Steering Torque Full Failure Condition Exists 520224 31 C1053
Greater than 110° C (230° F) 16 C1054
EPS Inverter Temperature 520225
Greater than 120° C (248° F) 0 C1055
EPS CAN Communications 
No RX Message for 2 Seconds 520226 2 U0100
Receive Error
EPS CAN Communications 
No TX Message for 2 Seconds 520227 2 U1100
Transmit Error
Position Encoder Error Position Encoder Error 520228 11 C1065
EPS Software Error Software Error 520229 12 C1070
IC CAN Communication with EPS EPS Off Line (EPS DM1 not seen) 520230 31 U0131
EPS: Key On, Engine Off, 5 Minute
EPS Power Save Condition 520231 31 C1071
Power Save/Timeout
Idle Air Control Valve (IAC)
M17; IAC Stepper Pin 3
4.38
EFI Troubleshooting Poor Idle
Symptom: Idle Too High (if > 1400 RPM when warm).
Fuel Starvation / Lean Mixture
• Throttle stop screw tampering
Symptoms: Hard start or no start, bog, backfire, popping
through intake / exhaust, hesitation, detonation, low • Throttle cable sticking, improperly adjusted, routed
power, spark plug erosion, engine runs hot, surging, high incorrectly
idle, idle speed erratic.
• Faulty electrical connection
• No fuel in tank Symptom: Idle Too Low (if < 1100 RPM when warm).
• Restricted tank vent, or routed improperly
• Plugged air filter
• Fuel lines or fuel injectors restricted
• Leaking injector (rich condition)
• Fuel filter plugged
• Belt dragging
• Fuel pump inoperative
• Air leak in system
• Throttle stop screw tampering 4
• Intake air leak (throttle shaft, intake ducts, air box Symptom: Erratic Idle.
cover) • Throttle cable incorrectly adjusted
Rich Mixture • Air Leaks, dirty injector
Symptoms: Fouls spark plugs, black, sooty exhaust • MAQS damaged (check with Digital Wrench®)
smoke, rough idle, poor fuel economy, engine runs rough/ • Tight valves (low compression or high leakdown)
misses, poor performance, bog, engine loads up, backfire.
• Ignition timing incorrect
• Air intake restricted (inspect intake duct)
• Belt dragging
• Air filter dirty/plugged
• Dirty air filter
• Poor fuel quality (old fuel)
• High percentage of cylinder leakdown (worn
• Fouled spark plug engine)
• Injector failure • Low compression (worn engine)
• Spark plug(s) fouled
• Spark plug wires loose or worn
• Faulty electrical connection
4.39
DIGITAL WRENCH® OPERATION
Digital Wrench® Diagnostic Software Overview
IMPORTANT: Refer to Section 2, 3 and 4 in the Instruction Manual provided in the Digital Wrench® Diagnostic
Kit to install the Polaris Digital Wrench® diagnostic software on your computer.
The Digital Wrench® diagnostic software allows the technician to perform the following tests and observations:
• View or clear trouble codes • Perform guided diagnostic procedures
• Analyze real-time engine data • Create customer service account records
• Reflash ECU calibration files • Perform output state control tests (some models)
Special Tools (also refer to page 4.2)

DIGITAL WRENCH® DIAGNOSTIC SOFTWARE PART NUMBER
Digital Wrench® Diagnostic Kit PU-47063-B
Digital Wrench® Software: PU-48731
Standard Interface Cable: PU-47151
PU-47063-B (listed above) INCLUDES:
SmartLink Module Kit: PU-47471
USB-Serial Adapter Cable: PU-50621
Fuel Pressure Gauge Kit PU-43506-A
Fuel Pressure Gauge Adapter PV-48656
Fluke 73 Digital Multi-Meter or Fluke 77 DMM PV-43546 (Fluke 77: PV-43568)
Commercially Available (refer to diagnostic software user
Laptop or Desktop Computer
manual or HELP section for minimum requirements)
Diagnostic Software Version Diagnostic procedures are added to subsequent versions

of Digital Wrench® as they become available. Check your
Always use the most current version of the Digital release version often and upgrade when available to be
Wrench® software to ensure you have the latest updates sure you are using the most current software available.
or enhancements. New reprogramming files and guided
diagnostic procedures are added to these updates as they Digital Wrench® Communication Errors
become available. For information on how to determine if
you have the latest update available, refer to “Digital If you experience problems connecting to a vehicle or any
Wrench® Version and Update ID”. Digital Wrench® related problem, visit the Digital
Wrench® Knowledge Base for the most current
ECU Replacement troubleshooting information, FAQs, downloads and
software updates at: http://polaris.diagsys.com/.
Although the need for ECU replacement is unlikely, a
specific replacement procedure is required to ensure that
all essential data contained within the original ECU is
Refer to procedure and carefully follow all instructions

provided in Digital Wrench®.
Guided Diagnostic Available

Guided diagnostics are available within Digital Wrench®
for all supported Trouble Codes (that is, any fault that will
turn on the ‘Check Engine’ indicator).
In addition, guided diagnostics are also available for many

other electrical sub systems.
4.40
Digital Wrench® - Diagnostic Connector Digital Wrench® Version and Update ID
Located under the dash connected to a sealed plug. Knowing what Digital Wrench® version and update is
installed will help determine which updates are required.
NOTE: Versions and updates are subject to change.
1. Open the Digital Wrench® software. Locate the

version ID shown on the lower right side of the Digital
Wrench® start-up screen.
Version
4
Follow these steps to connect the diagnostic interface
cable to the vehicle to allow Digital Wrench® use:
1. Assemble the SmartLink Module and attach the PC

Interface Cable to your laptop (see page 4.3).
2. Remove the protective cap from the Digital Wrench® 2. Proceed to http://polaris.diagsys.com to see if a
connector. newer update is available.
3. Connect the Vehicle Interface Cable to the Digital
Wrench® diagnostic connector.
4. Turn the ignition key to the ‘ON’ position, select the

appropriate vehicle and wait for the status to display
‘Connected’ in the lower left corner of the screen.
Digital Wrench Update
5. Once connected, proceed with using Digital
Wrench®.
Digital Wrench® Serial Number Location

Open the configuration screen by clicking on the wrench
icon. The serial number is located on the right side of the 3. If a newer update is available, it should be
screen. downloaded before using Digital Wrench® (see
“Digital Wrench® Updates”).
IMPORTANT: Always operate with the latest update.
4.41
Digital Wrench® Updates 6. If the update file date listed is newer than your current
version and update (see “Digital Wrench® Version
Updates are released for Digital Wrench® via the Internet and Update ID”), download the file.
at: http://polaris.diagsys.com. The Digital Wrench®
website can also be accessed through the dealer website
at: www.polarisdealers.com.
NOTE: Only authorized Polaris dealers and

distributors can access the dealer website.
1. Log on to www.polarisdealers.com.
2. Locate the “Service and Warranty” drop-down

menu.
3. Click on “Digital Wrench Updates”.
7. Click on the link shown above, save the file to your

hard disk and then double-click the icon to start the
update process.
NOTE: Do not "run" or "open" the file from where

they are. Select "save" and download them to your
PC before running the install.
8. When the update is complete, the version shown on

the right side of the Digital Wrench® start-up screen
should match the update you just downloaded.
4. The Digital Wrench® portal website should appear in

a new web browser.
5. Click on “Digital Wrench Version Updates”.
Digital Wrench Update
IMPORTANT: You must already have the current

version installed before adding an update. Updates Version
will not install if you are using an older version loaded
on your PC.
NOTE: Versions and updates are subject to change.
4.42
Digital Wrench® Feature Map
4.43
Engine Controller Reprogramming (Reflash) • KNOW THE PROCESS: If you are not familiar with
the entire reprogramming process, review the
Process Overview HELP section of the diagnostic software before
you attempt reprogramming. Click on the ? on the
The reprogramming feature is in the Special Tests menu tool bar or press F11. The information in the on-
on the Digital Wrench® screen. Start Digital Wrench® and line help is the most current and complete
click on the Special Tests menu icon (red tool box). A information available. This should be your first
technician should be familiar with the process and with step until you are familiar with the process.
computer operation in general before attempting to
reprogram an ECU. • COMMUNICATION PROBLEMS: If you have had
problems communicating with a vehicle while
The Digital Wrench® Engine Controller Reprogramming performing diagnostic functions, do not attempt
(or “Reflash”) feature allows reprogramming of the ECU reprogramming until the cause has been identified
fuel and ignition map. To successfully reprogram the ECU, and fixed. Check all connections, and be sure
an Authorization Key must be obtained by entering a battery voltage is as specified. 
Request Code in the box provided on the Reflash 
Authorization site. The Request Code is automatically Proceed to http://polaris.diagsys.com for
generated by Digital Wrench® during the reprogramming specific information and FAQs on how to
process. The Reflash Authorization site is located under troubleshoot communication problems.
the “Service and Warranty” drop down menu on the
dealer website at: www.polarisdealers.com.
IMPORTANT: Failure to follow the reprogramming

instructions completely and correctly can result in an
engine that does not run! Replacement ECUs are
programmed as “no-start” and require a reflash for
them to work.
Reprogramming (Reflash) Tips:
• BATTERY VOLTAGE: The majority of problems

with reprogramming can be attributed to a low
battery. Be sure the battery voltage (no load) is at
least 13 volts and at least 12.5 volts with the key
‘ON’. Connect a battery charger if necessary to
bring voltage level above minimum. Fully charge
the battery before you attempt to reprogram.
• DEDICATED LAPTOP: Best results are obtained
using a laptop computer that is “dedicated to
Digital Wrench®”. A laptop that is used by a variety • DON’T DISTURB THE PC: While reprogramming
of people and in several applications around the is in progress, don’t move the mouse and don’t
dealership is more likely to cause a touch the keyboard. The process only takes a few
reprogramming problem than one dedicated to minutes, and is best left alone until complete.
Digital Wrench® diagnostics only.
Reprogramming (Reflash) Procedure:
• OBTAINING THE LATEST UPDATE:
Reprogramming updates are provided periodically If you are not familiar with the reprogramming process,
and contain the most recent calibrations (see review the “Reprogramming (Reflash) Tips” before you
“Digital Wrench® Updates”). begin. Follow the on-screen instructions as you progress
• CLOSE NON-ESSENTIAL PROGRAMS: Polaris through the steps. If you encounter a problem, always
recommends that you DO NOT install non- check the On-Line help for current tips and information.
essential programs on a Service Department
laptop. Camera detection software, Virus 1. Verify the most current update has been downloaded
Scanners, Tool Bars, etc. may clog up memory if and loaded into Digital Wrench®. See “Digital
running in the background and make it harder for Wrench® Version and Update ID” on page 4.41.
the diagnostic software to operate.
4.44
2. Connect SmartLink Module cables to PC and vehicle. 6. Select “Engine Controller Reprogramming”.
See “Digital Wrench® - Diagnostic Connector” on
page 4.41.
7. Select the file you want to load into the ECU then click
the “Continue” icon to proceed to the Integrity Check
4
and obtain a Request Code.
3. Open the Digital Wrench® program.
4. Select the model year, product line and vehicle

description by selecting the “Change Vehicle Type”
icon.
8. Copy (CTRL+C) the Request Code that will be

required on the dealer website in the next step. DO
NOT CLOSE Digital Wrench® or the Request Code
will be invalid. NOTE: All characters are letters;
there are no numbers in a request code.
5. Select the “Special Tests” icon. Authorization Key goes here after
obtained from the dealer website
Copy Request Code to

obtain Authorization Key
NOTE: Request Codes and Authorization Keys must

be entered EXACTLY as they appear on the screen.
4.45
9. Go to www.polarisdealers.com and click on 12. An “Authorization Key” will appear in the upper left
“ReFlash Authorization” from the “Service and corner of the screen. Copy (CTRL+C) this key exactly
Warranty” drop-down menu. as it appears.
“Authorization Key”
“Service and Warranty” “Reflash Authorization”
10. Enter or paste (CTRL+V) the Request Code into the 13. Enter or paste (CTRL+V) the Authorization Key in the
box. box located on the Digital Wrench® screen. Click the
‘Continue’ button and follow instructions provided on
the screen to complete reprogramming procedure.
Enter the
“Request Code”
Enter the
“Authorization Key”
11. Select the same file type from the list that you selected
previously while in Digital Wrench®. Enter the VIN
along with the customer’s name and address. When
14. At this point the reflash process will begin. Do not
completed, click the Authorize button once to
touch the vehicle or PC during the process.
proceed.
Enter ALL the information and

click on the “Authorize” button
15. Once the ECU reprogramming procedure is

complete, click the ‘Finish’ button on the screen.
Verify the reflash was a success by starting the
vehicle.
4.46
BODY / STEERING / SUSPENSION
CHAPTER 5
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
CAB FRAME (RZR XP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
CAB FRAME (RZR XP 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
BODY EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
SIDE SAFETY NETS (RZR XP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
SIDE SAFETY NETS (RZR XP 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
DASH INSTRUMENTS / CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10
HOOD / FRONT BODY WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
SEAT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
SEAT BELTS / MOUNTING (RZR XP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
SEAT BELTS / MOUNTING (RZR XP 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
FLOOR / ROCKER PANELS (RZR XP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
FLOOR / ROCKER PANELS (RZR XP 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
REAR CARGO BOX / FENDERS (RZR XP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
REAR CARGO BOX / FENDERS (RZR XP 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17
CHASSIS / MAIN FRAME (RZR XP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18
CHASSIS / MAIN FRAME (RZR XP 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
5
FRONT / REAR BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20
BODY COMPONENT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
SEATS / ENGINE SERVICE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
FRONT / REAR BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21
HOOD AND FRONT BODY WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.22
REAR FENDER FLAIR / BOX SIDE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23
CARGO BOX ASSEMBLY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23
ROCKER PANELS, CONSOLE AND FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24
DECAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
STEERING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.26
STEERING WHEEL REMOVAL (NON-EPS MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
STEERING SHAFT REMOVAL (NON-EPS MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . 5.27
STEERING SHAFT BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.28
ELECTRONIC POWER STEERING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.29
UPPER STEERING SHAFT REMOVAL (EPS MODELS) . . . . . . . . . . . . . . . . . . . . . . . 5.30
STEERING WHEEL REMOVAL (EPS MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.31
POWER STEERING UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.31
LOWER STEERING SHAFT REMOVAL / INSTALLATION (EPS MODELS). . . . . . . . . 5.33
POWER STEERING UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.34
UPPER STEERING SHAFT INSTALLATION (EPS MODELS) . . . . . . . . . . . . . . . . . . . 5.35
FRONT A-ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.36
BALL JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.38
BALL JOINT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.38
BALL JOINT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.39
FRONT STABILIZER BAR (INT’L). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40
STABILIZER BAR LINKAGE REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 5.40
STABILIZER BAR REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.40
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.41
REAR RADIUS RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.42
REAR TRAILING ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.43
TRAILING ARM REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.43
TRAILING ARM SPHERICAL BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 5.45
REAR SUSPENSION EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.45
REAR STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.46
5.1
SHOCKS / SPRINGS / FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.47
FRONT / REAR SHOCK EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.47
SHOCK REMOVAL / INSTALLATION / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 5.47
FOX™ SHOCK EXPLODED VIEWS (RZR XP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.48
FOX™ 2.0 ‘PIGGYBACK’ SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.48
FOX™ SHOCK SERVICE (RZR XP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.49
GENERAL SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.49
FRONT SHOCK SERVICE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.49
REAR SHOCK SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.50
FOX™ SHOCK REBUILD INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.51
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.51
FOX™ SHOCK DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.51
FOX™ SHOCK BODY AND RESERVOIR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . 5.53
FOX™ SHOCK COMPONENT REBUILD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.54
FOX™ SHOCK ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.55
WALKER EVANS™ SHOCK EXPLODED VIEWS (RZR XP 4) . . . . . . . . . . . . . . . . . . . 5.59
WALKER EVANS™ 2.0" FRONT SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.59
WALKER EVANS™ 2.5" REAR SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.60
WALKER EVANS™ SHOCK SERVICE (RZR XP 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.61
GENERAL SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.61
FRONT SHOCK SERVICE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.61
REAR SHOCK SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.62
WALKER EVANS™ SHOCK REBUILD INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 5.63
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.63
VALVE SHIM ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.63
PISTON ORIENTATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.63
WALKER EVANS™ SHOCK DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.64
WALKER EVANS™ SHOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.67
5.2
TORQUE SPECIFICATIONS SPECIAL TOOLS
ITEM TORQUE VALUE PART NUMBER TOOL DESCRIPTION
Front LH / RH 2200421 Gas Shock Recharging Kit
40 ft-lbs (54 Nm)
Upper / Lower A-Arm Bolt
Shock Spring Preload Spanner Wrench
Outer Tie Rod to 2877408
42.5 ft-lbs (58 Nm) (FOX™)
Bearing Carrier Housing
Shock Spring Preload Spanner Wrench
Front Ball Joint Pinch Bolts 44 ft-lbs (60 Nm) 2878925
(Walker Evans™)
Front Shock Mounting Bolts 45 ft-lbs (61 Nm)
2876389 Multi-Function Pliers
Upper: 50 ft-lbs (67.7 Nm)
Rear Shock Mounting Bolts FOX™: See “Special Tools” on page 5.51.
Lower: 70 ft-lbs (95 Nm)
Wheel Hub Castle Nuts 80 ft-lbs (108 Nm) Walker Evans™: See “Special Tools” on page 5.63.
Wheel Nuts 30 ft-lbs (41 Nm) SPX Corp: 1-800-328-6657 or http://polaris.spx.com/
(Cast Aluminum Rims) + 90° (1/4 turn)
Tie Rod End Jam Nut 13 ft-lbs (18 Nm) Multi-Function Pliers
Radius Rod Fasteners (Inner) 40 ft-lbs (54 Nm) Included in the tool kit, the multi-function pliers is designed
to remove the plastic push rivets used to fasten body
Radius Rod Fasteners (Outer) 45 ft-lbs (61 Nm)
components.
Trailing Arm to
Main Frame Bolt
70 ft-lbs (95 Nm) 5
Bearing Carrier to
40 ft-lbs (54 Nm)
Trailing Arm Bolts
Rear Brake Caliper
40 ft-lbs (54 Nm)
Mounting Bolts
Front Brake Caliper
40 ft-lbs (54 Nm)
Mounting Bolts
Front Stabilizer Bar
40 ft-lbs (54 Nm)
Upper Linkage Bolt (INT’L)
Front Stabilizer Bar
43 ft-lbs (58 Nm)
Lower Linkage Bolt (INT’L)
Rear Stabilizer Bar Linkage 31-34 ft-lbs (42-46 Nm)
Rear Stabilizer Bar
17 ft-lbs (23 Nm)
Bushing Bracket Bolts
Rear Stabilizer Bar
10 ft-lbs (13.5 Nm)
Locating Clamp Bolts
Seat Belt to Seat Base 43 ft-lbs (58 Nm)
Tilt Shock Upper Fastener 7 ft-lbs (10 Nm)
Tilt Shock Lower Fastener 12 ft-lbs (16 Nm)
Steering Pivot Tube Fasteners 23 ft-lbs (31 Nm)
Steering Wheel to Shaft 65 ft-lbs (88 Nm)
Upper Steering Shaft to EPS Models
Power Steering Unit 15 ft-lbs (20 Nm)
Lower Steering Shaft to EPS Models
Power Steering Unit 17 ft-lbs (23 Nm)
Power Steering Unit to EPS Models
Pliers
Mount Bracket 22 ft-lbs (30 Nm)
Lower Steering Shaft to
30 ft-lbs (41 Nm)
Gear Box
Steering Gear Box 17 ft-lbs (23 Nm) Push Rivet
5.3
CAB FRAME (RZR XP) 6. To remove the cab frame, reverse the assembly
procedure (steps 1-5).
Assembly / Removal
NOTE: Finger tighten all components until cab
frame is completely assembled on vehicle, then
tighten to specifications listed.
1. Assemble the rear cab frame and the front cab frame
at the coupler joints and secure with four (3/8-16 x 1
1/4) screws and (3/8-16 Nyloc) nuts. Tighten screws
to specification.
=T
3/8-16 Screws:
25-28 ft-lbs (34-38 Nm)
2. Place the assembled cab frame onto the vehicle and

align the rear mount holes. Fasten the rear cab frame
brackets to vehicle with four (M10x1.5x25) bolts and
(M10x1.5) nuts. Tighten bolts to specification. Fasten
the two self-tapping screws to the rear inner portion
of the bracket on each side. Tighten screws to
specification.
=T
M10x1.5 Bolts: 30 ft-lbs (41 Nm)
Self-Tapping Screws: 15 ft-lbs (20 Nm)
3. Place the straps from the safety net over the front
coupler posts.
4. Fasten the front of the cab frame to the base brackets

and secure with four (3/8-16 x 1 1/4) screws and (3/
8-16 Nyloc) nuts. Tighten screws to specification.
=T
3/8-16 Screws:
25-28 ft-lbs (34-38 Nm)
5. Attach side bars to cab frame using M8 screws and

nuts on top and M8 screws and nuts on the bottom.
Tighten to specification.
=T
M8 Screws:
16-18 ft-lbs (22-24 Nm)
5.4
5.5
CAB FRAME (RZR XP 4) 5. Fasten side bars by sliding the lower portion into the
U-shaped bracket on the mid cab frame. Fasten the
Assembly / Removal upper portion to the rear cab frame using bolts (M8-
1.25 x 25) and nuts (M8-1.25). Tighten bolts to
NOTE: Finger tighten all components until cab specification. Fasten (1/4-20 x 3/4) Torx-head screws
frame is completely assembled on vehicle, then into lower portion of side bars through bracket slot.
tighten to specifications listed. Tighten tap screws to specification.
1. Place rear cab frame and mid cab frame in the

vehicle so they line up with the mounting holes. You =T
may have to pull the rocker panels out slightly to get
the mid cab frame into place. Assemble at the coupler M8x1.25 Bolts: 16-18 ft-lbs (22-24 Nm)
joint and secure with bolts (3/8-16 x 1 1/4) and nuts 1/4-20 Tap Screws: 6-8 ft-lbs (8-11 Nm)
(3/8-16 Nyloc). Tighten bolts to specification.
6. To remove the cab frame, reverse the assembly
procedure (steps 1-5).
=T
3/8-16 Bolts:
25-28 ft-lbs (34-38 Nm)
2. Fasten rear cab frame brackets to vehicle with bolts

(M10-1.5 x 25) and nuts (M10-1.5). Tighten bolts to
specification. Fasten a tap screw (M8-1.25 x 20) to the
rear of the bracket on each side. Tighten tap screws
to specification.
=T
M8x1.25 Tap Screws: 15 ft-lbs (20 Nm)
3. Insert strap from safety net over front coupler post on

front cab frame. Fasten the front of the cab frame to
the base brackets and mid cab frame using the (3/8-
16 x 1 1/4) bolts and (3/8-16 Nyloc) nuts. Tighten bolts
to specification.
=T
3/8-16 Bolts:
25-28 ft-lbs (34-38 Nm)
4. Fasten mid cab frame brackets to the vehicle with

bolts (M10-1.5 x 25) and nuts (M10-1.5). Tighten bolts
to specification. Fasten tap screws (M8-1.25 x 20) to
the outsides of each bracket. Tighten tap screws to
specification.
=T
M8x1.25 Tap Screws: 15 ft-lbs (20 Nm)
5.6
5.7
BODY EXPLODED VIEWS
Side Safety Nets (RZR XP)
5.8
Side Safety Nets (RZR XP 4)
Strap Latch
Washer
Screw
Screw
Rear LH Net
Washer
Screw
Washers
Front LH Net
Nyloc Nut
5.9
Dash Instruments / Controls
A. Instrument Cluster / Speedo D. 12 Volt Accessory Receptacle

B. Headlight Switch or Hazard Switch (INT’L) E. Key Switch
C. AWD/2WD Switch or AWD/2WD/TURF Switch (INT’L) F. Switch; Turn, Lights, Horn (INT’L)
5.10
Hood / Front Body Work
Center Access Hood
1/4 Turn Latch
Washer
Grommet
T25 Screws Hood Retention Panel

Front LH
Fender Flair
5
Hood / Dash
T27 Screws
Front RH
Fender Flair
Push Rivet
Mud Shield
T27 Screws
Front Bumper
Push Rivet
Mud Shield
5.11
Seat Assembly
Seat Back
Seat
Hoop Tube
48 in-lbs
(5.4 Nm)
Seat Bottom
Latch Body Nuts
Lever
Spring Seat Base Asm.
Plate
Cap
41-57 in-lbs 41-57 in-lbs

(4.6-6.4 Nm) (4.6-6.4 Nm) Grommets
Seat Belts / Mounting (RZR XP)
3 Point Seat Belt

(Drivers Side Shown)
Retainer
40 ft-lbs
(54 Nm)
43 ft-lbs
(58 Nm)
Shoulder Bolt
Latch
Washer Plunger
40 ft-lbs
(54 Nm)
17 ft-lbs
40 ft-lbs (23 Nm)
Rear
(54 Nm) Seat Base
5.12
Seat Belts / Mounting (RZR XP 4)
Rear Seats
40 ft-lbs
(54 Nm)
3 Point
Seat Belts
40 ft-lbs
Front Seats 40 ft-lbs
(54 Nm) 5
(54 Nm)
Rear
Seat Base
40 ft-lbs
(54 Nm)
Spacer
17 ft-lbs
(23 Nm)
40 ft-lbs
(54 Nm)
Rubber Latch
Spacer Bumpers Plunger
40 ft-lbs
(54 Nm) 40 ft-lbs
Front (54 Nm)
Rear Seat Base
Seat Support
40 ft-lbs
(54 Nm)
3 Point
40 ft-lbs Seat Belts
(54 Nm)
17 ft-lbs
(23 Nm)
5.13
Floor / Rocker Panels (RZR XP)
LH Rocker
Push Rivets
Block Off Flap
T27 Seal
Screws
Console Cover
T27
Screws
T27
Seal Screws
Close Off Panel
U-Type
Push Rivets Nuts
Upper Floor
Torx
Screws T27
Screws
RH Rocker
Self-Tapping
Screws
Lower Floor
5.14
Floor / Rocker Panels (RZR XP 4)
Seal
Self-Tapping
Screws
Console Cover
Push Rivets
Rear Floor LH Rocker
T27
Screw 5
Torx
Screws
T27
Screw
RH Rocker
Self-Tapping
Torx Screws
Seal
Block Off
Flap
U-Type
Nuts
T27
Self-Tapping Screw
Screws Lower Floor
Close Off
Upper Floor Panel
5.15
Rear Cargo Box / Fenders (RZR XP)
Cargo Box Screws
Access Panel
Rear LH
Fender / Flair Intake Grill
Latch Asm. Foam Filter

Tie Down
& Screw Latch Plunger
Nut
Rear RH
Fender / Flair
Rear Rear
Bumper Support Cargo Box
Torx
Screws Rear LH
Divider Panel
1/4 Turn
Latch
Intake Grill Grommet
Heat Shield
Foam Filter
Cover
T25
Divider Panel Screws
Heat Shield Engine
Service Panel
Rear RH
Divider Panel
5.16
Rear Cargo Box / Fenders (RZR XP 4)
Cargo Box Screws
Access Panel
Rear LH
Fender / Flair Intake Grill
Latch Asm. Foam Filter

Tie Down
& Screw Latch Plunger
5
Nut
Rear RH
Fender / Flair
Rear Rear
Bumper Support Cargo Box
Torx
Screws
Rear LH
Divider Panel
Intake Grill Heat Shield
Foam Filter
1/4 Turn
T25 Latch
Screws
Divider Panel
Heat Shield
Cover
Rear RH
Divider Panel Grommet
Engine
Service Panel
5.17
Chassis / Main Frame (RZR XP)
Rear Bumper
Support
40 ft-lbs
(54 Nm)
Bolt-In Brace /
Screws Front Cross Member
17 ft-lbs
(23 Nm)
Main Frame
40 ft-lbs
(54 Nm)
Front Bumper
Support
Screws
Skid Plate
17 ft-lbs
(23 Nm)
Washer
Screws
6.5 ft-lbs
(8.5 Nm)
5.18
Chassis / Main Frame (RZR XP 4)
Bolt-In Brace /
Front Cross Member
Rear Bumper
Support
40 ft-lbs
(54 Nm)
Main Frame
Screws
17 ft-lbs Front Frame
(23 Nm)
5
Rear
Skid Plate
17 ft-lbs Front Bumper
(23 Nm) Support
38 ft-lbs
(52 Nm)
Screws
17 ft-lbs
(23 Nm)
Washers Front
Skid Plate
Screws
6.5 ft-lbs
(8.5 Nm)
5.19
Front Bumper
Front
Bumper Support
Screws Side Panel
Front Bumper
Bolt
17 ft-lbs Nut
(23 Nm)
Deflector
Panel
T25
Screws T27
Screw
Deflector
Panel
Winch Pocket T25 Grill
Spring Headlight
Cover Screw
Rear Bumper
Rear Bumper
Bulb
Socket
T27
Screws
Speed
Tail Light Nuts
Rear
Bumper Support
5.20
BODY COMPONENT REMOVAL Front Bumper
1. Remove the (2) push rivets from the sides of the front
Seats
bumper.
1. To remove any of the seats, lift upward on the latch
lever located behind the seat bottom.
Push
Rivet
Latch
Lever
Torx
Screws
2. Remove the (8) Torx screws retaining the upper,

2. Lift upward and forward on the seat while lifting up on
the latch lever and remove the seat from the vehicle.
middle and lower portion of the bumper.
5
3. Disconnect the front head lamp connectors and
remove the front bumper from the vehicle.
Engine Service Panel
1. Remove the seats: Rear Bumper
1. Disconnect the harness connectors at the tail lights.
• RZR XP: Remove the driver and passenger seats
2. Remove the (10) T-27 Torx screws retaining rear
• RZR XP 4: Remove the rear passenger seats
bumper to the cargo box and vehicle frame.
2. Turn both latches 1/4 turn to disengage the panel.
1/4 Turn
Latches
RZR XP Shown Service Panel 3. Remove rear bumper from vehicle.
3. Lift the panel upward and towards the front of the

vehicle to remove it.
5.21
Hood and Front Body Work 4. Remove the push rivets and screws that attach the
dash assembly to the rocker panels on each side.
Hood Removal
1. To remove the hood, turn both 1/4 turn latches to
disengage the rear portion of the hood.
RZR XP Shown
5. Remove the (2) push rivets that retain the rear portion
of the dash assembly.
Push
Rivets
Vehicle shown is
for reference only.
2. Lift rear of hood and slide forward to disengage the

front tabs and remove the hood from the vehicle.
Front Body / Dash Removal

1. Remove the hood as previously described.
2. Remove the front bumper (see “BODY COMPONENT 6. Disconnect all electrical dash components noting their
REMOVAL - Front Bumper”). location and wire routing.
3. Remove the front portion of the cab frame assembly 7. Remove the dash assembly from the vehicle.
to allow dash removal. Refer to appropriate “CAB
FRAME - Assembly / Removal” procedure for Front Fender Flair Removal
assembly torque specifications.
1. Remove the (6) T27 Torx screws and remove fender
flairs from the dash assembly.
Remove
Fender
Flare
RZR XP Shown
5.22
Rear Fender Flair / Box Side Removal 7. Remove the (4) Torx screws (E) that attach the rear
bumper to the vehicle frame.
1. Remove the (9) T27 Torx screws. Remove the fender
flair / box side from the vehicle.
Torx
Screws
A
Fender Flair /
Box Side
Torx 8. Loosen the hose clamp (F) and disconnect the engine
Screws intake hose from the resonator baffle box.
5
Cargo Box Assembly Removal
1. Remove the driver and passenger seats.
2. Remove cargo box panel and engine service panel.
3. Remove the (4) Torx screws (A) retaining the front of F

the cargo box to the vehicle frame.
4. Remove the (6) Torx screws (B) from both the RH and
LH side of the vehicle. G
5. Remove the (2) Torx screws (C) from both the RH and
LH side of the vehicle. 9. Remove the (2) Torx screws (G) from each side of the
vehicle securing the LH resonator box support bracket
6. Remove the (6) Torx screws (D) from the rear cargo and the RH clutch intake box support bracket.
box area.
10. Loosen the hose clamp (H) and remove the clutch
intake hose from the inner clutch cover.
D
B H
C
5.23
11. Disconnect the cargo box tail light harness (I) located Rocker Panels, Console and Floor
above the LH resonator box support bracket.
Rocker Panel Removal
1. Remove the push rivets and Torx screws retaining
the rocker panel and remove panel from the vehicle.
I
12. Slide back the hose clamp (J) and remove the engine
breather hose (K) from the crankcase.
RZR XP Shown
Console and Lower Floor Removal (RZR XP)

1. Remove both seats and rocker panels (see “Rocker
Panel Removal”).
2. Remove the T27 screws retaining the console to the
floor.
K
3. Remove shift handle knob and remove the console.
13. With the aid of an assistant, carefully lift and guide the
cargo box assembly up and off the vehicle frame.
Make note of wire and hose routings for reassembly.
4. Remove the Torx screws retaining the upper floor to

the lower floor.
5. Remove the Torx screws retaining the rear portion of
the floor and remove the lower floor from the vehicle.
5.24
Rear Floor Removal (RZR XP 4) DECAL REPLACEMENT
1. Remove all four seats and both rocker panels (see
“Rocker Panel Removal”).
2. Remove the T27 screws retaining the console to the

WARNING
floor.
The following procedure involves the use of an
3. Remove the shift handle knob and remove the open flame. Perform this procedure in a well
console. ventilated area, away from gasoline or other
flammable materials. Be sure the area to be
4. Disconnect the battery and remove it from the vehicle. flame treated is clean and free of gasoline
5. Remove the (8) fasteners that retain the lower portion or flammable residue.
of the mid cab frame to the main frame.
6. Remove the (2) fasteners that retain the side bars to WARNING
the mid cab frame.
Do not flame treat components that are installed
7. Remove the (8) fasteners that retain the upper portion on the vehicle. Remove the component from the
of the mid cab frame. vehicle before flame treating.
8. Using care, remove the mid cab frame from the
vehicle as an assembly.
The body cab components are plastic polyethylene
material. Therefore, they must be “flame treated” prior to 5
installing a decal to ensure good adhesion. A bonus of the
flame treating procedure is it can be used to reduce or
eliminate the whitish stress marks that are sometimes left
after a fender or cab is bent, flexed, or damaged.
CAUTION
Do not flame treat painted plastic components.

Painted plastic surfaces should only be wiped
clean prior to decal adhesion.
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.
9. Remove the Torx screws retaining the rear floor.
10. Disconnect the 12V outlet connector.
11. Remove the rear floor from the vehicle.
5.25
STEERING ASSEMBLY
Exploded View (Non-EPS Models)
65 ft-lbs (88 Nm)
Apply Red Loctite 271
Cap
Spacer
Thick
Steering Wheel Thin Washers
Washer
Thin
Washer
Thick
Washer
Thin
Washer
Steering Shaft
Pivot Tube
Spacer
Bearing
7 ft-lbs Bushing 42.5 ft-lbs

(10 Nm) (58 Nm)
23 ft-lbs
(31 Nm)
27-33 ft-lbs
(37-45 Nm)
Bushing
23 ft-lbs
(31 Nm) LH Boot 12-14 ft-lbs
Oil Locking Bearing
Gear Box (16-19 Nm)
Shock Asm.
Asm.
12 ft-lbs RH Boot
(16 Nm)
42.5 ft-lbs
(58 Nm)
Boot 17 ft-lbs
(23 Nm) 17 ft-lbs
(23 Nm)
12-14 ft-lbs
(16-19 Nm)
Nut Tie Rod
Cotter Pin
Rod End
5.26
Steering Wheel Removal (Non-EPS Models) Steering Shaft Removal (Non-EPS Models)
1. Remove the pinch bolt retaining the lower portion of
CAUTION the steering shaft to the steering gear box assembly.
Steering Shaft
This procedure should NOT be used on EPS
models. Using this procedure on an EPS model Pinch Bolt
can permanently damage the EPS unit and
cause a Power Steering Fault.
1. Remove the steering wheel cap.

Gear Box
Asm.
2. Loosen the nut and back it half way off the steering
shaft.
3. With a glove on your hand, place it under the steering Figure 5-16
wheel. Lift upward on the inner portion of the steering
wheel while using a hammer to strike the steering
shaft nut. 2. Remove the fastener retaining the upper portion of the
steering wheel tilt shock to the pivot tube.
IMPORTANT: If the steering wheel will not pop loose,
proceed to “Steering Shaft Removal”. Figure 5-17 5
4. Once the steering wheel pops loose, completely Pivot Tube
remove the nut and lift the steering wheel off the shaft.
Tilt Shock
3. Remove the (2) fasteners that retain the pivot tube.
4. Remove the steering shaft, pivot tube and steering

wheel from the vehicle as an assembly.
5. Refer to steps 11-13 of the “Steering Shaft Bearing

Replacement” procedure for installation.
5.27
Steering Shaft Bearing Replacement NOTE: Bearings will be seated in the pivot housing
upon tightening the steering wheel nut in step 14.
IMPORTANT: Replacement pivot tube assembly
comes with new upper and lower bearings installed. 9. Reinstall the upper washers and spacers in the order
Use this procedure if replacing just the bearings only. in which they were removed.
1. Perform the “Steering Shaft Removal” procedure. 10. Install the steering wheel and hand tighten the nut.
Apply Loctite® 271™.
2. Remove the steering wheel cap and retaining nut.
11. Reinstall the steering shaft assembly in the vehicle.
3. Press steering shaft out of the steering wheel and Install the lower portion of the steering shaft onto the
pivot tube. steering gear box assembly (see Figure 5-16). Torque
the lower pinch bolt to specification.
4. Note the order and location of the washers and
spacers between the steering wheel and pivot tube.
=T
5. Drive the bearings out of the pivot tube using a drift
punch. Lower Steering Pinch Bolt:
30 ft-lbs (41 Nm)
6. Inspect the pivot tube bearing surfaces for signs of
excessive wear or damage.
12. Install the (2) fasteners that retain the pivot tube (see
7. Apply Loctite® 271™
(Red) to the outer circumference Figure 5-17). Torque fasteners to specification.
of the new lower bearing race. Slide the new lower
bearing onto the steering shaft and install the steering
shaft through the pivot tube. =T
NOTE: Use care not to allow any of the Loctite® to Pivot Tube Bolts:
get in the bearing. 23 ft-lbs (31 Nm)
Thick 13. Install the fastener retaining the upper portion of the
Washer steering wheel tilt shock to the pivot tube (see Figure
Spacer 5-17). Torque fastener to specification.
Pivot Tube
Cap
=T
Nut
Tilt Shock Bolt:
Bearing Spacer 7 ft-lbs (10 Nm)
Thin
Washer
Thick
Washers 14. Be sure the front wheels are facing straight forward.
Remove the steering wheel and align as needed.
Torque the steering wheel nut to specification. Apply
Bearing Thin Loctite® 271™
Washers
NOTE: Be sure the lower washers and spacers are =T

still on the steering shaft.
Steering Wheel Nut:
8. Apply Loctite® 271™ (Red) to the outer circumference 65 ft-lbs (88 Nm)
of the new upper bearing race. Slide the new upper
bearing onto the steering shaft and press it into the
15. Wipe the pivot tube clean of any excess Loctite®.
pivot tube by hand.
16. Install steering wheel cap and field test steering
NOTE: Use care not to allow any of the Loctite® to operation.
get in the bearing.
5.28
ELECTRONIC POWER STEERING ASSEMBLY
Exploded View (EPS Models)
65 ft-lbs (88 Nm)
Apply Red Loctite 271
Spacer
Thick Thick
Thin
Washer Washers
Washer
Thin
Cap Thin Washer
Washer Upper
Steering Shaft
Bearing
Steering
Wheel Pivot Tube
7 ft-lbs
Spacer 15 ft-lbs
(10 Nm) (20 Nm)
23 ft-lbs Power Steering

(31 Nm)
Bushing
Unit
Mounting
5
Bracket
Bushing
Oil Locking 23 ft-lbs
Shock Asm. (31 Nm)
Bearing
12 ft-lbs
(16 Nm)
20-24 ft-lbs
(27-33 Nm) 15-19 ft-lbs
Collar (20-26 Nm)
Lower 42.5 ft-lbs

(58 Nm)
Pivot Tube Steering Shaft
Screw
Steering 30 ft-lbs
Lock (41 Nm) LH Boot
12-14 ft-lbs
INT’L Models Gear Box (16-19 Nm)
Asm.
RH Boot
42.5 ft-lbs
(58 Nm)
Boot
17 ft-lbs 17 ft-lbs
(23 Nm) (23 Nm)
12-14 ft-lbs
(16-19 Nm)
Nut
Rod End
Tie Rod
Cotter Pin
5.29
Upper Steering Shaft Removal (EPS Models) 4. Lift the steering wheel up and remove the (2)
fasteners that retain the pivot tube.
1. Remove the (2) Torx-head fasteners retaining the
black plastic cover and remove the cover from the
vehicle.
Remove
5. Remove the steering shaft, pivot tube and steering

wheel from the vehicle as an assembly.
2. Remove the pinch bolt retaining the upper steering

shaft to the power steering unit. Remove as
an assembly
6. If replacing the upper steering shaft or steering wheel,

refer to “Steering Wheel Removal (EPS Models)”.
3. Remove the fastener retaining the upper portion of the

steering wheel tilt shock to the pivot tube. Swing the
shock down out of the way.
Remove
5.30
Steering Wheel Removal (EPS Models) 5. Using a large bronze drift and hammer, strike the
steering shaft nut to pop the steering wheel off the
1. Remove the upper steering shaft, pivot tube and shaft taper.
steering wheel as an assembly before attempting to
remove the steering wheel. Refer to “Upper Steering
Shaft Removal (EPS Models)”.
CAUTION
Striking the steering wheel or steering shaft

while installed in the vehicle can permanently Remove
damage the EPS unit and cause a
Power Steering Fault.
2. Remove the steering wheel cap.
6. Once the steering wheel pops loose, completely

remove the nut and lift the steering wheel off the shaft.
5
Power Steering Unit Removal
1. Remove the upper steering shaft, pivot tube and
steering wheel from the vehicle as an assembly.
Refer to “Upper Steering Shaft Removal (EPS
Models)”.
CAUTION
3. Loosen the nut and back it half way off the steering
shaft. Striking the steering wheel or steering shaft
while installed in the vehicle can permanently
damage the EPS unit and cause a
Power Steering Fault.
2. Disconnect the (2) electrical harnesses from the

power steering unit.
Remove
4. Place the assembly in a vise.
5.31
3. Remove the pinch bolt retaining the lower steering 6. If replacing the power steering unit, remove the (4)
shaft to the power steering unit. bolts that retain the power steering unit to the mount
bracket.
Remove
Remove
4. While supporting the power steering unit, remove the

(4) nuts from the mount bracket.
WARNING
Electronic Power Steering (EPS) units are

programmed to be vehicle specific and are not
interchangeable between product lines.
Remove
5. Carefully remove the power steering unit and mount

bracket from the vehicle as an assembly.
5.32
Lower Steering Shaft Removal (EPS Models) Lower Steering Shaft Installation
1. Use the steering wheel to position the front wheels so
(EPS Models)
they point straight ahead.
1. Install the lower steering shaft onto the gear box and
align the marks made during step 2 of the “Lower
2. Locate the lower steering shaft through the left front
Steering Shaft Removal (EPS Models)” procedure.
wheel well. Mark the lower steering shaft, gear box
stub shaft and gear box to aid installation.
2. Install the pinch bolt that retains the lower steering
shaft to the gear box assembly and torque to
Mark prior to removal specification.
=T
Pinch Bolt:
30 ft-lbs (41 Nm)
3. Install the power steering unit and reassemble the

vehicle (see “Power Steering Unit Installation”
procedure).
5
3. Remove the power steering unit (see “Power Steering
Unit Removal” procedure).
4. Remove the pinch bolt retaining the lower steering

shaft to the steering gear box assembly.
Lower
Steering Shaft
Pinch Bolt
Gear Box
Asm.
5. Lift up on the shaft and remove it through the floor

panel.
5.33
Power Steering Unit Installation 4. Position the lower steering shaft on the power steering
unit stub shaft and install the pinch bolt. Torque to
1. If the power steering unit was removed from the specification.
mount bracket, reinstall it prior to vehicle installation.
Torque the mounting bolts to specification.
=T
Lower Steering Shaft Pinch Bolt:
17 ft-lbs (23 Nm)
5. Torque the (4) mount bracket nuts to specification.
16 ft-lbs (22 Nm)

2. Install the power steering unit into the vehicle and
align the skip-tooth spline on the power steering stub
shaft with the opening in the lower steering shaft. =T
Power Steering Unit Mount Bracket Nuts:
16 ft-lbs (22 Nm)
6. Proceed to “Upper Steering Shaft Installation (EPS

Skip-Tooth
Models)” to complete the installation procedure.
Shaft
Opening
3. Place the power steering mount bracket over the top

of the brake pedal mount studs and finger tighten the
(4) nuts.
5.34
Upper Steering Shaft Installation (EPS Models) 4. Be sure the front wheels are pointing straight ahead
and install the steering wheel and retaining nut.
IMPORTANT: If steering wheel was removed, follow Torque the nut to specification and reinstall the plastic
this procedure to ensure the upper steering shaft is wheel cover.
properly positioned on the power steering stub shaft.
=T
CAUTION
Steering Wheel Nut:
Striking the steering wheel or steering shaft 65 ft-lbs (88 Nm)
can permanently damage the EPS unit
and cause a Power Steering Fault. 5. Install a new upper steering shaft pinch bolt and nut.
Torque pinch bolt to specification.
NOTE: Be sure upper steering shaft hardware is
positioned correctly (see “Exploded View’).
=T
1. Install the upper steering shaft and align the skip-
tooth spline on the power steering stub shaft with the Upper Steering Shaft Pinch Bolt:
opening in the upper steering shaft. 15 ft-lbs (20 Nm)
Shaft
Opening
6. Reconnect both electrical harnesses onto the power
steering unit. Be sure the connectors snap into place. 5
7. Reinstall the black plastic cover over the power
steering unit and install the (2) Torx-head fasteners.
8. Turn the key switch on and test EPS operation.
Skip-Tooth
2. Install the pivot tube and torque fasteners to

specification.
=T
Pivot Tube Fasteners:
23 ft-lbs (31 Nm)
3. Install the tilt shock and torque fastener to

specification.
=T
Upper Tilt Shock Fastener:
7 ft-lbs (10 Nm)
5.35
FRONT A-ARMS 15. INT’L Models: Attach stabilizer linkage to A-arm (G)
with fastener. Torque linkage fastener to
Removal / Replacement specification.
The following procedure details upper and lower A-arm 16. Remove lower ball joint pinch bolt (E) from bearing
removal and replacement on one side of the vehicle. carrier.
1. Elevate and safely support the front of the vehicle and 17. Using a soft face hammer, tap on bearing carrier to
remove the front wheel. loosen the lower A-arm ball joint end while pushing
downward on the lower A-arm. Completely remove
2. Remove lower shock fastener (A) from upper A-arm. the ball joint end from the bearing carrier.
3. INT’L Models: Remove lower stabilizer linkage 18. Loosen and remove the lower A-arm through-bolt
fastener from upper A-arm (G). fastener (F) and remove the lower A-arm from the
vehicle.
4. Remove upper ball joint pinch bolt (B) from bearing
carrier. 19. Examine A-arm bushings and pivot tube (D). Replace
if worn. Discard hardware.
5. Using a soft face hammer, tap on bearing carrier to
loosen the upper A-arm ball joint end while lifting 20. If not replacing the A-arm, thoroughly clean the A-arm
upward on the upper A-arm. Completely remove the and pivot tube.
ball joint end from the bearing carrier.
21. Install new ball joint into A-arm. Refer to “Ball Joint
6. Remove the front bumper to allow A-arm bolt removal. Replacement” section.
7. Loosen and remove the upper A-arm through-bolt 22. Insert new A-arm bushings and pivot tube into new A-
fastener (C) and remove the upper A-arm from the arm. A light press force may be needed.
vehicle.
23. Install new lower A-arm assembly onto vehicle frame.
8. Examine A-arm bushings and pivot tube (D). Replace Torque new bolt to specification.
if worn. Discard hardware.
24. Insert lower A-arm ball joint end into the bearing
carrier. Install lower ball joint pinch bolt (E) into the
WARNING bearing carrier and torque bolt to specification.
The locking agent on the existing bolts was
destroyed during removal. DO NOT reuse old WARNING
hardware. Serious injury or death could result if
fasteners come loose during operation. Upon A-arm installation, test vehicle at low
speeds before putting into service.
9. If not replacing the A-arm, thoroughly clean the A-arm
and pivot tube.
=T
10. Install new ball joint into A-arm. Refer to “Ball Joint
Replacement” section. Front Upper / Lower A-arm Bolts:
40 ft-lbs (54 Nm)
11. Insert new A-arm bushings and pivot tube into new A-
arm.
=T
12. Install new upper A-arm assembly onto vehicle frame.
Torque new bolt to specification. Front Ball Joint Pinch Bolts:
44 ft-lbs (60 Nm)
13. Insert upper A-arm ball joint end into the bearing
carrier. Install upper ball joint pinch bolt (B) into the
bearing carrier and torque bolt to specification. =T
14. Attach shock to A-arm with fastener (A). Torque lower
Front Shock Mounting Bolts:
shock bolt to specification.
45 ft-lbs (61 Nm)
5.36
45 ft-lbs
(61 Nm)
C 40 ft-lbs
(54 Nm)
40 ft-lbs
5
F
(54 Nm)
A
45 ft-lbs
(61 Nm)
44 ft-lbs
(60 Nm)
5.37
BALL JOINT SERVICE Ball Joint Removal
1. Remove the retaining ring from the ball joint.
Service Preparation
Picture For Reference Only
IMPORTANT: Do not reuse a ball joint if it has been
removed. If removed, it must be replaced. Use this Ball Joint
removal procedure only when replacing the ball joint.
NOTE: Ball joint tool PU-50506 will allow the upper

and lower ball joints to be replaced with the A-arm
installed on the vehicle.
PU-50506
Press Asm. (C)
Upper A-arm
Removal
Adapter (B)
Retaining Ring
2. Install Spacer (A) over the top of the ball joint face.
Ball Joint Face
Installation Spacer (A)

Adapter (D) A-arm
B
C
The A-arm does not need to be removed to perform this
procedure if ball joint tool PU-50506 is used.
1. Properly lift and support the vehicle by the frame.
2. Remove the appropriate front wheel.
3. To service the upper ball joint: 3. Place Removal Adaptor (B) over the ball joint shaft.

- Remove and discard the two front brake caliper 4. Install the Press Asm. (C) onto the A-arm to engage
mounting bolts and remove the caliper from the brake the ball joint Removal Adapter.
disc (see “Brakes” chapter).
 IMPORTANT: Be sure the Press Asm. opening is only
- Remove and discard the upper ball joint pinch bolt. contacting the Spacer (A) and not the ball joint face.

- If necessary, remove the lower front shock fastener 5. Tighten the Press Asm. screw and fully remove the
from the A-arm to gain enough clearance to install ball ball joint from the A-arm.
joint tool (PU-50506) on the upper ball joint.
4. To service the lower ball joint:


- Remove and discard the lower ball joint pinch bolt.
 C A
B
- If necessary, remove the lower front shock fastener
from the A-arm to gain enough clearance to install ball
joint tool (PU-50506) on the lower ball joint.
Ball Joint Removal
5.38
Ball Joint Installation 6. After the new ball joint is fully installed into the A-arm,
install a new retaining ring.
1. By hand, install the NEW ball joint into the A-arm.
Picture For Reference Only
2. Position the Installation Adapter (D) over the face of Ball Joint
the ball joint.
D Upper A-arm
Retaining Ring
7. Repeat the ball joint service procedure for any

A-arm additional A-arm ball joint replacements.
A
8. Insert upper / lower A-arm ball joint end into the
3. Position the Spacer (A) over the shaft of the ball joint
bearing carrier. Install new pinch bolts and nuts.
Torque to specification.
5
so it is against the A-arm.
9. If needed, install new brake caliper mounting bolts
4. Install the Press Asm. (C) onto the A-arm to engage and torque to specification.
the Installation Adapter and Spacer.
5. Tighten the Press Asm. screw and fully install the ball CAUTION
joint into the arm.
New bolts have a pre-applied locking agent
which is destroyed upon removal. Always use
A D new brake caliper mounting bolts
upon assembly.
10. Install wheel and (4) wheel nuts. Torque wheel nuts
C to specification.
=T
Front Ball Joint Pinch Bolts: 44 ft-lbs (60 Nm)
Ball Joint Installation Front Shock Mounting Bolts: 45 ft-lbs (61 Nm)
Front Caliper Mounting Bolts: 40 ft-lbs (54 Nm)
Wheel Nuts (Alum): 30 ft-lbs (41 Nm) + 90° (1/4 turn)
Wheel Nuts (Steel): 27 ft-lbs (37 Nm)
5.39
FRONT STABILIZER BAR (INT’L) 2. Remove the (2) fasteners on each side of the vehicle
retaining the front stabilizer bar to the frame.
Stabilizer Bar Linkage Removal / Installation
1. Elevate and safely support the front of the vehicle.
2. Remove the lower linkage mounting fastener from the

upper A-arm on each side of the vehicle (see
“Exploded View”).
3. Remove the linkage mounting fasteners that attach

the upper portion of each linkage to the stabilizer bar
clamps. Remove the linkages from the vehicle (see
“Exploded View”).
4. Inspect the linkage assemblies for signs of excessive

wear or damage. Replace linkage assembly if
damaged.
3. Lift up on the stabilizer bar to free it from the mount
5. Reverse this procedure for installation. Torque the bracket. Remove the stabilizer bar and bushings from
linkage fasteners to specification (see “Exploded the vehicle.
View”).
4. Inspect the stabilizer bar for straightness. Inspect the
bushings and replace if needed.
Stabilizer Bar Removal / Installation
5. Reverse this procedure for installation. Torque the
1. If stabilizer bar linkages are installed, remove the linkage fasteners to specification (see “Exploded
bolts that attach the upper portion of the linkages to View”).
the stabilizer bar clamps. Only remove clamps if
replacing stabilizer bar. 6. If the clamp was removed from stabilizer bar, refer to
the following image for installation reference. The
clamps should be flush with the end of the stabilizer
bar.
P-Clamp
5.40
Exploded View
Upper T30
Bracket Screws Clamp
Stabilizer
Bar
Grease
Zerk
Clamp
5
Bushings
Nuts
Linkage
40 ft-lbs
(54 Nm) Linkage
43 ft-lbs
(58 Nm)
Spacer
Upper A-Arm
5.41
REAR RADIUS RODS 5. Remove bolts (C and D) attaching radius rods to the
vehicle frame. Discard the nuts.
Removal / Installation
The following procedure details upper and lower radius
rod removal and replacement on one side of the vehicle.
Repeat the following steps to remove the A-arm from the C
opposite side. D
1. Raise and support vehicle by main frame.
CAUTION
Serious injury may result if machine tips or falls.

Be sure machine is secure before beginning this
service procedure.
2. Remove the rear wheel nuts and rear wheel. 6. Remove radius rods from vehicle.
3. Identify / mark radius rods “upper” and “lower”. 7. Examine radius rod shafts, boots and spherical
bearings. Replace entire radius rod if any excessive
4. Remove the nut, bolt and washer (A and B) attaching wear is evident.
the upper and lower radius rod to the bearing carrier.
Discard the nuts. 8. Reverse this procedure to reinstall the radius rods.
9. Torque all fasteners to specification.

A
NOTE: Use new attaching nuts upon installation of
the rear radius rods.
=T
Radius Rod Mounting Bolts:
Inner: 40 ft-lbs (54 Nm)
Outer: 45 ft-lbs (61 Nm)
RZR XP Shown B WARNING
Upon radius rod installation, test vehicle at low

speeds before putting into service.
5.42
REAR TRAILING ARM 5. Remove the two brake caliper mounting bolts. 
CAUTION: Do not hang the caliper by the brake line.
Trailing Arm Removal / Installation Use wire to hang caliper to prevent damage to the
brake line.
NOTE: Use new attaching nuts upon installation of
the rear trailing arm and bearing carrier.
1. Raise and support vehicle by main frame.
CAUTION

service procedure.
2. Remove the (4) wheel nuts and remove the rear

wheel. RZR XP Shown
3. Remove the cotter pin and loosen the rear wheel hub
castle nut. Remove the nut, and (2) cone washers 6. Remove the rear wheel hub and brake disk assembly.
from the rear wheel hub assembly.
7. Remove the (5) remaining bolts that attach the rear
5
bearing carrier to trailing arm. Discard the nuts.
Cotter Pin
Castle Nut
Cone
Washers
4. Remove the lower radius rod mounting bolt, nut and

washer from the bearing carrier. Swing radius rod
8. Remove the bearing carrier from the rear drive shaft
down. Discard the nut.
and trailing arm.
RZR XP Shown
5.43
9. Rotate bearing by hand and check for smooth
rotation. Visually inspect bearing for moisture, dirt, or
=T
corrosion. Replace bearing if moisture, dirt, corrosion,
or roughness is evident (see Chapter 7).
Trailing Arm to Main Frame Bolt:
10. Remove the (2) fasteners that secure the brake line (Trailing arm spherical bearing bolt)
retainers to the trailing arm. 70 ft-lbs (95 Nm)
11. Remove the lower stabilizer bar linkage fastener.
Discard the nut. =T
12. Support trailing arm with suitable jack stand or
support. Rear Shock Mounting Bolts:
Upper: 50 ft-lbs (67.7 Nm)
13. Remove the lower shock bolt. Discard the nut. Lower: 70 ft-lbs (95 Nm)
=T
Rear Stabilizer Bar Linkage:
31-34 ft-lbs (42-46 Nm)
=T
Radius Rod Mounting Bolts:
Remove Inner: 40 ft-lbs (54 Nm)
Outer: 45 ft-lbs (61 Nm)
Support Trailing Arm
14. Remove the front trailing arm bolt. Discard the nut. =T
Bearing Carrier to Trailing Arm Bolts:
40 ft-lbs (54 Nm)
=T
Rear Brake Caliper Mounting Bolts:
40 ft-lbs (54 Nm)
=T
Rear Wheel Hub Castle Nut:
80 ft-lbs (108 Nm)
15. Remove trailing arm from vehicle. Visually inspect
trailing arm, bushings, o-rings and spherical bearing =T
for wear. If bearing requires replacement, refer to
“Trailing Arm Spherical Bearing Replacement”. Wheel Nuts:
16. Replace trailing arm if physically damaged. 30 ft-lbs (41 Nm) + 90° (1/4 turn)
17. Reverse this procedure to reinstall rear trailing arm.
NOTE: Use new fastener nuts upon installation of WARNING
the rear trailing arm and bearing carrier.
Upon rear trailing arm installation, test vehicle at
18. Torque all fasteners to specification. low speeds before putting into service.
5.44
Trailing Arm Spherical Bearing Replacement 5. Be sure to only press on outer most surface of bearing
race, do not press on the center spherical bearing.
1. Remove trailing arm (see “REAR TRAILING ARM”).
2. Remove bushings and O-rings.
3. Remove snap ring that retains the spherical bearing.
6. Inspect trailing arm bearing housing for wear or

damage. Replace trailing arm if damaged.
7. Press in new bearing until fully seated into trailing arm
casting.
4. Properly support the trailing arm and press the
spherical bearing out of trailing arm casting.
8. Install new snap ring, new O-rings and bushings.
5
Rear Suspension Exploded View
40 ft-lbs
(54 Nm)
Shock
50 ft-lbs
(67.7 Nm)
Stabilizer Bar
Radius Rods
31-34 ft-lbs
(42-46 Nm)
70 ft-lbs 45 ft-lbs
(95 Nm) (61 Nm)
Bushing
Link
40 ft-lbs Trailing Arm Snap

(54 Nm) Ring
Bushing
Bearing Carrier
70 ft-lbs
31-34 ft-lbs Spherical
(95 Nm)
(42-46 Nm)
O-Ring Bearing
5.45
REAR STABILIZER BAR Stabilizer Bar Installation
1. Carefully install stabilizer bar through the LH wheel
Stabilizer Bar Removal
well area.
1. Lift and support vehicle by main frame. NOTE: Be sure fuel lines and shift cable are routed
2. Remove rear wheels nut and wheels. ABOVE the stabilizer bar.
3. Identify / mark top side of the stabilizer bar to 2. Fully install stabilizer bar, bushings, bracket and
reference during installation. bracket fasteners and stabilizer links. Center
stabilizer bar in the frame. Torque fasteners to
4. Remove the fasteners retaining the stabilizer bar to
specification (see below).
the linkage on each side of the vehicle.
3. Install stabilizer bar locating clamps on the INSIDE of
Remove the pivot bushing and brackets. There should be a
0.10” (2.5mm) gap between the bushing face and the
locating clamps. Torque locating clamps fasteners to
specification.
Locating Clamp
Bushing Bracket
5. Remove the (4) fasteners retaining the stabilizer bar
to the vehicle frame (see below).
6. Remove the bushing brackets and bushings for ease
of removal.
7. Carefully remove the stabilizer from the LH wheel well 4. Torque all fasteners to specification (see below).
area of the vehicle. 5. Lubricate stabilizer bar pivot bushings via grease
8. Mark the location and remove the two stabilizer bar fitting (fittings are accessible through skid plate).
locating clamps (if replacing stabilizer bar). 6. Install rear wheels and wheel nuts. Torque wheel nuts
9. Inspect the stabilizer bar for straightness. Inspect the to specification.
pivot bushings and replace if needed.
17 ft-lbs
(23 Nm)
Bushing Bracket
Stabilizer Bar
Bushings
10 ft-lbs
(13.5 Nm)
31-34 ft-lbs
(42-46 Nm)
Locating Clamps
Grease Fitting
Link
31-34 ft-lbs
(42-46 Nm)
5.46
SHOCKS / SPRINGS / FASTENERS Shock Removal / Installation
1. Elevate the vehicle off the ground to relieve the
Front Shock Exploded View
suspension load.
2. Support under A-arm or trailing arm.
3. Remove the upper and lower fasteners retaining the

shock and remove the shock from the vehicle. Discard
nuts and replace with new upon installation.
4. Reverse the procedure to reinstall the shock. Torque

new fasteners to specification (refer to exploded
views).
=T
Shock Mounting Bolts:
Retainer gap
Front: 45 ft-lbs (61 Nm)
should be 180° Rear Upper: 50 ft-lbs (67.7 Nm)
from spring end Rear Lower: 70 ft-lbs (95 Nm)
5
Shock Replacement
1. Remove the shock and note the spring preload
distance (see Chapter 2 for factory settings).
RZR XP Shown 2. Loosen the jam nut (if applicable) and adjustment ring
until the spring is loose. If needed, use a spring
compressor to compress the spring far enough to
Rear Shock Exploded View
remove the spring retainer.
3. Remove the spring and spring retainer from the

existing shock and install components onto the new
Bushings
shock.
Springs
4. Install the spring(s) and spring retainer.
IMPORTANT: The spring retainer gap should be 180°

from the end of the spring upon installation.
5. Tighten the spring adjustment ring to set the preload

Shock 50 ft-lbs distance noted in Step 1 (see Chapter 2 for factory
(67.7 Nm) settings).
Spring Retainer 6. Reinstall the shock onto the vehicle and torque new
Retainer gap
should be 180° fasteners to specification.
from spring end
70 ft-lbs
(95 Nm)
O-Rings
RZR XP Shown Guard
5.47
FOX™ SHOCK EXPLODED VIEWS (RZR XP)
FOX™ 2.0 ‘Piggyback’ Shock
22 ft-lbs
(30 Nm)
Loctite® 638™ / Primer N™

100 ft-lbs (136 Nm) Loctite® 638™ / Primer N™
50 ft-lbs (68 Nm)
Preload Ring
10 ft-lbs (14 Nm)
Ref. Qty Description Ref. Qty Description

1. 1 Body Cap Asm. 12. 1 Reservoir End Cap Asm.
2. 1 Body Cap 13. 1 Preload Ring, Jam Nut
3. 1 Body 14. 1 Preload Ring
4. 1 Eyelet 15. 1 Damping Adjust Asm., Piston
5. 1 Shaft 16. 1 Damping Adjust Asm., Concentric
6. 1 Bearing Cap Asm. 17. 2 Bearing, External
7. 1 Bearing Asm. 18. 1 Bumper
8. 1 Valving Asm. 19. 2 Bearing, Spherical
9. 1 Lock Nut 20. 4 Retaining Ring
10. 1 Reservoir 21. 2 Retaining Ring
11. 1 Piston Asm, Floating (IFP) 22. - Shock Oil (2870995)
5.48
FOX™ SHOCK SERVICE (RZR XP)
General Service Information
Recommended Service Intervals
FOX™ Racing Shocks will perform the best if serviced at regular intervals:
• Every ride - Wash and dry the vehicle and suspension

• Every 100 hours - Visually inspect shock seals
• Every 1500 miles or Annually - Change shock oil and replace seals
Front Shock Service Information

SHOCK VALVING
COMPRESSION REBOUND
1.600 x 0.008 1.425 x 0.010
1.600 x 0.008 1.425 x 0.010
0.900 x 0.006 1.425 x 0.010 5
1.600 x 0.008 1.100 x 0.004
1.425 x 0.010 1.425 x 0.010
1.300 x 0.010 1.350 x 0.012
1.250 x 0.010 1.250 x 0.012
3.40”
IFP Depth 1.250 x 0.010 1.100 x 0.012
1.100 x 0.015 1.000 x 0.012
SHOCK DESIGN DETAILS 1.100 x 0.015 1.230 x .082 Top-Out

0.900 x 0.010 0.875 x .100 Back-Up
Travel 6.62”
0.900 x 0.010
Extended Length 22.87”
1.570 x .128 Top-Out
IFP Location 3.40” (86.4 mm)
Piston Orifice: 2x 0.070
Nitrogen Pressure 200 psi +/- 5%
Gas Shock Oil 2870995 (qt.)
5.49
Rear Shock Service Information
SHOCK VALVING
COMPRESSION REBOUND
1.600 x 0.008 1.425 x 0.012
1.600 x 0.010 1.425 x 0.010
1.600 x 0.010 1.100 x 0.004
1.250 x 0.004 1.425 x 0.010
1.600 x 0.015 1.350 x 0.010
1.425 x 0.015 1.250 x 0.010
1.425 x 0.015 1.100 x 0.010
3.40”
IFP Depth 1.350 x 0.015 0.950 x 0.010
1.300 x 0.015 1.230 x .082 Top-Out
SHOCK DESIGN DETAILS 1.250 x 0.015 0.800 x .020 Back-Up

1.250 x 0.015
Travel 7.62”
1.100 x 0.015
1.100 x 0.015
1.100 x 0.015
0.950 x 0.010
0.950 x 0.010
1.570 x .128 Top-Out
Piston Orifice: 1x 0.098
5.50
FOX™ Shock Rebuild Information FOX™ Shock Disassembly
When performing maintenance on FOX™ shocks, use the IMPORTANT: To prevent damage or marks to the
Gas Shock Recharging Kit (PN 2200421), as it contains shock, the use of special tools and a soft jaw vise is
the necessary valves, pressure gauge, and fittings to recommended.
deflate and pressurize shocks.
WARNING
WARNING
FOX™ shocks contain high pressure nitrogen
FOX™ shocks contain high pressure nitrogen gas. Extreme caution must be used while
gas. Extreme caution must be used while handling and working with FOX™ shocks and
handling and working with FOX™ shocks and related high pressure service equipment. The
related high pressure service equipment. The pressure must be released from the shock
pressure must be released from the shock before disassembly. It is strongly recommended
before disassembly. It is strongly recommended you wear safety glasses and ear protection
you wear safety glasses and ear protection during these procedures.
during these procedures.
1. Remove the shock from the vehicle and note the
TIP: Extreme cleanliness is very important during all spring preload distance (see Chapter 2 for factory
disassembly and reassembly operations. This prevents
dirt or foreign particles from entering the shock, which
settings).
5
causes premature failure. 2. Thoroughly clean all shock components and shock
body prior to disassembly.
Special Tools 3. Back preload adjuster all the way down and carefully
remove spring retainer and spring.
PART NUMBER DESCRIPTION 4. Use the appropriate shock body holding tool (PS-
45281-A) to properly secure the shock body assembly
2200421 Gas Shock Recharging Kit
into a vice for service.
7052069-A Gas Shock Recharging Needle
5. Remove the nylon ball from the reservoir cap using a
2871351 IFP Tool heavy duty pick. Discard nylon ball and replace with
Shock Body Holding Tool new upon assembly.
PS-45281-A
(Front and Rear)
2872429 Shock Rod Holding Tool
PU-50939 Shock Seal Protector Sleeve
6. Slowly loosen nylon ball retainer from reservoir cap

and allow nitrogen to completely escape.
7. Remove the nylon ball retainer.
5.51
8. Depress reservoir cap and remove retaining ring from 14. Install the Shock IFP Tool (2871351) onto the IFP
the reservoir. located in the reservoir.
15. Push downward on the IFP tool while pulling upward

on the shock shaft to remove the shock shaft
assembly.
16. Remove the center screw and O-ring from the IFP.
17. Remove the IFP using the Shock IFP Tool (2871351).
18. Remove shock body assembly from the vise. Drain

and properly dispose of shock oil.
19. Secure the shock rod in a vice using the shock rod
holding tool (2872429). Position the shock rod so the
threaded end is facing upward.
9. Remove the reservoir cap.
20. Using a 3/4" wrench, remove and discard the lock nut
10. Install the Bearing Cap Removal Tool (commercially
from the end of shock rod.
available) around shock body.
11. Place a retaining ring (A) in the groove between the

body and the cap.
IMPORTANT: Keep the rebound and compression

valve stacks in the order they were removed. If unsure
of order, refer to “Shock Valving” under the “Shock
Service Information” provided earlier in this section.
12. Tap tool upward with a rubber mallet to release and
remove bearing cap. 21. Remove the shims and piston from the shock rod.
13. Press downward on the bearing assembly (B) to 22. A tie strap can be used to keep the shims in the proper
expose the retaining ring (C). Remove the retaining order.
ring from the shock body.
B C
23. Inspect the valve shims for kinks, waves, pits or

foreign material.
5.52
24. Inspect the piston wear band and replace if damaged 4. Clean the adhesive out of the threads with a wire
or worn. brush and/or a small pick.
25. Replace the piston O-ring (if equipped).
26. Make note of the positioning of the piston for proper

assembly. The compression side of the piston has
larger ports with raised edges.
27. Remove and replace jounce bumper from shock rod.
FOX™ Shock Body and Reservoir Service
WARNING
5. Apply Loctite® 7649™ primer to shock body and
The following procedure involves the use of an reservoir threads and let dry for reassembly.
open flame. Perform this procedure in a well-
ventilated area, away from gasoline or other 6. Remove the low speed compression cap using a #10
flammable materials. Be sure the area to be Torx bit driver.
flame treated is clean and free of gasoline
or flammable residue. 7. Use a 5/8" socket to remove the LSC / DSC
5
compression control.
on the vehicle. Remove the component from the 8. Replace the O-rings on the low speed compression
vehicle before flame treating. piston.
9. Inspect the LSC / DSC blow out control with low

Disassembly pressure compressed air and replace O-rings.
1. Use the appropriate shock body holding tool (PS-
10. Replace the internal and external O-rings on the
45281-A) to properly secure the shock body
reservoir body. Be sure O-rings are lubricated with
assembly into a vice for service.
shock oil before and after installation.
2. Heat the body cap and reservoir base with a small
heating torch to break the adhesive bond between cap Assembly
and shock body. 1. Apply Loctite® 620™ on primed shock body and
reservoir threads.
2. Use a spanner or strap wrench to torque the reservoir

body to specification.
=T
Reservoir Body: 30 ft-lbs (40 Nm)
Shock Body: 50 ft-lbs (40 Nm)
3. Remove excess Loctite® 620™ from body surface.
4. Install and torque the DSC and LSC to specification.

3. Use a spanner or strap wrench to remove the shock
body tube and reservoir from the body cap.
=T
DSC: 35 ft-lbs (47 Nm)
LSC: 14 ft-lbs (19 Nm)
5.53
FOX™ Shock Component Rebuild Bearing Cap
IMPORTANT: To prevent damage or marks to the 1. Use a small pick to remove seal from the bearing cap.
shock, the use of special tools and a soft jaw vise is
recommended.
WARNING

gas. Extreme caution must be used while
handling and working with FOX™ shocks and
related high pressure service equipment. The
pressure must be released from the shock
before disassembly. It is strongly recommended
you wear safety glasses and ear protection
during these procedures.
2. Lubricate a new seal and fully install into bearing cap.
IFP and Reservoir Cap
3. Push the Shock Seal Protector Sleeve (PU-50939)
1. Use a small pick to remove the IFP piston bearing through the bearing cap seal to insure proper
(A), IFP O-ring (B) and the reservoir cap O-ring (not installation.
shown).
2. Lubricate NEW O-rings and bearing with shock oil

before and after installation onto the piston and cap.
3. Install a new pellet into the reservoir cap.
4. Refer to the assembly instructions for component

installation onto the shock asm.
A
B 4. Refer to the assembly instructions for component
installation onto the shock asm.
Bearing Assembly
1. Use a small pick to remove the U-cup seal (C),
internal (D) and external (E) O-rings from the bearing
assembly.
D E
5.54
2. Thread a 5/8" NC tap into the bearing. FOX™ Shock Assembly
IMPORTANT: To prevent damage or marks to the
recommended.
WARNING

gas. Extreme caution must be used while
handling and working with FOX™ shocks and
related high pressure service equipment. The
pressure must be released from the shock
before disassembly. It is strongly recommended
you wear safety glasses and ear protection
3. Use a large punch to drive out the bearing. during these procedures.
WARNING
The following procedure involves the use of an 5

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.

on the vehicle. Remove the component from the
vehicle before flame treating.
4. Using an arbor press, install a new bearing into the
bearing assembly. 1. Secure the shock rod in a vice using the shock rod
holding tool (2872429) so the threaded end is facing
5. Lubricate and install the O-rings and U-cup seal. upward.
6. Push the Shock Seal Protector Sleeve (PU-50939) 2. Install the jounce bumper onto the shock rod.
through the bearing assembly O-ring and U-cup seal
to insure proper installation. 3. Install the Shock Seal Protector Sleeve (PU-50939)
onto the shaft threads.
4. Lubricate the shock rod and the Shock Seal Protector

Sleeve with new shock oil.
5.55
5. Lubricate and install the bearing cap onto the shock 11. Install NEW lock nut and torque to specification.
rod.
IMPORTANT: Be sure to keep the piston compression
ports and shim in time while torquing nut (if
equipped).
6. Lubricate and install the bearing assembly onto the

shock rod.
=T
Shock Rod Nut:
18 ft-lbs (24 Nm)
12. Remove the shock rod assembly from the vise and
place on a clean shop towel.
13. Use the appropriate shock body holding tool 

(PS-45281-A) to properly secure the shock body
assembly into a vice for service.
7. Remove the Shock Seal Protector Sleeve. 14. Fill the reservoir 3/4 full with the proper shock oil.
8. Lubricate and install the compression valve stack. If 15. Verify the center screw and O-ring are not installed
your compression valve stack had a bleed shim, it into the IFP.
must be installed in time with the compression ports.
16. Install the IFP into the reservoir. Keep top of reservoir
9. Install the piston assembly onto shock rod. Be sure covered with a clean shop towel.
rebound side of the piston is facing up.
17. Press IFP downward until 1/4" (6.35 mm) of shock oil
is on top of the IFP.
18. Install a new O-ring on the IFP center screw and install
the screw. Tighten the screw sufficiently.
19. Install the IFP tool and fully depress IFP into the
reservoir bore until bottomed. Measure IFP height for
later reference.
20. Fill the main shock body with shock oil until it is 2"
(50.8 mm) from the top of the shock body.
21. Pass a small heating torch over the shock body to

10. Lubricate and install the rebound valve stack. remove any air bubbles from the oil.
5.56
22. Insert the shock rod / piston assembly into shock 31. Add shock oil to reservoir until it is 1" (25.4 mm) above
body. Be sure the piston band stays in the proper the top of the IFP.
position. Do not install bearing assembly at this time.
32. Remove the IFP center screw and O-ring.
33. Pull upward on shock shaft until fully extended and

seated against the bearing assembly retaining ring.
34. Set the IFP depth to the recommended height.
IMPORTANT: Keep sufficient amount of shock oil

above the IFP and pull it past the recommended IFP
depth.
23. Press shaft downward. Rotate and wiggle the shaft as

it submerges in the shock oil until no more air bubbles
rise out of the shock oil.
24. Hold pressure downward on IFP tool. Stroke shock

rod assembly up and down 1/4" (6.35 mm) to work the
5
air bubbles out of the piston and piston ports.
25. Slide the bearing assembly partially into the shock

body. 3.40”
26. Tap shock rod eyelet with a rubber mallet 3-5 times IFP Depth - Front and Rear
to remove any trapped air from the valve shims.
NOTE: ALWAYS reset IFP depth in a downward
motion.
35. Remove the IFP tool.
36. Hold IFP with a 9/16" wrench to prevent IFP rotation.
37. Install the IFP center screw and O-ring; tighten the IFP
center screw sufficiently.
38. Drain and properly dispose of the shock oil from on top
of the IFP.
27. Slide bearing assembly up and pass a small heating

torch over the shock body to remove any air bubbles
from the oil.
28. Add shock oil to 1/8" (3.18 mm) below the top of the
shock body.
29. Wrap a clean shop towel around top of shock body

and depress the bearing assembly downward below
the retaining ring groove.
30. Install the bearing assembly retaining ring and clean

excess shock oil. Properly dispose of shop towel.
5.57
39. Remove oil residue from above the IFP with a clean 48. Use a dead blow hammer to fully seat a new nylon ball
shop towel. into the reservoir cap.
40. Lubricate and install a new pellet into the reservoir

cap.
41. Install the pellet retainer.
42. Lubricate the reservoir cap O-ring.
43. Install and depress the reservoir cap past the retaining
ring groove.
44. Install the reservoir cap retaining ring.
WARNING 49. Install suspension spring(s) and reset preload to

factory settings.
CHARGE THE SHOCK USING NITROGEN
GAS ONLY. DO NOT FILL WITH ANY OTHER 50. Adjust external adjusters to the factory settings
GASES. Doing so compromises the
performance of the shock and may be 51. Install shock onto the vehicle and torque fasteners to
EXTREMELY DANGEROUS! specification.
45. Use the nitrogen charging needle (7052069-A) and

safely charge the reservoir to the recommended
pressure.
Nitrogen Pressure (Front and Rear):

200 psi (1379 kPa) +/- 5%
46. Stroke the shock through its travel and adjust the
external adjusters to ensure they are functioning
properly.
47. Use a rubber mallet to fully seat the bearing cap into
position.
5.58
WALKER EVANS™ SHOCK EXPLODED VIEWS (RZR XP 4)
Walker Evans™ 2.0" Front Shock
28 14 30
8 9
12 10 28
29 22
13 18
37
15 3
5
31 7
23 27 4 8
1 8
17
16
11
21
35
5
26
36 20
33
32
19
20
34 2 19
24

1. 1 Body Cap Asm. 20. 2 Spherical Bearing
2. 1 Seal Head Asm. 21. 1 Schraeder Valve
3. 1 Internal Bump Stop 22. 1 Snap Ring
4. 1 Shaft Bushing (0.625") 23. 2 Piston Wear Band (1.750" OD)
5. 1 O-Ring 24. 1 Bump Stop
6. 1 Seal 25. - N/A
7. 1 Wiper 26. 1 Shaft Loop
8. 3 O-Ring 27. 1 Shaft Spacer (1.235" x 1.985")
9. 1 Piston, Clicker 28. 2 O-Ring
10. 2 Clicker Bolt 29. 1 Screw (8/32")
11. 1 Clicker Knob 30. 1 O-Ring
12. 1 Clicker Stud 31. 1 O-Ring
13. 1 Screw (10/32") 32. 1 Detent Spring
14. 1 Piston Asm, Floating (IFP) 33. 1 Detent Ball
15. 1 Reservoir End Cap 34. 1 Shock Body
16. 1 Reservoir Body 35. 1 Spring Adjustment Nut
17. 1 Washer (1.50" x 0.125" x 0.348") 36. 1 Shaft, Chrome
18. 1 Crimp Nut (7/16") 37. 1 2-Piece Piston Asm.
19. 4 Snap Ring
5.59
Walker Evans™ 2.5" Rear Shock
13 9
21
8
4
3
43
22 6 7
11
19
2
18
5
25 26 42
24 23
10
39 36 21
3
17
38
15 41
30
39 32 37
29
16
28 40
32
35 42
12 1 31 14
33 41
20 27 34

1. 1 Piston Asm, Floating (IFP) 23. 1 Spacer
2. 1 Clicker Knob 24. 1 O-Ring
3. 2 Spherical Bearing 25. 1 O-Ring
4. 4 Snap Ring 26. 1 O-Ring
5. 1 Screw (10/32") 27. 1 Detent Spring
6. 1 Bump Stop 28. 1 Detent Ball
7. 1 Shaft Loop 29. 1 Schraeder Valve
8. 1 Body Cap Asm. 30. 1 Screw (8/32")
9. 1 Spring Adjustment Nut 31. 1 O-Ring
10. 1 Piston Asm. 32. 2 O-Ring
11. 1 Bridge 33. 1 O-Ring
12. 1 Reservoir Mount 34. 1 O-Ring
13. 1 Lock Nut 35. 1 O-Ring
14. 1 Reservoir End Cap 36. 1 Shaft Bushing (0.750")
15. 1 Check Valve 37. 1 Seal
16. 1 Clicker Bolt 38. 1 Wiper
17. 1 Ball (.250") 39. 2 Crimp Nut (7/16")
18. 1 Reservoir Body 40. 1 Snap Ring
19. 1 Retention Nut 41. 2 O-Ring
20. 1 Adjuster Knob 42. 2 Piston Wear Band (2.125" OD)
21. 1 Shaft, Chrome 43. 1 Seal Head Asm.
22. 1 Shock Body
5.60
WALKER EVANS™ SHOCK SERVICE (RZR XP 4)
General Service Information
Recommended Service Intervals
Walker Evans™ Racing Shocks will perform the best if serviced at regular intervals:
• Every ride - Wash and dry the vehicle and suspension

• Every 100 hours - Visually inspect shock seals
• Every 1500 miles or Annually - Change shock oil and replace seals
Front Shock Service Information

SHOCK VALVING
COMPRESSION REBOUND
3.375”
IFP Depth 0.900 x 0.008 0.800 x 0.015
0.900 x 0.010 1.450 x 0.012
0.900 x 0.010 1.300 x 0.012 5
1.450 x 0.010 1.200 x 0.012
1.000 x 0.008 1.100 x 0.012
1.300 x 0.008 1.000 x 0.012
1.200 x 0.008 0.900 x 0.012
1.000 x 0.008 0.800 x 0.012
0.900 x 0.008 1.000 x .095 Back-Up
0.800 x 0.012
0.750 x 0.060
SHOCK DESIGN DETAILS 1.500 x .125 Top-Out

Piston Bleed Orifice: 0.070
Travel 6.62”
5.61
Rear Shock Service Information
SHOCK VALVING
COMPRESSION REBOUND
1.550 x 0.008 1.450 x 0.008
1.500 x 0.008 1.200 x 0.010
1.450 x 0.008 1.450 x 0.010
1.300 x 0.008 1.300 x 0.010
1.200 x 0.008 1.200 x 0.010
1.100 x 0.008 1.100 x 0.010
1.000 x 0.008 1.000 x 0.010
0.900 x 0.008 0.900 x 0.012
3.375” 0.800 x 0.008 0.800 x 0.015
IFP Depth
1.500 x 0.015 1.000 x .100 Back-Up
1.450 x 0.015
SHOCK DESIGN DETAILS 1.300 x 0.015

1.200 x 0.015
Travel 7.64”
1.100 x 0.015
1.000 x 0.015
0.900 x 0.015
0.800 x 0.015
0.700 x 0.015
1.500 x .100 Top-Out
Piston Bleed Orifice: 0.073
5.62
Walker Evans™ Shock Rebuild Information Special Tools
When performing maintenance on Walker Evans™
shocks, use the Gas Shock Recharging Kit (PN 2200421), PART NUMBER DESCRIPTION
as it contains the necessary valves, pressure gauge, and 2200421 Gas Shock Recharging Kit
fittings to deflate and pressurize shocks.
PS-45908 IFP Tool
WARNING PU-50979 Shock Body Holding Tool - Front
PU-50938 Shock Body Holding Tool - Rear
Walker Evans™ shocks contain high pressure nitrogen
gas. Extreme caution must be used while handling and 2872429 Shock Rod Holding Tool - Front
working with Walker Evans™ shocks and related high
PS-50931 Shock Rod Holding Tool - Rear
pressure service equipment. The pressure must be
released from the shock before disassembly. It is PU-50939 Shock Seal Protector Sleeve - Front
strongly recommended you wear safety glasses and
PU-50952 Shock Seal Protector Sleeve - Rear
ear protection during these procedures.
Valve Shim Arrangement

Shown below is an example of how valving stacks are arranged.
NOTE: The rebound and compression valve stacks will always be positioned as shown in the illustration, 5
regardless of how the shock assembly is installed.
FULLY COMPRESSED SHOCK ROD FULLY EXTENDED
PISTON
SHOCK ROD
REBOUND VALVE STACK COMPRESSION VALVE STACK
Piston Orientation
The face of the piston with the greater number of relief ports will always face the rebound valve stack.
= Relief Port
Faces Rebound Stack Faces Compression Stack
5.63
Walker Evans™ Shock Disassembly 5. Carefully depressurize the shock.
IMPORTANT: To prevent damage or marks to the

recommended.
WARNING
Walker Evans™ shocks contain high pressure nitrogen

gas. Extreme caution must be used while handling and
working with Walker Evans™ shocks and related high
pressure service equipment. The pressure must be
released from the shock before disassembly. It is
strongly recommended you wear safety glasses and
ear protection during these procedures.
6. Using a snap ring pliers, remove the retaining ring
1. Clean and carefully remove shock from the vehicle.
from the reservoir.
2. Back preload adjuster all the way down and carefully
remove spring retainer and spring(s).
Spring
Retainer
Valve
Cap
Spring
Remove
Preload 7. Carefully remove the cap from the reservoir body.
3. Use the appropriate shock body holding tool to

properly secure the shock assembly into a vice for
service.
Front Shock Body Holding Tool: PU-50979

Rear Shock Body Holding Tool: PU-50938
4. Remove the valve cap from the valve fitting on the top
of the reservoir.
5.64
8. Using a 1" open-end wrench or adjustable wrench, NOTE: Insert the IFP Tool (PS-45908) and cycle the
loosen and remove the bearing cap from the shock Internal Floating Piston (IFP) a few times to purge
body. the shock oil from the reservoir.
11. Remove the floating piston from the shock reservoir

using the IFP Tool (PS-45908).
PS-45908
9. Slowly lift up and remove the shock rod assembly from
the shock body.
12. Clean and inspect ALL parts and replace as needed.

5
IMPORTANT: Seal kits are available and should be
installed at this time if seals or O-rings are damaged
or worn.
13. Use the appropriate shock rod holding tool and a vise
to mount the shock rod vertically with the threaded
end upward.
Front Shock Rod Holding Tool: 2872429

Rear Shock Rod Holding Tool: PU-50931
14. Using an 11/16" socket, remove the nut retaining the

10. Remove and properly dispose of the oil from the shock valve stack and piston.
body.
5.65
IMPORTANT: Keep the rebound and compression 19. Front Shocks Only: Using a 9/16" socket w/
valve stacks in the order they were removed. If unsure extension, remove the fastener retaining the clicker
of order, refer to “Shock Valving” under the “Shock valve stack. Place the valve stack on a clean shop
Service Information” provided earlier in this section. towel in order of removal.
Rebound side
of piston
Remove
Compression Clicker
valve stack valve stack
15. Place the valve stack on a clean shop towel in order IMPORTANT: Keep the valve stack in the order it was
of removal. removed. If unsure of order, refer to “Shock Valving”
under the “Shock Service Information” provided
16. Inspect the valves for kinks, waves, pits or foreign earlier in this section.
material.
20. Inspect the valves for kinks, waves, pits or foreign
17. Inspect the piston wear band and replace if damaged material
or worn.
21. Thoroughly clean all shock components and shock
18. Use the appropriate shock body holding tool to body prior to assembly.
service.

5.66
Walker Evans™ Shock Assembly 8. Place a new lock nut onto the shock rod. Torque the
new lock nut to specification.
1. Install new seals and O-rings on the seal head
assembly. IMPORTANT: Do not over torque the nut or damage to
the valve stack can occur.
2. Use the appropriate shock rod holding tool and a vise
to mount the shock rod vertically with the threaded
end upward. =T
Lock Nut:
Front Shock Rod Holding Tool: 2872429 14 ft-lbs (19 Nm)
Rear Shock Rod Holding Tool: PU-50931
NOTE: Make sure “Top-Out” washers are orientated
3. Install the appropriate Shock Seal Protector Sleeve as shown.
over the shaft threads.
Front Shock Seal Protector Sleeve:

PU-50939
Rear Shock Seal Protector Sleeve: PU-50952 Top-Out
Washers
4. Install seal head assembly onto the shock shaft. 5

5. Remove the Shock Seal Protector Sleeve.
6. Place the compression valve stack on the rod in the

reverse order of disassembly. NOTE: Actual valve stack may
differ from what is shown here.
7. Place valve piston on top of the compression stack.
Rebound side 9. Front Shocks Only: Assemble the clicker valve stack
of piston on top of the fastener and install the assembly into the
reservoir body. Tighten the valve stack fastener
securely.
Compression
valve stack
IMPORTANT: If unsure of the valve stack order, refer

to “Shock Valving” under the “Shock Service
Information” provided earlier in this section.
5.67
10. Turn the compression adjuster knob counter- 13. Using a 3/32" Allen wrench, remove IFP bleed screw.
clockwise (soft) until it stops, so damping is in the full
open position.
14. Apply a thin film of oil to IFP O-ring and wear band.
Insert IFP into reservoir until completely submerged.
11. Use the appropriate shock body holding tool to Allow air to escape as you install the piston.
service.

12. Fill the shock body and remote reservoir 1/2 full of the
recommended gas shock oil.
15. Screw IFP Tool (PS-45908) onto the floating piston.
Recommended Shock Oil: PS-45908

Racing Gas Shock Oil (PN 2874124) (Quart)
10 Weight for Walker Evans Shocks
16. Slowly cycle the IFP up and down.

• Be sure to bottom out piston in the reservoir body.
• Allow time for the bubbles to dissipate.
• Repeat the process until all air has been removed.
5.68
17. Pull IFP up until its top is approximately 1" (2.54 cm) NOTE: During installation, some shock oil will over
from top of reservoir and remove the IFP Tool. Using flow. Wrap a shop cloth around the shock body to
a 3/32" Allen wrench, install the IFP bleed screw. catch any oil overflow.
21. Pull the damping piston up until it is just below the
surface of the oil.
22. Hold the rod eyelet with one hand. With other hand,
slide the bearing cap down the shaft until contact with
the body is made. Oil will overflow from around the
bearing cap.
23. Screw the bearing cap assembly into the shock body
by hand, holding the rod up so that the bearing cap is
in contact with the bottom of the damping piston
assembly. Be careful not to cross-thread the bearing
assembly.
24. Using a 1" open-end wrench, tighten the bearing cap.
25. Using a 3/32" Allen wrench, remove the IFP bleed
IMPORTANT: When the IFP Tool is removed, the IFP
screw.
must remain submerged in shock oil to prevent air
from getting under the floating piston.
18. Fill the shock body with oil approximately 1/4" below
26. Set the IFP depth to the specified length from the top
of the reservoir.
5
the threads.
19. Apply a thin film of oil to the wear band on the damping
piston. Slowly insert the shock rod assembly into the
body until the damping piston assembly is
approximately 1" below the oil surface.
• Move rod up and down slowly over a range of
about 1" until no air bubbles rise from damping
piston. Be careful to keep damping piston at least
1/4" below the surface of the oil during this
process.
• While holding the shock rod, apply 2 - 3 sharp
blows to the rod eyelet with a rubber mallet driving
the piston down into the shock body. This opens
the valves on the damping piston. You will see the
released air bubbles come to the surface of the oil. 3.375”
IFP Depth
20. Add oil to the body tube until the surface of the oil is
at the top of the shock body threads.
= In. / mm.
IFP Depth - Front and Rear:

3.375” (85.7 mm)
27. Using a long 3/32” Allen wrench, install the IFP bleed
screw.
NOTE: Apply grease to the end of the Allen wrench
so the bleed screw sticks to it during installation.
5.69
28. Pour the residual shock oil out of the reservoir into a
proper disposal container. WARNING
29. Install the reservoir cap. Push down on the reservoir
cap using even pressure until the retaining ring groove CHARGE THE SHOCK USING NITROGEN
is exposed. GAS ONLY. DO NOT FILL WITH ANY OTHER
GASES. Doing so compromises the
30. Install the retaining ring and check to make sure performance of the shock and may be
retaining ring is seated properly. EXTREMELY DANGEROUS!
31. Push the shock rod assembly completely into the 35. Reinstall the valve cap.
shock body. It should go all the way down smoothly
without interference. If it does not, disassemble and 36. Clean all oil residue from the shock and reservoir with
reassemble per this procedure. solvent, and dry with low pressure compressed air in
a well ventilated area.
32. Secure the shock body in a vise by its lower mount.
37. Check shock for any leaks.
33. Pressurize the shock reservoir through the Schrader®
valve using the Gas Shock Recharging Kit (PN 38. Reinstall the compression spring and the spring
2200421). retainer.
39. Thread the spring preload adjuster down against the
spring and set the preload to the specified
measurement (see Chapter 2).
PN 2200421
40. Set the compression adjuster knob to the
recommended setting or the original setting upon
removal (see Chapter 2).
41. Remove the shock from the vise.
42. Reinstall spherical bearing O-rings and polyurethane
bushings.
NOTE: After installation, be sure to RIDE SLOWLY

initially to ensure the shock and the vehicle’s
suspension is performing correctly.
34. Continue filling until the shaft has fully extended and
the reservoir pressure is at 200 psi.
Nitrogen Pressure (Front and Rear):

200 psi (1379 kPa) +/- 5%
5.70
CLUTCHING (PVT)
CHAPTER 6
CLUTCHING (PVT)
SPECIAL TOOLS AND SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
HIGH ALTITUDE CLUTCH CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
2013 RANGER RZR XP 900 / EPS / INT’L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
2013 RANGER RZR XP 4 900 / EPS / INT’L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
PVT SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
GENERAL OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
DRIVE CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
DRIVEN CLUTCH OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
PVT BREAK-IN (DRIVE BELT / CLUTCHES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
MAINTENANCE / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
OVERHEATING / DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
PVT SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
PVT COVERS AND DUCTING COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
PVT DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
PVT ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9
BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
PVT BREAK-IN (DRIVE BELT / CLUTCHES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10
DRIVE CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
DRIVE CLUTCH EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
6
DRIVE CLUTCH DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12
DRIVE CLUTCH SPRING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
NEEDLE BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
SHIFT WEIGHT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13
BUTTON TO TOWER CLEARANCE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
SPIDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.14
ROLLER, PIN, AND THRUST WASHER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . 6.15
CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
MOVEABLE SHEAVE BUSHING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.16
BUSHING SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
DRIVE CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.19
DRIVEN CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21
CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.21
BUSHING SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.23
CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.25
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.28
6.1
CLUTCHING (PVT)
SPECIAL TOOLS AND SUPPLIES HIGH ALTITUDE CLUTCH CHARTS
PART NUMBER TOOL DESCRIPTION 2013 RANGER RZR XP 900 / EPS / INT’L
2872085 Drive Clutch Puller Shift Drive Driven
Altitude
Weight Spring Spring
9314177 Clutch Holding Wrench
0-1500 26-59 Blue / Yellow Red
2871358-A Clutch Holding Fixture Meters (0-5000) (1322981) (7043766) (3234452)
(Feet) 1500-3700 26-55 Blue / Yellow Red
PU- 50578 Spider Jam Nut Socket
(5000 - 12000) (1322982) (7043766) (3234452)
Drive Clutch Spider Removal and
2870341
Installation Tool
2013 RANGER RZR XP 4 900 / EPS / INT’L
2870910 Roller Pin Tool
Shift Drive Driven
Clutch Bushing Replacement Altitude
2871226 Weight Spring Spring
Tool Kit
0-1500 26-59 Purple Red
2870386 Piston Pin Puller Meters (0-5000) (1322981) (7043805) (3234452)
PU-50518 Driven Clutch Compression Tool (Feet) 1500-3700 26-55 Purple Red
(5000 - 12000) (1322982) (7043805) (3234452)
Clutch Bushing Replacement
2871025
Tool Kit
2877408
Shock Spanner / Clutch Spreader PVT SYSTEM OVERVIEW
(RZR XP)
Shock Spanner / Clutch Spreader
General Operation
2878925
(RZR XP 4)
WARNING
All PVT maintenance or repairs should be performed by
SPECIAL SUPPLIES PART NUMBER a certified Polaris Master Service Dealer (MSD)
Loctite® 609™ and 263™ N/A technician who has received the proper training and
understands the procedures outlined in this manual.
RTV Silicone Sealer 8560054 Because of the critical nature and precision balance
incorporated into the PVT components, it is
absolutely essential that no disassembly or repair
TORQUE SPECIFICATIONS be made without factory authorized special tools
and service procedures.
PVT System Fastener Torques The Polaris Variable Transmission (PVT) consists of three
major assemblies:
ITEM TORQUE VALUE
1) The Drive Clutch
Drive Clutch Retaining Bolt 96 ft-lbs (130 Nm) 2) The Driven Clutch
Driven Clutch Retaining Bolt 40 ft-lbs (54 Nm) 3) The Drive Belt
PVT Inner Cover Bolts 12 ft-lbs (16 Nm) The internal components of the drive clutch and driven
clutch control engagement (initial vehicle movement),
PVT Outer Cover Screws 45-50 in-lbs (5-5.6 Nm) clutch upshift and backshift. During the development of
Spider Jam Nut the Polaris vehicle, the PVT system is matched first to the
250 ft-lbs (339 Nm) engine power curve; then to average riding conditions and
(Apply 263 Loctite)
the vehicle’s intended usage. Therefore, modifications or
Drive Clutch Spider 280-300 ft-lbs variations of components at random are never
(Apply 263 Loctite) (379-406 Nm) recommended. Proper clutch setup and careful inspection
Drive Clutch Cover Plate 100 in-lbs (12 Nm) of existing components must be the primary objective
when troubleshooting and tuning.
6.2
CLUTCHING (PVT)
Drive Clutch Operation In situations where loads vary (such as uphill and downhill)
and throttle settings are constant, the drive and driven
Drive clutches primarily sense engine RPM. The two clutches are continually shifting to maintain optimum
major components which control its shifting function are engine RPM. At full throttle a perfectly matched PVT
the shift weights and the coil spring. Whenever engine system should hold engine RPM at the peak of the power
RPM is increased, centrifugal force is created, causing curve. This RPM should be maintained during clutch
the shift weights to push against rollers on the moveable upshift and backshift. In this respect, the PVT system is
similar to a power governor. Rather than vary throttle
sheave, which is held open by coil spring preload. When
position, as a conventional governor does, the PVT
this force becomes higher than the preload in the spring,
system changes engine load requirements by either
the outer sheave moves inward and contacts the drive upshifting or backshifting.
belt. This motion pinches the drive belt between the spin-
ning sheaves and causes it to rotate, which in turn PVT Break-In (Drive Belt / Clutches)
rotates the driven clutch.
A proper break-in of the clutches and drive belt will ensure
At lower RPM, the drive belt rotates low in the drive clutch a longer life and better performance. Break in the clutches
sheaves. As engine RPM increases, centrifugal force and drive belt by operating at slower speeds during the 10
causes the drive belt to be forced upward on drive clutch hours as recommended (see Chapter 3 “Engine Break-In
sheaves. Period” for break-in example). Avoid aggressive
acceleration and high speed operation during the break-in
Driven Clutch Operation period.
Driven clutches primarily sense torque, opening and Maintenance / Inspection

closing according to the forces applied to it from the drive
belt and the transmission input shaft. If the torque resis- Under normal use the PVT system will provide years of
trouble free operation. Periodic inspection and
tance at the transmission input shaft is greater than the
load from the drive belt, the drive belt is kept at the outer
maintenance is required to keep the system operating at 6
peak performance. The following list of items should be
diameter of the driven clutch sheaves. inspected and maintained to ensure maximum
As engine RPM and horsepower increase, the load from performance and service life of PVT components. Refer to
the drive belt increases, resulting in the belt rotating up the troubleshooting checklist at the end of this chapter for
toward the outer diameter of the drive clutch sheaves and more information.
downward into the sheaves of the driven clutch. This
1. Belt Inspection.
action, which increases the driven clutch speed, is called
upshifting. 2. Drive and Driven Clutch Buttons and Bushings,
Drive Clutch Shift Weights and Pins, Drive Clutch
Should the throttle setting remain the same and the
Spider Rollers and Roller Pins, Drive and Driven
vehicle is subjected to a heavier load, the drive belt rotates
Clutch Springs.
back up toward the outer diameter of the driven clutch and
downward into the sheaves of the drive clutch. This action, 3. Sheave Faces. Clean and inspect for wear.
which decreases the driven clutch speed, is called
backshifting. 4. PVT System Sealing. Refer to the appropriate
illustration(s) on the following pages. The PVT system
is air cooled by fins on the drive and driven clutch
stationary sheaves. The fins create a low pressure
area in the crankcase casting, drawing air into the
system through an intake duct. The opening for this
intake duct is located at a high point on the vehicle
(location varies by model). The intake duct draws
fresh air through a vented cover. All connecting air
ducts (as well as the inner and outer covers) must be
properly sealed to ensure clean air is being used for
cooling the PVT system and also to prevent water and
other contaminants from entering the PVT area. This
is especially critical on units subjected to frequent
water forging.
6.3
CLUTCHING (PVT)
Overheating / Diagnosis
During routine maintenance, or whenever PVT system overheating is evident, it’s important to check the inlet and outlet
ducting for obstructions. Obstructions to air flow through the ducts will significantly increase PVT system operating
temperatures. The vehicle should be operated in Low when extended low vehicle speed operation is anticipated.
CLUTCH DRIVE BELT & COVER RELATED ISSUES: DIAGNOSIS

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

Low gear should be used when riding through rough terrain or when basic operational ground speeds are less than 7
MPH. Use High gear when basic operational ground speeds are more than 7 MPH.
IMPORTANT: Using High gear for heavy loads, hilly terrain, or in wet, muddy conditions will increase the chance
of drive belt burning.
6.4
CLUTCHING (PVT)
PVT SYSTEM SERVICE
PVT Covers and Ducting Components
Clutch
Outlet Duct
Outlet Duct Screen Cover
Screws
45-50 in-lbs
(5 Nm)
Boot
Push
Rivets
Intake Box 17 ft-lbs
Bracket (23 Nm) Inner
Clutch Intake Clutch Cover
Box
Seal
Filter Outer
Intake Hose Clutch Cover
Guard Plates
Outer 6
Cover Seal
Bolt &
Washer
12 ft-lbs
Inlet Duct Inner Cover (16.6 Nm)
Cover Drain Seal
PVT Disassembly 1. Remove the seats and engine service panel (see
chapter 5).
CAUTION 2. Place transmission in neutral.
3. Raise and support the vehicle.

CAUTION

service procedure.
4. Remove the left rear wheel.
5. Remove the lower mounting bolt and nut from the left
rear shock. Discard the nut.
6. Swing shock outward toward the front of the vehicle.
6.5
CLUTCHING (PVT)
7. Remove the (8) clutch cover screws and remove the 11. Remove the drive clutch retaining bolt and remove the
outer clutch cover from the vehicle. drive clutch using Drive Clutch Puller 2872085.
Remove
2872085
Remove
Drive Clutch Puller 2872085

8. Mark the drive belt direction of rotation and remove
drive belt (see “DRIVE BELT - Belt Removal”).
IMPORTANT: Be sure to use the correct Drive Clutch
9. Remove the driven clutch retaining bolt and driven Puller (PN 2872085) to prevent damage to crankshaft.
clutch.
12. Remove the (4) push rivets that secure the upper
10. Install the Drive Clutch Holding Tool (9314177-A) on guard plate to the top of the inner PVT cover. Make
the drive clutch. note of the routing of the fuel lines, vent line, battery
cable and wire harness for proper assembly.
9314177-A
Drive Clutch Holding Tool 9314177-A
6.6
CLUTCHING (PVT)
13. Loosen the hose clamp attaching PVT inlet duct to the PVT Assembly
inner clutch cover. Disengage the hose from the inner
clutch cover. 1. Inspect inner clutch cover. Replace if cracked or
damaged.
2. Inspect the seal on the transmission input shaft.

Replace if damaged.
3. Inspect inner clutch cover seal (engine side). Replace

if cracked, torn or damaged.
14. Loosen hose clamps that attach clutch outlet duct to

inner clutch cover. Disengage hose from the cover.
Loosen Clamps
4. Install and properly align the inner clutch cover. Be

sure the fuel line, vent line and battery cables are
properly routed through the guard plate as shown.
6
Fuel Lines on Inside
Divider
Remove
15. Remove the (7) bolts that retain inner clutch cover to
engine and transmission. Remove inner clutch cover.
Hose / Battery Cables / Throttle Cable
6.7
CLUTCHING (PVT)
5. Install the protective cover and the (4) push rivets that 13. Install the Drive Clutch Holding Tool (9314177-A) and
secure the cover to the top of the inner PVT cover. torque the retaining bolt to specification.
9314177-A
6. Install the (4) inner clutch cover bolts and washers that
retain the cover to the transmission. Torque bolts to =T
9
specification.
Drive Clutch Retaining Bolt:
7. Install the (3) inner clutch cover bolts and washers that 96 ft-lbs (130 Nm)
retain the cover to the engine. Torque bolts to
specification. 14. Install the drive belt noting direction of belt rotation
(see “DRIVE BELT - Belt Installation”). If a new belt is
installed, install so numbers can be easily read.
=T
15. Install a new outer clutch cover seal with the colored
Inner Clutch Cover Bolts: stripe facing the inner clutch cover.
12 ft-lbs (16.6 Nm)
16. Reinstall outer clutch cover and secure with screws.
8. Clean the splines inside the driven clutch and on the Torque screws to specification.
transmission input shaft.
9. Apply a light film of grease to the splines on the shaft. =T

10. Install the driven clutch, washer and retaining bolt. Outer Clutch Cover Retaining Screws:
Torque to specification. 45-50 in-lbs (5.5 Nm)
17. Install inlet and outlet ducts and tighten hose clamps.
=T
18. Install the left rear shock lower mounting bolt and the
Driven Clutch Retaining Bolt: left rear wheel. Torque fasteners to specification.
40 ft-lbs (54 Nm)
11. Clean the end of the taper on the crankshaft and the =T
tapered bore inside the drive clutch.
Rear Shock Mounting Bolt:
12. Install the drive clutch onto the engine. Lower: 70 ft-lbs (95 Nm)
=T
Wheel Nuts:
30 ft-lbs (41 Nm) + 90° (1/4 turn)
19. Install engine service panel and both seats.

6.8
CLUTCHING (PVT)
DRIVE BELT 4. Insert clutch spreader tool (2877408 or 2878925) into
the driven clutch as shown (tool included with
Belt Removal vehicle’s tool kit).
IMPORTANT: Inspect the entire clutch outlet duct

(including the outlet duct screen) when replacing a
drive belt. Remove any debris found in the outlet duct
or outlet duct screen.
Clutch Tool
Inspect / Remove Debris

NOTE: Make sure the tool is square with the
moveable sheave surface of the driven clutch.
5. Rotate tool towards the clutch to open the sheaves.
1. Remove the (8) screws that retain the outer clutch

cover.
2. Maneuver the outer clutch cover outward as shown 6

below to access the drive belt.
6. Walk the belt out of the driven clutch and drive clutch.
Remove the belt from the vehicle.
Belt Inspection
1. Inspect belt for hour glassing (extreme circular wear
NOTE: Removal of left rear wheel or left rear shock in at least one spot and on both sides of the belt).
is NOT necessary for belt replacement. Hour glassing occurs when the drive train does not
move and the drive clutch engages the belt.
3. Mark the drive belt direction of rotation so that it can
be installed in the same direction. 2. Inspect belt for loose cords, missing cogs, cracks,
abrasions, thin spots, or excessive wear. Compare
belt measurements with a new drive belt. Replace if
necessary.
3. Belts with thin spots, burn marks, etc., should be

replaced to eliminate noise, vibration, or erratic PVT
operation. See the Troubleshooting Chart at the end
of this chapter for possible causes.
6.9
CLUTCHING (PVT)
Belt Installation
NOTE: Be sure to install belt in the same direction
as it was removed.
1. With the clutch spreader tool installed (2877408 or

2878925), loop the belt over the drive clutch and over
the driven clutch.
2. Rotate the driven clutch and walk the belt into the
clutch.
3. Remove the clutch spreader tool from driven clutch
4. Rotate / spin the driven clutch and belt approximately

5-7 times to properly seat the belt in the driven clutch.
5. Install the outer clutch cover and (8) screws. Torque

screws to specification.
=T
Outer Clutch Cover Retaining Screws:
45-50 in-lbs (5.5 Nm)
PVT Break-In (Drive Belt / Clutches)

A proper break-in of the clutches and drive belt will ensure
a longer life and better performance. Break in the clutches
and drive belt by operating at slower speeds during the 10
hour break-in period as recommended (see Chapter 3
“Engine Break-In Period” for break-in example). Pull only
light loads. Avoid aggressive acceleration and high speed
operation during the break-in period.
6.10
CLUTCHING (PVT)
DRIVE CLUTCH SERVICE
Drive Clutch Exploded View
Clutch
Washer
Bolt
96 ft-lbs
Spider (130 Nm)
Apply 263 Loctite Washer
280-300 ft-lbs
(379-406 Nm) Spring
Limiter
Spacer Bushing
Washers
Roller
Bushing
Shift Washers
Weight
Cover
6
Spacer Screws
100 in-lbs
Non-braking (12 Nm)
Needle Retaining
Bearing Ring
Pin
Cover
Button
Nut
20 in-lbs Jam Nut
Bolt (2.3 Nm) Apply 263 Loctite
250 ft-lbs
(339 Nm)
Moveable Sheave
Washers
Stationary
Sheave
6.11
CLUTCHING (PVT)
Drive Clutch Disassembly / Inspection 4. Inspect cover bushing (A). The outer cover bushing is
manufactured with a Teflon™ coating. Wear is
determined by the amount of Teflon™ remaining on
WARNING the bushing.
The clutch assembly is a precisely balanced

A
unit. Never replace parts with used parts from
another clutch assembly!
1. Using a permanent marker, mark the cover, spider,

moveable and stationary sheaves for reference, as
the cast in X's may not have been in alignment before
disassembly.
Cover Bushing Inspection:

Replace the cover bushing if more
brass than Teflon™ is visible on
the bushing. Refer to bushing
replacement in this chapter.
5. Inspect area on shaft where bushing rides for wear,

galling, nicks, or scratches. Replace clutch assembly
if worn or damaged.
2. Mark the stationary sheave and clutch shaft to verify
the shaft has not rotated in the sheave after tightening 6. Remove and inspect the clutch spring (B). Refer to
the spider during clutch assembly. “Drive Clutch Spring Inspection”.
7. Remove and inspect limiter spacer (C). Replace if

IMPORTANT: Upon reassembly, if the reference necessary.
marks created in step 2 are not in alignment, the
clutch will not be in balance and the assembly MUST
be replaced. CAUTION
3. Remove cover bolts evenly in a cross pattern and
DO NOT reassemble the drive clutch without the
remove cover plate.
limiter spacer. Belt life will be greatly reduced.
6.12
CLUTCHING (PVT)
Drive Clutch Spring Inspection Needle Bearing Inspection
1. Rotate the clutch bearing in both clockwise and
CAUTION counter-clockwise directions. The non-braking
needle bearing should rotate in both directions on the
Never shim a drive clutch spring to increase its shaft with only a slight amount of drag.
compression rate. This may result in complete 2. Verify there is no binding or rough spots. If problems
stacking of the coils and subsequent clutch are noted continue with disassembly.
cover failure.
The drive clutch spring is one of the most critical

components of the PVT system. It is also one of the
easiest to service. Due to the severe relaxation the spring
is subject to during operation, it should always be
inspected for tolerance limits during any clutch operation
diagnosis or repair.
With the spring resting on a flat surface, measure its free

length from the outer coil surfaces. Also check to see that
spring coils are parallel to one another. Distortion of the
spring indicates stress fatigue, requiring replacement.
Shift Weight Inspection

1. Remove shift weight bolts and weights. Inspect the
contact surface of each weight. The surface should
6
be smooth and free of dents or gall marks. Inspect the
weight pivot bore and bolts for wear or galling. If
weights or bolts are worn or broken, replace in sets of
three with new bolts and nuts.
WARNING
The clutch assembly is a precisely balanced

unit. Never replace parts with used parts from
RZR XP: another clutch assembly!
Drive Clutch Spring Specifications
NOTE: A damaged shift weight is usually caused by
Part Number 7043766 a damaged or stuck roller in the spider assembly.
Color Blue / Yellow See “Drive Clutch Roller Pin and Button Service”.
Free Length 2.651” (67.342 mm) Check Shift Weight For Wear
RZR XP 4:
Drive Clutch Spring Specifications
Part Number 7043805

Color Purple
Free Length 2.865” (72.771 mm)
Check Bolt For Wear
6.13
CLUTCHING (PVT)
Button To Tower Clearance Inspection Spider Removal
1. Inspect the button to tower clearance as shown. 1. Install clutch onto holding fixture (2871358-A) and
Replace the drive clutch if clearance is beyond secure in bench vice. Loosen and remove the spider
specification. jam nut (counterclockwise) using the Clutch Spider
Nut Socket (PU-50578).
PU-50578
Jam Nut
2871358-A
Button to Tower Clearance:

.000-.012 (.000-.304 mm) Clutch Spider Nut Socket: PU-50578
Clutch Holding Fixture: PN 2871358-A
2. Inspect the tower sheave surfaces. Replace the drive

clutch if worn, damaged or cracked. 2. Loosen and remove the spider (counterclockwise)
using Clutch Spider Removal / Installation Tool (PN
2870341).
2870341
2871358-A
Spider Removal / Installation Tool:

PN 2870341
Clutch Holding Fixture: PN 2871358-A
6.14
CLUTCHING (PVT)
Roller, Pin, and Thrust Washer Inspection Clutch Inspection
1. Inspect all rollers, roller bushings and roller pins by NOTE: Remove cover, spring, limiter spacer and
pulling a flat metal rod across the roller. spider following the instructions for drive clutch
disassembly, then proceed as follows:
2. Turn roller with your finger. If you notice resistance,
galling, or flat spots, replace the drive clutch. 1. Remove and inspect the moveable sheave spacer.
Visually inspect the spacer for damage and replace if
necessary.
Spacer
NOTE: Rollers, pins, thrust washers and buttons are

not serviceable at the time of this publication.
44.399 +/- .025 mm
32.004 +/- .076 mm 6
27.94 +/- .152 mm
2. Remove the moveable clutch sheave.
3. Lift bearing and thrust washers off the shaft. Replace

as an assembly if worn, damaged, or if operational
problems were noted prior to disassembly.
Non-bearing
Needle Bearing 3
4
Thrust Washers
6.15
CLUTCHING (PVT)
4. Inspect surface of shaft for pitting, grooves or Moveable Sheave Bushing Inspection
damage. Measure the outside diameter and compare
to specifications. Replace the drive clutch assembly Inspect the Teflon™ coating (arrow) on the moveable
if shaft is worn or damaged. sheave bushing. Inspect both sheaves for signs of wear,
grooving or cracking. De-glaze sheave surfaces with a
3M™ Scotch-Brite Pad if needed.
= In. / mm. Moveable Sheave Bushing Inspection:

Replace the cover bushing if more brass
than Teflon™ is visible on the bushing.
Shaft Diameter: Refer to bushing replacement
Standard: 1.3725” - 1.3712” in this chapter.
(34.8615 - 34.8488 mm)
Service Limit: 1.3704” (34.8088 mm)
5. Visually inspect the thrust washers for damage.

Measure the thickness and compare to specification.
Replace if worn or damaged.
= In. / mm.
Thrust Washer Thickness:

Standard: .030” (.76 mm)
Service Limit: .025” (.64 mm)
6.16
CLUTCHING (PVT)
Bushing Service
IMPORTANT: Special Tools Required CAUTION
EBS Clutch Bushing Tool Kit - 2201379 Clutch components will be hot! In order to avoid
serious burns, wear insulated gloves during the
Item Qty. Part # Tool Description removal process.
A, B 1 5132027 EBS Puller Tool
C 1 5132501 EBS Puller Nut Moveable Sheave - Bushing Removal
D 1 5132029 EBS Main Adapter 1. Remove clutch as outlined previously in this chapter.
E 1 5132028 EBS Bushing Removal
2. Install handle end of the Piston Pin Puller (PN
-- 1 9915111 Instructions 2870386) securely into bench vise and lightly grease
puller threads.
Additional Special Tools
Qty. Part # Tool Description Piston Pin Puller: PN 2870386
1 2871226 Clutch Bushing Replacement Tool
1 2870386 Piston Pin Puller 3. Remove nut from puller rod and set aside.
*Clutch Bushing Replacement Tool Kit (PN 2871226)

Piston Pin Puller
#2 (PN 2870386)
#3
#5
6
Main Puller Adapter (#8)
(PN 5020632)
#9
#10 4. Install puller adapter (Item 10 from kit PN 2871226).
#8
5. Install main adapter (Item D) onto puller.
Item Qty. Part # Tool Description Puller Tool (A,B) Nut (C)
P-90 Drive/Driven Clutch Side “A” toward
#2 1 5020628
Bushing Install Tool sheave
Drive Clutch Cover
Bushing Removal /
#3 1 5020629
Installation Tool
(all clutches)
P-90 Driven Clutch Cover
#5 1 5020631
Bushing Removal Tool
#8 1 5020632 Main Puller Adapter Puller
Adapter (10)
#9 1 5010279 Adapter Reducer
Number Two Puller Main Piston Pin
#10 1 5020633 Adapter (D) Puller
Adapter
NOTE: Bushings are installed at the factory using 6. With towers pointing toward the vise, slide sheave
Loctite™ 609. In order to remove bushings it will be onto puller rod.
necessary to apply heat evenly to the area around
each bushing. Clean all residual Loctite™ from 7. Install removal tool (Item A, B) into center of sheave
bushing bore prior to installing new bushing. with “A side” toward sheave.
6.17
CLUTCHING (PVT)
NOTE: Use Bushing Tool PA-47336. Cover Bushing Removal
8. Install nut (C) onto end of puller rod and hand tighten. 1. Install main adapter (Item 8) on puller.
Turn puller barrel to increase tension on sheave if Removal Tool Nut (C)
needed. Using a hand held propane torch, apply heat (3)
around outside of bushing until tiny smoke tailings
appear.
9. Turn sheave counterclockwise on puller rod until it

comes free. Lift sheave off puller.
10. Remove nut from puller rod and set aside.
11. Pull bushing removal tool and adapter from puller rod.
Remove bushing from tool and discard. Adapter Reducer
(9)
Moveable Sheave - Bushing Installation Main Piston Pin
Adapter (8) Puller
1. Place main adapter (Item 8) on puller.
Puller Tool (A,B) Nut (C) 2. Install adapter reducer (Item 9).
Side “A” toward
sheave 3. From outside of clutch cover, insert removal tool (Item
3) into cover bushing.
4. With inside of cover toward vise, slide cover onto

puller.
5. Install nut onto puller rod and hand tighten. Turn puller
barrel to increase tension as needed.
Bushing
Piston Pin 6. Turn clutch cover counterclockwise on puller rod until
Puller bushing is removed and cover comes free.
Main Adapter
(8) 7. Remove nut from puller rod and set aside.
2. Apply Loctite 609 evenly to bushing bore inside 8. Remove bushing and bushing removal tool from
moveable sheave. puller. Discard bushing.
3. Set bushing in place on sheave. Cover Bushing Installation

1. Apply Loctite™ 609 evenly to bushing bore in cover.
4. Insert installation puller tool (Item A/B) with “A” side
down, into center of bushing.
2. Working from inside of cover, insert new bushing and
bushing installation tool into center of clutch cover.
5. With towers pointing upward, slide sheave, bushing
and tool onto puller rod.
3. With main adapter on puller, insert cover onto puller
rod, placing outside of cover toward vise.
6. Install nut on puller rod and hand tighten. Turn barrel
to apply additional tension if needed.
4. Install nut on rod and hand tighten. Turn puller barrel
to apply more tension if needed.
7. Turn sheave counterclockwise, making sure bushing
is drawn straight into bore. Continue until bushing is
5. Turn clutch cover counterclockwise on puller rod until
seated.
bushing is seated.
8. Remove nut from puller rod and set aside.
6. Remove nut from puller rod. Take installation tool and
clutch cover off rod.
9. Remove sheave from puller.
10. Remove installation tool.
6.18
CLUTCHING (PVT)
Drive Clutch Assembly 3. Install moveable sheave onto stationary sheave shaft.
Be sure the moveable sheave slides freely on the
spacer.
CAUTION
4. Apply Loctite® 263™ to the spider threads.
Do not apply oil or grease to the bushings.
5. Install the spider assembly onto the shaft threads. Be
Reassemble the drive clutch in the following sequence. Be sure all of the alignment marks are in alignment.
sure marks that were made during disassembly are
Moveable Sheave Jam Nut
aligned during each phase of assembly.
Assembly
Spider
Align All Marks
6. Install clutch onto holding fixture (PN 2871358-A) and

secure in a bench vice. Tighten the spider using
1. Install the shift weights, bolts and nuts onto the
Clutch Spider Tool (PN 2870341). Torque spider to
specification.
6
moveable sheave. Torque shift weight bolts to
specification.
=T
Shift Weight Bolts:
2870341
15-20 in-lbs (11-18 Nm)
2. Install the non-braking needle bearing, the (2)

washers and the spacer onto the stationary sheave.
Washers
2871358-A
Spacer =T
Spider Assembly:
Non-breaking 280 - 300 ft-lbs (379 - 406 Nm)
Needle Bearing Apply Loctite® 263™ to threads
7. Apply Loctite® 263™ to the threads of the spider jam

Stationary Sheave nut. Install spider jam nut onto stationary shaft
threads.
6.19
CLUTCHING (PVT)
8. Tighten the spider jam nut using Clutch Spider Nut 10. Install the limiter spacer (A) and the clutch spring (B).
Socket (PU-50578). Torque jam nut to specification.
PU-50578
B
Jam Nut
2871358-A
CAUTION
=T
DO NOT reassemble the drive clutch without the
Spider Jam Nut: limiter spacer. Belt life will be greatly reduced.
250 ft-lbs (339 Nm)
Apply Loctite® 263™ to threads 11. Install the drive clutch cover (C). Be sure all alignment
marts are in alignment.
9. After the spider and jam nut have been torqued,
remove the clutch assembly from the holding fixture
and inspect the alignment marks made during
disassembly.
IMPORTANT: If the marks illustrated below are not in

alignment upon assembly, the clutch will not be in
balance and the drive clutch assembly must be
replaced. C
12. Install cover bolts and torque in a cross pattern evenly

to specification.
=T
Drive Clutch Cover Bolts:
100 in-lbs (12 Nm)
6.20
CLUTCHING (PVT)
DRIVEN CLUTCH SERVICE 4. Place the driven clutch into the Universal Clutch
Compressor PU-50518.
Clutch Disassembly
PU-50518
1. Remove driven clutch from the transmission input
shaft. Do not attempt disassembly of the driven clutch
from the outside snap ring. The driven clutch must be
disassembled from the helix side.
5. Press down on the top of the spider assembly,

pushing the spider onto the shaft. Remove snap ring
(A) and slowly release the assembly.
Do not disassemble from this side
A
2. It is important to mark the position of the shaft, cam
cover and sheave before disassembly or use the X’s Press down
on the components for reference. This will aid in on spider
assembly and maintains clutch balance. 6
3. Remove the four screws that secure the cam (helix)

assembly using a T25 Torx driver.
6.21
CLUTCHING (PVT)
6. Remove the spider assembly and spring (B). 10. Press out the spring pins (I) in the inner sheave.
NOTE: Spring is compression only and has no

I
torsional wind.
B
11. Pull out the clutch roller pins (J) and rollers (K).
7. Remove the inside spider plate (D) and spider K J

dampener (E). Inspect the spider dampener (E) for
wear and replace if needed.
12. Press the shaft and bearing out of the outer sheave
using an arbor press.
8. Remove the E-clips (F), washers (G), and the clutch

rollers (H). Inspect the rollers for wear; replace if worn.
F G H
9. Remove the clutch assembly from the holding tool.
6.22
CLUTCHING (PVT)
13. Inspect the bearing for wear. Spin the bearing, if the Bushing Service
bearing does not spin smoothly, replace it. To replace
the bearing, remove the snap ring from the end of the IMPORTANT: Special Tools Required
shaft and press the bearing off the shaft.
EBS Clutch Bushing Tool Kit - 2201379
Item Qty. Part # Tool Description
A, B 1 5132027 EBS Puller Tool
C 1 5132501 EBS Puller Nut
D 1 5132029 EBS Main Adapter
E 1 5132028 EBS Bushing Removal
-- 1 9915111 Instructions
Additional Special Tools

Qty. Part # Tool Description
1 2871226 Clutch Bushing Replacement Tool
1 2870386 Piston Pin Puller
*Clutch Bushing Replacement Tool Kit (PN 2871226)
#2 #3
#5
14. Inspect the cam (helix) assembly bushing for wear. If
the bushing is worn or the shaft does not fit snug into
the bushing, replace the cam (helix) assembly.
6
Inspect Bushing
#9
#10
#8
Item Qty. Part # Tool Description

P-90 Drive/Driven Clutch
#2 1 5020628
Bushing Install Tool
Drive Clutch Cover
Bushing Removal/
#3 1 5020629
Installation Tool
15. Inspect the sheaves for excessive wear or damage.
(all clutches)
P-90 Driven Clutch Cover
#5 1 5020631
Bushing Removal Tool
#8 1 5020632 Main Puller Adapter
#9 1 5010279 Adapter Reducer
Number Two Puller
#10 1 5020633
Adapter
NOTE: Bushings are installed at the factory using

Loctite™ 609. In order to remove bushings it will be
necessary to apply heat evenly to the area around
each bushing. Clean all residual Loctite™ from
Inspect Sheave Surface
bushing bore prior to installing new bushing.
6.23
CLUTCHING (PVT)
Clutch Bushing Removal Clutch Bushing Installation
1. Install main puller adapter (Item 8) onto puller. 1. Install puller adapter (Item 10) onto puller.
2. Install adapter reducer (Item 9). 2. Install adapter (Item 9) onto puller.
3. Using a hand held propane torch, apply heat around

outside of bushing until tiny smoke tailings appear.
4. Flip sheave over so bushing faces downward and

install onto puller.
5. Install bushing tool (Item 2).
3. Apply Loctite™ 609 evenly to bushing bore inside

moveable sheave.
4. Install sheave face down on puller.
5. Install new bushing on installation tool (Item 2) and

install assembly into sheave.
6. Install left hand nut (C) and spacer onto puller rod and 6. Install left hand thread nut (C) onto puller rod and hand
tighten by hand. Turn puller barrel for further tension tighten against installation tool.
if needed.
7. Turn clutch sheave counterclockwise, making sure
7. Turn clutch sheave counterclockwise until bushing is bushing is drawn straight into bore. Continue until
removed and sheave comes free. bushing is seated.
8. Remove nut (C) (left hand thread) from puller rod and 8. Remove nut (C) from puller rod and set aside.
set aside.
9. Remove installation tool and clutch sheave from
9. Remove adapters from puller. puller.
10. Remove bushing and removal tool from adapters.

Discard bushing.
6.24
CLUTCHING (PVT)
Clutch Assembly 3. Line up the “X” on the moveable sheave with the “X”
on the stationary sheave or use the marks previously
1. Install a new bearing onto the clutch shaft using an used. Put the sheaves together.
arbor press. Once bearing is fully seated, install a
new snap ring.
Align X’s
2. Install the shaft and bearing assembly into the outer

sheave.
4. Install the roller (A) onto the roller pin (B) on both
sides.
NOTE: Press only on the outer race of the bearing
during installation to prevent damaging the bearing.
6.25
CLUTCHING (PVT)
5. Install the roller pin into the sheave assembly on both 9. Install the spider dampener (G) inside the outer spider
sides. The flat side of the roller pin faces downward and install the inside spider plate (H).
when the shaft side is laying flat on the bench.
Outer Spider D E F
H
Flat Side Down
10. Install the spider assembly onto the shaft with the
6. Install the spring pins (C) to secure the roller pins. retaining ring on top of the spider. NOTE: Use the
Install until flush with sheave surface. marks previously made to align the skip tooth spider,
or use the “X” on top of the spider and align it with the
C skip tooth on the shaft.
7. Install the spring over the shaft. Align Marks
11. Place the driven clutch into the Universal Clutch

Compressor PU-50518.
PU-50518
8. Install the clutch rollers (D) onto each side of the

outside spider. Install the washers (E) and E-clips (F)
to secure the rollers. The rollers should spin freely.
6.26
CLUTCHING (PVT)
12. Press down on the top of the spider assembly, 14. Install the cam (helix) assembly over the shaft. Line
pushing the spider onto the shaft. up the “X” on the cam, “X” on spider, and “X” on the
stationary sheave or use the marks previously made
before disassembly. NOTE: If the cam assembly
(helix) is difficult to install, be sure the sheaves are
aligned. To align the sheaves place the clutch
Press down assembly on a flat surface with the cam assembly
on spider (helix) side down. Press down on the moveable
sheave belt face with both hands and the helix will
release.
Press Down to Loosen Helix
15. Use a T25 Torx driver to install the four helix retaining
screws and torque to specification.
13. Slowly compress the spider into place. If the spider
appears to bind while compressing, stop and make
6
sure the skip-tooth on the shaft and the spider are
aligned. Once the spider passes the retaining ring
notch on the shaft, install the retaining ring.
=T
Helix Retaining Screws:
42-52 in-lbs (4.75 - 5.88 Nm)
6.27
CLUTCHING (PVT)
Exploded View
T25
Screws
42-52 in-lbs
(4.75 - 5.88 Nm)
E-Clips
Thrust Spider
Washer Dampener
Roller
Compression
Spring
Cam
(Helix)
Retaining
Ring
Moveable
Sheave
Outer Roller
Spider
Pin
Spider
Insert
Clutch
Shaft
Slotted
Spring Pin
Retaining
Ring
Stationary
Sheave Ball
Bearing
6.28
CLUTCHING (PVT)
TROUBLESHOOTING
Situation Probable Cause Remedy
-Wrong or broken drive clutch spring. -Replace with recommended spring.
Engine RPM below  
specified operating -Drive clutch shift weight too heavy. -Install correct shift weight kit to match engine
range, although  application.
engine is properly  
tuned. -Driven clutch spring broken or installed in -Replace spring; refer to proper installation
wrong helix location. location.
-Drive clutch binding. A. Disassemble drive clutch; inspect shift weights
 for wear and free operation.
 B. Clean and polish stationary shaft hub;
 reassemble clutch without spring to determine
 problem area.
Erratic engine
 
operating RPM
-Belt worn unevenly - thin / burnt spots. Replace belt.
during acceleration
 
or load variations.
-Driven clutch malfunction. A. Replace ramp buttons.
 B. Inspect movable sheave for excessive bushing
 clearance.
 
-Sheave face grooved. -Replace the clutch.
-Incorrect drive clutch spring (too high of rate). -Install correct recommended spring.

-Drive clutch shift weights incorrect for

-Install correct recommended shift weights.
6
application (too light). 
 
-Drive clutch binding. -Disassemble and clean clutch, inspecting shift
 weights and rollers. Reassemble without the spring
Engine RPM above
 and move sheaves through entire range to further
specified operating
 determine probable cause.
range.
 
-Driven clutch binding. -Disassemble, clean, and inspect driven clutch,
 noting worn sheave bushing and ramp buttons and
 helix spring location.
 
-Converter sheaves greasy; belt slipage. -Clean sheaves with denatured alcohol or brake
cleaner, install new belt.
-Drive belt worn too narrow. -Replace belt.
Harsh drive clutch  
engagement. -Excessive belt / sheave clearance with new -Perform belt / sheave clearance adjustment with
belt. shim washers beneath spider.
Drive belt turns -Wrong belt for application. -Replace with correct belt.
over
-Abuse (continued throttle application when -Caution operator to operate machine within
vehicle is stationary, excess load) guidelines.
 
Belt burnt, thin
-Dragging brake -Inspect brake system.
spots

-Slow, easy clutch engagement -Fast, effective use of throttle for efficient
engagement.
6.29
CLUTCHING (PVT)
Troubleshooting, Continued.....
Situation Probable Cause Remedy
-Plugged air intake or outlet. -Clear obstruction
 
-Belt slippage due to water, oil, grease, etc., -Inspect system. Clean , repair or replace as
rubbing on cover. necessary. 
Seal PVT system ducts.
PVT cover

overheating
-Clutches or weight being applied to cover -Remove weight. Inform operator.
(melting)
while in operation. 
 
-High vs. low range. -Instruct operator on guidelines for operation in
proper driving range for different terrain as outlined
in Owner’s Safety and Maintenance Manual.
-Cover seals or ducts leaking -Find leak and repair as necessary.
 
Water ingestion -Operator error -Instruct operator on guidelines for operation in wet
terrain as outlined in Owner’s Safety and
Maintenance Manual.
-Belt worn out -Replace belt.
 
Belt slippage -Water ingestion -Inspect and seal PVT system.
 
-Belt contaminated with oil or grease -Inspect and clean.
-Belt worn or separated, thin spots, loose belt -Replace belt.

PVT noise
-Broken or worn clutch components, cover -Inspect and repair as necessary.
hitting clutches
-Thin spots on belt, worn belt -Replace belt. Refer to belt burnt troubleshooting
Engagement and instruct operator.
erratic or stabby
-Drive clutch bushings stick -Inspect and repair clutches.
6.30
FINAL DRIVE
CHAPTER 7
FINAL DRIVE
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
FRONT BEARING CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
BEARING CARRIER INSPECTION / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
BEARING CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
DRIVE SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
DRIVE SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
PROPSHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
FRONT PROPSHAFT REMOVAL (RZR XP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
FRONT PROPSHAFT REMOVAL (RZR XP 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
FRONT PROPSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
REAR PROPSHAFT REMOVAL (RZR XP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
REAR PROPSHAFT REMOVAL (RZR XP 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
REAR PROPSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.14
SUPPORT BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
PROPSHAFT U-JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
FRONT GEARCASE / CENTRALIZED HILLIARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
CENTRALIZED HILLIARD EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18
ALL WHEEL DRIVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.19
AWD DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
FRONT GEARCASE REMOVAL / DISASSEMBLY / INSPECTION. . . . . . . . . . . . . . . . 7.21
FRONT GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24
FRONT GEARCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.26
REAR BEARING CARRIER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27
BEARING CARRIER INSPECTION / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.27
BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.29
7
BEARING CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.30
REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.31
DRIVE SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.31
DRIVE SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32
DRIVE SHAFT CV JOINT / BOOT REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.34
DRIVE SHAFT / CV JOINT HANDLING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.34
OUTER CV JOINT / BOOT REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.34
INNER PLUNGING JOINT / BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 7.36
DRIVE SHAFT EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.38
WHEEL HUBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.39
FRONT / REAR HUB EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.39
7.1
FINAL DRIVE
SPECIAL TOOLS FRONT BEARING CARRIER
Bearing Carrier Inspection / Removal
PART NUMBER TOOL DESCRIPTION
1. Elevate front of vehicle and safely support machine
2872608 Roll Pin Removal Tool
under the frame area.
CV Boot Clamp Pliers
8700226
(earless type)
CAUTION
PU-48951 Axle Boot Clamp Tool
SPX Corp: 1-800-328-6657 or http://polaris.spx.com/ Serious injury may result if machine tips or falls.
service procedure. Wear eye protection when
removing bearings and seals.
TORQUE SPECIFICATIONS
Wheel and Hub Torque Table 2. Check bearings for side play by grasping the top and
bottom of the tire firmly and checking for movement.
The tire should rotate smoothly without binding or
ITEM SPECIFICATION rough spots.
30 ft-lbs (41 Nm)
Wheel Nuts
+ 90° (1/4 turn)
Front Hub Castle Nut 80 ft-lbs (108 Nm)
Rear Hub Castle Nut 80 ft-lbs (108 Nm)
Ball Joint Pinch Bolts 44 ft-lbs (60 Nm)
Front Brake Caliper
40 ft-lbs (54 Nm)
Mounting Bolts
Tie Rod End Fastener 42.5 ft-lbs (58 Nm)
Propshaft Support
30-35 ft-lbs (41-47 Nm) Raise and
Bearing Fasteners
Support Vehicle
Front Gearcase
7-11 ft-lbs (10-15 Nm)
Cover Plate Screws
3. Remove the (4) wheel nuts and remove the front
Front Gearcase wheel.
30 ft-lbs (41 Nm)
Mounting Bolts
Bearing Carrier to 4. Remove the cotter pin and loosen the front wheel hub
40 ft-lbs (54 Nm) castle nut. Remove the nut, and (2) cone washers
Trailing Arm Bolts
from the front wheel hub assembly.
Radius Rod to
45 ft-lbs (61 Nm)
Bearing Carrier Bolts
Rear Brake Caliper
40 ft-lbs. (54 Nm)
Mounting Bolts
Cone
Washers Castle Nut
Cotter Pin
7.2
FINAL DRIVE
5. Remove the fastener retaining the steering tie rod end Bearing Replacement
to the front bearing carrier.
Bearing Removal
6. Remove and discard the two front brake caliper
mounting bolts and remove the caliper from the brake 1. Remove the outer snap ring.
disc (see Chapter 9).
CAUTION: Do not hang the caliper by the brake line. Snap Ring
Use wire to hang caliper to prevent damage to the
brake line.
7. Remove the front wheel hub assembly.
8. Remove and discard the upper and lower ball joint

pinch bolts.
2. From the back side of the bearing carrier, tap on the

Pinch outer bearing race with a drift punch in the reliefs as
Bolts
shown.
9. Using a soft faced hammer, lightly tap on the bearing

carrier while removing the upper and lower ball joint
ends.
7
10. Remove the bearing carrier from the front drive shaft.
11. Rotate bearing by hand and check for smooth

rotation. Visually inspect bearing for moisture, dirt, or
corrosion.
NOTE: Due to extremely close tolerances and 3. Drive bearing out evenly by tapping on outer race
minimal wear, the bearings must be inspected only. Once bearing is at bottom of casting, support
visually, and by feel. While rotating bearings by casting on outer edges so bearing can be removed.
hand, inspect for rough spots, discoloration, or
corrosion. The bearings should turn smoothly and 4. Inspect the bearing carrier housing for scratches,
quietly, with no detectable up and down movement wear or damage. Replace front bearing carrier if
and minimal movement sideways between inner and damaged.
outer race.
12. Replace bearing if moisture, dirt, corrosion, or

roughness is evident.
7.3
FINAL DRIVE
Bearing Installation Bearing Carrier Installation
5. Thoroughly clean the front bearing carrier housing 1. Install drive shaft axle through the backside of the
and the outer race on the new bearing. Be sure that bearing carrier.
all oil residue has been removed from each surface.
2. Install the upper and lower ball joint ends into the front
6. Support the bottom of the bearing carrier housing. bearing carrier.
3. Install new pinch bolts and nuts. Torque to

CAUTION specification.
Use an arbor and press only on the outer race,
otherwise bearing damage may occur.
7. Apply Loctite® 603™ retaining compound to the

outer circumference of the new bearing race and
carefully press the new bearing into the bearing
carrier housing. Pinch
Bolts
Apply
Loctite® 603™
Snap Ring
=T
Ball Joint Pinch Bolts:
44 ft-lbs (60 Nm)
Bearing
4. Apply Anti-Seize to drive shaft axle splines.
NOTE: Use care to not allow any of the Loctite® 5. Install front wheel hub assembly, cone washers, and
compound to get in the bearing. hand tighten the castle nut. Install washers with
domed side out.
8. Wipe the housing clean of any excess compound and
install the snap ring. Cone Washers
Wheel
Hub
Out
6. Install new brake caliper mounting bolts and torque to

specification.
=T
Front Caliper Mounting Bolts:
40 ft-lbs (54 Nm)
7.4
FINAL DRIVE
9. Torque wheel hub nut to specification and install a
CAUTION new cotter pin. Tighten nut slightly if necessary to
align cotter pin holes. Bend both ends of cotter pin
New bolts have a pre-applied locking agent around end of spindle in different directions.
new brake caliper mounting bolts
upon assembly.
7. Install the steering tie rod end onto the front bearing 80 ft-lbs
carrier. (108 Nm)
NEW Cotter Pin
NOTE: Refer to the photos below to ensure proper
placement of the tie rod end.
42.5 ft-lbs
58 (Nm) =T
Wheel Hub Castle Nut:
80 ft-lbs (108 Nm)
Tie Rod End 10. Install wheel and (4) wheel nuts. Torque wheel nuts
to specification.
8. Torque the tie rod end fastener to specification and

=T
install a new cotter pin.
Wheel Nuts:
7
=T 30 ft-lbs (41 Nm) + 90° (1/4 turn)
Tie Rod End Fastener: 11. Rotate wheel and check for smooth operation.
42.5 ft-lbs (58 Nm)
7.5
FINAL DRIVE
FRONT DRIVE SHAFT 6. Remove and discard the upper and lower ball joint
pinch bolts and nuts.
Drive Shaft Removal
1. Elevate front of vehicle and safely support machine
under the frame area.
CAUTION
Pinch
Serious injury may result if machine tips or falls. Bolts
2. Remove the (4) wheel nuts and remove the front

wheel.
3. Remove the cotter pin and loosen the front wheel hub 7. Using a soft faced hammer, lightly tap on the bearing
castle nut. Remove the nut, and (2) cone washers carrier while removing the upper ball joint end.
from the front wheel hub assembly.
8. Remove the drive shaft from the front bearing carrier.
Cone
Washers Castle Nut
Cotter Pin
4. Remove and discard the two front brake caliper

9. With a short, sharp jerk, remove drive shaft from the
mounting bolts and remove the caliper from the brake
front gearcase.
disc (see Chapter 9).
brake line.
5. Remove the front wheel hub assembly.
7.6
FINAL DRIVE
Drive Shaft Installation 5. Install new pinch bolts and nuts. Torque to
specification.
1. Install new spring ring on drive shaft. Apply an anti-
seize compound to the splines.
NEW
Spring Ring
Pinch
Bolts
Apply
Anti-Seize
2. Align splines of drive shaft with front gearcase and =T

reinstall the drive shaft. Use a rubber mallet to tap on
the outboard end of the drive shaft if necessary Ball Joint Pinch Bolts:
44 ft-lbs (60 Nm)
7. Install front wheel hub assembly, cone washers, and

hand tighten the castle nut. Install washers with
domed side out.
Cone Washers
7
Wheel
Hub
3. Install drive shaft into the front bearing carrier. Out
4. Install the upper and lower ball joint ends into the front
bearing carrier.
7.7
FINAL DRIVE
8. Torque wheel hub nut to specification and install a
new cotter pin. Tighten nut slightly if necessary to
align cotter pin holes. Bend both ends of cotter pin
around end of spindle in different directions.
80 ft-lbs
(108 Nm)
NEW Cotter Pin
=T
Wheel Hub Castle Nut:
80 ft-lbs (108 Nm)
9. Install new brake caliper mounting bolts and torque to

specification.
=T
Front Caliper Mounting Bolts:
40 ft-lbs (54 Nm)
CAUTION
New bolts have a pre-applied locking agent

new brake caliper mounting bolts
upon assembly.
to specification.
=T
Wheel Nuts:
30 ft-lbs (41 Nm) + 90° (1/4 turn)
11. Rotate wheel and check for smooth operation.
7.8
FINAL DRIVE
PROPSHAFT SERVICE 6. Slide the front propshaft off the rear propshaft and
remove it from the vehicle.
Front Propshaft Removal (RZR XP)
Rear
1. Remove both seats and engine service panel. Shaft
Front
2. Remove the gear selector knob and center console. Shaft
Cap
Torx Screw
Screws
Torx Screws
7. Proceed to “Front Propshaft Installation”.

Torx Screws
3. Locate the propshaft roll pin and use the Roll Pin
Removal Tool (PN 2872608) to remove the roll pin.
Discard roll pin.
Roll Pin Removal Tool:

PN 2872608
NOTE: Right front wheel can be removed to gain

better access to the propshaft roll pin.
4. Remove the (4) bolts retaining the front gearcase.
5. Carefully move the gearcase forward to remove the

front propshaft from the gearcase input shaft.
7.9
FINAL DRIVE
Front Propshaft Removal (RZR XP 4) 6. Slide the front propshaft forward to remove it from the
rear propshaft.
1. Remove both front seats.
2. Remove the gear selector knob and center console. Rear Front
Shaft Shaft
Cap
Torx Screw
Screws
Torx Screws
Torx Screws
7. Remove the (4) fasteners retaining the front portion of
the vehicle skid plate. Allow the front portion of the
skid plate to hang down for propshaft removal.
3. Locate the propshaft roll pin and use the Roll Pin
Removal Tool (PN 2872608) to remove the roll pin. 8. Move the front propshaft towards the rear of the
Discard roll pin. vehicle (over the top of the support bearing).
9. Remove the front propshaft from the vehicle through

the skid plate.
Roll Pin Removal Tool:

PN 2872608
10. Proceed to “Front Propshaft Installation”.
NOTE: Right front wheel can be removed to gain
better access to the propshaft roll pin.
5. Carefully move the gearcase forward to remove the

front propshaft from the gearcase input shaft.
7.10
FINAL DRIVE
Front Propshaft Installation Rear Propshaft Removal (RZR XP)
1. Reverse the appropriate “Front Propshaft Removal” 1. Remove both seats and engine service panel.
procedure to reinstall the front propshaft.
2. Remove the gear selector knob and center console.
2. Lubricate front gearcase shaft splines with Anti-Seize.
Cap
3. Lubricate the front and rear propshaft mid joint with Torx Screw
Polaris All Purpose Grease. Screws
4. Align the front and rear propshafts as shown below

and slide them together.
Staked Tooth
Missing Tooth
for Alignment Torx Screws
for Alignment
Torx Screws
3. Remove the (2) fasteners retaining the support

bearing to the frame.
Support
Bearing
Front
Shaft
NOTE: Paint marks are applied to the front and rear

propshafts to aid shaft alignment. Reference these
marks during installation if still visible.
7
5. When installing the front propshaft onto the front
Remove
gearcase, use a new roll pin.
6. Reposition the front gearcase and install the (4) bolts

that secure the front gearcase to the frame. Torque
bolts to specification. 4. Remove the (4) bolts retaining the front gearcase.
5. Carefully move the gearcase forward to slide the front

=T propshaft off the rear propshaft.
Front Gearcase Mounting Bolts:
30 ft-lbs (41 Nm)
7.11
FINAL DRIVE
6. Once the front and rear propshafts have been 10. Position the rear propshaft yoke between the engine
separated, slide the rear propshaft forward to remove mount tube and rear stabilizer bar to allow the
it from the transmission output shaft. propshaft to be slid further back.
Rear
Shaft
Mount
Tube
Stabilizer
Bar
7. Remove the (7) fasteners retaining the front portion of 11. Remove the rear propshaft assembly from the vehicle
the vehicle skid plate. Allow the front portion of the through the skid plate.
skid plate to hang down for propshaft removal.
8. Remove the (3) bolts retaining the gear selector
support bracket to the frame. Remove the support
bracket from the vehicle.
Support
Bracket
IMPORTANT: Do not attempt to separate the support
bearing assembly from the rear propshaft. Doing so
will cause damage to the support bearing and rubber
isolator. Remove the rear propshaft from the vehicle
9. Pull the rear propshaft towards the front of the vehicle as an assembly.
and position it as shown.
12. Proceed to “Rear Propshaft Installation”.
7.12
FINAL DRIVE
Rear Propshaft Removal (RZR XP 4) 6. Once the front and rear propshafts have been
separated, lift up on the floor and slide the front
1. Remove both front seats. propshaft underneath the floor as shown.
2. Remove the gear selector knob and center console.
Lift
Cap Here
Torx Screw
Screws
Torx Screws
Torx Screws
7. Slide the rear propshaft forward to remove it from the

transmission output shaft.
3. Remove the (2) fasteners retaining the support
bearing to the frame. 8. Lift up on the floor and slide the rear propshaft through
the floor opening as shown.
Support Front
Bearing Shaft Lift
Here
7
Remove

9. Remove the (4) fasteners retaining the front portion of
5. Carefully move the gearcase forward in the frame to the vehicle skid plate. Allow the front portion of the
slide the front propshaft off the rear propshaft. skid plate to hang down for propshaft removal.
10. Pull the rear propshaft towards the front of the vehicle.
7.13
FINAL DRIVE
11. Remove the rear propshaft assembly from the vehicle Rear Propshaft Installation
through the skid plate.
1. Reverse the appropriate “Rear Propshaft Removal”
procedure to reinstall the rear propshaft.
2. Lubricate the transmission output shaft splines with

Polaris All Purpose Grease.
3. Lubricate the front and rear propshaft mid joint with

Polaris All Purpose Grease.
4. Align the front and rear propshafts as shown below

and slide them together.
Staked Tooth
Missing Tooth
for Alignment
for Alignment
IMPORTANT: Do not attempt to separate the support

bearing assembly from the rear propshaft. Doing so
will cause damage to the support bearing and rubber
isolator. Remove the rear propshaft from the vehicle
as an assembly.
12. Proceed to “Rear Propshaft Installation”.
NOTE: Paint marks are applied to the front and rear

propshafts to aid shaft alignment. Reference these
marks during installation if still visible.
5. Torque the support bearing fasteners to specification.
=T
Support Bearing Fasteners:
30-35 ft-lbs (41-47 Nm)
6. Reposition the front gearcase and install the (4) bolts

that secure the front gearcase to the frame. Torque
bolts to specification.
=T
30 ft-lbs (41 Nm)
7.14
FINAL DRIVE
Support Bearing Replacement 6. Using an appropriate bearing/bushing installation
sleeve, drive the support bearing assembly onto the
1. Remove the rear propshaft from the vehicle (see propshaft until it seats against the shoulder on the
“Rear Propshaft Removal” procedure). shaft.
2. Using a rubber mallet, remove the rubber isolated Drive on

bearing support from the shaft to expose the bearing. Inner Race
Bearing
Remove IMPORTANT: Take care while installing the support

bearing assembly. Be sure to only drive on the inner
race of the bearing. Driving on the bearing or support
3. Using a commercially available 2-jaw puller, remove in any other location will damage the bearing or
the bearing from the end of the propshaft. support assembly.
4. Clean the bearing mounting surface on the shaft and 7. Wipe the bearing and shaft clean of any excess
apply Loctite® 603™ retaining compound to the clean retaining compound.
surface.
NOTE: Use care to not allow any of the Loctite®
compound to get in the bearing.
Clean
8. Install the rear propshaft into the vehicle (see “Rear
7
Propshaft Installation” procedure).
Apply
Loctite® 603™
5. Install the new support bearing assembly onto the end

of the propshaft.
IMPORTANT: Do not attempt to separate the bearing

from the rubber isolated support assembly upon
installation.
7.15
FINAL DRIVE
PROPSHAFT U-JOINT SERVICE
Disassembly
CAUTION
Always wear eye protection.
1. Remove internal or external snap ring from bearing

caps.
4. Force U-joint cross to one side and lift out of inner

yoke.
NOTE: If yoke or bearing is removed, cross bearing

must be replaced. Note orientation of grease fitting
and mark inner and outer yoke for correct re-
positioning during installation.
2. Support inner yoke as shown and drive outer yoke

down (bearing cap out) with a soft face hammer.
Assembly
1. Install new bearing caps in yoke by hand. Carefully
install U-joint cross with grease fitting properly
positioned inward toward center of shaft. Take care
not to dislodge needle bearings upon installation of
cross joint.
2. Tighten vise to force bearing caps in.
3. Support U-joint in vise as shown and drive inner yoke

down to remove remaining bearing caps.
7.16
FINAL DRIVE
3. Using a suitable arbor, fully seat the bearing cap in
one side. Continually check for free movement of
bearing cross as bearing caps are assembled.
4. Install snap ring to contain bearing cap just installed.

Repeat procedure for other side.
5. Install outer yoke, aligning marks made at

disassembly and repeat Steps 1-3 to install bearing
caps on outer yoke.
6. Seat all bearing caps against snap rings by supporting

cross shaft and tapping on each corner as shown.
7. When installation is complete, yokes must pivot freely

in all directions without binding. If the joint is stiff or
binding, tap the yoke lightly to center the joint until it
pivots freely.
7.17
FINAL DRIVE
FRONT GEARCASE / CENTRALIZED HILLIARD
Centralized Hilliard Exploded View
8-10 ft-lbs
(11-14 Nm)
8-10 ft-lbs
(11-14 Nm)
7-11 ft-lbs
(10-15 Nm)
REF# DESCRIPTION QTY REF# DESCRIPTION QTY

1 O-Ring 1 17 Roll Cage 1
2 O-Ring 1 19 Hub / Race Assembly 2
3 Dowel Pin 1 20 Hub Sub-Assembly (Female) 1
4 Vent Hose Fitting 1 21 Hub Sub-Assembly (Male) 1
5 Ball Bearing 2 22 Rollers 20
6 Ball Bearing (Double Row) 1 23 Torsion Spring 1
7 Bushing 1 24 H-Clip Spring 20
8 Bushing 1 26 Nylon Spacer 2
9 Oil Seal 2 27 Backlash Spacer 1
10 Oil Seal 1 28 Ring Gear Spacer 1
11 Retaining Ring, Internal 1 29 Torsion Spring Retainer 1
12 Retaining Ring 1 30 Pinion Gear 1
13 Cover Screws, M6 (T30 Torx) 7 31 Armature Plate 1
14 Cover Plate Assembly 1 32 AWD Coil 1
15 Gearcase Housing 1 35 Fill Plug 1
16 Clutch Housing (Ring Gear) 1 36 Drain Plug, Magnetic 1
7.18
FINAL DRIVE
All Wheel Drive Operation AWD Engagement: When the AWD switch is activated,
the AWD coil is powered by a 12 Vdc input which creates
The AWD switch may be turned on or off while the vehicle a magnetic field. This magnetic field attracts an armature
is moving, however, AWD will not enable until the engine plate that is keyed to the roll cage. When the ring gear and
RPM drops below 3100. Once the AWD is enabled, it roll cage are spinning (vehicle is moving), the energized
remains enabled until the switch is turned off. coil and armature plate will apply drag to the roll cage that
indexes the rollers inside the ring gear to an engagement
Engage the AWD switch before getting into conditions position. While in the engagement position, the front drive
where the front wheel drive may be needed. If the rear will be in an “over-running” condition (not engaged), until
wheels are spinning, release the throttle before switching the rear wheels lose traction. Once the rear wheels begin
to AWD. to lose traction, the front drive will engage by coupling the
output hubs to the ring gear via the rollers. The front drive
CAUTION will remain engaged until the torque requirement goes
away (i.e. rear wheels regain traction).
Switching to AWD while the rear wheels are AWD Disengagement: Once the rear wheels regain
spinning may cause severe drive shaft and traction, the front wheels will return to the “over-running”
gearcase damage. Always switch to AWD while condition. The vehicle is now back to rear wheel drive until
the rear wheels have traction or are at rest. the next loss of rear wheel traction occurs.
With the AWD switch off, the vehicle drives through the Torsion Spring Operation: The torsion spring acts as a
rear wheels only (2 wheel drive). When the AWD is return mechanism to help disengage the coupling of the
enabled, the front drive acts as an on-demand AWD output hubs and ring gear by creating an “over-running”
system. This means, the front drive will engage once the condition for the rollers upon disengagement.
rear wheels have lost traction, and will remain engaged
until the torque requirement goes away (i.e. rear wheels Centers Roll Cage and
regain traction). Rollers in Ring Gear Output
Hub
CAUTION
If the rear wheels are spinning, release the

7
throttle before turning the AWD switch on.
Roll Cage
If AWD is engaged while the wheels are & Rollers
spinning, severe drive shaft and front
Armature
gearcase damage could result. Plate Ring Torsion
Gear Spring
7.19
FINAL DRIVE
AWD Diagnosis 5. Check to make sure the coil is seated in the U-shaped
insert that is pressed into the gearcase cover. The top
Symptom: AWD Will Not Engage of the coil should be seated below the U-shaped
insert. The U-shaped insert controls the pole gap. If
1. Check the gearcase coil resistance. To test the coil the top of the coil is above the surface of the U-shaped
resistance, measure between Grey and Brown/White insert it raises the armature plate, thereby increasing
wires. Measurement should be within specification. pole gap. If the pole gap increases the coil will not be
strong enough to engage the AWD system. If this is
found, replace the cover plate assembly.
Gearcase Cover Plate Asm.
Coil
Side cutaway
view of cover U-shaped insert
Front Gearcase Coil Resistance:
21.6 - 26.4 Ohms 6. Inspect the rollers for nicks and scratches. The rollers
must slide up, down, in and out freely within the roll
2. Turn on ignition and AWD switches and place gear cage sliding surfaces and H-springs.
selector in High or Low. Check for minimum battery
voltage at Gray and Brown/White chassis wires that 7. Inspect the roll cage assembly for cracks or excessive
power the coil. Should have a minimum of 11 Vdc. wear. If damaged, replace the roll cage assembly.
3. If electrical tests are within specification, remove Roll Cage Assembly

gearcase (see “Gearcase Removal”) and inspect Rollers
components.
4. Inspect armature plate for a consistent wear pattern.

There should be two distinct wear bands (one band
inside the other). If only one band of wear is present
(or if there is wear between the two bands), inspect
the coil area as indicated in Step 5. A wear band with
an interrupted wear mark may indicate a warped
plate, which may cause intermittent operation.
Check for
wear bands
Armature Plate
7.20
FINAL DRIVE
Front Gearcase Removal 8. Rotate front of gearcase up so the input shaft is facing
down. Lift and remove the gearcase from the front LH
1. Raise and support vehicle wheel well area and slide it out of the vehicle above
the upper A-arm.
2. Place gear selector in neutral.
3. Refer to “FRONT DRIVE SHAFT - Drive Shaft

Removal” and remove both front drive shafts from the
front gearcase.
4. Remove the front section of the propshaft (see

“PROPSHAFT SERVICE”).
5. Disconnect the wire harness for the front gearcase

and remove the harness from the retaining dart.
6. Remove the vent line from the front gearcase and plug
vent line fitting.
Front Gearcase Disassembly / Inspection

AWD Harness
1. Drain and properly dispose of gearcase fluid.
Remove any metal particles from the drain plug
magnet.
2. Remove the (7) cover screws and remove the cover

plate assembly.
Vent Line Retaining Dart

7
7. Remove the (4) bolts securing the front gearcase to
the frame.
7.21
FINAL DRIVE
3. Remove the LH output hub assembly from the clutch 5. Remove the torsion spring retainer and torsion spring
housing or outer cover plate assembly. from the top of the ring gear.
Spring Retainer
LH Output Hub
Non-serviceable Torsion Spring

DO NOT Remove
LH Output Hub
NOTE: Nylon spacer is non-serviceable and should 6. Remove the clutch housing / ring gear and roll cage
not be removed. assembly from the gearcase housing.
4. Remove and inspect the armature plate. Refer to

Remove as
“AWD Diagnosis” for detailed inspection process.
an assembly
Armature Plate
7.22
FINAL DRIVE
7. Remove the RH output hub assembly from the 10. Inspect the AWD coil located in the outer cover plate
gearcase housing. assembly. Refer to “AWD Diagnosis” for detailed
inspection process. Replace the cover plate seal and
O-ring.
Inspect
Coil
Replace
O-Ring & Seal
8. Remove pinion seal, internal retaining ring and pinion
gear assembly from the gearcase housing. Inspect
and clean the gearcase housing and replace all oil 11. Remove the roll cage assembly and rollers from the
seals and O-rings. clutch housing. Use a shop towel to cover the housing
in order to retain all the rollers.
Pinion
Shaft NOTE: Rollers are spring loaded. Take care not to
allow them to fall out or lose them upon removal of
External
the roll cage.
Snap Ring
12. Thoroughly clean all parts and inspect the rollers (A)
for nicks and scratches. The rollers must slide up and
down and in and out freely within the roll cage (B)
Replace
Seal sliding surfaces and H-springs. 7
B C
Bearing
Internal
Snap Ring
9. Inspect the pinion gear for chipped, broken or missing

teeth. Inspect the pinion bearing for signs of wear and
the pinion shaft seal surface for pitting.
IMPORTANT: Refer to the “Electronic Parts Catalog”

for individual part availability. Most parts are to be
replaced as an assembly or as a complete kit.
13. Inspect clutch housing / ring gear (C) for a consistent

wear pattern. Inspect the ring gear for chipped,
broken, or missing teeth.
Inspect
7.23
FINAL DRIVE
14. Inspect the roll cage assembly (B) sliding surfaces Front Gearcase Assembly
and H-springs. The sliding surfaces must be clean
and free of nicks, burrs or scratches. If damaged, 1. As mentioned during gearcase disassembly section,
replace the roll cage assembly. replace all O-rings, seals and worn components.
2. Install pinion shaft assembly and install internal snap

H-Spring B
ring.
NOTE: If bearing replacement was required, press

new bearing onto the pinion shaft and install a new
external snap ring.
3. Install a new pinion shaft seal into the pinion gear

housing. Using a universal seal installer, press the
new seal into the housing until the seal is just below
the housing chamfer.
Press in oil seal

just past chamfer
15. Inspect both output hub assemblies. Inspect the

bearings and replace if needed.
Thrust
Bearing
Bearing
4. Install the RH output hub into the gearcase housing.
Roller RH Output Hub

Spacer Surface
16. Clean and inspect all remaining front gearcase

components. Check each for excessive wear or
damage.
7.24
FINAL DRIVE
5. Carefully install the rollers into the roll cage assembly 8. Check the action of the torsion spring by rotating in
while installing the assembly into the clutch housing. both directions to ensure the spring and retainer are
installed properly.
NOTE: Install roll cage so that the ring gear grooves
line up with the roll cage windows (see below). Be
sure role cage top groove is facing upward.
Roll Cage Top Groove

Facing Upward
Align during
installation
9. Install armature plate. Be sure all of the armature plate

tabs are fully engaged into the roll cage assembly and
that it is resting properly on the torsion spring retainer.
6. Install the torsion spring by wrapping each leg of the
spring around the dowel pin on the ring gear. Engage
Tabs
NOTE: Verify armature plate tabs are in the roll cage

slots and that it rests properly on the spring retainer.
7. Align spring retainer dowel pin with ring gear dowel pin
and install the retainer on top of the torsion spring. 10. Carefully install the ring gear and roll cage assembly
into the gearcase housing.
Align during
installation
7.25
FINAL DRIVE
11. Install a new O-ring on the cover plate assembly. Front Gearcase Installation
NOTE: Be sure the square O-ring is placed flat on 1. Install the gearcase back into the vehicle through the
the cover surface. If the O-ring is twisted fluid LH wheel well area, above the upper A-arm.
leakage may occur.
12. Carefully install the LH output hub assembly into the

cover plate. Take care not to damage the new cover
plate seal while installing the output hub.
Non-serviceable
DO NOT Remove
2. Lubricate the front gearcase splines with Anti-Seize.
LH Output Hub 3. Install the propshaft onto the front gearcase input
shaft. Use a NEW spring pin in the front propshaft.
4. Install the (4) bolts that secure the front gearcase to

13. Install the output cover assembly onto the gearcase the frame and torque to specification.
housing. Install the (7) cover plate screws and torque
to specification.
=T
Torque Screws
30 ft-lbs (41 Nm)
5. Install the vent line.
Install
Vent Line
=T
Cover Plate Screws:
7-11 ft-lbs (10-15 Nm)
30 ft-lbs
(41 Nm)
7.26
FINAL DRIVE
6. Connect the AWD wire harness. REAR BEARING CARRIER
Bearing Carrier Inspection / Removal
1. Elevate rear of vehicle and safely support machine
AWD Harness under the frame area.
CAUTION

2. Check bearings for side play by grasping the top and

bottom of the tire firmly and checking for movement.
7. Refer to “FRONT DRIVE SHAFT - Drive Shaft The tire should rotate smoothly without binding or
Installation” and install both front drive shafts into the rough spots.
gearcase. 3. Remove the (4) wheel nuts and rear wheel.
8. Add the proper lubricant to the front gearcase. Refer 4. Remove the cotter pin and loosen the rear wheel hub
to Chapter 2 for fluid fill and change information. castle nut. Remove the nut, and (2) cone washers
=
Cotter Pin
Recommended Front Gearcase Fluid:
Polaris Demand Drive Plus
(PN 2877922) (Quart)
Capacity: 6.75 oz. (200 ml)

7
Castle Nut
Cone
Washers
5. Remove the lower radius rod outer mounting bolt, nut

and washer from the bearing carrier. Swing radius rod
RZR XP Shown
7.27
FINAL DRIVE
6. Remove the two brake caliper mounting bolts. 10. Rotate bearing by hand and check for smooth
Remove the rear brake caliper assembly. rotation. Visually inspect bearing for moisture, dirt, or
CAUTION: Do not hang the caliper by the brake line. corrosion.
brake line. NOTE: Due to extremely close tolerances and
minimal wear, the bearings must be inspected
visually, and by feel. While rotating bearings by
hand, inspect for rough spots, discoloration, or
corrosion. The bearings should turn smoothly and
quietly, with no detectable up and down movement
and minimal movement sideways between inner and
outer race.
11. Replace bearing if moisture, dirt, corrosion, or

roughness is evident.
RZR XP Shown
7. Remove the rear wheel hub and brake disk assembly.

8. Remove the (5) remaining bolts that attach the rear
bearing carrier to the trailing arm. Discard the nuts.
9. Remove the bearing carrier from the rear drive shaft

and trailing arm.
7.28
FINAL DRIVE
Bearing Replacement Bearing Installation
Bearing Removal 5. Thoroughly clean the rear bearing carrier housing and
the outer race on the new bearing. Be sure that all oil
1. Remove the outer snap ring. residue has been removed from each surface.
6. Support the bottom of the bearing carrier housing.

Snap Ring
CAUTION
Use an arbor and press only on the outer race,
otherwise bearing damage may occur.
7. Apply Loctite® 603™ retaining compound to the outer

circumference of the new bearing race and carefully
press the new bearing into the bearing carrier
housing.
Apply
Loctite® 603™
2. From the back side of the bearing carrier, tap on the
outer bearing race with a drift punch in the reliefs as
shown.
Snap Ring
Bearing
7
NOTE: Use care to not allow any of the Loctite®
compound to get in the bearing.
8. Wipe the housing clean of any excess compound and

install the snap ring.
3. Drive bearing out evenly by tapping on outer race
only. Once bearing is at bottom of casting, support
casting on outer edges so bearing can be removed.
4. Inspect the bearing carrier housing for scratches,

wear or damage. Replace rear bearing carrier if
damaged.
7.29
FINAL DRIVE
Bearing Carrier Installation 4. Install rear wheel hub assembly, cone washers, and
hand tighten the castle nut. Install washers with
1. Install drive shaft through the backside of the bearing domed side out.
carrier.
Cone Washers
Wheel
Hub
Out
5. Install the rear brake caliper assembly and new bolts.

2. Install the (4) fasteners that attach the rear bearing

carrier to the trailing arm. Install the (1) fastener that
attaches the upper radius rod to the bearing carrier.
Torque bolts to specification.
40 ft-lbs
NOTE: Use new nuts upon installation of the rear (54 Nm)
bearing carrier.
RZR XP Shown
=T
Rear Caliper Mounting Bolts:
40 ft-lbs (54 Nm)
=T
Bearing Carrier to Trailing Arm Bolts:
40 ft-lbs (54 Nm)
=T
Radius Rod to Bearing Carrier Bolts:
45 ft-lbs (61 Nm)
3. Apply anti-seize to drive shaft splines.
7.30
FINAL DRIVE
6. Torque wheel hub nut to specification and install a REAR DRIVE SHAFT
new cotter pin. Tighten nut slightly if necessary to
align cotter pin holes. Drive Shaft Removal
80 ft-lbs
(108 Nm)
NEW Cotter Pin

CAUTION

procedure. Always wear eye protection.
2. Remove the (4) wheel nuts and rear wheel.
3. Remove the cotter pin and loosen the rear wheel hub
castle nut. Remove the nut, and (2) cone washers
=T
Wheel Hub Castle Nut: Cotter Pin
80 ft-lbs (108 Nm)

to specification.
Castle Nut
=T
Wheel Nuts:
30 ft-lbs (41 Nm) + 90° (1/4 turn)
Cone
Washers 7
8. Rotate wheel and check for smooth operation. Bend 4. Remove the (2) bolts retaining the upper and lower
both ends of cotter pin around end of spindle in radius rods to the bearing carrier. Discard the nuts. Let
different directions. the radius rods swing downward.
5. Remove the brake caliper mounting bolts. Remove

the rear brake caliper assembly.
brake line.
Remove
RZR XP Shown
7.31
FINAL DRIVE
6. Remove the rear hub assembly from the bearing Drive Shaft Installation
carrier.
1. Install new spring ring on drive shaft. Apply an anti-
7. Support the trailing arm from underneath. seize compound to the splines.
8. Remove the lower shock mounting bolt and nut. NEW

Swing the shock inward. Discard the nut. Spring Ring
9. Remove the stabilizer bar mounting bolt, washer and

nut. Discard the nut.
10. Lift the trailing arm assembly upward so the rear drive
shaft is parallel with the ground.
11. Leaving the drive shaft in the transmission, swing the

rear trailing arm assembly outward until it is free from Apply
the rear drive shaft. Anti-Seize
12. Lower the trailing arm.

2. Align splines of drive shaft with transmission splines
and reinstall the drive shaft. Use a rubber mallet to tap
on the outboard end of the drive shaft if necessary.
13. With a short, sharp jerk, remove drive shaft from the
transmission splines.
3. Swing the rear trailing arm assembly outward and
upward until the rear axle can be inserted into the
bearing carrier. Support the trailing arm from
underneath.
7.32
FINAL DRIVE
4. Install the lower shock mounting bolt and new nut. 8. Install the radius rod bolts, washers and new nuts.
Torque fastener to specification. Torque fasteners to specification.
=T =T
Lower Shock Bolt to Trailing Arm: Radius Rods to Bearing Carrier:
70 ft-lbs (95 Nm) 45 ft-lbs (61 Nm)
5. Install the stabilizer bar mounting bolt, washer and 9. Install the rear brake caliper assembly and new bolts.
new nut. Torque fastener to specification. Torque to specification.
=T
Stabilizer Bar Linkage:
31-34 ft-lbs (42-46 Nm)

40 ft-lbs
7. Install rear wheel hub assembly. Install the (2) cone
(54 Nm)
washers and castle nut. Torque castle nut to
specification. Install new cotter pin.
Cone Washers RZR XP Shown
Wheel =T
Hub
Rear Caliper Mounting Bolts:
Out 40 ft-lbs (54 Nm) 7
80 ft-lbs to specification.
(108 Nm)
NEW Cotter Pin =T

Wheel Nuts:
30 ft-lbs (41 Nm) + 90° (1/4 turn)
=T
Rear Wheel Hub Castle Nut:
80 ft-lbs (108 Nm)
7.33
FINAL DRIVE
DRIVE SHAFT CV JOINT / BOOT 2. Remove the large end of the boot from the CV joint
and slide the boot down the shaft.
REPLACEMENT
Drive Shaft / CV Joint Handling Tips
Care should be exercised during drive shaft removal or
when servicing CV joints. Drive shaft components are
precision parts.
Cleanliness and following these instructions is very

important to ensure proper shaft function and a normal
service life.
• The complete drive shaft and joint should be

handled by getting hold of the interconnecting
shaft to avoid disassembly or potential damage to
the drive shaft joints.
• Over-angling of joints beyond their capacity could 3. Clean the grease from the face of the joint.
result in boot or joint damage.
4. Place the drive shaft in a soft-jawed vise. Using a soft-
• Make sure surface-ground areas and splines of faced hammer, or brass drift, strike the inner race of
shaft are protected during handling to avoid the joint to drive the joint off the drive shaft. Be sure
damage. to tap evenly around the joint to avoid binding.
• Do not allow boots to come into contact with sharp
edges or hot engine and exhaust components. Brass Drift Shown
• The drive shaft is not to be used as a lever arm to

position other suspension components.
• Never use a hammer or sharp tools to remove or
to install boot clamps.
• Be sure joints are thoroughly clean and that the
proper amount and type of grease is used to refill
when joint boots are replaced and when joints are
cleaned. Refer to text for grease capacity of CV
joints and CV joint boots.
Outer CV Joint / Boot Replacement

1. Use a side cutters to cut and discard the boot clamps. IMPORTANT: Tap on inner race only!
5. Make sure circlip is on the shaft and not left in the joint.
Circlip
Actual boot clamp may

differ from what is shown
7.34
FINAL DRIVE
6. Remove the CV boot from the shaft. 12. Grease the joint with the special CV joint grease
provided in the boot replacement kit. Fill the cavity
behind the balls and the splined hole in the joint’s inner
CAUTION race. Pack the ball tracks and outer face flush with
grease. Place any remaining grease into the boot.
Complete disassembly of the CV joint is NOT
recommended. The internal components are
precision fit and develop their own characteristic CAUTION
wear patterns. Intermixing the internal
components could result in looseness, binding, The grease provided in the replacement kit is
and/or premature failure of the joint. specially formulated for wear resistance and
durability. DO NOT use substitutes
IMPORTANT: If the grease in the joint is obviously or mix with other lubricants.
contaminated with water and/or dirt, the joint should
be replaced. NOTE: The amount of grease provided in the boot
kit is pre-measured. Use entire contents of package.
13. Slide the joint onto the drive shaft splines and align the
circlip with the lead-in chamfer on the inner race of the
joint.
7. Thoroughly clean the joint with an appropriate solvent 7

and dry the joint to prevent any residual solvent from
being left in the joint upon reassembly.
8. Visually inspect the joint by tilting the inner race to one

side to expose each ball. Severe pitting, galling, play 14. Use a soft-faced hammer to tap the joint onto the drive
between the ball and its cage window, any cracking shaft until it locks into place.
or damage to the cage, pitting or galling or chips in
raceways call for joint replacement. 15. Pull on the joint to make sure it is securely locked in
place.
NOTE: Shiny areas in ball tracks and on the cage
spheres are normal. Do not replace CV joints 16. Remove excess grease from the CV joint's external
because parts have polished surfaces. Replace CV surfaces and place the excess grease in the boot.
joint only if components are cracked, broken, worn
or otherwise unserviceable. 17. Pull the boot over the joint and position the boot lips
into the grooves on the joint housing and shaft. Make
9. Clean the splines on the end of the shaft and apply a sure the boot is not dimpled or collapsed.
light coat of grease prior to reassembly.
10. Slide the small boot clamp and boot (small end first)
onto the drive shaft and position the boot in it’s groove
machined in the shaft.
11. Install a new circlip on the end of the shaft.
7.35
FINAL DRIVE
18. Install and tighten the large clamp using the Inner Plunging Joint / Boot Replacement
appropriate clamp tool.
1. Use a side cutters to cut and discard the boot clamps.
Actual boot clamp may

Axle Boot Clamp Tool: PU-48951

2. Remove the large end of the boot from the plunging
or
joint and slide the boot down the shaft.
CV Boot Clamp Pliers: 8700226
19. While pulling out on the CV shaft, fully extend the CV

joint and slide a straight O-ring pick or a small slotted
screw driver between the small end of the boot and
the shaft. This will allow the air pressure to equalize
in the CV boot in the position that the joint will spend
most of its life. Before you remove your instrument,
be sure the small end of the boot is in its correct
location on the shaft.
20. Install and tighten the small clamp on the boot using
the appropriate clamp tool.
3. Clean the grease from the face of the joint and place
the drive shaft in a soft-jawed vise.
4. Using a soft-faced hammer, or brass drift, strike the

inner race of the joint to drive the joint off the shaft. Be
sure to tap evenly around the joint to avoid binding.
Brass Drift Shown

or
7.36
FINAL DRIVE
IMPORTANT: Tap on inner race only! 9. Clean the splines on the end of the shaft and apply a
light coat of grease prior to reassembly.
5. Make sure the circlip is on the shaft and not left in the
joint. 10. Slide the small boot clamp and boot (small end first)
onto the drive shaft and position the boot in its groove
Circlip machined in the shaft.
11. Install a new circlip on the end of the shaft.
12. Grease the joint with the special joint grease provided
in the boot replacement kit. Fill the cavity behind the
balls and the splined hole in the joint’s inner race.
Pack the ball tracks and outer face flush with grease.
Place any remaining grease into the boot.
CAUTION
The grease provided in the replacement kit is

specially formulated for wear resistance and
6. Remove the boot from the shaft.
durability. DO NOT use substitutes
or mix with other lubricants.
CAUTION
NOTE: The amount of grease provided in the boot
Complete disassembly of the plunging joint is kit is pre-measured. Use entire contents of package.
NOT recommended. The internal components
13. Fully compress the joint and push the drive shaft firmly
are precision fit and develop their own
into the inner race.
characteristic wear patterns. Intermixing the
internal components could result in looseness, 14. Align the circlip with the lead-in chamfer.
binding, and/or premature failure of the joint.
IMPORTANT: If the grease in the joint is obviously

7
contaminated with water and/or dirt, the joint should
be replaced.
15. Use a soft-faced hammer to tap the joint onto the drive
shaft until you reach the end of the splines and the
joint locks in place.
16. Pull on the joint to test that the circlip is seated and
7. Thoroughly clean the joint with an appropriate solvent that the joint is securely fastened to the shaft.
and dry the joint to prevent any residual solvent from
being left in the joint upon reassembly. 17. Remove excess grease from the plunging joint’s
external surfaces and place the excess grease in the
8. Visually inspect the joint for damage. Replace if boot.
needed.
7.37
FINAL DRIVE
18. Pull the boot over the joint and position the boot lips Drive Shaft Exploded View
into the grooves on the joint housing and shaft. Make
sure the boot is not dimpled or collapsed.
19. Install and tighten the small clamp using the Spring Ring
appropriate clamp tool.
Plunging
Joint
Spring Ring
Large Clamp
Gear Side
Boot Kit
Small Clamp
or
Wheel Side
Boot Kit
20. Pull out on the drive shaft to center the joint in the
housing. Slide a straight O-ring pick or a small slotted
screw driver between the large end of the boot and the Large Clamp
joint housing and lift up to equalize the air pressure in
Spring Ring
the boot.
21. Position the boot lip in its groove. Install and tighten CV Joint
the large clamp using the appropriate clamp tool.
Drive shaft design may


or
7.38
FINAL DRIVE
WHEEL HUBS
Front Hub Exploded View
Front Rim Bearing

(Aluminum) Carrier
Retaining
Ring
Studs
Wheel Hub
Sealed
Castle Nut
Ball Bearing
80 ft-lbs
(108 Nm)
Wheel Cap Bolts
Wheel Nuts Brake Disc

30 ft-lbs (41 Nm)
+ 90° (1/4 turn) Cone
Washers
Cotter Pin
Rear Hub Exploded View 7

Rear Rim
(Aluminum) Bearing
Carrier
Retaining
Ring
Studs
Wheel Hub
Castle Nut Sealed

80 ft-lbs Ball Bearing
(108 Nm)
Wheel Cap
Bolts
Wheel Nuts
30 ft-lbs (41 Nm) Brake Disc
+ 90° (1/4 turn)
Cone
Cotter Pin Washers
7.39
FINAL DRIVE
NOTES
7.40
TRANSMISSION
CHAPTER 8
TRANSMISSION
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
TRANSMISSION MOUNTING AND TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
SHIFT CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
TRANSMISSION SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
GEAR / SHAFT / BEARING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16
SNORKEL GEAR BACKLASH PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.17
TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.19
TRANSMISSION SERVICE (INT’L). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.23
DIFFERENTIAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.23
TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.24
PLANETARY DIFFERENTIAL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.28
PLANETARY DIFFERENTIAL BUSHING REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . 8.29
PLANETARY DIFFERENTIAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.31
GEAR / SHAFT / BEARING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.31
SNORKEL GEAR BACKLASH PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.32
TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.34
TRANSMISSION EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.40
TRANSMISSION EXPLODED VIEW (INT’L). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.42
8.1
TRANSMISSION
SPECIFICATIONS Special Tools
PART NUMBER TOOL DESCRIPTION
Torque Specifications
PA-50231 Snorkel Tool
ITEM TORQUE VALUE
2871698
Bearing Retaining Rear Output Seal Driver
8-10 ft-lbs (11-14 Nm) (Part of 2871702 Kit)
Plate Screws
2871699
Bell Crank Nut 12-18 ft-lbs (16-24 Nm) Rear Driveshaft Seal Guide
(Part of 2871702 Kit)
Fill / Drain Plugs 10-14 ft-lbs (14-19 Nm) 2871282 Bearing Seal Driver (50 mm)
Gear Sector Cover 9-12 ft-lbs (12-16 Nm) PU-50566 Transmission Nut Socket
Park Brake Disc PU-50658 Clutch Center Distance Tool
8-10 ft-lbs (11-14 Nm)
Mounting Bolt (INT’L)
Park Flange Screws 8-10 ft-lbs (11-14 Nm)
Rear Transmission
40 ft-lbs (54 Nm) Lubrication
Isolator Bolt
Refer to “Snorkel Gear
Snorkel Tube
Backlash Procedure”
=
Snorkel Tube
8-10 ft-lbs (11-14 Nm)
Locking Screw Recommended Transmission Lubricant:
Support and Shift Cable AGL Plus (PN 2878068) (Quart)
17 ft-lbs (23 Nm)
Bracket Bolts
Capacity (Standard): 44 oz. (1300 ml)
Transmission Case Screws 15-20 ft-lbs (20-27 Nm)
Capacity (INT’L): 41 oz. (1200 ml)
Speed Sensor Screw 9-12 ft-lbs (12-16 Nm)
Transmission Mounting and Torque Values

17 ft-lbs 17 ft-lbs * Reference “Transmission Installation”
(23 Nm) (23 Nm) procedure for torque sequence.
64 ft-lbs
(87 Nm)*
40 ft-lbs
(54 Nm)
44 ft-lbs
(60 Nm)*
44 ft-lbs
(60 Nm)*
8.2
TRANSMISSION
SHIFT LEVER 4. Remove the retaining ring and slide the shift lever off
the mounting bracket and out from the frame.
Removal
1. Remove the shift knob cover, retaining screw and shift
knob from the shift lever.
5. Remove both bushings from the shift lever and

2. Remove the screws retaining the center console service as needed.
using a T27 and T30 Torx driver. Remove the console
from the vehicle.
Installation
3. Remove the clip and washer retaining the shift cable
to the shift lever and disconnect the cable end from 1. Perform the removal steps in reverse order to install
the lever. the gear shift lever (lever, cable, console, shift knob).
8.3
TRANSMISSION
SHIFT CABLE 3. If adjustment is required, loosen the lower jam nut and
pull the cable out of the mount to move the upper jam
Inspection nut.
Shift cable adjustment may be necessary if symptoms

Upper
include:
Jam Nut
• No gear position or AWD display on instrument
cluster
• Ratcheting noise on deceleration
• Inability to engage into a gear
• Excessive gear lash (noise)
• Gear selector moving out of desired range Lower
Jam Nut
Inspect shift cable, clevis pins, and pivot bushings and
replace if worn or damaged.
4. Adjust the shift cable so there is the same amount of

Adjustment cable travel when shifting slightly past HIGH gear and
PARK.
1. Locate the shift cable attached to the transmission
case in the right rear wheel well area. 5. Thread the upper or lower jam nut as required to
obtain proper cable adjustment.
2. Inspect shift cable, clevis pin, pivot bushings, and dust
boot. Replace if worn or damaged. NOTE: This procedure may require a few attempts to
obtain the proper adjustment.
Shift Cable 6. Once the proper adjustment is obtained, place the
Mount
shift cable and upper jam nut into the mount. Tighten
the lower jam nut against the mount.
Shift Cable 7. Start engine and shift through all gears to ensure the
shift cable is properly adjusted. If transmission still
ratchets after cable adjustment, the transmission will
require service.
Dust Boot
8.4
TRANSMISSION
TRANSMISSION REMOVAL IMPORTANT: Be sure to use the correct Drive Clutch
Puller (PN 2872085) to prevent damage to crankshaft.
CAUTION CAUTION
procedure. Always wear eye protection.
1. Remove the seats, console cover and engine service

panel (see Chapter 5).
2. Disconnect the (-) negative battery cable from the

battery.
3. Remove the rear bumper and cargo box as an

assembly (see Chapter 5).
4. Remove the air box assembly (see Chapter 4 “ECT

Sensor Replacement”).
6. Remove the propshaft from the transmission output 11. Loosely install the left rear shock bolt to hold left rear
shaft (see Chapter 7). trailing arm up in position.
12. Remove the stabilizer bar mounting bolt and nut from
both sides. Discard nuts and replace with new upon
assembly.
7. Remove rear wheels from the vehicle.
8. If internal transmission repair is required, drain the

transmission lubricant (see Chapter 2).
9. Remove the lower mounting bolt from the left rear

shock. Swing shock outward.
10. Remove the outer clutch cover, drive belt, drive clutch,
driven clutch, inner clutch cover and clutch outlet duct
(see Chapter 6).
8.5
TRANSMISSION
13. Remove the (4) bolts attaching the upper and lower 16. Place a spacer or support between the vehicle frame
radius rods to the bearing carriers (left and right side). and engine to hold the engine up in position.
Discard nuts and replace with new upon assembly.
Allow the radius rods swing downward.
17. Remove vent hose from transmission.
14. Remove both lower shock bolts (left and right side) 18. Remove the gear position switch connector (A),
while supporting the trailing arms from underneath. speed sensor connector (B), crankshaft position
Lift training arms up and swing trailing arms outward sensor connector (C), shift bracket bolts and shift
to remove the drive shafts from the transmission. bracket (D), shift cable clevis pin and washer (E) from
the transmission.
15. Maneuver the drive shafts out of the vehicle frame.
Reinstall the lower shock bolts to hold the trailing arms C
up during the rest of the removal procedure.
B D
Reinstall Shock Bolts
8.6
TRANSMISSION
19. Remove the wire ties retaining harness to 22. Remove the (6) bolts (H) attaching the rear
transmission and mounts. transmission mount bracket assembly (J) to the
frame. Remove the (3) bolts (K) that attach the (2) rear
mounts (L) to the transmission. Remove the mount
assemblies from the vehicle.
H
J
20. Using a 15mm socket, remove the (4) bolts from the
left side (F) and right side (G), securing the
transmission to the engine.
H
F
K
23. Slide transmission towards the rear of the vehicle. Lift

and rotate the top of the transmission towards the left
side of the vehicle. With the help of an assistant,
remove transmission from the left rear wheel well
area.
G
21. Remove the (2) rear exhaust springs securing the

muffler to the rear transmission mounting bracket.
8.7
TRANSMISSION
TRANSMISSION INSTALLATION 4. Install the (2) rear exhaust springs securing the
muffler to the rear transmission mounting bracket.
1. With the help of an assistant, position the
transmission into the vehicle frame through the left 5. Install the Clutch Center Distance Tool (PU-50658)
rear wheel well area. onto the crankshaft and transmission input shaft to
properly position the clutch center distance. The
2. Slide transmission towards rear of the vehicle and pictures below show the tool (PU-50658) properly
rotate the top of the transmission toward the right side installed.
of the vehicle.
Drive Clutch Bolt Installed
3. Install the rear transmission mount assemblies.

Torque all fasteners to specification.
17 ft-lbs
(23 Nm)
Tool Fully Seated Inward
17 ft-lbs
(23 Nm)
6. Loosen the (2) bolts retaining the transmission

coupler bracket to the engine on the right side.
15-20 ft-lbs
(20-27 Nm)
=T
Rear Transmission Mount Bracket Bolts:
17 ft-lbs (23 Nm) 7. Align front transmission mounting holes with
transmission joint bracket mounting holes on engine.
Rear Mount Bracket to Transmission Bolts:
15-20 ft-lbs (20-27 Nm)
8.8
TRANSMISSION
8. Loosely install the (2) longer bolts into left side 12. Remove the spacer or support between the vehicle
mounting holes and (2) shorter bolts with washers into frame and engine.
right side mounting holes.
IMPORTANT: DO NOT torque fasteners at this time.
9. Torque left side mounting bolts to specification in

sequence.
Remove Spacer / Support
13. Install and properly route the gear position switch

2 connector (A), speed sensor connector (B),
crankshaft position sensor connector (C), shift
bracket and shift bracket bolts (D), shift cable clevis
pin and washer (E) onto the transmission.
10. Torque right side mounting bolts to specification using C

5 A
6
D
B
E
4 8
3, 7
14. Torque the (2) shift cable bracket bolts to

specification.
=T
=T
Engine / Transmission Mounting Bolts:
Shift Cable Bracket Bolts:
Step 1-2: 64 ft-lbs (87 Nm) 17 ft-lbs (23 Nm)
11. Remove the clutch center distance tool.
8.9
TRANSMISSION
15. Install (3) wire ties to retain wire harness to 21. Install the rear shocks onto the trailing arms and install
transmission and mounts. the lower mounting bolts with new retaining nuts.
22. Install the (4) rear radius rods to the bearing carriers
on each side. Use new retaining nuts. Torque to
specification.
16. Install and properly route the vent hose.
17. Lubricate the transmission splines and mid propshaft

joint splines with Polaris All Purpose Grease. Install
the propshaft onto the transmission output shaft (see
Chapter 7). 23. Install the stabilizer bar link mounting bolts and new
nuts. Torque to specification.
18. Install inner clutch cover, outlet duct, drive clutch,
driven clutch, belt and outer clutch cover (see Chapter
6).
19. Install new spring ring on rear drive shafts. Apply an

anti-seize compound to the splines.
NEW
Spring Ring
Apply 24. Install rear wheels and wheel nuts. Torque to

Anti-Seize specification.
20. Remove lower shock mounting bolt and swing the rear
trailing arm out and up. Align the splines of the drive =T
shaft with the transmission splines. Push inward on
the trailing arm assembly until the rear drive shafts Rear Shock Lower Bolt: 70 ft-lbs (95 Nm)
lock into the transmission splines. Outer Radius Rod Bolts: 45 ft-lbs (61 Nm)
Stabilizer Bar Linkage: 32 ft-lbs (44 Nm)
Wheel Nuts: 30 ft-lbs (41 Nm) + 90° (1/4 turn)
25. Properly lower the vehicle.
8.10
TRANSMISSION
26. Install the air box assembly as outlined in the EFI
Chapter (see Chapter 4 “ECT Sensor Replacement”).
27. Install the rear bumper and cargo box as an assembly

(see Chapter 5).
29. Install the engine service panel, console cover and

seats.
30. If transmission lubricant was drained, fill the

transmission with the specified amount of Polaris
AGL Plus (see Chapter 2 “Transmission
Lubrication”).
Recommended Transmission Lubricant:

AGL Plus (PN 2878068) (Quart)
Capacity (Standard): 44 oz. (1300 ml)

Capacity (INT’L): 41 oz. (1200 ml)
8.11
TRANSMISSION
TRANSMISSION SERVICE 7. Remove the detent star (I). Note how the detent star
fits onto the splined shaft with the raised edge facing
Transmission Disassembly outward for reassembly.
NOTE: Refer to the exploded view at the end of this 8. Remove the spacer (J).
chapter as a reference.
9. Remove the shift shaft (K), detent pawl (L) and the
1. Place transmission in High gear before disassembly. shift sector gears (M and N).
2. Drain and properly dispose of the transmission IMPORTANT: Note the timing marks on the shift gears
lubricant (see Chapter 2). (M and N) for reassembly purposes.
3. Remove the bellcrank nut (A) and bellcrank (B). 10. Remove the O-rings (P) from each shaft and discard.
Use new O-rings upon assembly.
G C F 11. Remove all the transmission case bolts. Using

A E suitable pry bars, remove the cover using the
designated pry points (indicated by the black arrows
B in the illustration below).
4. Remove E-clip (C) that retains spring washer (D), flat

washer (D) and gear switch (E). Remove the switch.
5. Remove the sector cover bolts (F) and remove the

sector cover (G).
NOTE: Removal can be aided by using your thumbs

to press in on the shafts while pulling out the cover
with your fingers.
CAUTION
6. Remove the compression spring (H).
Do not pry on case sealing surfaces.
M Use only the designated pry points
on the transmission.
K
L
H
P
I J N
P
8.12
TRANSMISSION
12. Lift up on the shift shaft rail (Q) and move the rail 15. Remove the idler gear shaft assembly (T) and gear
assembly rearward to allow the shift fork pins to be cluster assembly (U) from the transmission housing
removed from the shift drum (R). Remove the shift by pulling both assemblies straight up.
drum (R) from the transmission housing.
T
U
Q R
16. Place the gear cluster assembly on a clean surface for

13. Remove the shift shaft rail (Q) and shift forks from the inspection. If disassembly is required, refer to “Gear
transmission housing as an assembly. Cluster Disassembly”.
17. Using a 5 mm Allen wrench, remove the screws that

Q secure the pinion shaft assembly (V). Lift the pinion
shaft assembly straight up to remove it from the
housing. Note the longer screw (W) that locks the
snorkel tube.
8
W
14. Remove the rear output shaft assembly (S) by lifting
underneath the gear or by tapping the shaft from the
opposite side.
18. Remove all seals from the gearcase halves and clean
the cases in preparation for assembly.
S
8.13
TRANSMISSION
Gear Cluster Disassembly 23. If necessary, disassemble the other end of the reverse
shaft. Remove the bearing, engagement dog,
19. Remove the bearing from the reverse shaft using a retaining ring, washer, gear and needle bearing from
bearing puller. Remove the retaining ring and slide the the reverse shaft (see Figure 8-2).
washers, 53T gear and needle bearing off the reverse
shaft (see Figure 8-1). Figure 8-2
Figure 8-1
24. To disassemble the shift shaft rail remove the snap

ring (X) from the end of the shift rail on either side.
X X
20. Remove the retaining ring and engagement dog from

the reverse shaft (see Figure 8-1).
21. Remove the retaining ring, washer, needle bearing,

and sprocket from the reverse shaft (see Figure 8-1).
22. Tilt the two shafts towards each other and remove the
silent chain from the two shafts.
CAUTION
Use caution when disassembling the shift rail.
The compressed springs on the shift rail may
pop off causing eye or face injury.
8.14
TRANSMISSION
Snorkel Shaft Removal / Disassembly 27. Remove the snorkel tube and shaft assembly from the
transmission case.
CAUTION
The pinion shaft must be removed prior to removing

the snorkel shaft assembly. Failure to remove pinion
shaft, will result in damage to the snorkel shaft.
25. Extract the seal from the snorkel shaft to access the
snorkel tube for removal.
28. Remove the snap ring (Y) and shim (Z) from the
snorkel shaft.
Seal Removed
26. Using the Snorkel Tool (PA-50231), fully loosen the

snorkel tube.
Y Z
29. Use an arbor press to remove the snorkel tube from 8

the snorkel shaft.
30. Remove the snap ring (A) and shim (B) retaining the
bearing in the snorkel tube.
PA-50231
B A
8.15
TRANSMISSION
31. Lightly tap on the bearing from the opposite side to 32. Remove the retaining ring to remove the remaining
remove it from the snorkel tube. washer, bearing and gear from the snorkel shaft.
Gear / Shaft / Bearing Inspection
Inspect all gear sets and shafts for

IMPORTANT: If gear replacement is

required, be sure to also replace the
corresponding gear or gear shaft.
Inspect all bearings for signs of

wear or damage. If replacement is
required, use a standard bearing
puller or an arbor press.
8.16
TRANSMISSION
Snorkel Gear Backlash Procedure 5. Install the snorkel shaft into the gearcase. Using the
Snorkel Tool (PA-50231), tighten the snorkel tube until
1. Reassemble the snorkel tube and snorkel shaft it is lightly seated in the transmission housing.
assembly by reversing the disassembly procedure
(see “Snorkel Shaft Removal / Disassembly”).
Retaining
Ring
Bearing
Snorkel
Shaft
Washer
Bearing PA-50231
Retaining
13T Ring
Gear
Retaining
Ring 6. Inspect the pinion shaft assembly. Replace bearings
if needed. Inspect each gear for damage, chips or
Snorkel abnormally worn teeth.
Tube
Shim
Shim
Seal
2. After the 13T gear and bearing are pressed onto the
snorkel shaft (flush to the shoulder), install the washer
and new retaining ring.
3. Press the gear back towards the retaining ring. Avoid

excessive force so the retaining ring is not damaged
or pre-stressed significantly.
8
IMPORTANT: Failure to press the gear back against
the washer and retaining ring will lead to a gear
backlash change after vehicle is placed into service.
4. Apply a small amount of white lithium grease or Anti-

Seize on the threads of the snorkel tube. NOTE: If pinion shaft was disassembled, the bearing
cover must be installed on the shaft before installing
the 46T gear.
Grease Threads
8.17
TRANSMISSION
7. Install the pinion shaft assembly. Be sure to properly 12. Look down into the transmission housing to see the
mesh the snorkel shaft bevel gear with the pinion shaft snorkel locking screw hole opening to reference your
bevel gear. starting point.
8. Apply Loctite® 242™ to the threads of the bearing NOTE: If you have a hard time seeing into the hole,
cover retaining screws. insert a small Allen wrench, punch or screwdriver
into the hole to feel when the notch is aligned with
9. Using a 5 mm Allen wrench, install only the (3) screws the hole.
that secure the pinion shaft assembly as shown
below. Leave the longer locking screw (A) out at this 13. Slowly rotate the snorkel tube clockwise while
point. counting the number of notches passing through the
hole opening as you rotate the tube. Rotate the
DO NOT Install snorkel tube to the 3rd notch from the ‘zero’ backlash
Locking Screw position obtained in step 11.
Count 3 notches through

the locking screw hole
IMPORTANT: DO NOT install the longer screw (A).

Installing the longer screw will lock the snorkel tube
and not allow for backlash setting adjustment.
14. Check the pinion shaft gear backlash again by feel. If
10. Torque the bearing cover retaining screws to the pinion shaft gear lash appears to be too tight,
specification. rotate the snorkel shaft clockwise to the next notch
(4th notch).
=T 15. Once the backlash is set, apply Loctite® 242™ to the
threads and install the locking screw to secure the
Bearing Cover Retaining Screws: snorkel tube.
8-10 ft-lbs (11-14 Nm)
11. Rotate the snorkel tube counterclockwise using the

snorkel tool (PA-50231) until the snorkel gear and
pinion gear have ‘zero’ backlash.
IMPORTANT: DO NOT overtighten the snorkel tube

when backing it out. At the 'zero' backlash position,
you should still be able to turn the snorkel shaft using
your fingers, but it will feel rough and may have some
tight spots.
8.18
TRANSMISSION
16. Torque the locking screw to specification. Transmission Assembly
IMPORTANT: The snorkel shaft and pinion shaft must
8-10 ft-lbs
be installed prior to transmission assembly. The
(11-14 Nm)
snorkel shaft cannot be installed after assembling the
transmission.
1. Clean both transmission case halves thoroughly.

Inspect case half mating surfaces for damage.
2. Assemble the reverse shaft assembly and input shaft

assembly if previously disassembled (see
illustrations).
=T
Snorkel Locking Screw:
8-10 ft-lbs (11-14 Nm)
8.19
TRANSMISSION
3. Install the idler gear shaft assembly (A) and gear 6. Install the shift shaft rail (D) and shift forks into the
cluster assembly (B) into the transmission housing, all transmission housing as an assembly. Be sure the
at the same time. shift forks are engaged into the engagement dogs.
A
B D
Pins should be offset to this side
4. Install the rear output shaft assembly (C). NOTE: Shift fork pins should be offset towards the
input shaft as shown above.
7. Inspect the shift drum for any damage or wear. Inspect

the splines of the shift drum.
5. Assemble the shift shaft rail if previously

disassembled.
8. Install the shift drum (E) into the transmission housing.

Pins should offset to the same side
Lift up on the shift shaft rail (D) and move the rail
assembly towards the shift drum to allow the shift fork
ends to be installed into the shift drum (E).
D E
NOTE: Both shift forks need to be orientated the

same way, so that the shift fork pins are both offset
to the same side of the rail.
8.20
TRANSMISSION
9. Apply a continuous bead of Crankcase 3 Bond 12. Thoroughly clean the shift shaft housing. Be sure the
Sealant (PN 2871557) to left-hand transmission transmission is in High gear prior to reassembly.
mating surface.
10. Install the transmission case cover and retaining
bolts. Torque bolts to specification.
13. Install the sector gear (16T) onto the shift drum shaft.
Install the shift shaft assembly and sector gear (11T)
into the bushing pocket on the left side. Align the
timing marks on the gears as shown.
=T
Transmission Case Bolts:
15-20 ft-lbs (20-27 Nm)
11. Install new seals into the transmission case halves.

Timing Marks
• The snorkel shaft seal (F), should be pressed in
until it seats against the housing counter-bore.
• The input shaft seal (G), should be pressed in until High Gear Shown
it seats flush with the housing. 8
• The rear output shaft seals (H), can be installed
using a standard bushing installation tool. Seals 14. Install the spacer onto the shift drum shaft.
should be installed just past the case lead-in
chamfer (.070" or 1.8 mm from outer face of bore).
H
G
Spacer
8.21
TRANSMISSION
15. Install the detent star onto the shift drum shaft. Be sure 21. Install the transmission drain plug and torque to
to install the detent star with the raised edge facing specification.
outward and skip-tooth aligned.
16. Install the detent pawl onto the shift shaft and carefully =T
install the compression spring.
Fill / Drain Plug:
Detent Star 10-14 ft-lbs (14-19 Nm)
22. Install the bellcrank onto the shift shaft. Note the key
splined on the bellcrank and shift shaft. Install the nut
and torque to specification.
Spring
=T
Bellcrank Nut:
12-18 ft-lbs (16-24 Nm)
Detent Pawl
23. Refer to “Transmission Installation” to complete the
repair.
17. Install a new O-ring on each shift shaft. Apply a small
amount of white lithium grease on the O-rings, shift
shafts and component contact surfaces prior to
installing the sector cover.
Dowel
O-Rings
18. Clean the transmission and gear sector cover mating

surfaces thoroughly.
19. Apply Crankcase Sealant (3-Bond) (PN 2871557)

onto the cover and transmission case mating surface.
20. Install the sector cover and align the transmission

case dowel with the alignment hole. Install and torque
the bolts to specification.
=T
Sector Cover Bolts:
9-12 ft-lbs (12-16 Nm)
8.22
TRANSMISSION
TRANSMISSION SERVICE (INT’L) When switch position is set
to “Unlock”, the solenoid is
Differential Operation powered and the plunger
extends to disengage the
The INT’L transmission has two traction operational
side gear and unlock
modes: Differential Lock and Differential Unlock. Locking the differential.
the rear differential is beneficial in low traction and rough
terrain conditions. Unlocking the rear differential makes
maneuvering easier and minimizes damage to terrain.
AWD
When “Differential-Lock” is selected, power is removed
from the electrical solenoid allowing the solenoid plunger
to retract. Spring tension moves the shift fork back into
Differential - Lock
place and mates the engagement dog to the side gear that
is part of the planetary differential assembly. This locks the
rear differential as a solid rear axle, increasing traction.
Differential - Unlock
When switch position is set
to “Lock”, power is removed
from the solenoid and spring
tension retracts the plunger
When “Differential-Unlock” is selected, the rear differential
to engage the clutch gear
becomes unlocked for tighter turns. An electrical solenoid and lock the differential.
mounted in the rear portion of the gearcase actuates the
shift fork. The solenoid plunger extends out to move the
fork and slides the engagement dog away from the side
gear that is part of the planetary differential assembly. This
unlocks the rear differential. The rear drive shafts are now
dependent on the differential allowing for tighter turns.
Planetary Differential Components Shift Fork
Torsion Retainer 8
Spring
Spring
Differential Cover
Assembly Solenoid
Screw
Female Side Gear
Assembly
Planet Gear
Bearing
Assembly
Male Side Gear Engagement Dog
Assembly
Ring Gear
Assembly
Planetary Differential
Assembly
8.23
TRANSMISSION
Transmission Disassembly 7. Remove the detent star (I). Note how the detent star
fits onto the splined shaft with the raised edge facing
NOTE: Refer to the exploded view at the end of this outward for reassembly.
chapter as a reference.
8. Remove the spacer (J).
1. Place transmission in High gear before disassembly.
9. Remove the shift shaft (K), detent pawl (L) and the
2. Drain and properly dispose of the transmission shift sector gears (M and N).
lubricant (see Chapter 2).
IMPORTANT: Note the timing marks on the shift gears
3. Remove the bellcrank nut (A) and bellcrank (B). (M and N) for reassembly purposes.
G C F 10. Remove the O-rings (P) from each shaft and discard.
E Use new O-rings upon assembly.
A
11. Remove the bolt and washer retaining the brake disc
B to transmission pinion shaft. Remove disc from shaft.
12. Remove all transmission case bolts. Using suitable

pry bars, remove the cover using the designated pry
points (indicated by black arrows in illustration below).
4. Remove E-clip (C) that retains spring washer (D), flat

washer (D) and gear switch (E). Remove the switch.
5. Remove the sector cover bolts (F) and remove the

sector cover (G).
NOTE: Removal can be aided by using your thumbs

to press in on the shafts while pulling out the cover
with your fingers.
6. Remove the compression spring (H).
M
K
CAUTION
L
Do not pry on case sealing surfaces.
Use only the designated pry points
on the transmission.
H
P
I J N
P
8.24
TRANSMISSION
13. Lift up on the shift shaft rail (Q) and move the rail 16. Remove the idler gear shaft assembly (T) and gear
assembly rearward to allow the shift fork pins to be cluster assembly (U) from the transmission housing
removed from the shift drum (R). Remove the shift by pulling both assemblies straight up.
drum (R) from the transmission housing.
T
R U
Q
17. Place the idler gear shaft assembly (T) and gear
14. Remove the shift shaft rail (Q) and shift forks from the cluster assembly (U) on a clean surface for inspection.
transmission housing as an assembly. If disassembly is required, refer to “Gear Cluster
Disassembly”.
Q
18. Slide engagement dog (X) off of shift fork guides.
19. Remove (2) screws and retaining plates, then lift shift
fork (Y) and torsion spring out of transmission
housing.
8
15. Remove the rear output shaft assembly (S) by lifting
X
underneath the gear or by tapping the shaft from the
opposite side. If use of a pry bar is necessary, take
care not to pry on sealing surfaces of case.
Y
8.25
TRANSMISSION
20. Using a 5 mm Allen wrench, remove the screws that 23. Remove the retaining ring and engagement dog from
secure the pinion shaft assembly (V). Lift the pinion the reverse shaft (see Figure 8-1).
shaft assembly straight up to remove it from the
housing. Note the longer screw (W) that locks the 24. Remove the retaining ring, washer, needle bearing,
snorkel tube. and sprocket from the reverse shaft (see Figure 8-1).
V 25. Tilt the two shafts towards each other and remove the
W silent chain from the two shafts.
26. If necessary, disassemble the other end of the reverse

shaft. Remove the bearing, engagement dog,
retaining ring, washer, gear and needle bearing from
the reverse shaft (see Figure 8-2).
Figure 8-2
21. Remove all seals from the gearcase halves and clean
the cases in preparation for assembly.
Gear Cluster Disassembly

22. Remove the bearing from the reverse shaft using a
bearing puller. Remove the retaining ring and slide the
washers, 53T gear and needle bearing off the reverse
shaft (see Figure 8-1).
Figure 8-1
27. To disassemble the shift shaft rail remove the snap
ring (X) from the end of the shift rail on either side.
X X
CAUTION
Use caution when disassembling the shift rail.
The compressed springs on the shift rail may
pop off causing eye or face injury.
8.26
TRANSMISSION
Snorkel Shaft Removal / Disassembly 30. Remove the snorkel tube and shaft assembly from the
transmission case.
CAUTION
The pinion shaft must be removed prior to removing

the snorkel shaft assembly. Failure to remove pinion
shaft, will result in damage to the snorkel shaft.
28. Extract the seal from the snorkel shaft to access the
snorkel tube for removal.
31. Remove the snap ring (Y) and shim (Z) from the
snorkel shaft.
Seal Removed
29. Using the Snorkel Tool (PA-50231), fully loosen the

snorkel tube.
Y Z
32. Use an arbor press to remove the snorkel tube from 8

the snorkel shaft.
33. Remove the snap ring (A) and shim (B) retaining the
bearing in the snorkel tube.
PA-50231
B A
8.27
TRANSMISSION
34. Lightly tap on the bearing from the opposite side to Planetary Differential Disassembly
remove it from the snorkel tube.
NOTE: If the gearcase is completely assembled,
perform the “Gearcase Disassembly and Inspection”
procedure.
1. Use a scribe to mark the differential cover and ring

gear prior to disassembly.
Scribe
35. Remove the retaining ring to remove the remaining

washer, bearing and gear from the snorkel shaft.
2. Remove the (6) screws retaining the differential cover

and remove the cover.
3. Remove the (6) planet gears and each side gear

assembly from the ring gear.
Planet
Gears
Side
Gears
8.28
TRANSMISSION
4. Inspect the female side gear (A), male side gear (B), 4. Install the bushing to the specified depth as shown.
planet gears (C) and ring gear (D). Replace
components or bushings as needed. Bushing Install bushing flush to
replacement can be performed on all necessary .039 in. (1 mm) recessed
differential components. If bushing replacement is from end face of hub
required, proceed to Planetary Differential Bushing
Replacement”.
A B
C
C
Planetary Differential Bushing Replacement

NOTE: If the differential is completely assembled, New
perform the “Planetary Differential Disassembly” Bushing
procedure.
Ring Gear Bushing Replacement

1. Press the old bushing out of the ring gear.
2. Thoroughly clean the bore of the ring gear and check Planet Gear Bushing Replacement
for any unwanted burs. 1. Press the old bushing out of the planet gear.
3. Press the new bushing into the ring gear housing.
2. Thoroughly clean the bore of the planet gear and 8
check for any unwanted burs.
3. Press the new bushing into the planet gear until it is

flush on each end. Repeat this procedure for the
remaining planet gears.
Bushing
8.29
TRANSMISSION
Differential Cover Bushing Replacement Female Side Gear Bushing Replacement
1. Press the old bushing out of the differential cover. 1. Locate the bushing split. Using a small chisel or flat
blade screwdriver, peel back and remove the old
2. Thoroughly clean the bore of the differential cover and bushing from the side gear, being careful not to
check for any unwanted burs. damage the side gear.
3. Press the new bushing into the differential cover. Bushing Peel Back
Split Here
2. Thoroughly clean the bore of the side gear and check

for any unwanted burs.
3. Press the new bushing into the side gear until it

bottoms out.
4. Install the bushing to the specified depth as shown.
8.30
TRANSMISSION
Planetary Differential Assembly 5. Install screws hand tight. Place assembly in soft jaw
vise and torque to specification.
1. Thoroughly clean the differential components.
2. Assemble the side gears and place them onto the ring
gear along with the (6) planet gears.
Planet
Gears
Side
Gears =T
3. Align and install the differential cover using the Differential Cover Screws:
previously made scribe marks. 18-22 ft-lbs (24-30 Nm)
4. Apply Loctite® 2760™ to cover screws.
Gear / Shaft / Bearing Inspection
Inspect all gear sets and shafts for

IMPORTANT: If gear replacement is
required, be sure to also replace the
corresponding gear or gear shaft.
Inspect all bearings for signs of

wear or damage. If replacement is
required, use a standard bearing
puller or an arbor press.
8.31
TRANSMISSION
Snorkel Gear Backlash Procedure 5. Install the snorkel shaft into the gearcase. Using the
Snorkel Tool (PA-50231), tighten the snorkel tube until
1. Reassemble the snorkel tube and snorkel shaft it is lightly seated in the transmission housing.
assembly by reversing the disassembly procedure
(see “Snorkel Shaft Removal / Disassembly”).
Retaining
Ring
Bearing
Snorkel
Shaft
Washer
Bearing PA-50231
Retaining
13T Ring
Gear
Retaining
Ring 6. Inspect the pinion shaft assembly. Replace bearings
if needed. Inspect each gear for damage, chips or
Snorkel abnormally worn teeth.
Tube
Shim
Shim
Seal
2. After the 13T gear and bearing are pressed onto the
snorkel shaft (flush to the shoulder), install the washer
and new retaining ring.
3. Press the gear back towards the retaining ring. Avoid

excessive force so the retaining ring is not damaged
or pre-stressed significantly.
IMPORTANT: Failure to press the gear back against

the washer and retaining ring will lead to a gear
backlash change after vehicle is placed into service.
4. Apply a small amount of white lithium grease or Anti-

Seize on the threads of the snorkel tube. NOTE: If pinion shaft was disassembled, the bearing
cover must be installed on the shaft before installing
the 46T gear.
Grease Threads
8.32
TRANSMISSION
7. Install the pinion shaft assembly. Be sure to properly 12. Look down into the transmission housing to see the
mesh the snorkel shaft bevel gear with the pinion shaft snorkel locking screw hole opening to reference your
bevel gear. starting point.
8. Apply Loctite® 242™ to the threads of the bearing NOTE: If you have a hard time seeing into the hole,
cover retaining screws. insert a small Allen wrench, punch or screwdriver
into the hole to feel when the notch is aligned with
9. Using a 5 mm Allen wrench, install only the (3) screws the hole.
that secure the pinion shaft assembly as shown
below. Leave the longer locking screw (A) out at this 13. Slowly rotate the snorkel tube clockwise while
point. counting the number of notches passing through the
hole opening as you rotate the tube. Rotate the
A snorkel tube to the 3rd notch from the ‘zero’ backlash
position obtained in step 11.
Count 3 notches through

the locking screw hole
DO NOT install
locking screw
IMPORTANT: DO NOT install the longer screw (A).

Installing the longer screw will lock the snorkel tube
and not allow for backlash setting adjustment.
14. Check the pinion shaft gear backlash again by feel. If
10. Torque the bearing cover retaining screws to the pinion shaft gear lash appears to be too tight,
specification. rotate the snorkel shaft clockwise to the next notch
(4th notch).
=T 15. Once the backlash is set, apply Loctite® 242™ to the
threads and install the locking screw to secure the 8
Bearing Cover Retaining Screws: snorkel tube.
8-10 ft-lbs (11-14 Nm)
11. Rotate the snorkel tube counterclockwise using the

snorkel tool (PA-50231) until the snorkel gear and
pinion gear have ‘zero’ backlash.
IMPORTANT: DO NOT overtighten the snorkel tube

when backing it out. At the 'zero' backlash position,
you should still be able to turn the snorkel shaft using
your fingers, but it will feel rough and may have some
tight spots.
8.33
TRANSMISSION
16. Torque the locking screw to specification. Transmission Assembly
IMPORTANT: The snorkel shaft and pinion shaft must
8-10 ft-lbs
be installed prior to transmission assembly. The
(11-14 Nm)
snorkel shaft cannot be installed after assembling the
transmission.
1. Clean both transmission case halves thoroughly.

Inspect case half mating surfaces for damage.
2. Install shift fork (S) and torsion spring into

transmission housing as an assembly. Load spring as
shown in image below
3. Apply Loctite® 242™ to (2) screws (T) and install with

retaining plates over shift fork. Torque to specification.
=T
U
Snorkel Locking Screw:
8-10 ft-lbs (11-14 Nm)
=T
Shift Fork Screws:
7-10 ft-lbs (10-14 Nm)
4. Slide engagement dog (U) onto retaining pins of shift

fork.
8.34
TRANSMISSION
5. Assemble the reverse shaft assembly and input shaft 6. Install the idler gear shaft assembly (A) and gear
assembly if previously disassembled (see cluster assembly (B) into the transmission housing, all
illustrations). at the same time.
A
B
7. Install the rear output shaft assembly (C). Rotate

output shaft assembly to align slots with engagement
dog. Ensure bearing is fully seated upon assembly.
C
8
8. Assemble shift shaft rail if previously disassembled.
Pins should offset to the same side
NOTE: Both shift forks need to be orientated the

same way, so that the shift fork pins are both offset
to the same side of the rail.
8.35
TRANSMISSION
9. Install the shift shaft rail (D) and shift forks into the 12. Apply a continuous bead of Crankcase 3 Bond
transmission housing as an assembly. Be sure the Sealant (PN 2871557) to the left hand transmission
shift forks are engaged into the engagement dogs. mating surface.
D 13. Install the transmission case cover and retaining

bolts. Torque bolts to specification.
Pins should be offset to this side
NOTE: Shift fork pins should be offset towards the

input shaft as shown above.
10. Inspect the shift drum for any damage or wear. Inspect
the splines of the shift drum.
=T
Transmission Case Bolts:
15-20 ft-lbs (20-27 Nm)
14. Install new seals into the transmission case halves.
• The snorkel shaft seal (F), should be pressed in

until it seats against the housing counter-bore.
• The input shaft seal (G), should be pressed in until
it seats flush with the housing.
11. Install the shift drum (E) into the transmission housing.
Lift up on the shift shaft rail (D) and move the rail
assembly towards the shift drum to allow the shift fork
ends to be installed into the shift drum (E).
D E
8.36
TRANSMISSION
• The rear output shaft seals (H) and pinion shaft 16. Thoroughly clean the shift shaft housing. Be sure the
seal (J) can be installed using a standard bushing transmission is in High gear prior to reassembly.
installation tool. Seals should be installed just past
the case lead-in chamfer (.070" or 1.8 mm from
outer face of bore).
H G
17. Install the sector gear (16T) onto the shift drum shaft.
F Install the shift shaft assembly and sector gear (11T)
J into the bushing pocket on the left side. Align the
timing marks on the gears as shown.
15. Install the brake disc onto the pinion shaft. Install the
washer and apply Loctite® 262™ or 2760™ to the
mounting bolt threads. Torque the bolt to
specification.
Timing Marks
High Gear Shown

8
18. Install the spacer onto the shift drum shaft.
=T
Park Brake Disc Mounting Bolt: Spacer
18-22 ft-lbs (24-30 Nm)
8.37
TRANSMISSION
19. Install the detent star onto the shift drum shaft. Be sure 25. Install the transmission drain plug and torque to
to install the detent star with the raised edge facing specification.
outward and skip-tooth aligned.
20. Install the detent pawl onto the shift shaft and carefully =T
install the compression spring.
Fill / Drain Plug:
Detent Star 10-14 ft-lbs (14-19 Nm)
26. Install the bellcrank onto the shift shaft. Note the key
splined on the bellcrank and shift shaft. Install the nut
and torque to specification.
Spring
=T
Bellcrank Nut:
12-18 ft-lbs (16-24 Nm)
Detent Pawl
27. Refer to “Transmission Installation” to complete the
repair.
21. Install a new O-ring on each shift shaft. Apply a small
amount of white lithium grease on the O-rings, shift
shafts and component contact surfaces prior to
installing the sector cover.
Dowel
O-Rings
22. Clean the transmission and gear sector cover mating

surfaces thoroughly.
23. Apply Crankcase Sealant (3-Bond) (PN 2871557)

onto the cover and transmission case mating surface.
24. Install the sector cover and align the transmission

case dowel with the alignment hole. Install and torque
the bolts to specification.
=T
Sector Cover Bolts:
9-12 ft-lbs (12-16 Nm)
8.38
TRANSMISSION
TROUBLESHOOTING
Troubleshooting Checklist
Check the following items when shifting difficulty is
encountered.
• Shift cable adjustment/condition

• PVT alignment (clutch center distance)
• Idle speed (throttle cable routing)
• Transmission lubricant type/quality
• Loose fasteners on sector gear cover
• Worn rod ends, clevis pins, or pivot arm bushings
• Shift selector rail travel
• Worn, broken or damaged internal transmission
components
NOTE: To determine if shifting difficulty or problem
is caused by an internal transmission problem,
isolate the transmission by disconnecting the shift
cable end from the transmission bellcrank. Manually
select each gear range at the transmission bellcrank,
and test ride vehicle. If it functions properly, the
problem is outside the transmission.

If transmission problem remains, disassemble
transmission and inspect all gear dogs for wear
(rounding) or damage. Inspect all bearings, circlips,
thrust washers and shafts for wear.
8.39
FOR REASSEMBLY
8.40
Apply White Lithium
Based Grease.
Apply Polaris
Crankcase Sealant.
Apply Loctite® to
TRANSMISSION
10-14 ft-lbs
the bolt threads. (14-19 Nm)
Refer to “Snorkel Gear

Backlash Procedure”
242 ™
8-10 ft-lbs
TRANSMISSION EXPLODED VIEW
(11-14 Nm)
8-10 ft-lbs
(11-14 Nm)
242 ™
12-18 ft-lbs

(16-24 Nm)
10-14 ft-lbs
15-20 ft-lbs (14-19 Nm)
(20-27 Nm)
15-20 ft-lbs
(20-27 Nm)

9-12 ft-lbs
(12-16 Nm)
TRANSMISSION
Exploded View, Continued
Ref. Qty. Description Ref. Qty. Description
1. 1 Fill Plug 44. 1 Gear, Sector 16T
2. 1 Drain Plug, Magnetic 45. 1 Gear, Sector 31T
3. 14 Screw, M8 x 1.25 x 30 46. 1 Pawl, Detent
4. 6 Screw, M6 x 1 x 20 47. 1 Star, Detent
5. 3 Screw, M8 x 50 48. 1 Plate, Park, 12-Face
6. 1 Screw, M6 x 1 x 40 49. 1 Shaft, Output 53T
7. 6 Screw, M6 x 1 x 18 50. 1 Shaft, Idler 29T
8. 1 Nut, NyLoc, M8 x 1.25 51. 1 Shaft, Reverse 29T
9. 2 Washer, Cup 52. 1 Shaft, Front Output
10. 3 Washer 53. 1 Shaft, Input Helical
11. 1 Washer 54. 1 Bellcrank
12. 1 Washer 55. 1 Collar, Shift
13. 2 Pin, Dowel 56. 1 Rail, Shift Shaft
14. 1 Pin, Spring 57. 1 Tube, Vent, 1/4 in.
15. 1 Retaining Ring, External 58. 1 Shift Dog, Park
16. 1 Snap Ring 59. 1 Gear, 44T
17. 1 Retaining Ring, External 60. 2 Fork, Shift
18. 1 Retaining Ring, External 61. 1 Sprocket, 48T, 6-Face
19. 1 Retaining Ring, Internal 62. 1 Gear, Low 67T
20. 2 Retaining Ring, External 63. 1 Engagement Dog, 6-Face
21. 2 Retaining Ring, External 64. 1 Gear, 53T
22. 3 Retaining Ring, External 65. 1 Shaft, Pinion 11T
24. 2 Washer, Thrust 67. 1 Gear, Snorkel 13T
25. 1 Washer, Thrust 68. 1 Shaft, Shift
26. 1 Shim 69. 1 Weldment, Rear Mount Bracket
27. 1 Shim 70. 1 Bracket, Rear Mount
28. 2 Bearing, Needle Cage 71. 1 Cover, Bearing, Center Drive
29. 2 Bearing, Ball 72. 1 Spacer
30. 2 Bearing, Ball 73. 1 Chain, Silent
31. 2 Bearing, Ball 74. 1 Switch, Rotary, 2-Pin
32.
33.
3
1
Bearing, Ball
Bearing, Needle Cage
75.
76.
1
1
O-Ring
O-Ring
8
34. 1 Bearing, Ball 77. 1 O-Ring
35. 2 Bearing, Ball 78. 1 Seal, Triple Lip
36. 2 Spring, Compression 79. 1 Seal, Dual Lip
37. 2 Spring, Compression 80. 2 Seal, Triple Lip
38. 1 Spring, Compression, Detent 81. - N/A
39. 1 Tube, Snorkel 82. 1 Sensor, Speed
40. 1 Cover, Sector Gears 85. 1 Bearing, Ball
41. 1 Case, RH 86. 1 Spring, Wave
42. 1 Case, LH 88. 1 Bracket, Wire Harness
43. 1 Drum, Shift 89. 1 Collar Sleeve, Input Shaft
8.41
FOR REASSEMBLY
8.42
Apply White Lithium 18-22 ft-lbs
Based Grease. (24-30 Nm)
2760 ™
Apply Polaris
Crankcase Sealant.
Apply Loctite® to
TRANSMISSION
the bolt threads.
10-14 ft-lbs
(14-19 Nm)
TRANSMISSION EXPLODED VIEW (INT’L)
7-10 ft-lbs Refer to “Snorkel Gear

(10-14 Nm) Backlash Procedure”
242 ™

8-10 ft-lbs
(11-14 Nm)
12-18 ft-lbs 8-10 ft-lbs

(16-24 Nm) (11-14 Nm)
242 ™

15-20 ft-lbs
(20-27 Nm)
18-22 ft-lbs
15-20 ft-lbs
(24-30 Nm)
(20-27 Nm)
262 ™
9-12 ft-lbs 10-14 ft-lbs
(12-16 Nm) (14-19 Nm)
TRANSMISSION
Exploded View, Continued
Ref. Qty. Description Ref. Qty. Description
1. 1 Fill Plug 54. 1 Star, Detent
2. 1 Drain Plug, Magnetic 55. 1 Plate, Park, 12-Face
4. 14 Screw, M8 x 1.25 x 30 56. 1 Shaft, Idler 29T
5. 6 Screw, M6 x 1 x 20 57. 1 Shaft, Reverse 29T
6. 3 Screw, M8 x 50 58. 1 Shaft, Front Output
7. 1 Screw, M6 x 1 x 40 59. 1 Shaft, Input Helical
8. 6 Screw, M6 x 1 x 18 60. 1 Shaft, Pinion, 11T
9. 2 Screw, M6 x 1 x 16 61. 1 Disc, Brake
10. 1 Nut, NyLoc, M8 x 1.25 62. 1 Bellcrank
11. 2 Washer, Cup 63. 1 Collar, Shift
12. 1 Washer 64. 1 Rail, Shift Shaft
13. 3 Washer 65. 1 Tube, Vent, 1/4 in.
14. 1 Washer 66. 1 Fork, Pivot Shaft
15. 1 Washer 67. 1 Dog, Engagement
16. 2 Pin, Dowel 68. 1 Shift Dog, Park
17. 1 Pin, Spring 69. 1 Gear, 44T
18. 1 Retaining Ring, External 70. 2 Fork, Shift
19. 1 Snap Ring 71. 1 Sprocket, 48T, 6-Face
20. 1 Retaining Ring, External 72. 1 Gear, Low 67T
21. 1 Retaining Ring, External 73. 1 Engagement Dog, 6-Face
22. 1 Retaining Ring, Internal 74. 1 Gear, 53T
24. 2 Retaining Ring, External 76. 1 Gear, Snorkel 13T
25. 3 Retaining Ring, External 77. 1 Shaft, Shift
26. 1 Retaining Ring, External 78. 1 Weldment, Rear Mount Bracket
27. 2 Washer, Thrust 80. 2 Retainer, Fork
28. 1 Washer, Thrust 81. 1 Bracket, Rear Mount
29. 1 Shim 82. 1 Cover, Bearing, Center Drive
30. 1 Shim 83. 1 Spacer
31. 2 Bearing, Needle Cage 84. 1 Chain, Silent
32. 2 Bearing, Ball 85. 1 Solenoid
33.
34.
1
2
Bearing, Ball
Bearing, Ball
86.
87.
1
1
Switch, Rotary, 2-Pin
O-Ring
8
35. 3 Bearing, Ball 88. 1 O-Ring
36. 1 Bearing, Needle Cage 89. 1 O-Ring
39. 1 Bearing, Ball 92. 1 Seal, Dual Lip
40. 2 Spring, Compression 93. 2 Seal, Triple Lip
41. 2 Spring, Compression 95. 1 Sensor, Speed
42. 1 Spring, Torsion 98. 1 Bracket, Wire Harness
43. 1 Spring, Compression 99. 2 Plug, Expansion
44. 1 Spring, Compression, Detent 100. 1 Side Gear, Male, 39T
45. 1 Spring, Washer 101. 3 Bearing, Plain
46. 1 Tube, Snorkel 102. 1 Side Gear, Female, 39T
47. 1 Cover, Sector Gears 103. 1 Diff Cover
48. 1 Case, LH 104. 6 Planet Gear
49. 1 Case, RH 105. 7 Screw, M8 x 1.25 x 25
50. 1 Drum, Shift 106. 1 Ring Gear, 53T
51. 1 Gear, Sector 16T 108. 6 Bearing, Plain
52. 1 Gear, Sector 31T 109. 1 Collar Sleeve, Input Shaft
53. 1 Pawl, Detent
8.43
TRANSMISSION
NOTES
8.44
BRAKES
CHAPTER 9
BRAKES
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
BRAKE SYSTEM SERVICE NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
BRAKE NOISE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
HYDRAULIC BRAKE SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
BRAKE SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
RZR XP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
RZR XP 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
MASTER CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
BRAKE PEDAL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
BRAKE BLEEDING / FLUID CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
PARKING BRAKE (INT’L MODEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10
PARKING BRAKE INSPECTION / CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 9.11
PARKING BRAKE CALIPER SERVICE (INT’L MODEL). . . . . . . . . . . . . . . . . . . . . . . . . 9.12
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
CALIPER DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
NEW BRAKE PAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
PARKING BRAKE DISC (INT’L MODEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
FRONT BRAKE PADS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
PAD REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
PAD ASSEMBLY / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
FRONT CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
CALIPER INSPECTION / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
FRONT BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
REAR BRAKE PADS (RZR XP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
PAD INSPECTION / ASSEMBLY / INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24
REAR BRAKE PADS (RZR XP 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.26
PAD INSPECTION / ASSEMBLY / INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
9
REAR CALIPER SERVICE (RZR XP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
CALIPER INSPECTION / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.31
REAR CALIPER SERVICE (RZR XP 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.33
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.33
CALIPER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.35
CALIPER ASSEMBLY / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.36
REAR BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.38
9.1
BRAKES
GENERAL SPECIFICATIONS
FRONT BRAKE SYSTEM
Item Standard Service Limit
Front Brake Pad Thickness .297 ± .007" (7.54 ± .178 mm) .180" (4.6 mm)
Front Brake Disc Thickness .188" (4.78 mm) .170" (4.32 mm)
Front Brake Disc Runout - .010" (.254 mm)
REAR BRAKE SYSTEM

Rear Brake Pad Thickness .298 ± .007" (7.57 ± .178 mm) .180" (4.6 mm)
Rear Brake Disc Thickness .188" (4.78 mm) .170" (4.32 mm)
Rear Brake Disc Runout - .010" (.254 mm)
PARK BRAKE SYSTEM (INT’L MODEL)

Inboard - 0.300” (7.62 mm) 0.240” (6.10 mm)
Park Brake Pad Thickness
Outboard - 0.250” (6.35 mm) 0.190" (4.83 mm)
Park Brake Disc Thickness 0.175” - 0.185” (4.44 - 4.70 mm) 0.150" (3.81 mm)
TORQUE SPECIFICATIONS SPECIAL TOOLS

Torque Torque Part Number Tool Description
Item
ft-lbs Nm
2870975 Mity Vac™ Pressure Test Tool
Front Caliper Mounting Bolts 40 54
Rear Caliper Mounting Bolts 40 54 SPX Corp: 1-800-328-6657 or http://polaris.spx.com/
Brake Line Flare 12-15 16-20

Brake Line Banjo Bolts
15 20
(Caliper Attachment)
Brake Line Banjo Bolt
15 20
(Master Cylinder Attachment)
Brake Switch 15 20
Brake Disc to Hub Bolts 30 41
Master Cylinder to Frame 23 31
Brake Pedal Mounting Bracket
16 22
to Frame
Park Brake Assembly Bolts 37 50
Park Brake Disc Mounting Bolt 18-22 24-30
Park Brake Lever Mount Bolts 16 22
Park Brake Mount Bracket to
37 50
Transmission Bolts
9.2
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.
• DO NOT over-fill the master cylinder fluid reservoir.

• Make sure the brake pedal returns freely and completely.
• Adjust stop pin on brake caliper(s) after pad service.
• Check and adjust master cylinder reservoir fluid level after pad service.
• Make sure atmospheric vent on reservoir is unobstructed.
• Test for brake drag after any brake system service and investigate cause if brake drag is evident.
• Make sure caliper moves freely on guide pins (where applicable).
• Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely.
• Perform a brake burnishing procedure after installing new pads to maximize service life.
• DO NOT lubricate or clean the brake components with aerosol or petroleum products. Use only approved brake
cleaning products.
BRAKE NOISE TROUBLESHOOTING

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

Possible Cause Remedy
Spray disc and pads with CRC Brakleen™ or an equivalent
Dirt, dust, or imbedded material on pads or disc non-flammable aerosol brake cleaner. Remove pads and/
or disc hub to clean imbedded material from disc or pads.
Pad(s) dragging on disc (noise or premature pad wear) Adjust pad stop (front calipers)
because of improper adjustment 
Master cylinder reservoir overfilled Set to proper level
Master cylinder compensating port restricted Clean compensating port 9
Master cylinder piston not returning completely Inspect. Repair as necessary
Caliper piston(s) not returning Clean piston(s) seal 
Operator error (riding the brake) Educate operator
Loose wheel hub or bearings Check wheel and hub for abnormal movement.
Brake disc warped or excessively worn Replace disc
Brake disc misaligned or loose Inspect and repair as necessary
If noise does not change when brake is applied check
Noise is from other source (axle, hub, disc or wheel)
other sources. Inspect and repair as necessary
9.3
BRAKES
HYDRAULIC BRAKE SYSTEM OPERATION
The Polaris brake system consists of the following components or assemblies: brake pedal, master cylinder, hydraulic
brake lines, brake calipers, brake pads, and brake discs, which are secured to the drive line.
When the foot activated brake lever is applied it applies pressure on the piston within the master cylinder. As the master
cylinder piston moves inward it closes a small opening (compensating port) within the cylinder and starts to build pressure
within the brake system. As the pressure within the system is increased, the pistons located in the brake calipers move
outward and apply pressure to the moveable brake pads. These pads contact the brake discs and move the calipers in
their floating bracket, pulling the stationary side pads into the brake discs. The resulting friction reduces brake disc and
vehicle speed.
The friction applied to the brake pads will cause the pads to wear. As these pads wear, the piston within the caliper moves
further outward and becomes self adjusting. Fluid from the reservoir fills the additional area created when the caliper
piston moves outward.
Brake fluid level is critical to proper system operation. Too little fluid will allow air to enter the system and cause the brakes
to feel spongy. Too much fluid could cause brakes to drag due to fluid expansion.
Located within the master cylinder is the compensating port which is opened and closed by the master cylinder piston
assembly. As the temperature within the hydraulic system changes, this port compensates for fluid expansion or
contraction. Due to the high temperatures created within the system during heavy braking, it is very important that the
master cylinder reservoir have adequate space to allow for fluid expansion. Never overfill the reservoir! Do not fill the
reservoir beyond the MAX LEVEL line!
When servicing Polaris brake systems use only Polaris DOT 4 Brake Fluid (PN 2872189).
WARNING: Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws.
Do not store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture.
This causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the
possibility of serious injury.
9.4
BRAKES
BRAKE SYSTEM EXPLODED VIEW
RZR XP
LH Rear Line LH Front 2

1 2 Brake Line
Master Cylinder 1
3
Front Calipers
2
Rear Calipers
3
MC Rear 1
Cross Brake Line 1
Fitting
Brake
Switch
2 1
Master Cylinder Side View
RH Rear Line RH Front
Brake Line
Caliper Banjo Style Fittings:

1
15 ft-lbs (20 Nm).
All Caliper Bleed Screws:
2 47 in-lbs (5.3 Nm)
All Flare Style Fittings:
3 12-15 ft-lbs (16-20 Nm)
9.5
BRAKES
RZR XP 4
Seals Seals
1
1
Rear Caliper
Brake Seals
Switch
LH Rear Line Master Cylinder
MC Rear
Brake Line
LH Front
Brake Line
RH Front
Brake Line
RH Rear Line
3
2
Cross Fitting
Caliper Banjo Style Fittings:

1 15 ft-lbs (20 Nm).
All Caliper Bleed Screws:
2 47 in-lbs (5.3 Nm) Seals
1
All Flare Style Fittings:
3 12-15 ft-lbs (16-20 Nm) Front Caliper
9.6
BRAKES
MASTER CYLINDER NOTE: Make note of front and rear brake line
locations to master cylinder.
Removal 4. Loosen the brake line banjo bolts (C) and allow fluid
1. Locate the master cylinder above the left front tire in to drain.
the wheel well area. NOTE: Dispose of fluid properly. Do not re-use.
5. Remove the two mounting fasteners (D) that secure
the master cylinder to the frame.
Installation
1. Reverse Steps 1-5 for master cylinder installation.
Master Cylinder Refer to the torque specifications in the
illustration.
2. After installing the foot brake check pedal freeplay.
Pedal freeplay should not exceed .090” (2.286 mm).
BRAKE PEDAL LEVER

2. Remove the clip (A) from the clevis pin (B) that Pedal Removal
attaches the master cylinder to the brake pedal lever.
1. Locate the brake pedal lever (L) and remove the clip
(A) and master cylinder clevis pin (B).
23 ft-lbs
B (31 Nm)
D
2. Remove the E-ring (E) from the pedal mount and
remove the brake pedal lever (L) from the vehicle.
E
A
B
9
C
15 ft-lbs
(20 Nm)
3. Place a container to catch brake fluid under the Pedal Installation

master cylinder brake line banjo bolts (C).
1. Reverse the “Removal” steps to install brake pedal
lever. Brake pedal freeplay should not exceed .090”
CAUTION (2.28 mm).
Brake fluid will damage finished surfaces.

Brake Pedal Freeplay:
Do not allow brake fluid to come in contact
.090” (2.28 mm)
with finished surfaces.
9.7
BRAKES
BRAKE BLEEDING / FLUID CHANGE 5. Have an assistant slowly pump foot pedal until
pressure builds and holds.
NOTE: When bleeding the brakes or replacing the
fluid always start with the furthest caliper from the 6. Hold brake pedal down to maintain pedal pressure,
master cylinder. This procedure should be used to and open bleeder screw. Close bleeder screw and
change fluid or bleed brakes during regular release pedal.
maintenance.
CAUTION
Always wear safety glasses.
CAUTION
Brake fluid will damage finished surfaces.

Do not allow brake fluid to come in contact
with finished surfaces.
1. Clean master cylinder reservoir cover thoroughly and

remove the cover. NOTE: Do not release foot pedal before bleeder
screw is tight or air may be drawn into master
Remove cylinder.
Cover
7. Repeat procedure until clean fluid appears in bleeder
hose and all air has been purged. Add fluid as
necessary to maintain level in reservoir.
Master Cylinder
CAUTION
Maintain at least 1/2"(1.27 cm) of brake fluid in

the reservoir to prevent air from
entering the master cylinder.
8. Tighten bleeder screw securely and remove bleeder

2. If changing fluid, remove old fluid from reservoir with hose. Torque bleeder screw to specification.
a Mity Vac™ pump or similar tool.
=T
Mity Vac™: PN 2870975
Bleeder Screw:
47 in-lbs (5.3 Nm)
3. Add brake fluid to the indicated MAX level of reservoir.
9. Repeat steps 5 - 8 for the remaining calipers.
Polaris DOT 4 Brake Fluid
(PN 2872189) 10. Add brake fluid to MAX level inside reservoir.
4. Begin bleeding procedure with the caliper that is Master Cylinder Fluid Level
farthest from the master cylinder. Install a box end
wrench on caliper bleeder screw. Attach a clean, clear Between MIN and MAX lines on reservoir.
hose to fitting and place the other end in a clean
container. Be sure the hose fits tightly on fitting. 11. Install master cylinder reservoir cover.
9.8
BRAKES
12. Field test machine at low speed before putting into
service. Check for proper braking action and pedal
reserve. With pedal firmly applied, pedal reserve
should be no less than 1/2"(1.3 cm).
13. Check brake system for fluid leaks.
9.9
BRAKES
PARKING BRAKE (INT’L MODEL)
Exploded View
37 ft-lbs
(50 Nm)
Assembly
Bolts
Spacer
Parking Brake
Caliper
Parking Brake
Lever
Parking Brake Caliper / Shift Cable

Mount Bracket
Parking Brake Lever

Mount Bracket
Mounting Clip Nuts
Bolts 16 ft-lbs
37 ft-lbs (22 Nm)
(50 Nm)
Clevis
Pin
Clip
14 ft-lbs
(19 Nm) Bolts
Clevis
Pin
Tie Strap
Cable
9.10
BRAKES
Parking Brake Inspection 1. Pull back on parking brake lever (located in the dash).
1. Inspect parking brake cable and brake pads for wear. 2. After 3 to 4 clicks “BRAKE” should display on the
instrument cluster and the wheels should not rotate
2. Refer to “Parking Brake Cable Adjustment” if when turning by hand. After 8 full clicks of lever travel,
adjustment is necessary. Refer to “Parking Brake the vehicle should not roll while parked.
Caliper Service” for brake pad replacement.
3. If the vehicle moves, adjustment is necessary.
4. Adjust the parking brake cable where it attaches to the

Inspect Cable caliper mount / shift cable bracket. The mount bracket
is located on the right-hand side of the transmission.
Adjustment Procedure
1. Place the vehicle in neutral on a flat level surface.
2. Locate the parking brake cable adjustment area

where the cable attaches to the caliper mount bracket.
Parking Brake
Cable Adjustment
Outboard Pad
Inboard Pad
Mount Bracket
3. Use two open-end wrenches and loosen the outer jam

nut (D). Back out the outer jam nut (D) 1 1/2 turns.
To Parking
Parking Brake Cable Adjustment Brake Caliper
D C
When the parking brake is fully engaged and “BRAKE” is
displayed on the instrument cluster, engine speed is
limited to 1500 RPM while in gear. If throttle is applied, this
9
limiting feature prevents operation, which protects the
parking brake pads from excessive wear.
NOTE: Inspect parking brake cable tension after the

first 25 hours of operation and every 100 hours of Mount Bracket
operation afterwards to ensure proper cable tension.
4. Now hold the outer jam nut (D) and turn in the inner
Loss of tension in the parking brake cable will cause jam nut (C) clockwise, until the jam nut is tight against
illumination of the parking brake indicator and activation of the bracket.
the limiting feature. If this occurs, inspect and adjust
parking brake cable tension. If performing this service is 5. Repeat Step 3 and Step 4 until the proper adjustment
difficult due to conditions or location, temporarily is obtained for the parking brake.
disconnect the parking brake switch electrical connector.
Reconnect the connector as soon as practicable and NOTE: See Chapter 10 for more information on the
adjust the parking brake cable to proper tension. parking brake switch.
9.11
BRAKES
PARKING BRAKE CALIPER SERVICE (INT’L MODEL)
Caliper Exploded View
Figure 9.1 Pad & Holder Thrust Washer Lever

Apply Anti-Seize Lubricant
Assembly
Bolt
Sleeve
Nuts
37 ft-lbs
(50 Nm)
Sleeve
Steel Balls (3)
Assembly Shim Pack (4 Shims)

Bolt Apply Anti-Seize Lubricant Stationary Actuator
Spring
Caliper Removal
NOTE: Do not get oil, grease, or fluid on the parking 2. Remove the two fasteners (B) retaining the parking
brake pads. Damage to or contamination of the pads brake caliper mount / shift cable bracket.
may cause the pads to function improperly.
1. Remove the clip pin and pin (A) from the parking
brake cable.
NOTE: Be sure the parking brake is not engaged. Mount

Bracket
A B
3. Lift the parking brake caliper off the brake disc and
remove it from the vehicle.
9.12
BRAKES
Caliper Disassembly / Inspection New Brake Pad Installation
NOTE: Refer to the “Electronic Parts Catalog” for 1. Install new pads and assemble the caliper with one
parking brake caliper replacement parts information. shim. For shim location, see Figure 9.1 on page 9.11.
1. Remove the two caliper assembly bolts (C). 2. Measure gap for the brake disc and compare to gap
specification. Disassemble and add shim(s) between
thrust washer and the inside brake pad as needed to
close the gap to .207-.217 in. (5.25-5.51 mm).
Add shims until gap

measures .207”-.217”
(5.25-5.51 mm)
2. Slide the brake pads and springs from the assembly.

NOTE: Retain the lever and ball bearings for
reassembly.
3. Once you have determined the correct amount of
3. Inspect brake pads for excessive wear. Replace as
shims to use, reassemble the caliper and apply an
needed.
Anti-Seize Lubricant to the thrust washer and shims.
4. Check the three steel balls for any signs of cracking.
Replace as needed. 4. Torque the caliper assembly bolts to specification.
5. Check ball seats in lever and stationary actuator. If
excessively worn, replace parts as needed. =T
6. Measure thickness of the rear caliper parking brake
pads. Replace assembly or pads as needed. Refer to Parking Brake Caliper - Assembly Bolts:
the following image for brake pad specifications. 37 ft-lbs (50 Nm)
5. Ensure the parking brake assembly functions properly

Outboard Inboard by actuating the lever. Install the mounting sleeves (D)
Pad Pad before installation.
D
Outboard Pad Thickness Inboard Pad Thickness
New 0.250” (6.35 mm) New 0.300” (7.62 mm)
Limit: 0.190” (4.83 mm) Limit: 0.240” (6.10 mm)
9.13
BRAKES
Caliper Installation PARKING BRAKE DISC (INT’L MODEL)
1. Install the parking brake caliper over the brake disc.
Disc Inspection
Align the caliper mounting sleeves with the holes in
the mount bracket. 1. Measure the brake disc with a micrometer. If the
thickness of the disc is less than specified, replace
2. Install and tighten the two caliper mount / shift cable the brake disc (see “Disc Replacement”).
bracket fasteners to specification.
Mount
Bracket
Service Limit:
.150” (3.81 mm)
Disc Replacement
=T
1. Remove the parking brake caliper from the disc (see
“Caliper Removal”).
Parking Brake Caliper - Mount Bracket Bolts:
37 ft-lbs (50 Nm) 2. Using a 1/2” socket and ratchet, remove the brake
disc retaining bolt and flat washer.
3. Install the cable, pin and clip pin. Test the park brake
for proper function. 3. Remove the disc from the transmission shaft.
4. Install the new brake disc. Install the mounting bolt

and flat washer. Torque the mounting bolt to
specification.
Disc Bolt Washer
=T
Parking Brake Disc Mounting Bolt:
18-22 ft-lbs (24-30 Nm)
9.14
BRAKES
FRONT BRAKE PADS 6. Push the mounting bracket inward and slip the outer
brake pad out between the bracket and caliper body.
Pad Removal
1. Elevate and support front of vehicle.
CAUTION
Use care when supporting vehicle so that it

does not tip or fall.
Severe injury may occur if machine tips or falls.
2. Remove the wheel nuts and front wheel.

3. Loosen the pad adjuster screw 2-3 turns.
7. Remove the inner pad from the bracket and caliper.
Pad Inspection
1. Measure the thickness of the pad material. Replace
pads if worn beyond the service limit.
4. Remove the upper and lower caliper mounting bolts

and remove the caliper from the front hub.
NOTE: When removing caliper, use care not to
damage brake line. Support caliper to avoid kinking
or bending brake line.
5. Push caliper piston into caliper bore slowly using a
C-clamp or locking pliers with pads installed.
Measure
Thickness
Front Brake Pad Thickness:

NOTE: Brake fluid will be forced through .297 ± .007" (7.5 ± .178 mm)
compensating port into master cylinder fluid Service Limit: .180" (4.6 mm)
reservoir when piston is pushed back into caliper.
Remove excess fluid from reservoir as required.
9.15
BRAKES
Pad Assembly / Installation 4. Slowly pump the brake pedal until pressure has been
built up. Maintain at least 1/2" (12.7 mm) of brake fluid
1. Lubricate mounting bracket pins with a light film of in the reservoir to prevent air from entering the brake
silicone grease and install rubber dust boots. system.
5. Install the adjustment set screw and turn clockwise

Apply Grease to Each
Bracket Pin until stationary pad contacts disc, then back off 1/2
turn (counterclockwise).
1/2 Turn
2. Compress mounting bracket and make sure dust

boots are fully seated. Install pads with friction
material facing each other.
6. Verify fluid level in reservoir is up to MAX line inside

WARNING reservoir and install reservoir cap.
If brake pads are contaminated with grease, oil, Master Cylinder Fluid
or liquid soaked do not use the pads.
Use only new, clean pads. Up to MAX line inside reservoir
3. Install caliper onto front hub and torque mounting

bolts to specification. 7. Install wheel and torque wheel nuts to specification.
=T
Wheel Nuts:
30 ft-lbs (41 Nm) + 90° (1/4 turn)
Brake Burnishing Procedure

It is required that a burnishing procedure be performed
after installation of new brake pads to extend service life
40 ft-lbs and reduce noise.
(54 Nm)
Start machine and slowly increase speed to 30 mph.
Gradually apply brakes to stop machine. Allow pads and
disc to cool sufficiently during the procedure. Do not
=T
allow pads or disc to become hot or warping may result.
Repeat this procedure 10 times. Do not make more
Front Caliper Mount Bolt:
than 3 stops per 1 mile (1.6 km).
40 ft-lbs (54 Nm)
9.16
BRAKES
FRONT CALIPER SERVICE

Apply Polaris DOT 4 Brake
Fluid to Components
C
Apply Silicone Grease
B 47 in-lbs
(5.3 Nm)
D A
E D
F
G
H
A. Socket Set Screw 
B. Bleeder Screw 
I C. Caliper Assy. 
D. Boots 
E. Square O-rings
F. Pistons 
J G. Caliper Mount 
H. Brake Pads
I. Brake Scraper
J. Bolts
Caliper Removal
1. Elevate and safely support the front of the vehicle. 4. Place a container below the caliper to catch brake fluid
when removing the line. Remove brake line from
2. Remove the (4) wheel nuts and the front wheel. caliper.
9
CAUTION

tip or fall. Severe injury may occur.
3. Clean caliper area before removal.
Remove
Brake Line
9.17
BRAKES
5. Loosen brake pad adjustment set screw 2-3 turns to 3. Thoroughly clean the caliper before disassembly and
allow brake pad removal after the caliper is removed. prepare a clean work area for disassembly.
4. Use a commercially available caliper piston pliers to

extract the pistons from the caliper.
6. Remove the two caliper mounting bolts and remove

the caliper assembly from the front hub.
IMPORTANT: Do not remove the caliper pistons with

a standard pliers. The piston sealing surfaces will
become damaged if a standard pliers is used.
5. Once the pistons are removed, use a pick to carefully

remove the square O-rings from the caliper. O-rings
should be replaced during caliper service.
Remove
Caliper Disassembly
1. Remove both brake pads from the caliper (see
“FRONT BRAKE PADS - Pad Removal”).
2. Remove mount bracket assembly and dust boots.
9.18
BRAKES
6. Clean the caliper body, pistons and retaining bracket
with brake cleaner or alcohol.
Clean
Components
= In. / mm.
NOTE: Be sure to clean seal grooves in caliper
body. Front Caliper Piston O.D.:
Std: 1.370” (34.80 mm)
Caliper Inspection
3. Inspect the brake disc and pads as outlined in this
1. Inspect caliper body for nicks, scratches, pitting or
chapter.
wear. Measure bore size and compare to
specifications. Replace if damaged or worn beyond
service limit. Caliper Assembly
1. Install new O-rings in the caliper body. Be sure the
grooves are clean and free of residue or brakes may
drag upon assembly.
Seal
Grooves
9
New
O-Rings
= In. / mm.
Front Caliper Piston Bore I.D.: 2. Coat pistons with clean Polaris DOT 4 Brake Fluid.
Std: 1.373” (34.87 mm) Install pistons with a twisting motion while pushing
Service Limit: 1.375” (34.93 mm) inward. Piston should slide in and out of bore
smoothly, with light resistance.
2. Inspect piston for nicks, scratches, pitting or wear.
Measure piston diameter and replace if damaged or
worn beyond service limit.
9.19
BRAKES
3. Lubricate the mounting bracket pins with silicone 3. Torque the banjo bolt to the proper torque
grease and install the rubber dust seal boots. specification.

Bracket Pin
15 ft-lbs
(20 Nm)
4. Compress the mounting bracket and make sure the 4. Install the adjustment set screw and turn clockwise
dust seal boots are fully seated. Install the brake pads. until stationary pad contacts disc, then back off 1/2
Clean the disc and pads with brake parts cleaner or turn (counterclockwise).
denatured alcohol to remove any dirt, oil or grease.
Caliper Installation
1/2 Turn
1. Install the brake line onto the caliper taking care not
to allow any debris to enter the caliper.
2. Install the caliper and torque the mounting bolts to

specification.
IMPORTANT: If disc scraper was removed, reinstall it

upon caliper installation.
Disc
Scraper
5. Perform brake bleeding procedure as outlined earlier
in this chapter.
6. Install wheel and torque wheel nuts to specification.
=T
Wheel Nuts:
40 ft-lbs 30 ft-lbs (41 Nm) + 90° (1/4 turn)
(54 Nm)
7. Field test unit for proper braking action before putting
into service. Inspect for fluid leaks and firm brakes.
=T Make sure the brake is not dragging when pedal is
released. If the brake drags, re-check assembly and
Front Caliper Mount Bolt: installation.
40 ft-lbs (54 Nm)
NOTE: If new pads are installed, refer to “FRONT
BRAKE PADS - Brake Burnishing Procedure”.
9.20
BRAKES
FRONT BRAKE DISC
Brake Disc Thickness
Disc Runout New: .188” (4.78 mm)
1. Mount dial indicator as shown to measure disc Service Limit: .170” (4.32 mm)
runout. Slowly rotate the disc and read total runout on
the dial indicator. Replace the disc if runout exceeds
specification. Brake Disc Thickness Variance
difference between measurements
Disc Replacement
1. Remove the front brake caliper (see “FRONT
CALIPER SERVICE”).
2. Remove wheel hub cotter pin, castle nut and washers.
3. Remove the wheel hub assembly from the vehicle and

remove the (4) bolts retaining the disc to the hub.
(4) Bolts
Cotter
Pin
Washers
Brake Disc Runout:

Nut
Disc Inspection
4. Clean the wheel hub mating surface and install new
1. Visually inspect disc for scoring, scratches, or disc on wheel hub.
gouges. Replace disc if deep scratches are evident.
2. Use a 0-1” micrometer and measure disc thickness at

eight different points around the pad contact surface.
9
Replace disc if worn beyond service limit.
Measure
Thickness
Front
Disc
9.21
BRAKES
5. Install new bolts and torque to specification.
30 ft-lbs
(41 Nm)
=T
New Bolts:
30 ft-lbs (41 Nm)
CAUTION
Always use new brake disc mounting bolts. The

bolts have a pre-applied locking agent which is
destroyed upon removal.
6. Install wheel hub assembly, washers, and castle nut.

Torque castle nut to specification and install a new
cotter pin.
=T
Castle Nut:
80 ft-lbs (108 Nm)
7. Install the front brake caliper (see “FRONT CALIPER

SERVICE”).
8. Follow bleeding procedure outlined earlier in this

chapter.

Make sure the brake is not dragging when pedal is
released. If the brake drags, re-check assembly and
installation.
9.22
BRAKES
REAR BRAKE PADS (RZR XP) 5. Remove the two caliper mounting bolts and lift caliper
off the brake disc.
Pad Removal
1. Elevate and support rear of vehicle.
CAUTION

2. Remove the rear wheel.
3. Loosen pad adjuster screw 2-3 turns.
NOTE: When removing caliper, be careful not to

6. Push caliper piston into the caliper bore slowly using

a C-clamp or locking pliers with pads installed.

NOTE: Brake fluid will be forced through

compensating port into master cylinder fluid
reservoir when piston is pushed back into caliper. 9
9.23
BRAKES
7. Push caliper mounting bracket inward and slip outer Pad Assembly / Installation
brake pad past the edge to remove.
1. Lubricate mounting bracket pins with a light film of
silicone grease and install rubber dust boots.
8. Remove the inner brake pad.

boots are fully seated. Install pads with friction
WARNING
If brake pads are contaminated with grease,

oil, or liquid soaked do not use the pads.
Use only new clean pads.
3. Install the caliper and torque the new mounting bolts

to specification.
Pad Inspection
1. Clean the caliper with brake cleaner or alcohol.

40 ft-lbs
(54 Nm)
Measure
Thickness =T
Rear Caliper Mount Bolt:
40 ft-lbs (54 Nm)
Rear Brake Pad Thickness:
.298” ± .007” (7.57 mm ± .178 mm)
Service Limit: .180” (4.6 mm)
9.24
BRAKES
4. Install lower radius rod bolt, washer and new nut. Brake Burnishing Procedure
and reduce noise.

allow pads or disc to become hot or warping may result.
=T
Radius Rod to Bearing Carrier Bolt:
45 ft-lbs (61 Nm)
5. Slowly pump the brake pedal until pressure has been

built up. Maintain at least 1/2, (12.7 mm) of brake fluid
in the reservoir to prevent air from entering the brake
system.
6. Install the adjustment set screw and turn clockwise

until the stationary pad contacts the disc, then back
off 1/2 turn.
7. Verify fluid level in reservoir is up to the MAX line

inside reservoir and install reservoir cap.
Master Cylinder Fluid
Up to MAX line inside reservoir

9
=T
Wheel Nuts:
30 ft-lbs (41 Nm) + 90° (1/4 turn)
9.25
BRAKES
REAR BRAKE PADS (RZR XP 4) 5. Remove the two caliper mounting bolts and lift caliper
off the brake disc.
Pad Removal
1. Elevate and support rear of vehicle.
CAUTION

2. Remove the rear wheel.
3. Loosen pad adjuster screw 2-3 turns.
NOTE: When removing caliper, be careful not to

6. Push caliper piston into the caliper bore slowly using

a C-clamp or locking pliers with pads installed.

NOTE: Brake fluid will be forced through

compensating port into master cylinder fluid
reservoir when piston is pushed back into caliper.
9.26
BRAKES
7. Push the mounting bracket inward and slip outer Pad Assembly / Installation
brake pad out between the bracket and caliper body.
1. Lubricate mounting bracket pins with a light film of
silicone grease and install rubber dust boots.

Bracket Pin
8. Remove the inner pad from the bracket and caliper.

Pad Inspection boots are fully seated. Install pads with friction
WARNING
If brake pads are contaminated with grease,

oil, or liquid soaked do not use the pads.
Use only new clean pads.
3. Install the caliper and torque the new mounting bolts

to specification.
40 ft-lbs
(54 Nm) 9
Measure
Thickness =T
Front Brake Pad Thickness 40 ft-lbs (54 Nm)
New: .298 ± .007” (7.56 ± .178 mm)
9.27
BRAKES
4. Install lower radius rod bolt, washer and new nut. 8. Install wheel and torque wheel nuts to specification.
=T
Wheel Nuts:
30 ft-lbs (41 Nm) + 90° (1/4 turn)
Brake Burnishing Procedure

and reduce noise.

=T allow pads or disc to become hot or warping may result.
45 ft-lbs (61 Nm)
5. Slowly pump the brake pedal until pressure has been

built up. Maintain at least 1/2" (12.7 mm) of brake fluid
in the reservoir to prevent air from entering the brake
system.
6. Install the pad adjuster set screw and turn clockwise

until stationary pad contacts disc, then back off 1/2
turn (counterclockwise).
1/2 Turn
Pad
Adjuster
7. Verify fluid level in reservoir is up to the MAX line

inside reservoir and install reservoir cap.
Master Cylinder Fluid
Up to MAX line inside reservoir
9.28
BRAKES
REAR CALIPER SERVICE (RZR XP)

Fluid to Component
D Apply Silicone Grease

47 in-lbs
(5.3 Nm) G
I
H A
E
F
A. Brake Pad
B. Mount Bracket C
C. Piston
D. Caliper Assy.
E. Square Ring (thick)
F. Square Ring (thin) B
G. Boot, Pin Bushing
H. Boot, Pin Seal
I. Bleeder Screw
K. Set Screw
Caliper Removal
1. Elevate and safely support the rear of the vehicle. 3. Place a container below the caliper to catch the brake
fluid when removing the line. Remove brake line from
CAUTION
caliper. 9
2. Remove the (4) wheel nuts and rear wheel. Clean

caliper area before removal.
9.29
BRAKES
4. Remove the lower radius rod outer mounting bolt, nut Caliper Disassembly
down. Discard nut. 1. Remove brake pad adjustment set screw (K).
2. Push upper pad retainer pin inward and slip brake
pads past the edge and remove from the caliper.
3. Remove mount bracket (B) and dust boots (G and H).
D
G
K
Pads
H
E F
C
5. Loosen the brake pad adjustment set screw to allow

B
brake pad removal after the caliper is removed.
6. Remove the two caliper mounting bolts and remove 4. Using a hammer and a small punch, remove the
the caliper. piston (C) from the caliper body (D). Remove the
square O-rings (E) and (F) from the caliper body (D).
5. Clean the caliper body, piston, and retaining bracket

NOTE: Be sure to clean caliper body seal grooves.
Clean Components
9.30
BRAKES
Caliper Inspection Caliper Assembly
1. Inspect caliper body for nicks, scratches or wear. 1. Install new caliper seals (A) in the caliper body (B).
Measure bore size and compare to specifications. Be sure groove is clean and free of residue or brakes
Replace if damage is evident or if worn beyond may drag upon assembly.
service limit.
B
2. Coat piston with clean Polaris DOT 4 Brake Fluid (PN

2872189). Install piston (D) with a twisting motion
= In. / mm. while pushing inward. Piston should slide in and out
of bore smoothly with light resistance.
Rear Caliper Piston Bore I.D.: 3. Lubricate the mounting bracket pins with silicone
Standard: 1.505” (38.23 mm) grease and install the rubber dust seal boots.
2. Inspect piston for nicks, scratches, wear or damage.

Measure diameter and replace if damaged or worn
beyond service limit.
4. Compress the mounting bracket and make sure the

9
dust seals are fully seated. Install the brake pads.
Clean the disc and pads with brake parts cleaner or
= In. / mm.
Rear Caliper Piston O.D.:

Standard: 1.500” (38.10 mm)

chapter.
9.31
BRAKES
Caliper Installation 3. Install lower radius rod bolt, washer and new nut.
1. Install the rear caliper with new mounting bolts.
Torque mounting bolts to specification.
40 ft-lbs
(54 Nm)
=T
=T Radius Rod to Bearing Carrier Bolt:
45 ft-lbs (61 Nm)
40 ft-lbs (54 Nm)
4. Install the pad adjustment screw and turn until
stationary pad contacts disc, then back off 1/2 turn.
2. Install brake line banjo bolt and torque to specification.
5. Follow bleeding procedure outlined earlier in this
chapter.
=T
Wheel Nuts:
30 ft-lbs (41 Nm) + 90° (1/4 turn)
NOTE: If new pads are installed, refer to “REAR

9.32
BRAKES
REAR CALIPER SERVICE (RZR XP 4)
Rear Caliper Exploded View

Fluid to Component 47 in-lbs B
(5.3 Nm)
Apply Silicone Grease A
E
H
D
I
A. Socket Set Screw

B. Bleeder Screw
C. Caliper Asm.
D. Boot
E. Square O-rings (large)
F. Square O-rings (small)
G. Piston
H. Caliper Mount
I. Brake Pads
Caliper Removal
1. Elevate and safely support the rear of the vehicle. 4. Place a container below the caliper to catch brake
9
fluid. Remove brake line from caliper.
CAUTION

2. Remove (4) wheel nuts and rear wheel.
3. Clean caliper area before removal.

Remove
Brake Line
9.33
BRAKES
5. Remove the lower radius rod outer mounting bolt, nut Caliper Disassembly
down. Discard nut. 1. Remove both brake pads from the caliper. Refer to
“REAR BRAKE PADS (RZR XP 4)”.
2. Remove mount bracket assembly and dust boots from

caliper. Thoroughly clean caliper before disassembly
and prepare a clean work area for disassembly.
6. Loosen the brake pad adjustment set screw to allow

brake pad removal after the caliper is removed.
7. Remove the two caliper mounting bolts and remove

the caliper.
3. Use a commercially available caliper piston pliers to
extract the pistons from the caliper.
IMPORTANT: Do not remove the caliper pistons with

a standard pliers. The piston sealing surfaces will
become damaged if a standard pliers is used.
9.34
BRAKES
4. Once the pistons are removed, use a pick to carefully Caliper Inspection
remove the square O-rings from the caliper. O-rings
should be replaced during caliper service. 1. Inspect caliper body for nicks, scratches, pitting or
wear. Measure bore size and compare to
specifications. Replace if damaged or worn beyond
service limit.
5. Clean the caliper body, piston, and retaining bracket

= In. / mm.
Caliper Piston Bore I.D.:

Std: 1.192” (30.28 mm)
2. Inspect piston for nicks, scratches, pitting or wear.

Measure piston diameter and replace if damaged or
worn beyond service limit.
Clean
Components
IMPORTANT: Be sure to clean the seal grooves in

caliper body.
= In. / mm.
Caliper Piston O.D.:

Std: 1.186” (30.12 mm)

chapter.
9.35
BRAKES
Caliper Assembly Caliper Installation
1. Install new O-rings in the caliper body. Be sure the 1. Install the rear caliper with new mounting bolts.
grooves are clean and free of residue or brakes may Torque mounting bolts to specification.
drag upon assembly.
40 ft-lbs
(54 Nm)
Seal
Grooves
New
O-Rings
2. Coat pistons with clean Polaris DOT 4 Brake Fluid. =T

Install pistons with a twisting motion while pushing
inward. Piston should slide in and out of bore Rear Caliper Mount Bolt:
smoothly, with light resistance. 40 ft-lbs (54 Nm)
3. Lubricate the mounting bracket pins with silicone 2. Install the brake line and torque the banjo bolt to the
grease and install the rubber dust seal boots. proper torque specification.

Bracket Pin
15 ft-lbs
(20 Nm)
4. Compress the mounting bracket and make sure the

dust seal boots are fully seated. Install the brake pads.
Clean the disc and pads with brake parts cleaner or
9.36
BRAKES
3. Install the pad adjustment screw and turn until
stationary pad contacts disc, then back off 1/2 turn.
1/2 Turn
Pad
Adjuster
4. Install lower radius rod bolt, washer and new nut.

=T
45 ft-lbs (61 Nm)
5. Follow brake bleeding procedure outlined earlier in

9
this chapter.
=T
Wheel Nuts:
30 ft-lbs (41 Nm) + 90° (1/4 turn)
NOTE: If new pads are installed, refer to “REAR

9.37
BRAKES
REAR BRAKE DISC Disc Replacement
1. Remove rear brake caliper (see “REAR CALIPER
Disc Inspection
SERVICE”).
1. Visually inspect disc for scoring, scratches, or
gouges. Replace disc if deep scratches are evident. 2. Remove wheel hub cotter pin, castle nut and washers.
2. Use a 0-1” micrometer and measure disc thickness at 3. Remove the hub assembly from the vehicle and
eight different points around the pad contact surface. remove the (4) bolts retaining the disc to the hub.
Replace disc if worn beyond service limit.
(4) Bolts
Cotter
Side Pin
View
Front Washers
View
Measure Nut
Thickness
4. Clean the wheel hub mating surface and install new
disc on wheel hub.
Brake Disc Thickness
5. Install new bolts and torque to specification.
New: .188” (4.78 mm)
Brake Disc Thickness Variance

Difference Between Measurements
3. Mount a dial indicator and measure disc runout.

Slowly rotate the disc and read total runout on the dial
30 ft-lbs
indicator. Replace the disc if runout exceeds
(41 Nm)
specifications.
Brake Disc Runout:

Service Limit: .010” (.254 mm) CAUTION
Always use new brake disc mounting bolts. The

bolts have a pre-applied locking agent which is
destroyed upon removal.
=T
Brake Disc Mounting Bolts:
30 ft-lbs (41 Nm)
9.38
BRAKES
6. Install wheel hub assembly, washers, and castle nut. TROUBLESHOOTING
Torque castle nut to specification and install a new
cotter pin. Brakes Squeal / Poor Brake Performance
• Air in system
=T
• Water in system (brake fluid contaminated)
Rear Wheel Hub Castle Nut: • Caliper or disc misaligned
80 ft-lbs (108 Nm)
• Caliper dirty or damaged
7. Install rear caliper (see “REAR CALIPER SERVICE”). • Brake line damaged or lining ruptured
Follow bleeding procedure outlined earlier in this • Worn disc and/or friction pads
chapter.
• Incorrectly adjusted stationary pad
• Worn or damaged master cylinder or components
Make sure brakes do not drag when pedal is released. • Damaged break pad noise insulator
If the brakes drag, re-check assembly and installation.
• Brake pads dragging
• Brake caliper dragging
Pedal Vibration
• Disc damaged
• Disc worn (runout or thickness variance exceeds
service limit)
Caliper Overheats (Brakes Drag)

• Compensating port plugged
• Pad clearance set incorrectly
• Parking brake lever incorrectly adjusted (INT’L
Model)
• Brake pedal binding or unable to return fully
• Parking brake left on (INT’L Model)
• Residue build up under caliper seals
• Operator riding brakes
9
Brakes Lock
• Alignment of caliper to disc
• Caliper pistons sticking
• Improper assembly of brake system components
9.39
BRAKES
NOTES
9.40
ELECTRICAL
CHAPTER 10
ELECTRICAL
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
UNDER-DASH COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
RIDER INFORMATION DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
INFORMATION DISPLAY AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
DIAGNOSTIC MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8
INSTRUMENT CLUSTER PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9
INSTRUMENT CLUSTER REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 10.10
SWITCHES / CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
BRAKE LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
IGNITION KEY SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
IGNITION KEY SWITCH (INT’L). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
AWD / 2WD SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
AWD / 2WD / TURF SWITCH (INT’L). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
TURN SIGNAL SWITCH (INT’L). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
HAZARD SWITCH (INT’L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
TRANSMISSION (GEAR POSITION) SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
PARKING BRAKE SWITCH (INT’L MODEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
THROTTLE RELEASE SWITCH (TRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
REAR DIFF SOLENOID (INT’L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
ALL WHEEL DRIVE COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
HEAD LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
HEADLIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
HEADLAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
HEADLAMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
TAIL / BRAKE LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
BULB REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
COOLING SYSTEM BREAK-OUT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
FAN CONTROL CIRCUIT OPERATION / TESTING / CIRCUIT BYPASS TEST. . . . . 10.23
COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
EFI DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
FUEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23
FUSE BOX: FUSES / RELAYS / CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
OVERVIEW / OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
FUSE BOX DETAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
RELAY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
10
CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
CHARGING SYSTEM “BREAK EVEN” TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28
CHARGING SYSTEM STATOR (ALTERNATOR) TESTS . . . . . . . . . . . . . . . . . . . . . . 10.29
STATOR (ALTERNATOR) REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
REGULATOR / RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
CHARGING SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
10.1
ELECTRICAL
BATTERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
BATTERY SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
GENERAL BATTERY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
BATTERY REMOVAL / INSTALLATION / OFF SEASON STORAGE . . . . . . . . . . . . . 10.33
BATTERY TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
OCV - OPEN CIRCUIT VOLTAGE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
BATTERY CONDUCTANCE ANALYZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34
CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34
STARTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
STARTER MOTOR REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35
STARTER SOLENOID BENCH TEST / OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 10.36
STARTING SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37
ELECTRONIC POWER STEERING (EPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38
EPS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38
PROPER EPS SYSTEM DIAGNOSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38
EPS SYSTEM BREAKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
EPS TROUBLESHOOTING (EPS NON-FUNCTIONAL WITH MIL ON) . . . . . . . . . . . 10.40
EPS TROUBLESHOOTING (EPS NON-FUNCTIONAL WITH MIL OFF) . . . . . . . . . . 10.41
EPS TROUBLESHOOTING (USING DIGITAL WRENCH®) . . . . . . . . . . . . . . . . . . . . 10.42
ELECTRICAL SYSTEM BREAKOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.43
AWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.43
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.43
COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.44
CHASSIS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.45
STARTER-INTERLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.45
KEY-ON BATTERY POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.46
LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.47
CHARGING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.48
10.2
ELECTRICAL
GENERAL INFORMATION Under-Dash Components
The following switches and components can be accessed
Special Tools
underneath the instrument / dash panel:
Part Number Tool Description • Speedometer
PV-43568 Fluke™ 77 Digital Multimeter • Digital Wrench® Diagnostic Connector
PV-43526 Connector Test Kit • AWD Switch
2870630 Timing Light • Headlamp Switch
PU-50338 Battery Hydrometer • 12 Vdc Accessory Power Point
2460761 Hall Effect Sensor Probe Harness • Ignition Switch
2871745 Static Timing Light Harness • Fuse / Relay Box
Battery Conductance Analyzer

PU-50296
(MDX-610P)
PU-49466 Relay Bypass
- Digital Wrench® (see Chapter 4)
Electrical Service Notes

Keep the following notes in mind when diagnosing an
electrical problem:
• Refer to wiring diagram for stator and electrical
component resistance specifications.
• When measuring resistance of a component that
has a resistance value under 10 Ohms, remember
to subtract meter lead resistance from the reading.
Connect the leads together and record the
resistance. The resistance of the component is
equal to tested value minus the lead resistance.
• Become familiar with the operation of your meter.
Be sure leads are in the proper jack for the test
being performed (i.e. 10A jack for current
readings). Refer to the Owner’s Manual included
with your meter for more information.
• Voltage, amperage, and resistance values
included in this manual are obtained with a
Fluke™ 77 Digital Multimeter (PV-43568). This
10
meter is used 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.
10.3
ELECTRICAL
INSTRUMENT CLUSTER
Overview
The instrument cluster displays critical vehicle information to the user. Reference the following page for display functions
and descriptions.
NOTE: Some features are not applicable to all models.
IMPORTANT: The use of a high pressure washer may damage the instrument cluster. Wash the vehicle by hand
or with a garden hose using mild soap. Certain products, including insect repellents and chemicals, will damage
the instrument cluster lens. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to
contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster.
10.4
ELECTRICAL
Rider Information Display 12. Neutral Gear Indicator - LED icon illuminates when
gear selector is in the neutral (N) position.
The rider information display is located in the instrument
cluster. All segments will light up for 1 second at start-up. 13. Gear Position Indicator - Displays gear selector
position.
NOTE: If the instrument cluster fails to illuminate, a
battery over-voltage may have occurred and the H = High
instrument cluster may have shut off to protect the
L = Low
electronic speedometer.
N = Neutral
1. Vehicle Speed Display - Analog display of vehicle
R = Reverse
speed in MPH or km/h.
P = Park
2. Information Display Area - Odometer / Trip Meter
-- = Gear Signal Error (shifter stuck between gears)
/ Tachometer / Engine Temperature / Engine
Hours / Service Info / Clock - LCD display of the 14. Power Steering System MIL - LED icon illuminates
service hour interval, total vehicle miles or km., total when a fault has occurred with the power steering
engine hours, a trip meter, engine RPM and engine system. This indicator illuminates when the key is
temperature. turned to the ON position and goes off when the
engine is started (EPS Option Only).
3. MPH / KM/H Display - MPH is displayed when the
instrument cluster is in the Standard mode. KM/H is 15. Turn Signal / Hazard Lamp Indicator - LED icon
displayed when the instrument cluster is in the Metric illuminates whenever the LH, RH or hazard lamps are
mode. activated (INT’L Models Only).
4. High Beam Indicator LED icon illuminates whenever 16. Helmet / Seat Belt Indicator - LED icon illuminates
the Headlamp switch is in the high beam position. for several seconds when the key is turned to the ON
position. The lamp is a reminder to the operator to
5. Fuel Level Indicator - LCD bar graph indicating ensure all riders are wearing helmets and seat belts
current fuel level. All segments will flash when the last before operating the vehicle.
segment is cleared indicating a low fuel warning.
6. Clock - Displays current time in either 12-hour or 24- Information Display Area
hour formats.
The LCD portion of the instrument cluster is the
7. Engine Temperature Indicator - LED icon information display area. Information displayed in this
illuminates when the ECM determines the engine is area includes: odometer, trip meter, engine RPM, engine
overheating. The indicators will initially flash to hours, service interval, clock, engine Diagnostic Trouble
indicate the engine is overheating. The indicators will Codes (DTCs) and power steering DTCs.
stay lit and not flash if a severe overheating condition
exists. Odometer
8. Service Interval Indicator - Preset at the factory and

adjustable by the user, a flashing wrench symbol
alerts the operator that the preset service interval has
been reached and maintenance should be performed.
The wrench icon will flash for 10 seconds upon start- 10
up once it reaches 0.
9. Check Engine MIL - Illuminated when the ECM has

detected a Diagnostic Trouble Code in the engine
management system.
10. AWD Indicator - Illuminated when the AWD / TURF

switch is in the AWD position.
The odometer records and displays the total distance
11. TURF Indicator - Illuminated when the AWD / TURF traveled by the vehicle. The odometer can not be reset.
switch is in the TURF position (INT’L Model Only).
10.5
ELECTRICAL
Trip Meter Engine Hours
The trip meter records the miles traveled by the vehicle on Engine hours are logged anytime the engine is running.
each trip. To reset the trip meter: Total hours can not be reset.
1. Toggle the MODE button to TRIP 1. Programmed Service Interval
2. To reset to 0, push and hold the MODE button until

the distance display changes to 0.
Tachometer (RPM)
The initial factory service interval setting is 50 hours. Each

time the engine is started, the engine hours are subtracted
from the service interval hours. When the service interval
reaches 0, the LCD wrench icon will flash for
approximately 10 seconds each time the engine is started.
Engine RPM can be displayed digitally.
To change the hour setting or reset the function, follow
Engine Temperature these steps:
1. Toggle the MODE button until the wrench icon is

displayed in the information area.
2. Press and hold the MODE button until the information

display area begins to flash.
3. Toggle the MODE button to increase the service

interval hours in 5 hour increments to a maximum of
100 hours.
4. To turn off the service interval function, toggle the

MODE button until “OFF” is displayed.
Engine temperature can be displayed in ° F or ° C. Refer

to “Units of Measurement” to change the format.
10.6
ELECTRICAL
Clock Units of Measurement
Standard Display Metric Display
Distance Miles (MPH) Kilometers (KM/H)

Time 12-Hour Clock 24-Hour Clock
Temperature Fahrenheit Celsius
To change between Standard and Metric units of

measurement, follow these steps:
1. Turn the key to the OFF position.
2. Press and hold the MODE button while turning the key
The clock displays the time in a 12-hour or 24-hour format. to the ON position.
Refer to “Units of Measurement” to change the format
(Standard 12-hour / Metric-24 hour). To set the clock, 3. When the display flashes the distance setting, tap the
follow these steps: MODE button to advance to the desired setting.
1. Toggle the MODE button until the odometer is

displayed.
2. Press and hold the MODE button until the hour

segment flashes. Release the button.
3. With the segment flashing, tap the MODE button to

advance to the desired setting.
4. Press and hold the MODE button until the next

segment flashes. Release the button.
5. Repeat steps 3-4 twice to set the 10 minute and 1

minute segments. After completing the 1-minute
segment, step 4 will save the new settings and exit the
clock mode.
10
4. Press and hold the MODE button to save the setting
and advance to the next display option.
5. Repeat the procedure to change remaining display

settings.
10.7
ELECTRICAL
Under / Over Voltage Park Brake Indicator (INT’L Model Only)
This warning usually indicates that the vehicle is operating This warning is used to notify the operator that the park
at an RPM too low to keep the battery charged. It may also brake lever is engaged.
occur when the engine is at idle and a high electrical load
is applied (lights, cooling fan or other accessories). When the park brake is fully engaged, “BRAKE” appears
in the rider information display. Engine speed is limited to
If battery voltage drops below 11 volts, a warning screen 1500 RPM in all gears, except neutral. If throttle is applied,
will display “Lo” and provide the present battery voltage. If this limiting feature prevents operation, which protects the
voltage drops below 8.5 volts, LCD backlighting and icons park brake pads from excessive wear.
will turn off.
If battery voltage rises above 15 volts, a warning screen Diagnostic Mode

will display “OV” and provide the present battery voltage.
If voltage rises above 16.5 volts, LCD backlighting and The diagnostic mode is accessible only when the check
icons will turn off. engine MIL has been activated.
Use the following procedure to display diagnostic trouble

codes that were activated during current ignition cycle
causing the MIL to illuminate. Diagnostic trouble codes will
remain stored in the gauge (even if MIL turns off) until the
key is turned off.
1. If the trouble code(s) are not displayed, use the

MODE button to toggle until “CK ENG” displays on
the information display area.
2. Press and hold the MODE button to enter the

diagnostics code menu.
10.8
ELECTRICAL
3. A set of three numbers will appear in the information Instrument Cluster Pinouts
area.
• The first number (located far left) can range from 0

to 9. This number represents the total number of
trouble codes present (example: 2 means there
are 3 codes present).
• The second number (located top right) can be 2 to
6 digits in length. This number equates to the
suspected area of fault (SPN).
• The third number (located bottom right) can be 1 to
2 digits in length. This number equates to the fault
mode (FMI).
FUNCTION PIN
CAN High 1
CAN Low 2
Switched Power (Vdc) 3
Constant Power (Vdc) 4
Ground 5
High Beam Input 8
Fuel Level Sensor 11
International Models Only
Turn Signal Input, LH 6
Turn Signal Input, RH 7
4. Use the trouble code reference table in the EFI

Chapter for a description of each code (see Chapter
4).
5. If more than one code exists, press the MODE button

to advance to the next trouble code.
6. To exit the diagnostic mode, press and hold the

MODE button or turn the ignition key OFF once the
codes are recorded.
NOTE: If there is a diagnostic problem with the

power steering system, the power steering MIL will
illuminate and blink in place of the check engine MIL.
10
10.9
ELECTRICAL
Instrument Cluster Removal Instrument Cluster Installation
NOTE: Do not allow alcohol or petroleum products 1. Spray a soap and water mixture onto the outer
to come in contact with the instrument cluster lens. surface area of the instrument cluster. This will help
the instrument cluster slide into the rubber mount
1. Disconnect the wire harness connector from the back more easily.
side of the instrument cluster.
2. Push the instrument cluster out from the back side of

the dash while securely holding the dash and rubber
mount.
Push Instrument Dash Panel
Cluster Outward
2. Be sure the rubber mount inside the dash is fully

installed and that the indexing key on the rubber
mount is lined up with the keyway in the dash.
3. Hold the dash securely and insert the instrument

Rubber Mount cluster into the dash. Twist the instrument cluster
gently in a clockwise motion to properly seat the
instrument cluster into the rubber mount. Apply
Instrument Cluster pressure on the bezel while pressing down on the
Bezel instrument cluster.
NOTE: Do not remove the rubber mount from the

dash panel. Only remove the rubber mount if
necessary. The bezel is a snap-on assembly and is a
serviceable part.
10.10
ELECTRICAL
SWITCHES / CONTROLS Headlamp Switch
1. Disconnect the headlamp switch harness by
Brake Light Switch
depressing the connector locks and pulling on the
1. The brake light switch is located on the front brake connector. Do not pull on the wiring.
line banjo bolt of the master cylinder. The brake
switch can be accessed through the left front wheel 2. Test between the 3 sets of outputs (OFF / LOW /
well opening. HIGH). If any of the tests fail, replace headlamp switch
assembly.
• Move the switch to HIGH. There should be

continuity between switch pins 2 and 3; 5 and 6.
Brake Light Switch • Move the switch to LOW. There should be
• Move the switch to OFF. There should be
2. Disconnect wire harness from switch and connect an

ohmmeter across switch contacts. The reading
should be infinite (OL).
3. Apply the brake and check for continuity. If there is no

continuity or if resistance is greater than 0.5 ohms,
clean the switch terminals. Re-test and replace switch
if necessary.
4. For switch replacement, refer to Chapter 9 “Brakes”.
NOTE: Pins 7 and 8 provide power and ground to

light the switch lamp.
10
10.11
ELECTRICAL
Ignition Key Switch Ignition Key Switch (INT’L)
1. Disconnect the key switch harness by depressing the 1. Disconnect the key switch harness by lifting the
connector lock and pulling on the connector. Do not connector lock and pulling on the connector. Do not
pull on the wiring. pull on the wiring.
2. Test between the 3 sets of outputs (OFF / ON / 2. Test between the 4 sets of outputs (OFF / ON LIGHTS
START). If any of the tests fail, replace ignition switch / ON / START). If any of the tests fail, replace ignition
assembly. switch assembly.
• Turn the ignition key to ON. There should be • Turn the ignition key to ON LIGHTS. There should
continuity between switch pins C and D. be continuity between switch pins A, E and F; C
and D.
• Turn the ignition key to START. There should be
continuity between switch pins A and B; C and D. • Turn the ignition key to ON. There should be
continuity between pins C and D; E and F.
• Turn the ignition key to START. There should be
continuity between pins A and B; C and D; E and
F.
10.12
ELECTRICAL
AWD / 2WD Switch AWD / 2WD / TURF Switch (INT’L)
1. Disconnect the AWD / 2WD switch harness by 1. Disconnect the AWD / 2WD / TURF switch harness
depressing the connector locks and pulling on the by depressing the connector locks and pulling on the
connector. Do not pull on the wiring. connector. Do not pull on the wiring.
2. Test between the 2 sets of outputs (AWD / 2WD). If 2. Test between the 3 sets of outputs (AWD / 2WD /
any of the tests fail, replace the switch assembly. TURF). If any of the tests fail, replace the switch
assembly.
• Move the switch to AWD (ON). There should be
continuity between switch pins 2 and 3. • Move the switch to AWD. There should be
• Move the switch to 2WD (NONE / OFF). There
should be no continuity between any pins. • Move the switch to 2WD. There should be no
continuity between any pins.
• Move the switch to TURF. There should be
10
10.13
ELECTRICAL
Turn Signal Switch (INT’L) Transmission (Gear Position) Switch
1. Disconnect the Turn Signal switch harness by 1. The transmission (gear position) switch is located on
depressing the connector locks and pulling on the the RH side of the transmission and can be accessed
connector. Do not pull on the wiring. through the RH wheel well area.
2. Test between the 5 sets of outputs (HI BEAM / LO 2. Disconnect the transmission switch harness by lifting
BEAM / L-TURN / R-TURN / HORN). If any of the tests the connector lock and pulling on the connector. Do
fail, replace the switch assembly. not pull on the wiring.
3. Test the transmission switch continuity readings for
each gear position and compare to the specification
table below.
Orientation
Tab
1 2 3 4 6 7 8 9
HI BEAM
LO BEAM
L - TURN
R - TURN
HORN
Hazard Switch (INT’L)

1. Disconnect wires or harness from the Hazard switch.
2. Test between the outputs (ON / NONE / OFF). If any

of the tests fail, replace the switch assembly.
• Move switch to ON. There should be continuity
between switch pins 2 and 3.
• Move switch to NONE / OFF. There should be no
continuity between switch pins.
Resistance Value
Gear Position when measured at
switch terminals A and B
HIGH 24 
LOW 75 
NEU 160 
REV 300 
PARK 620 
10.14
ELECTRICAL
Parking Brake Switch (INT’L Model) Testing The Parking Brake Switch
The parking brake switch is located within the parking 1. Disconnect the harness connector at the parking
brake lever. Remove the rubber boot covering the parking brake switch (Orange/Red and Red/Blue wires).
brake lever to locate the internally mounted switch.
2. Place the ohmmeter leads onto the switch terminals.
The reading should be infinite (OL).
3. Apply the parking brake. Continuity should now exist

between the switch terminals. If no continuity exists
when the parking brake is applied, try to clean the
switch terminals and re-test. Replace switch if
necessary.
Park Brake Indicator

This warning is used to notify the operator that the park
The switch remains in the “open” position when the park brake lever is engaged.
brake lever is not applied.
When the parking brake is fully engaged, “BRAKE”
When the parking brake lever is applied, the switch makes appears in the rider information display. Engine speed is
contact and sends voltage to the ECU to illuminate limited to 1500 RPM in all gears, except neutral. If throttle
“BRAKE” in the instrument cluster rider information is applied, this limiting feature prevents operation, which
display area (see “Park Brake Indicator”). protects the park brake pads from excessive wear.
NOTE: If the parking brake is applied the ECU will

rev limit the engine at 1500 RPM until the parking
brake is released. This feature has been added to
prevent drive-away with the parking brake applied.
10
10.15
ELECTRICAL
Throttle Release Switch (TRS) TRS Testing
TRS System Operation The TRS is a serviceable item and can be tested using
Digital Wrench® or an Ohm meter.

This vehicle is equipped with a throttle release switch
1. Disconnect the TRS harness connection located by
(TRS) to detect when the throttle pedal has returned to the
the fuse box.
rest position.
NOTE: The throttle pedal lever is designed to have a

few degrees of freeplay prior to engaging the throttle
arm that pulls the throttle cable.
With the pedal in the rest position, the "blade" at the top of
the pedal is almost out of the TRS switch slot, exposing the
TRS switch to magnetic force in the opposite side of the
sensor. When the pedal is depressed, the throttle pedal
blade blocks the magnetic force from the TRS switch.
TRS Location
The TRS switch (A) is located in the drivers foot control
area, mounted on the top of the throttle pedal assembly.
2. With the throttle pedal “at rest”, connect an

A
ohmmeter between the TRS pin terminals. A
resistance value of 2.15k Ohms +/- 5% at room
temperature should be obtained. If the sensor reading
is more than 2.26k Ohms, it is out of specification and
needs to be replaced.
3. With the throttle pedal fully depressed, connect an

ohmmeter between the TRS pin terminals. A
resistance value of 11.7k Ohms +/- 5% at room
temperature should be obtained. If the sensor reading
is less than 11.1k Ohms, it is out of specification and
needs to be replaced.
Throttle Throttle
“At Rest” Fully Depressed
2.15k Ohms +/-5% 11.7k Ohms +/-5%

Replace sensor if Replace sensor if
reading is more than: reading is less than:
2.26k Ohms 11.1k Ohms
10.16
ELECTRICAL
TRS Removal TRS Installation / Adjustment
1. Remove the drivers seat and disconnect the negative 1. Place the TRS on throttle pedal assembly and loosely
(-) battery cable. install the (2) fasteners.
2. Remove the (2) bolts securing the TRS to the throttle 2. The TRS mounting holes are oblonged to allow for
pedal assembly. switch alignment. Visually center the TRS slot with the
throttle pedal blade (C). It may be necessary to
manually cycle the throttle pedal to verity the center
alignment.
C
3. Remove the TRS from the vehicle.
3. Torque the (2) mounting bolts to specification and

connect the TRS harness connection.
=T
TRS Retaining Nuts:
7 ft-lbs (10 Nm)
4. Manually cycle the throttle pedal to verify the throttle

pedal blade is centered in the TRS slot.
5. Connect the negative (-) battery cable and install the

drivers seat.
10
10.17
ELECTRICAL
REAR DIFF SOLENOID (INT’L)
Differential Solenoid Overview
The differential solenoid is located on the rear portion of
the transmission case. The solenoid actuates a shift fork
with an engagement dog, which locks and unlocks the rear
differential. Refer to Chapter 8 for more information.
Differential Solenoid
Differential Solenoid Circuit Operation

The Rear Diff Solenoid Relay is attached to the lower
airbox bracket and can be accessed through the right rear
wheel well.
When the switch is pushed to activate “TURF”, a ground
signal is provided to the ECU from the AWD / 2WD / TURF
Switch.
Depending on engine speed and gear position criteria, the
ECU energizes the Rear Diff Solenoid Relay allowing it to
enable the differential solenoid.
If the rear diff fails to switch from operational modes:
• Check the solenoid and relay connectors. Look for
loose wires or bad connections.
• Check for power from the relay connector, to
ensure the solenoid has power to be activated.
• Check the AWD / 2WD / TURF Switch wires for
loose connections.
• Remove solenoid from rear differential and ensure
the solenoid plunger is actuating.
CAUTION
Do not power the solenoid with 12 Volts for more

than 1 second, or damage may occur to solenoid.
10.18
ELECTRICAL
VEHICLE SPEED SENSOR ALL WHEEL DRIVE COIL
Speed Sensor Location Operation Overview
The speed sensor is located on the RH side of the • When the key switch is “ON”, 12 VDC power is
transmission, accessed through the rear RH wheel well. present at the hub coil.
• When the AWD switch is “ON”, and if the criteria is
met, the Engine Controller provides a ground path
(brown/white wire). When this occurs the AWD
icon should display in the instrument cluster.
• The AWD system must be grounded to operate.
Diagnosing System Failures

• Verify the AWD switch is functional and that a
Speed Sensor minimum of 11 volts is present at the hub coil.
• Verify the AWD hub coil is functional. Test the
AWD hub coil using an ohm meter. See
specifications below:
Speed Sensor Testing

Special Tools Required:
Static Timing Light Harness (PN 2871745)
Hall Sensor Probe Harness (PN 2460761) Test Resistance
Readings should be:
1. Disconnect the 3 wire harness from the speed sensor GY to BN/WH: ~ 24 Ohms
and remove the sensor from the transmission. GY to Ground: No Connection
2. Connect the wires from the Static Timing Light
Harness to the sensor 3 pin connector using the Hall
Sensor Probe Harness (PN 2460761).
3. Pass a screwdriver back and forth in front of the
sensor tip.
4. Be sure connections are good and 9V battery is in AWD Hub Coil Resistance:
good condition. If the light flashes, the sensor is good. 24  ± 5%
• Verify the wiring harness, wiring, connectors,

connector pins and grounds are undamaged,
clean and connect properly.
• Verify continuity of wire connections with a known
good volt/ohm meter.
IMPORTANT: Verify all wires and wiring connections 10
have been tested properly with a known good volt/
ohm meter before suspecting a component failure.
80% of all electrical issues are caused by bad/failed
connections and grounds.
10.19
ELECTRICAL
HEAD LIGHTS 6. Adjust the beam to desired position. Repeat the
procedure to adjust the other headlight.
Headlight Adjustment
The headlight beams are adjustable. WARNING
1. Place the vehicle on a level surface with the headlight
Due to the nature of light utility vehicles and
approximately 25 ft. (7.6 m) from a wall.
where they are operated, headlight lenses
become dirty. Frequent washing is necessary to
maintain lighting quality. Riding with poor
lighting can result in severe injury or death.
2” (5cm) Headlamp Replacement

IMPORTANT: If an LED headlamp has fogging or
moisture inside, disconnect the wire harness from the
headlamp(s) for a few days to allow the moisture to
clear out.
1. Disconnect wire harness from headlamp assembly.

Be sure to pull on the connector, not on the wiring.
2. Measure the distance from the floor to the center of
the headlight and make a mark on the wall at the same
height.
3. With the machine in Park, start the engine and turn the
headlight switch to the LOW position.
4. The most intense part of the LOW beam headlight

beam should be aimed 2 in. (5 cm) below the mark
placed on the wall in Step 2.
NOTE: Rider weight must be included in the seat

while performing this procedure.
5. Adjust the beam to the desired position by loosening

or tightening the (3) T-25 adjustment screws and
moving the lamp to the appropriate height. 2. Remove the (3) T-25 headlamp mounting screws and
(3) adjustment preload springs.
NOTE: The front bumper can be removed and
placed face down on a suitable workbench to ease
headlamp replacement (see Chapter 5).
10.20
ELECTRICAL
TAIL / BRAKE LIGHTS
Screw
Bulb Replacement
Before replacing the bulb(s), use a digital multi-meter to
test the harness to ensure the lamp is receiving 12 volts
and that a ground path is present.
If a tail light, brake light or turn signal (INT’L Only) does not
work the bulb may need to be replaced.
Spring
Mounting Boss
1. Disconnect the wire harness.
2. Remove bulb by turning the rubber base 1/4 turn and

pulling the bulb out. Replace it with recommended
3. Carefully lift and remove headlamp assembly from the bulb. Apply Dielectric Grease (PN 2871329).
bumper.
Tail / Brake
Light
Headlamp Installation
1. Install the headlamp adjustment springs onto the
front bumper mounting bosses.
2. Insert the (3) T-25 headlamp mounting screws into the

headlamp assembly mounting holes.
3. Maneuver the headlamp assembly into position. Be

sure all (3) headlamp springs and mounting screws
are properly aligned with mounting bosses on the front
bumper.
Screw INT’L Tail / Brake

Models Light
Spring
Mounting Boss
Turn Signal
Light
4. Fully tighten all (3) headlamp screws until the 10

headlamp assembly is fully seated. Back headlamp 3. Test the tail light, brake light and turn signal (INT’L
mounting screws off 1/8” to 1/4” (2-3 turns). Only) to verify it is working properly.
5. Install the front bumper as shown in Chapter 5 if
previously removed.
6. Connect headlamp electrical connector to the

headlamp assembly.
7. Perform the “Headlight Adjustment” procedure as

shown in this chapter.
10.21
ELECTRICAL
COOLING SYSTEM
Cooling System Break-Out Diagram
10.22
ELECTRICAL
Fan Control Circuit Operation / Testing EFI DIAGNOSTICS
Power is supplied to the fan via the Orange/Black wire
EFI Component Testing
when the relay is ON. The ground path for the fan motor
is through the Brown harness wire. Refer to “RELAYS” All EFI component information and diagnostic testing
later in this chapter for more information on fan functions. procedures are located in Chapter 4.
Refer to Chapter 4 “Electronic Fuel Injection System (EFI)”

CAUTION when diagnosing an EFI system or component.
Keep hands away from fan blades during FUEL SENDER

operation. Serious personal injury could result.
Testing
NOTE: The fan may not function or operation may
be delayed if coolant level is low or if air is trapped in 1. Remove the fuel pump assembly from the fuel tank
the cooling system. Be sure cooling system is full (see Chapter 4 “Fuel Pump Replacement”).
and purged of air.
2. Using an Ohm meter, measure the resistance of the
fuel sender as shown below.
Fan Control Circuit Bypass Test
1. Disconnect harness from coolant temperature sensor
on the engine cylinder head (see Chapter 4).
2. With the transmission in Park, start the engine. After
a few seconds, the fan should start running and the
“Check Engine” indicator should display on the
instrument cluster. This indicates all other
components are working properly.
3. If the fan does not run or runs slowly, check the fan
motor wiring, ground, motor condition, circuit breaker
and mechanical relay for proper operation. Repair or
replace as necessary. If the fan runs with the sensor
harness disconnected, but will not turn on when the
engine is hot, check the coolant temperature sensor
and connector terminals.
3. Allow the sender float to sit in the empty position and
Coolant Temperature Sensor compare to specification.
The coolant temperature sensor can be tested using an Fuel Sender - Empty: 90 ± 4.5 
ohmmeter or voltmeter.
1. With the engine and temperature sensor at room 4. Slowly move the sender float to the full position and
temperature (68F = 20C), disconnect the harness. compare to specification.
2. With the meter in the ohms mode, place the meter
leads onto the sensor contacts. Fuel Sender - Full: 6 ± 1 
10
3. Use the table Temperature / Resistance table to
5. If the readings are out of specification, or if the reading
determine if the sensor needs to be replaced.
is erratic or LCD display “sticks”, check the following
Temperature °F (°C) Resistance before replacing the fuel pump assembly:
• Loose float
68 °F (20 °C) 2.5 k  ± 6%
• Float contact with tank
212 °F (100 °C) 186  ± 2% • Bent float rod
NOTE: If the coolant temperature sensor or circuit 6. If none of the conditions exist, the fuel sender
malfunctions the radiator fan will default to 'ON' assembly is faulty. Replace the fuel pump assembly
while the engine is running. (see Chapter 4).
10.23
ELECTRICAL
FUSE BOX: FUSES / RELAYS / CIRCUIT BREAKER
Overview / Operation
Located in the fuse box under the dash, the fuses provide overload protection for wiring and components such as the
instrument cluster, ECU, EFI system, main harness, lights, accessories and power steering. The relays assist with
component operation like the cooling fan, fuel pump, EFI system, drive system and electronic power steering. A separate
20-amp circuit breaker protects the fan motor circuit. Two separate relays located under the dash operate the headlights
and the “flash to pass” function on INT’L models.
10.24
ELECTRICAL
Fuse Box Detail
10
IMPORTANT: All relays (PN 4011283) located in fuse box

are the same and can be swapped out to help diagnose
electrical problems.
10.25
ELECTRICAL
Relay Operation FAN RELAY provides power to the following system:
Located in the fuse box under the dash, the relays assist • Fan Motor
with component operation like the cooling fan, fuel pump
and EFI system, drive system and EPS. Color Function
NOTE: The Rear Diff Solenoid Relay (INT’L) is 20-Amp circuit breaker protected
Red
mounted separately, attached to the lower airbox 12 Vdc constant battery power.
bracket, accessed through the right rear wheel well. Orange / White ECU ground input to enable relay.
NOTE: The Headlight Relay (INT’L) and Flash to 12 Vdc switched power from EFI
Red / Dark Blue
Pass Relay (INT’L) are also mounted separately, relay.
located under the dash. Provides 12 Vdc power for fan
Orange / Black
operation.
CHASSIS RELAY provides power to the following
systems:
FUEL PUMP RELAY provides power to the following
• Lights (Headlights / Taillights) system:
• Drive (AWD) • Fuel Pump
• Accessory (12V Receptacles / Accessory Options)
Color Function
Color Function 10-Amp fuse protected 12 Vdc
Red / Green
battery voltage.
30-Amp fuse protected 12 Vdc
Red
constant battery voltage. Dark Green / Yellow ECU ground input to enable relay.
Brown Relay coil ground. 12 Vdc switched power from EFI
Red / Dark Blue
relay.
12 Vdc power input from key
Orange
switch to enable relay. Provides 12 Vdc power for fuel
Red / Blue
pump operation.
Provides 12 Vdc power for lights,
White
drive and accessory circuits.
EPS RELAY (OPT) provides power to the following
system:
EFI RELAY provides power to the following systems:
• Electronic Power Steering Unit
• Fuel Injectors
• Ignition Coil Color Function
• Fan Relay 30-Amp fuse protected 12 Vdc
Red
• Fuel Pump Relay constant battery voltage.
Brown Relay coil ground.
Color Function
12 Vdc power input from key
Orange
20-Amp fuse protected 12 Vdc switch to enable relay.
Red / White
constant battery voltage.
Provides 12 Vdc power for EPS
Orange
Dark Green / Yellow ECU ground input to enable relay. operation.
Red / White
constant battery voltage.
Provides 12 Vdc power for EFI
Red / Dark Blue
system circuits.
10.26
ELECTRICAL
REAR DIFF SOLENOID RELAY (INT’L) provides power FLASH TO PASS RELAY (INT’L) provides power to the
to the following system: following system:
• Rear Differential Solenoid • Momentary High Beam Headlight Operation
Color Function Color Function

10-Amp fuse protected 12 Vdc 12 Vdc switched power from
Red / Dark Green
battery voltage. headlight relay used to operate
Dark Green
low beam headlights during
Dark Green / White ECU input to enable relay.
“normally closed” relay operation.
Relay switched power to operate
Red High beam input to “open” relay
the Rear Diff Solenoid.
and disable low beam headlights
Yellow
Ground to energize the Rear Diff in order to operate high beam
Blue
Solenoid. headlights momentarily.
“Normally closed” relay output to
Dark Green
HEADLIGHT RELAY (INT’L) provides power to the operate low-beam headlights.
following system:
• Headlights
Color Function
Red / Yellow
battery voltage.
White / Red Key switch input to enable relay.
Relay switched power to operate
Yellow / Dark Green
the Headlights.
10
10.27
ELECTRICAL
CHARGING SYSTEM Charging System “Break Even” Test
Current Draw - Key Off

CAUTION
CAUTION Do not allow the battery cables to become

disconnected with the engine running. Follow the
Do not connect or disconnect the battery cable steps below as outlined to reduce the chance of
or ammeter with the engine running. Damage will damage to electrical components.
occur to electrical components.
The “break even” point of the charging system is the point
Connect an ammeter in series with the negative battery at which the alternator overcomes all system loads (lights,
cable. Check for current draw with the key off. If the draw etc.) and begins to charge the battery. Depending on
is excessive, loads should be disconnected from the battery condition and system load, the break even point
system one by one until the draw is eliminated. Check may vary slightly. The battery should be fully charged
component wiring as well as the component for partial before performing this test.
shorts to ground to eliminate the draw.
Current Draw Inspection WARNING

Key Off
Never start the engine with an ammeter
connected in series. Damage to the meter or
meter fuse will result.
Do not run test for extended period of time.
Do not run test with high amperage accessories.
1. Using an inductive amperage metering device, (set to

DC amps) connect to the negative battery cable.
2. With engine off, key switch and lights in the on

position, the ammeter should read negative amps
(battery discharge).
Current Draw - Key Off:
Maximum of .01 DCA (10 mA) 3. Shift transmission into park and start the engine. With
the engine running at idle, observe meter readings.
4. Increase engine RPM while observing ammeter and

tachometer. Note the RPM at which the battery starts
to charge (ammeter indication is positive).
5. With lights and other electrical loads off, the “break

even” point should occur at approximately 1500 RPM
or lower.
6. With the engine running, turn the lights on and

depress the brake pedal to keep brake lights on.
7. Repeat test, observing ammeter and tachometer.

With lights on, charging should occur at or below 2000
RPM.
10.28
ELECTRICAL
Charging System Stator (Alternator) Tests TEST 3: Measure AC Voltage Output of Each Stator
Leg at Charging RPM
Three tests can be performed using a multi-meter to
determine the condition of the stator (alternator). 1. Set the selector dial to measure AC Voltage.
2. Start the engine and let it idle.
3. While holding the engine at a specified RPM,

separately measure the voltage across each ‘leg’ of
the stator by connecting the meter leads to the wires
leading from the alternator (Y1 to Y2, Y1 to Y3, Y2 to
Y3).
Y1 Y2 Y3 4. Refer to the following table for approximate AC
Voltage readings according to RPM. Test each leg at
the specified RPM in the table.

Example: The alternator current output reading
should be approximately 21 VAC at 1300 RPM
TEST 1: Resistance Value of Each Stator Leg
between each ‘leg’.
1. Measure the resistance value of each of the three
stator legs: Y1 to Y2, Y1 to Y3, and Y2 to Y3. Each NOTE: If one or more of the stator leg output AC
test should measure: 0.07 - 0.13  voltage varies significantly from the specified value,
the stator may need to be replaced.
Connect Meter
Test Ohms Reading RPM Reading AC Voltage (VAC) Reading
Leads To:
1300 21 VAC ± 25%
Battery Charge Coil Y1 to Y2 0.07 - 0.13 
3000 47 VAC ± 25%
5000 79 VAC ± 25%
NOTE: If there are any significant variations in ohm Stator (Alternator) Replacement
readings between the three legs it is an indication
that one of the stator legs may be weak or failed. Refer to Engine Chapter “Stator Cover Removal /
Inspection” procedure to service the stator.
TEST 2: Resistance Value of Each Stator Leg to
Ground NOTE: The stator cover can be removed with the
engine installed in the chassis.
1. Measure the resistance value of each of the stator
legs to ground: Y1 to Ground, Y2 to Ground, Y3 to IMPORTANT: Be sure to thoroughly clean the area
Ground. around the stator cover prior to removal.
Each test should measure: Open Line (OL)
Test
Connect Meter
Ohms Reading 10
Leads To:
Y1, Y2, or Y3 Open Line

Battery Charge Coil
to Ground (Infinity)
NOTE: Any measurement other than Infinity (open)

will indicate a failed or shorted stator leg.
10.29
ELECTRICAL
Regulator / Rectifier NOTE: If the regulator / rectifier case temperature
exceeds 230° F or 110° C, the unit will turn itself off
The regulator / rectifier (A) is located in the left rear wheel to cool down. The unit will turn on again after it has
well area in front of the left rear shock. It is mounted under cooled down to at least 212° F or 100° C. If it turns
the LH panel divider. off, verify the cooling fins are clean, free from debris
and that adequate airflow is present.
A
Fusible
Link
Battery
Leads
Stator
Lead
10.30
ELECTRICAL
Charging System Testing Flow Chart
Whenever charging system problems are suspected, proceed with the following system check after verifying that all wires
are in good condition, connected and not exposed or pinched.
Using a multitester set on D.C. volts, mea- Remove the battery and properly ser-
sure the battery open circuit voltage (test No vice. Reinstall the fully charged battery
with lights and accessories off). It should be or a fully charged shop battery.
12.4 volts or more. Is it?
Yes
Meter Setting: DC Volts

With the transmission in Park, start the
engine and increase RPM to between 3000
and 4000. Read battery voltage with the Yes Check Key off Current Draw.
multimeter. Readings should increase to
between 13.0 and 14.6 V D.C. Do they?
NOTE: Disconnect all accessories.
No
Check for owner modification, and
discuss operating habits. The battery
Meter Setting: DC Amps will continually discharge if operated
Perform system “Break Even Amperage” Yes below the “Break Even” RPM. Con-
test outlined in this chapter. tinued problems would call for battery
Does charging occur as specified? inspection.
No
Ohm stator wires, if bad replace stator, if good, Inspect the wiring harness between
continue with alternator output test.
the regulator and the stator for
Meter Setting: AC Volts
damage. If no damage is found,
Disconnect the Yellow wires from the regulator /
rectifier. Using a multimeter, perform an Alternator No remove the stator cover.
Output test. See test procedure on Page 10.29. Inspect the flywheel magnets, stator
coils and stator wires for damage.
Does output meet specification? Repair or replace any damaged
components.
Yes
Meter Setting: DC Volts

Reconnect the alternator wires. Measure
between the Red and Black terminals with the
harness disconnected. Battery voltage must be Check battery and battery connections.
present on harness side of voltage regulator. No Also check wire connections and wire
condition. Repair or replace faulty wiring
Is voltage present? or components. 10
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 wire harness, replace the voltage regulator.
10.31
ELECTRICAL
BATTERY SERVICE General Battery Information
Battery Specifications
WARNING
Polaris / Deka ETX30L
Type CALIFORNIA PROPOSITION 65 WARNING:
Sealed - Maintenance Free
Batteries, battery posts, terminals and related
Voltage 12 Vdc accessories contain lead and lead compounds, and
Nominal Capacity other chemicals known to the State of California to
30 AH cause cancer and birth defects or other reproductive
@ 10 HR Rate
harm. WASH HANDS AFTER HANDLING.
CCA 365
Nominal Open
12.8 Vdc or more. WARNING
Circuit Voltage
Recommended Battery electrolyte is poisonous. It contains acid!
1.8A @ 5-10 HR or 6.0A @ 1 HR
Charging Rate Serious burns can result from contact with the skin,
eyes, or clothing.
IMPORTANT: Never attempt to open the battery. If the
seal is broken, the battery will be ruined and will fail ANTIDOTE:
within a few weeks. External: Flush with water.
Internal: Drink large quantities of water or milk. Follow

with milk of magnesia, beaten egg, or vegetable oil.
Call a physician immediately.
Eyes: Flush with water for 15 minutes and get prompt

medical attention.
Batteries produce explosive gases. Keep sparks,

flame, cigarettes, etc. away. Ventilate when charging
or using in closed space. Always shield eyes when
working near batteries.
Keep out of reach of children.
1. Check battery voltage with a volt/ohm meter. A fully

charged battery should be 12.8 V or higher.
2. If the voltage is below 12.6 V, the battery will need to

be recharged (see “Charging Procedure”).
To service a Maintenance Free battery:
1. Remove battery from the vehicle (see Chapter 2).
2. Test battery with a voltage meter or load tester to

determine battery condition. This will determine the
length of time required to charge the battery to full
capacity. Refer to OCV table (see “OCV - Open Circuit
Voltage Test”).
3. Charge the battery as recommended (see “Charging

Procedure”).
10.32
ELECTRICAL
Battery Removal / Installation Load Test
See Chapter 2 “Maintenance” for battery removal and
installation procedures. CAUTION
Battery Off Season Storage To prevent shock or component damage, remove spark
plug high tension leads and connect securely to
Whenever vehicle is not used for a period of three months
engine ground before proceeding.
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 A battery may indicate a full charge condition in the OCV
place. Check battery voltage each month during storage test, but still may not have the storage capacity necessary
and recharge as needed to maintain a full charge. to properly function in the electrical system. For this
reason, a battery capacity or load test should be
NOTE: Battery charge can be maintained by using a
conducted whenever poor battery performance is
Polaris battery tender charger or by charging once a
encountered.
month to make up for normal self-discharge. Battery
tenders can be left connected during the storage To perform this test, use a load testing device that has an
period, and will automatically charge the battery if adjustable load. Apply a load of three times the ampere-
the voltage drops below a pre-determined point. hour rating. At 14 seconds into the test, check battery
voltage. A good 12V battery will have at least 10.5 volts.
Battery Testing If the reading is low, charge the battery and retest.
Whenever a service complaint is related to either the
starting or charging systems, the battery should be
checked first.
The following are two tests which can easily be made on

a sealed Maintenance Free battery to determine its
condition: OCV Test and a Load Test.
OCV - Open Circuit Voltage Test

Battery voltage should be checked with a digital
multitester. Readings of 12.6 volts or less require further
battery testing and charging. See the following chart and
“Load Test”.
NOTE: Maintenance Free batteries should be kept at

a high state of charge during storage. If the battery is
stored or used at a low state of charge, hard crystal
sulfation will form on the plates, reducing the
efficiency and service life of the battery.
NOTE: Use a volt/ohm meter to test battery voltage.
OPEN CIRCUIT VOLTAGE 10

State of Charge Maintenance Free
100% 12.8 V and up
75% Charged 12.6 V
50% Charged 12.3 V
25% Charged 12.0 V
0% Charged 11.8 V or less
10.33
ELECTRICAL
Battery Conductance Analyzer Charging Procedure
Conductance describes the ability of a battery to conduct If battery voltage is 12.6 Vdc or less, the battery may need
current. A conductance tester functions by sending a low recharging. When using an automatic charger, refer to the
frequency AC signal through the battery and a portion of charger manufacturer’s instructions for recharging.
the current response is captured, from this output a
conductance measurement is calculated. Conductance Do not exceed 6 amps when charging the 4011224
testing is more accurate than voltage, specific gravity, or battery.
load testing.
NOTE: Charge the battery using an automatic
Authorized Polaris dealers/distributors are required to use charger that will not exceed 14.6 Vdc. An automatic
the conductance analyzer when testing 12V Polaris charger will signal when charging is complete.
batteries.
NOTE: Allow the battery to stand disconnected for
at least 1-2 hours after being properly charged. If the
voltage drops below 12.6 volts, charging was
ineffective or the battery needs to be replaced.
WARNING
An overheated battery could explode, causing severe
injury or death. Always watch charging times carefully.
Stop charging if the battery becomes very warm to the
touch. Allow it to cool before resuming charging.
State of Charge
Voltage (DC) Action
Charge Time
None, check
None
100% 12.8 or more again in 3
Required
months
May need
75% - 100% 12.6 - 12.8 3 - 6 hrs
slight charge
Polaris MDX-610P
SPX PN: PU-50296 50% - 75% 12.3 - 12.6 Needs Charge 5 - 11 hrs
At least
25% - 50% 12.0 - 12.3 Needs Charge
13 hrs
At least
0% - 25% 12.0 or less Needs Charge
20 hrs
NOTE: Follow the charger instructions supplied by

the manufacture regarding the order or connections,
switch positions and when to connect the charger to
an outlet.
10.34
ELECTRICAL
STARTING SYSTEM Starter Motor Removal
1. Remove driver side seat and disconnect the battery.
Troubleshooting
2. Raise and support rear of vehicle.
Starter Motor Does Not Run
3. Remove the RH rear wheel.
• Battery discharged
4. Remove (+) positive wire from starter motor terminal.
• Loose or faulty battery cables or corroded
connections (see Voltage Drop Tests) 5. From the RH side wheel well using an 8mm flex
socket, remove the negative battery cable nut and the
• Related wiring loose, disconnected, or corroded (2) fasteners securing the starter motor to the engine.
• Poor ground connections at battery cable, starter
motor or starter solenoid (see Voltage Drop Tests)
• Faulty key switch
• Faulty starter solenoid or starter motor
• Engine problem - seized or binding (can engine be
rotated easily)
Starter Motor Turns Over Slowly

• Battery discharged
• Excessive circuit resistance - poor connections
(see Voltage Drop Test)
• Engine problem - seized or binding (can engine be
rotated easily) NOTE: The (-) negative battery cable is mounted to
• Faulty or worn brushes in starter motor the engine using the upper starter mounting bolt /
stud.
Starter Motor Turns - Engine Does Not Rotate
6. Remove the starter from the engine.
• Faulty starter drive
• Faulty starter drive gears or starter motor gear
Starter Motor Installation
• Faulty flywheel gear or loose flywheel 1. Inspect and replace starter motor O-ring if needed.
2. Lubricate starter motor O-ring with fresh engine oil.
Voltage Drop Test
3. Install the starter motor onto the engine case.
The Voltage Drop Test is used to test for bad connections.
4. Hand tighten the upper starter mounting bolt / stud.
When performing the test, you are testing the amount of
voltage drop through the connection. A poor or corroded 5. Install and torque the lower mounting bolt to
connection will appear as a high voltage reading. Voltage specification.
shown on the meter when testing connections should not
IMPORTANT: Tighten the lower starter bolt first, as
exceed 0.1 VDC per connection or component.
the bottom hole acts as a pilot hole to properly align
To perform the test, place the meter on DC volts and place the starter drive (bendix) with the flywheel. This helps 10
the meter leads across the connection to be tested. Refer prevent binding and starter damage.
to the voltage drop tests on the starter system in this 6. Torque upper starter mounting screw to specification.
chapter.
7. Install (-) negative battery cable to the upper starter
mounting bolt / stud. Torque nut to specification.
Voltage should not exceed
.1 DC volts per connection
=T
Starter Mounting Bolts and Nut:
7 ft-lbs (10 Nm)
10.35
ELECTRICAL
Starter Solenoid Bench Test
Test the start solenoid by powering the solenoid using
battery voltage for a maximum of 5 seconds. With the
solenoid energized, resistance should read about 0 - 0.5
ohms between terminals (A) and (B). If resistance
measurement is out of specification, replace the starter
solenoid.
Energize
Here
A B
Starter Solenoid Operation

To energize the Starter Solenoid the following must occur:
• The brake must be applied to provide a ground

path via the Orange wire.
• The key switch must be turned to the “start”
position to provide 12V power via the Green /
White wire.
• Once the pull-in coil is energized, the solenoid
provides a current path for 12V power to reach the
starter motor.
NOTE: See “ELECTRICAL SYSTEM BREAOUTS:

Starter-Interlock” provided in this chapter for starter
solenoid operation.
10.36
ELECTRICAL
STARTING SYSTEM TESTING FLOW CHART
Condition: Starter fails to turn over the engine. 
With the tester on the VDC position, place the

tester's black lead on the battery negative and the
red lead on the battery positive. Reading should No Remove battery and properly service. Install
be 12.4 V D. C. or greater. fully charged shop battery to continue test.
Yes
Disconnect 2-wire connector at the solenoid. Check for voltage at the EFI 20 Amp fuse and
Using a multi-meter, connect the black meter lead then check for voltage entering the ignition
to the Orange harness wire and the red meter lead No switch. Battery voltage should be present. If
to the Green/White harness wire. Apply the brake battery voltage is present at the ignition
and turn ignition switch to the “start” position. switch, but not the solenoid, replace the
Meter should read battery voltage. switch. NOTE: The brake MUST be applied
when performing these tests.
Test the start solenoid by powering the solenoid via the 2-wire connection.
Yes With the solenoid energized, resistance should read about 0.5 ± 10%
between the two terminals. If resistance measurement is out of specification,
Voltage Drop replace the starter solenoid (see “Starter Solenoid Bench Test”)
Testing
Reconnect the solenoid. Connect the tester black lead No Clean the battery-to-solenoid cable ends
to the battery positive and the red lead to the solenoid or replace the cable.
end of the battery-to-solenoid wire. Apply the brake
and turn the ignition key to the “start” position. Reading
should be less than .1 V D.C.
Yes
Connect the black tester lead to solenoid end of

battery-to-solenoid cable. Connect red tester lead No
to solenoid end of solenoid-to-starter cable. Apply Replace the starter solenoid.
the brake and turn the ignition key to the “start”
position. Reading should be less than .1 V D.C.
Yes
Connect the black tester lead to the solenoid end of

the solenoid-to-starter cable. Connect red tester
lead to the starter end of the same cable. Apply the
No Clean the solenoid-to-starter cable ends or
replace the cable.
10
brake and turn the ignition key to the “start”
position. The reading should be less than .1 V D.C.
Yes
If all of these indicate a good condition, yet the starter still fails to
turn, the starter must be removed for static testing and inspection.
10.37
ELECTRICAL
ELECTRONIC POWER STEERING (EPS)
EPS Operation
The EPS module is an intelligent electronic power steering
system that operates off of the vehicle’s 12V electrical WIRE COLOR FUNCTION
system. It calculates steering assist by sensing the ORANGE (2-Pin) Main Power (30A Protected)
difference between the input torque of the steering post
and the output torque required to turn the wheels, and then BROWN (2-Pin) Ground
provides assist by energizing an electric motor. The ORANGE (8-Pin) Key-On Battery Voltage
process provides a smooth, seamless assist.
YELLOW (8-Pin) CAN High Signal
The system is continuously running diagnostic checks and
GREEN (8-Pin) CAN Low Signal
monitoring factors such as battery voltage, ground speed
and engine speed. In the event an internal or external
issue that affects the EPS system is detected, the system
Proper EPS System Diagnosing
will illuminate a fault indicator and transition to a normal
mechanically coupled steering system. The system is READ BEFORE YOU REPLACE THE EPS UNIT!
Polaris Digital Wrench® compatible for simplified
diagnostics and system troubleshooting through the IMPORTANT: Verify the EPS unit has the latest
vehicle’s diagnostic port. software version and calibration loaded before
replacing the EPS unit. If not, update to the latest
With the engine off and the key on, the power steering unit version for each and follow the guided diagnostic
will operate for up to five minutes. After the five minutes, procedure(s) available in Digital Wrench®.
you will need to cycle the key switch and restart the engine
to regain power steering operation.
NOTE: To conserve battery power, the EPS unit will

shut down 5 minutes after the engine has stopped if
the key remains in the ON position. At this point, the
EPS Malfunction Indicator Light will illuminate to
indicate the EPS has shut down and will set a fault
code in Digital Wrench®.
The Power Steering 30A Fuse.

• If the fuse fails, the Power Steering Malfunction
Indicator Light (MIL) on the instrument cluster will
illuminate. During this time, the vehicle will have
no power steering operation. You will be able to
connect and communicate with the vehicle’s
Engine Controller, but not the Power Steering
Controller, while using Digital Wrench®.
NOTE: DO NOT SPLICE OR CUT INTO THE CAN
CIRCUITS.
WARNING
Electronic Power Steering (EPS) units are not

interchangeable between ATV and RANGER
product lines.
NOTE: See Chapter 5 “Body/Steering/Suspension”

for power steering unit removal and installation
procedures.
10.38
ELECTRICAL
EPS System Breakout
10
10.39
ELECTRICAL
EPS Troubleshooting (Power Steering Non-Functional with MIL ON)
10.40
ELECTRICAL
EPS Troubleshooting (Power Steering Non-Functional with MIL OFF)
10
10.41
ELECTRICAL
EPS Troubleshooting (Using Digital Wrench®)
*
*
* These Error Codes must have multiple

occurrences or you must be able to
duplicate the condition before replacing
the EPS unit.
10.42
ELECTRICAL
ELECTRICAL SYSTEM BREAKOUTS
AWD
Vehicle Speed Sensor
10
10.43
ELECTRICAL
Cooling Fan
10.44
ELECTRICAL
Chassis Power
Starter-Interlock
10
10.45
ELECTRICAL
Key-On Battery Power
10.46
ELECTRICAL
Lights
10
10.47
ELECTRICAL
Charging System
10.48
2013 RANGER RZR XP
2013 RANGER RZR XP
2013 RANGER RZR XP (EPS)
2013 RANGER RZR XP (EPS)
2013 RANGER RZR XP INT’L
2013 RANGER RZR XP INT’L
2013 RANGER RZR XP 4
2013 RANGER RZR XP 4
2013 RANGER RZR XP 4 (EPS)
2013 RANGER RZR XP 4 (EPS)
2013 RANGER RZR XP 4 INT’L
2013 RANGER RZR XP 4 INT’L
2013 RANGER RZR XP / RZR XP 4 (CARGO BOX)
2013 RANGER RZR XP INT’L / RZR XP 4 INT’L (CARGO BOX)

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GENERAL INFORMATION

Engine Designation Number

Vehicle Identification Number (VIN) Designation

Vehicle Descriptors Vehicle Identifiers

Individual Serial No.

Figure 1-1 Figure 1-2

Model Model No. Owner’s Manual Parts Manual

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

Series# Part Number

Select “SPX Website - Tools, diagnostics” from

Hitch Towing Capacity This vehicle is not equipped with a

MODEL: 2013 RANGER RZR XP 900 EPS / INT’L

Hitch Towing Capacity This vehicle is not equipped with a

30 Amp: EFI (Feet) 1500-3700 26-55 Blue / Yellow Red

Hitch Towing Capacity This vehicle is not equipped with a

MODEL: 2013 RANGER RZR XP 4 900 EPS / INT’L

Hitch Towing Capacity This vehicle is not equipped with a

MISC. SPECIFICATIONS AND CHARTS

°C to °F: °C x 9/5 + 32 = °F °F to °C: °F - 32 x 5/9 = °C

Grade 2 Grade 5 Grade 8

Grade 2 Grade 5 Grade 8

1/4-20 5 (7) 8 (11) 12 (16)

Metric Bolt Torque Specification

Bolt Size 4.6 4.8 8.8 / 8.9 10.9 12.9

Ft. Lbs. (Nm) Dry Threads

M3 .3 (.5) .5 (.7) 1 (1.3) 1.5 (2) 1.5 (2)

Metric Tap / Drill Sizes

Severe Use Definition

Maintenance Chart Key

 Cooling System 50 H 6M 500 (800)

III. # Item Lube Rec. Method Frequency*

III. # Item Lube Rec. Method Frequency*

Item Method Recommended Lube Frequency

GENERAL VEHICLE INSPECTION Shift Cable Inspection / Adjustment

• Headlights/Taillights/Brakelights - also check

• Ignition switch - check for proper function

Fuel Tank Vent Line and Filter

1. Remove the seats and the engine service panel.

2. Locate and inspect the in-line filter (A). Note the

NOTE: Be sure to install the filter in the orientation

IMPORTANT: Make sure vent line is not kinked or

Fuel Pump / Fuel Filters

NOTE: Neither filter is servicable individually. Must

NOTE: The throttle pedal lever is designed to have a

Always check that the throttle pedal moves independently

There should be minimal freeplay between the throttle

IMPORTANT: Make sure lines are not kinked or

Check throttle pedal freeplay periodically in accordance

Inspection 1. Allow the engine and exhaust system to cool before

2. Start the engine, and warm it up thoroughly. CAUTION

2. Locate the throttle freeplay adjustment through the

A 3. Slide back the cable adjuster boot (C).

4. Using a 14 mm open-end wrench, loosen the

NOTE: While adjusting, lightly move the throttle

5. Apply Thread Sealant with Teflon® to the adjuster

6. Re-tighten the jam nut after final adjustment is made.

7. Slide the cable adjuster boot over the cable adjuster

3. Pull cover rearward far enough to remove air filter (D).

IMPORTANT: DO NOT attempt to clean the air filter.