Polaris ATV & LUV Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Polaris ATV and Light Utility Hauler, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Polaris ATV and Light Utility Hauler workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Polaris ATV and Light Utility Hauler SERVICE REPAIR MANUAL (PN 9912004 1985-1995 All-Models).pdf
Polaris ATV AND LIGHT UTILITY VEHICLE SERVICE MANUAL (9913680).pdf
Polaris Outlaw 50-90, Sportman 90 '13-'14 Service Repair Manual.pdf
Polaris Outlaw 450MXR_525S_525IRS '09 Service Repair Manual.pdf
Polaris Outlaw 500 '06-'07 Service Repair Manual.pdf
Polaris Outlaw 525 IRS '07 Service Repair Manual (9921126).pdf
Polaris Predator 500 '03 Service Repair Manual (9918062).pdf
Polaris Predator '03 Service Repair Manual.pdf
Polaris RZR XP, XP 4 1000 '14 Service Repair Manual (PN 9924874 R02).pdf
Polaris Scrambler 50-90, Sportsman 90, Predator 90 '03 Service Repair Manual (Sportsman Youth PN 9918068).pdf
Polaris Scrambler 500 2x2, 4x4 ATV '09 Service Repair Manual.pdf
Polaris Trail Boss330, Trail Blazer330 '09 Service Repair Manual.pdf
Polaris Trail Boss 330 '03 Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 3,702 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
Polaris ATV AND LIGHT UTILITY VEHICLE SERVICE MANUAL (9913680)....2
Foreword....2
Table of Contents....4
CHAPTER 1:GENERAL INFORMATION....6
CHAPTER 2:MAINTENANCE....57
CHAPTER 3:ENGINE....123
CHAPTER 4:FUEL SYSTEM/CARBURETION....229
CHAPTER 5:BODY AND STEERING....291
CHAPTER 6:CLUTCHES....345
CHAPTER 7:FINAL DRIVE....391
CHAPTER 8:TRANSMISSION SERVICE....465
CHAPTER 9:BRAKES....515
CHAPTER 10ELECTRICAL....551
Polaris ATV and Light Utility Hauler SERVICE REPAIR MANUAL (PN 9912004 1985-1995 All-Models)....635
Table of Contents....638
1 - General Product Information....639
Publications....640
Model Identification....643
Service Tools Description....644
Service Tools & Supplies List....652
Specifications....653
1985 Models....653
1986 Models....654
1987 Models....655
1988 Models....656
1989 Models....657
1990 Models....658
1991 Models....660
1992 Models....662
1993 Models....664
1994 Models....666
1995 Models....669
Accessory Fit Chart....672
Routing Diagrams....676
How to Handle a Service Complaint....688
Service Tips....689
Warranty Policy....690
2 - Body, Steering and Suspension....691
Torque Specifications and Special Tools....692
Body Assembly Exploded View (Except Magnum, Xplorer, and Scrambler)....694
Body Assembly Exploded View, Magnum....695
Cover/Panel Removal (All Except Xplorer and Scrambler)....696
Body Assembly Exploded View, Xplorer....697
Xplorer Side Panel Removal....699
Body Assembly Exploded View, Scrambler....700
Oil Tank and Fuel Tank Assembly (Except Magnum and Scrambler)....701
Oil Tank and Fuel Tank Assembly, Scrambler....702
Fuel Tank Assembly, Magnum....703
Fuel Tank Assembly, Xplorer....704
Camber and Caster Adjustment....705
Toe Alignment....706
Typical Steering Assembly, Exploded View, 4x4 (1988-1992)....708
Typical Steering Assembly, Exploded View, 2x4 (1988-1992)....709
Typical Steering Assembly, Exploded View, 2x4 (1993-Present Except Magnum)....710
Steering Assembly, Exploded View, Magnum 2x4....711
Typical Steering Assembly, Exploded View, 4x4 (1993-Present Except Xplorer and Scrambler)....712
Steering Assembly, Exploded View, Xplorer....713
Steering Stop Adjustments....714
Frame Straightening and Reinforcement....715
Front Wheel Removal -1985-86 Scrambler Models....716
Front Fork Service -1985-86 Scrambler Models....717
Rear Drive Axle, hub and Wheel Assembly, Magnum....720
Swing Arm and Rear Suspension Exploded View - 2x4, 4x4....721
Rear Swing Arm Weldment -Big Boss 4x6 and 6x6....722
Swing Arm and Rear Suspension Exploded View, 1995 Scrambler....723
Axle Housing and Swing Arm Removal and Inspection....724
Strut Assembly - 350/400L 4x4, Magnum 4x4....727
Front Strut Weldment Replacement....728
Front Strut Ball Joint Replacement....729
2x4 Hub Bearing Service....730
Fox Shock Maintenance....731
Lubrication Guide....738
Optional Suspension Springs (1994)....739
Optional Suspension Springs (1995)....740
1995 Paint Codes....742
3 - Brake Service....743
Type I Mechanical - Front....744
Type I Mechanical - Rear....745
Hydraulic Brake System Operation....747
Type I Hydraulic Master Cylinder....748
Type II Hydraulic Master Cylinder....749
Type I Hydraulic Caliper - Front....750
Type II Hydraulic Caliper - Front....752
Type I Hydraulic Caliper - Rear....754
Type II Hydraulic Caliper - Rear....756
Output Shaft Caliper Service....759
Type III Master Cylinder....772
Brake Bleeding Procedure....774
4 - Transmission Service....781
Specifications....782
Type 1 - Chain....785
Type 2 - Gear....791
Type 3 - Gear/Chain USA (EZ Shift)....798
Torque Stop/Shift Linkage Adjustment....801
Troubleshooting....803
Selector and Wiring Harness Removal....804
Selector Installation....805
Speedometer Service....806
5 - Final Drive System Service....807
Specifications....808
Chain and Sprocket Service....809
Rear Drive Chain Adjustment....810
1987/1988 4x4 Center and Forward Chain Adjustment....811
1989 to Present All-Wheel Drive Center and Forward Chain Adjustment....812
1989 to Present Wheel Drive Chain Slack Adjustment....813
Rear Axle Chain Adjustment, 4x6 and 6x6 Models....814
Axle/Eccentric Service....815
Demand 4 Operation....816
Front Drive System Overhaul - All-Wheel Drive Models....817
Front Hub Disassembly....818
Demand 4 Roller Clutch Inspection 1989 to Current....819
Hilliard Clutch Assembly Testing....820
Wheel Hub Seal Replacement....820
Strut Casting Seal Replacement....822
Drive Shaft CV Joint Boot Replacement....823
Front Axle Seal Sleeve Replacement....823
Pole Gap Adjustment....825
Front Clutch Reassembly....825
Bearing Torque Adjustment....826
Front Hub Installation....827
6 - PVT System....828
Specifications....829
Shift Weights....832
Drive Clutch Spring Specs....834
Overview....835
PVT System Introduction....836
Maintenance....837
PVT Disassembly....839
PVT Assembly....840
Drive Belt....842
Clutch Alignment/Offset....843
Driven Clutch Disassembly....844
Driven Clutch Assembly....846
Drive Clutch Disassembly....847
Drive Clutch Inspection....849
Drive Clutch Assembly....852
Clutch Bushing Removal and Installation....853
Troubleshooting....856
7 - Engines....857
Engine Specifications....859
Piston Identification....862
Magnum Service Data....863
Torque Specifications....865
Fluid Capacity....866
Cooling System....867
2 Stroke Maintenance....870
4 Stroke Maintenance....874
Engine Removal....886
Engine Disassembly (Air Cooled 2 Stroke)....888
Crankshaft Alignment....889
Crankshaft and Crankcase Reassembly....890
Engine Installation....896
Cylinder Honing....897
Piston/Cylinder Clearance....898
Engine Service, 350L/400L....899
Oil Check Valve Testing....905
350L/400L Water Pump....906
Oil Pump End Play Adjustment....907
300 Oil Pump Check Valve Testing....908
Recoil Disassembly (Early Style EC25PF-01/02 Engines)....909
Recoil Disassembly (Late Style EC25PF-03 and Later Engines)....910
Recoil Reassembly (EC28 and EC38 Engines)....912
Magnum EH42PL Engine Exploded View....913
Magnum Lubrication/Oil Flow....914
Magnum Engine Removal....916
Magnum Engine Installation....921
Magnum Engine Disassembly/Inspection....922
Magnum Engine Assembly....952
Recoil Disassembly/lnspection/Assembly....968
2 Stroke Engine Troubleshooting....971
4 Stroke Engine Troubleshooting....972
Mikuni VM Carburetor, Exploded View....975
Function of VM Carburetor....976
Starter System....977
Pilot System....978
Main System....979
Throttle Opening....980
Component Description....981
Mikuni BST 34 Carburetor, Exploded View....983
Magnum CV Carb Operation....984
Magnum Fuel Tank Removal....988
CV Carburetor Systems....989
Float Height....991
Carburetor Disassembly....992
Carburetor Cleaning....995
Carburetor Assembly....998
Carburetor Installation....1000
Fuel Pump, Exploded View....1002
Fuel Pump Disassembly/lnspection/Assembly....1003
Troubleshooting....1004
Jetting Compensation for Altitude and Temperature....1006
8 - Electrical....1010
General Specifications....1012
Ignition Timing....1014
Ignition System Components (Exploded View)....1016
Ignition System Components (Exploded View) EC38-PL....1017
Ignition System Components (Exploded View) EC42PL(E)....1018
Ignition System Test Sequence....1020
Battery Maintenance and Testing....1022
Electric Starter System Testing....1024
Magnum Starter System Testing....1027
Starting System Troubleshooting....1030
Charging System Testing....1031
Speed Limiter System Testing....1034
Electric Demand 4 Drive System Testing....1037
Wiring Schematics and Diagrams....1042
1985-87 Scrambler, Trail Boss, Trail Boss 4x4 Schematic....1042
1987 Cyclone Schematic....1043
1988 Trail Boss 2x4 and 4x4 Schematic....1044
1988 Trail Boss 250 R/ES Schematic....1045
1989 Circuit Board And Wire Color Coding....1046
1989 Trail Boss, Trail Boss 2x4, Big Boss 4x6 Diagram....1048
1989 Trail Boss, Trail Boss 2x4, Big Boss 4x6 Schematic....1049
1989 Trail Boss 4x4 Diagram....1050
1989 Trail Boss 4x4 Schematic....1051
1990 Trail Blazer Diagram....1052
1990, 1991 Trail Boss, 2x4, 4x6 Diagram....1053
1990, 1991 Trail Boss, 2x4, 4x6 Schematic....1054
1990, 1991 Trail Boss 4x4 (Except J Model), 1991 Big Boss 6x6 Diagram....1055
1990, 1991 Trail Boss 4x4 (Except 1991 J Model) 1991 Big Boss 6x6 Schematic....1056
1991, 1991 Trail Boss 2x4-350L Diagram....1057
1990, 1991 350L 2x4 Schematic....1058
1990, 1991 Trail Boss 4x4 (Except 1991 J Model) Diagram....1059
1990, 1991 350L 4x4 (Except 1991 J Model) ....1060
1991 Trail Boss 250 (J Model) Diagram....1061
1991 Trail Boss 250 4x4 (J Model) Schematic....1062
1991 4x4-350L (J Model) Diagram....1063
1991 350L 4x4 (J Model) Schematic....1064
1991 Trail Blazer Diagram....1065
1992 Trail Blazer Diagram....1066
1992 Trail Boss, 2x4, 4x6 Diagram....1067
1992 Trail Boss, 2x4, 4x6 Schematic....1068
1992 Trail Boss 250 4x4 and Big Boss 6x6 Diagram....1069
1992 Trail Boss 250 4x4 and Big Boss 6x5 Schematic....1070
1992 350L 2x4 Diagram....1071
1992 350L 2x4 Schematic....1072
1992 350L 4x4 Trail Boss Diagram....1073
1992 350L 4x4 Trail Boss Schematic....1074
1993 Trail Blazer Diagram....1075
1993 250 2x4 and Trail Boss Diagram....1076
1993 250 2x4 and Trail Boss Schematic....1077
1993 250 4x4 and 250 6x6 Diagram....1078
1993 250 4x4 and 250 6x6 Schematic....1079
1993 350 2x4 Diagram....1080
1993 350L 2x4 Schematic....1081
1993 350L 4x4 Diagram....1082
1993 350L 4x4 Schematic....1083
1993 Sportsman Schematic....1084
1993 350 6x6 Schematic....1085
1994 Trail Blazer Schematic....1086
1994 Trail Boss Schematic....1087
1994 300 2x4 Schematic....1088
1994 400L 2x4 Schematic....1089
1994 400L Sport Schematic....1090
1994 300 4x4, 6x6 Schematic....1091
1994 400L 4x4, Sportsman, 6x6 Schematic....1092
1995 Trail Blazer Schematic....1093
1995 Trail Boss Schematic....1094
1995 300 2x4 Schematic....1095
1995 400 2x4 Schematic....1096
1995 400 Sport Schematic....1097
1995 300 4x4 Schematic....1098
1995 Xplorer 4x4, Sportsman, 400 6x6 Schematic....1099
1995 Scrambler Schematic....1100
1995 Magnum 2x4 Schematic....1101
1995 Magnum 4x4 Schematic....1102
Polaris Outlaw 450MXR_525S_525IRS '09 Service Repair Manual....1103
9921810_Chapter_1....1103
GENERAL INFORMATION....1103
VEHICLE IDENTIFICATION....1104
Model Identification....1104
Engine Designation Numbers....1104
VIN Identification....1104
Vehicle Identification Number (VIN) Location....1104
Engine Serial Number Location....1104
VEHICLE INFORMATION....1104
Paint Codes....1104
Replacement Keys....1104
Publication Numbers....1105
Standard Torque Specifications....1105
SPECIFICATIONS....1106
MODEL: 2009 OUTLAW 450 “MXR”....1106
MODEL: 2009 OUTLAW 525 “S”....1106
MODEL: 2009 OUTLAW 525 “IRS”....1106
2009 OUTLAW 450 “MXR”....1107
2009 OUTLAW 525 “S”....1108
2009 OUTLAW 525 “IRS”....1109
SPECIAL TOOLS....1110
“Chassis” Special Tools....1110
“KTM Engine” Special Tool Cross-Reference....1110
KTM Engine Special Tools....1111
MISC. NUMBERS / CHARTS....1112
SAE Tap / Drill Sizes....1112
Metric Tap / Drill Sizes....1112
Decimal Equivalents....1112
Coversion Table....1113
Glossary of Terms....1114
9921810_Chapter_2....1115
MAINTENANCE....1115
PERIODIC MAINTENANCE CHART....1117
Periodic Maintenance Overview....1117
Break-In Period....1117
Maintenance Chart Key....1117
Pre-Ride Maintenance Interval....1118
Recommended Pre-Ride Fluid Level Checks....1118
10 - 60 Hour Maintenance Interval....1119
45 - 90 Hour Grease Lubrication Maintenance Interval....1120
90 - 300 Hour Maintenance Interval....1121
Maintenance References....1122
LUBRICANTS AND SERVICE PRODUCTS....1123
Polaris Lubricants, Maintenance and Service Products....1123
GENERAL VEHICLE INSPECTION AND MAINTENANCE....1124
Pre-Ride / Daily Inspection....1124
Frame, Nuts, Bolts, and Fasteners....1124
FUEL SYSTEM AND AIR INTAKE....1124
Fuel System....1124
Fuel Lines....1124
Vent Lines....1125
Fuel Valve....1125
Carburetor General Maintenance....1125
Carburetor Draining....1125
Idle Speed Adjustment....1126
Throttle Inspection....1126
Throttle Cable / Electronic Throttle Control (ETC) Adjustment....1126
Choke Operation....1127
Air Filter Service (“MXR” / “S”)....1127
Air Filter Service (“IRS”)....1128
Air Box Drain Tube....1128
ENGINE AND TRANSMISSION....1129
Engine Oil Level....1129
Engine Oil and Filter Service....1129
Cylinder Leakdown Test....1132
Valve Clearance Adjustment....1132
Exhaust Pipe / Spark Arrestor....1132
Engine Mount Locations....1132
LIQUID COOLING SYSTEM....1133
Cooling System Overview....1133
Coolant Strength / Type....1133
Cooling System Hoses....1133
Recovery Bottle / Coolant Level Inspection....1134
Radiator / Coolant Level Inspection....1134
Cooling System Bleeding....1134
Radiator Screen Removal....1135
FINAL DRIVE....1135
Hydraulic Clutch Lever Adjustment....1135
Hydraulic Clutch Oil level Inspection....1135
Hydraulic Clutch System Bleeding....1136
Reverse Lock-Out Lever Inspection and Cable Adjustment....1137
Sprocket Inspection....1137
Drive Chain Inspection / Replacement....1137
Drive Chain Tension....1138
Drive Chain Adjustment (“MXR” / “S”)....1138
Drive Chain Adjustment (“IRS”)....1139
Rear Driveshaft Boot Inspection (“IRS”)....1139
Driveshaft Boot Pressure Equalizing (“IRS”)....1140
ELECTRICAL AND IGNITION SYSTEM....1140
Battery Maintenance....1140
Battery Inspection / Removal....1141
Battery Terminals / Bolts....1141
Off Season Storage....1141
Charging Procedure (“MXR” / “S”)....1142
Charging Procedure (“IRS”)....1142
Spark Plug Removal / Inspection....1142
STEERING....1143
General Steering Information....1143
Controls / Handlebar....1143
Steering Inspection / Tie Rod Ends and Hubs ....1144
Toe Alignment Inspection....1144
Toe Adjustment....1145
SUSPENSION (450 “MXR” / 525 “S”)....1146
Front Suspension Set-Up....1146
Front Spring Preload Adjustment....1146
Front Shock Compression Adjustment (“MXR”)....1147
Rear Suspension Set-Up....1147
Rear Spring Preload Adjustment....1148
Rear Shock Compression Adjustment....1148
Rear Shock Rebound Adjustment....1149
SUSPENSION (525 “IRS”)....1149
Front Suspension Set-Up....1149
Front Spring Preload Adjustment....1150
Rear Suspension Set-Up....1150
Rear Spring Preload Adjustment....1151
Rear Shock Compression Adjustment....1151
BRAKE SYSTEM....1152
Brake System Inspection....1152
Brake Pad Inspection....1152
Brake Lever Position Adjustment....1152
Brake Pedal Testing / Brake Light Operation....1152
WHEELS AND TIRES....1153
Wheels....1153
Wheel, Hub, and Spindle Torque Table....1153
Wheel Removal: Front or Rear....1153
Tire Pressure....1153
Tire Inspection....1153
MAINTENANCE LOG....1154
9921810_Chapter_3....1155
ENGINE....1155
ENGINE SERVICE....1156
KTM 450/525 Engine....1156
GENERAL ENGINE INFORMATION....1156
Special Tools....1156
Accessible Components....1156
Engine Removal....1156
Engine Installation Notes....1160
Engine Break-In Period....1161
ES45KL / ES51KL Engine Lubrication....1161
ENGINE COOLING SYSTEM....1161
Coolant Temperature Sensor (Dual Temp Thermal Sensor)....1161
Cooling System Flow Chart....1161
Cooling System Pressure Test....1162
Cooling System Specifications....1162
9921810_Chapter_4....1163
FUEL SYSTEM....1163
CARBURETOR SERVICE....1164
Keihin FCR-MX 39 mm Carburetor....1164
GENERAL INFORMATION....1164
Jetting Guidelines....1164
Carburetor Jetting....1164
Keihin Optional Jet Part Numbers....1164
KEIHIN FCR-MX 3900 CARBURETOR....1165
Exploded View....1165
FUEL TANK....1166
Exploded View....1166
Fuel Tank Removal....1167
FUEL PUMP....1168
Location / Operation....1168
Service / Replacement....1168
9921810_Chapter_5....1169
BODY / STEERING / SUSPENSION....1169
GENERAL INFORMATION....1170
Torque Specifications....1170
Special Tools....1170
BODY ASSEMBLY....1171
Exploded View....1171
BODY COMPONENT REMOVAL....1172
Seat....1172
Front Cover....1172
Front Cab....1172
Side Panels....1173
Rear Cab....1173
Heel Pocket....1173
STEERING ASSEMBLY EXPLODED VIEW....1174
STEERING KNUCKLE....1175
Removal....1175
Installation....1175
BALL JOINT SERVICE....1175
Removal....1175
Installation....1176
FRONT WHEEL HUB....1177
Exploded View....1177
Wheel Hub Removal....1178
Wheel Hub Disassembly....1179
Wheel Hub Assembly....1179
Wheel Hub Installation....1180
FRONT SUSPENSION EXPLODED VIEW....1181
FRONT A-ARM REPLACEMENT....1182
A-arm Removal and Inspection....1182
A-arm Installation....1182
REAR SUSPENSION EXPLODED VIEW (“IRS”)....1183
REAR A-ARM REPLACEMENT (“IRS”)....1184
A-arm Removal....1184
A-arm Inspection....1184
A-arm Installation....1185
REAR HOUSING (“IRS”)....1186
Exploded View....1186
Housing Removal....1187
Housing Disassembly / Service....1188
Assembly....1190
Installation....1191
REAR BEARING CARRIER (“IRS”)....1192
Carrier Removal....1192
Carrier Disassembly / Inspection....1192
Carrier Assembly....1193
Carrier Installation....1194
REAR DRIVE CV JOINT (“IRS”)....1195
CV Joint Removal....1195
CV Joint Service....1196
CV Joint Installation....1197
REAR SUSPENSION SERVICE (“MXR” / “S”)....1198
Swing Arm Removal / Installation....1198
REAR AXLE SERVICE (“MXR” / “S”)....1199
Removal / Disassembly....1199
Installation / Assembly....1201
Axle Run-Out Inspection....1203
REAR AXLE HOUSING / AXLE (“MXR” / “S”)....1204
Exploded View....1204
DECAL REPLACEMENT....1205
FRONT SHOCK EXPLODED VIEWS....1206
FOX™ PODIUM X ‘Piggyback’ Front Shock (450 “MXR”)....1206
FOX™ PODIUM Front Shock (525 “S” / 525 “IRS”)....1207
REAR SHOCK EXPLODED VIEWS....1208
FOX™ PODIUM X ‘Piggyback’ Rear Shock (450 “MXR” / 525 “S”)....1208
FOX™ PODIUM-C Rear Shock (525 “IRS”)....1209
FOX™ PODIUM SHOCK SERVICE....1210
General Service Information....1210
FOX™ Front Shock Disassembly....1211
FOX™ Front Shock Assembly....1214
Shock Eyelet Replacement....1217
FOX™ PODIUM X SHOCK SERVICE....1218
General Service Information....1218
Front Shock Service Information (450 “MXR”)....1218
Rear Shock Service Information (450 “MXR” / 525 “S”)....1218
FOX™ PODIUM X Shock Rebuild Information....1219
FOX™ Podium X Shock Disassembly....1220
FOX™ Podium X Shock Rebuild....1222
FOX™ Podium X Shock Assembly....1223
FOX™ PODIUM-C SHOCK SERVICE....1226
General Service Information....1226
FOX™ PODIUM-C Rebuild Information....1227
FOX™ PODIUM-C Shock Disassembly....1228
FOX™ PODIUM-C Shock Assembly....1230
9921810_Chapter_6....1235
BRAKES....1235
BRAKE SPECIFICATIONS....1236
General Specifications....1236
Torque Specifications....1236
Special Tools....1236
BRAKE CALIPER EXPLODED VIEWS....1237
Front Brake Caliper Assembly....1237
Rear Brake Caliper Assembly....1237
BRAKE SYSTEM OVERVIEW....1238
Hydraulic System Operation....1238
Front Brake System - Exploded View....1239
Rear Brake System (“MXR” / “S”) - Exploded View....1240
Rear Brake System (“IRS”) - Exploded View....1241
Service Notes....1242
Brake Noise Troubleshooting....1242
Brake Fluid Replacement and Bleeding Procedure....1243
FRONT MASTER CYLINDER....1245
Brake Lever Position Adjustment....1245
Removal....1245
Installation....1246
FRONT CALIPER SERVICE....1247
Caliper Removal and Disassembly ....1247
Caliper Inspection....1249
Caliper Assembly....1249
Caliper Installation....1250
FRONT BRAKE PADS....1250
Pad Removal....1250
Pad Assembly....1251
Brake Burnishing Procedure....1252
FRONT BRAKE DISC....1252
Disc Inspection....1252
Disc Removal / Replacement....1252
REAR CALIPER SERVICE....1253
Caliper Removal (“MXR” / “S”)....1253
Caliper Removal (“IRS”)....1254
Caliper Disassembly....1254
Caliper Inspection....1255
Caliper Reassembly....1255
Caliper Installation (“MXR” / “S”)....1256
Caliper Installation (“IRS”)....1257
REAR BRAKE PADS....1257
Pad Removal....1257
Pad Installation....1258
Brake Burnishing Procedure....1259
REAR BRAKE DISC....1259
Disc Inspection....1259
Disc Removal / Replacement (“MXR” / “S”)....1260
Disc Removal / Replacement (“IRS”)....1260
Disc Installation....1260
TROUBLESHOOTING....1261
Brakes Squeal....1261
Poor Brake Performance....1261
Lever Vibration....1261
Brakes Lock....1261
9921810_Chapter_7....1263
ELECTRICAL....1263
GENERAL INFORMATION....1264
Special Tools....1264
Electrical Service Notes....1264
COMPONENT LOCATION (CHASSIS)....1264
450 “MXR” / 525 “S”....1264
525 “IRS”....1264
LIGHTING AND CONTROLS....1265
Transmission Switch Test....1265
Headlight Bulb Replacement....1265
Headlight Housing Replacement....1265
Headlight Adjustment....1266
Headlamp Switch Test....1266
Taillight / Brakelight Lamp Replacement....1266
Brake Light Switch Tests....1267
Clutch Switch Test....1267
Tether Switch Test (Accessory Option)....1267
Indicator Lamp Replacement....1267
Electronic Throttle Control (ETC) Switch....1268
ETC Operation Test....1268
IGNITION SYSTEM....1269
Ignition System Troubleshooting....1269
DC / CDI Ignition....1269
Circuit Breakers....1269
Cranking Output Tests....1270
Ignition System Breakout Diagram....1271
Ignition System Testing....1272
Components of DC / CDI Ignition....1273
COOLING SYSTEM....1274
Fan Control Circuit Operation....1274
Fan Switch Bypass Tests....1274
Fan Switch “Hot Light” Operation....1275
CHARGING SYSTEM....1275
Current Draw - Key Off....1275
Charging System “Break Even” Test....1275
Alternator Tests (Charging System)....1276
Charging System Testing Flow Chart....1277
BATTERY TESTS....1278
Battery Testing....1278
OCV - Open Circuit Voltage Test....1278
Load Test....1278
Battery Terminals / Bolts....1278
Battery Maintenance / Inspection / Removal....1278
Battery Charging Procedure....1278
STARTING SYSTEM....1279
Starting System Circuit....1279
Starter System Troubleshooting....1280
Clutch Switch Test....1280
Neutral Start Diode Test ....1280
Starter Voltage Drop Testing....1280
Starter Motor Removal....1280
Starter Motor Exploded View....1281
Starter Motor Disassembly....1282
Brush Inspection / Replacement....1282
Armature Testing....1283
Starter Reassembly....1283
Starter Motor Installation....1284
Starter One-Way Clutch Inspection....1284
Starter System Testing Flow Chart ....1285
9921810_Chapter_8_02....1287
9921810_Chapter_8_04....1295
9921810_Chapter_8_05....1308
9921810_Chapter_8_06....1333
9921810_Chapter_8_08....1351
9921810_Chapter_8_09....1365
9921810_Chapter_8_10....1369
9921810_Wire_Diagram....1374
Polaris Outlaw 50-90, Sportman 90 '13-'14 Service Repair Manual....1376
9924867 Youth 4-Stroke....1376
2013–2014 Youth 4–Stroke ....1376
Copyright Info ....1377
Understanding Manual Safety Labels and Directions ....1377
Trademarks ....1378
PERIODIC MAINTENANCE CHART ....1396
PERIODIC MAINTENANCE OVERVIEW ....1396
MAINTENANCE CHART KEY ....1396
PRE-RIDE - 10 HOUR MAINTENANCE INTERVAL ....1397
20 - 300 HOUR MAINTENANCE INTERVAL ....1398
POLARIS LUBRICANTS AND SERVICE PRODUCTS ....1399
LUBRICANTS AND SERVICE PRODUCTS ....1399
MAINTENANCE REFERENCES ....1400
GENERAL VEHICLE INSPECTION AND MAINTENANCE ....1401
PRE-RIDE / DAILY INSPECTION ....1401
VEHICLE COMPONENT INSPECTION LOCATIONS ....1401
FRAME, NUTS, BOLTS AND FASTENER INSPECTION ....1402
STANDARD TORQUE SPECIFICATIONS ....1402
KICK-START LEVER AND OPERATION ....1402
FUEL SYSTEM AND AIR INTAKE ....1403
FUEL SYSTEM SAFETY ....1403
SPEED CONTROL SYSTEM ....1403
THROTTLE STOP SPEED CONTROL SYSTEM ....1403
THROTTLE RELEASE SWITCH (TRS) ....1403
TRS OPERATION ....1404
TRS SWITCH ADJUSTMENT ....1404
CHOKE CABLE ADJUSTMENT ....1405
IDLE SPEED ADJUSTMENT ....1405
FUEL LINES ....1405
PILOT AIR SCREW ADJUSTMENT ....1406
VENT LINES ....1406
FUEL FILTER ....1407
FUEL VALVE LOCATION ....1407
CARBURETOR DRAINING ....1408
AIR FILTER SERVICE ....1409
AIR BOX SEDIMENT TUBE ....1410
ENGINE ....1411
ENGINE OIL LEVEL ....1411
ENGINE OIL AND FILTER CHANGE ....1411
COMPRESSION / LEAKDOWN TEST ....1412
VALVE CLEARANCE ADJUSTMENT ....1412
ENGINE MOUNTS ....1413
ENGINE FASTENER TORQUE ....1413
CVT DRYING (90CC MODELS) ....1413
EXHAUST SPARK ARRESTOR CLEANING ....1414
TRANSMISSION AND FINAL DRIVE ....1415
TRANSMISSION LUBRICATION ....1415
TRANSMISSION LUBRICANT LEVEL ....1415
TRANSMISSION LUBRICANT CHANGE ....1415
DRIVE CHAIN INSPECTION - 90CC MODELS ....1416
DRIVE CHAIN INSPECTION - 50CC MODELS ....1416
DRIVE CHAIN ADJUSTMENT - 50 AND 90CC MODELS ....1416
SPROCKET INSPECTION ....1417
ELECTRICAL AND IGNITION SYSTEM ....1418
BATTERY MAINTENANCE SERVICE NOTES ....1418
BATTERY REMOVAL - 50CC ....1418
BATTERY REMOVAL - 90CC ....1419
BATTERY CLEANING ....1419
BATTERY INSTALLATION ....1419
BATTERY STORAGE ....1420
FUSES / FUSE HOLDER LOCATION ....1420
SPARK PLUG INSPECTION ....1420
IGNITION TIMING ....1421
ENGINE / FRAME GROUND ....1421
STEERING AND SUSPENSION ....1422
STEERING ....1422
TIE ROD END / STEERING INSPECTION ....1422
WHEEL ALIGNMENT ....1423
TOE ADJUSTMENT ....1424
FRONT SUSPENSION INSPECTION ....1424
REAR SUSPENSION INSPECTION ....1425
SUSPENSION SPRING ADJUSTMENT ....1425
BRAKE SYSTEM ....1426
BRAKE SYSTEM INSPECTION ....1426
BRAKE LEVER TRAVEL ....1426
BRAKE FREEPLAY ....1426
FRONT BRAKE ADJUSTMENT ....1426
REAR BRAKE ADJUSTMENT ....1427
BRAKE SHOE INSPECTION ....1428
WHEELS AND TIRES ....1429
WHEELS ....1429
WHEEL, HUB AND SPINDLE TORQUE TABLE ....1429
WHEEL INSPECTION ....1429
WHEEL REMOVAL - FRONT / REAR ....1429
WHEEL INSTALLATION - FRONT / REAR ....1429
TIRE PRESSURE ....1430
TIRE INSPECTION ....1430
ENGINE SERVICE ....1434
ENGINE EXPLODED VIEWS & TORQUE VALUES ....1434
SPECIAL TOOLS ....1437
ENGINE SERVICE DATA ....1437
OIL FLOW DIAGRAM ....1441
PISTON / RING IDENTIFICATION ....1442
ACCESSIBLE COMPONENTS ....1442
ENGINE REMOVAL ....1442
ENGINE INSTALLATION NOTES ....1443
ENGINE LUBRICATION ....1444
TRANSMISSION LUBRICATION ....1444
ENGINE BREATHER / OIL SEPARATOR ....1444
FINDING TOP DEAD CENTER (TDC) ....1446
TOP-END DISASSEMBLY ....1447
ENGINE DISASSEMBLY ....1447
CAM CHAIN TENSIONER REMOVAL ....1447
CAM CHAIN TENSIONER INSPECTION ....1447
CYLINDER HEAD REMOVAL ....1447
ROCKER ARM DISASSEMBLY / INSPECTION ....1448
CAMSHAFT REMOVAL ....1449
CAMSHAFT INSPECTION ....1449
CYLINDER HEAD INSPECTION ....1450
CYLINDER HEAD SURFACE INSPECTION ....1450
COMBUSTION CHAMBER INSPECTION ....1450
CYLINDER HEAD DISASSEMBLY ....1450
VALVE INSPECTION ....1451
VALVE SEAT RECONDITIONING ....1452
CYLINDER HEAD ASSEMBLY ....1455
VALVE SEALING TEST ....1455
CYLINDER REMOVAL ....1455
CAM CHAIN TENSIONER BLADE ....1456
PISTON REMOVAL ....1456
CYLINDER INSPECTION ....1456
CYLINDER HONING PROCEDURE ....1457
HONING TO DEGLAZE ....1457
PISTON INSPECTION ....1458
PISTON RING INSTALLED GAP ....1459
BOTTOM-END DISASSEMBLY ....1460
FLYWHEEL REMOVAL / INSPECTION ....1460
STATOR REMOVAL ....1460
OIL PUMP REMOVAL ....1460
CRANKCASE DISASSEMBLY ....1461
CRANKSHAFT REMOVAL ....1461
CRANKSHAFT / CAM CHAIN / SPROCKET INSPECTION ....1462
CRANKCASE OIL STRAINER INSPECTION ....1462
ENGINE ASSEMBLY ....1463
CRANKCASE ASSEMBLY ....1463
PISTON RING INSTALLATION ....1463
PISTON INSTALLATION ....1463
TENSIONER BLADE INSTALLATION ....1464
CYLINDER INSTALLATION ....1464
CYLINDER HEAD & CAMSHAFT INSTALLATION ....1465
CAM CHAIN TENSIONER INSTALLATION ....1467
TRANSMISSION ....1468
TRANSMISSION DISASSEMBLY AND INSPECTION ....1468
TRANSMISSION INSPECTION ....1471
TRANSMISSION ASSEMBLY ....1474
STARTER DRIVE MECHANISM (ELECTRIC) ....1475
KICK START ....1479
KICK START DISASSEMBLY / INSPECTION ....1479
KICK START ASSEMBLY ....1480
TROUBLESHOOTING ....1483
SPARK PLUG FOULING ....1483
ENGINE (GENERAL) ....1483
CARBURETION SYSTEM ....1488
SPECIAL TOOLS ....1488
CARBURETOR FUNCTION ....1488
CARBURETION SPECIFICATIONS ....1489
CARBURETOR OPERATION ....1489
OPERATION OVERVIEW ....1489
FLOAT SYSTEM ....1490
PILOT JET ....1490
PILOT MIXTURE SCREW ....1490
AIR / FUEL MIXTURE RATIO ....1491
JET NEEDLE ....1492
NEEDLE JET ....1492
THROTTLE OPENING VS. FUEL FLOW ....1492
THROTTLE SLIDE ....1493
MAIN JET ....1493
PILOT SYSTEM (IDLE - 3/8 THROTTLE) ....1494
SLIDE CUTAWAY (1/8 - 3/8 THROTTLE) ....1494
JET NEEDLE/NEEDLE JET (3/8 - 3/4 THROTTLE) ....1495
MAIN SYSTEM (3/4 TO FULL THROTTLE) ....1495
FUEL DELIVERY ....1496
VENT SYSTEM ....1496
CARBURETOR SERVICE ....1496
CARBURETOR FLOAT BOWL DRAINING ....1496
CARBURETOR REMOVAL - GENERAL ....1497
CARBURETOR DISASSEMBLY - 50CC (MIKUNI) ....1497
CARBURETOR DISASSEMBLY - 90CC (KEIHIN/SUNWORLD) ....1498
CARBURETOR CLEANING ....1499
CARBURETOR INSPECTION ....1500
FLOAT HEIGHT ADJUSTMENT ....1501
CARBURETOR ASSEMBLY ....1502
NEEDLE AND SEAT LEAK TEST ....1502
FUEL TANK EXPLODED VIEW ....1503
FUEL TANK REMOVAL ....1504
FUEL VALVE LOCATION ....1504
FUEL VALVE SERVICEOUTLAW 50 / OUTLAW 90 ....1505
FUEL VALVE LAYOUT ....1505
AIR FILTER ....1506
AIR CLEANER EXPLODED VIEW ....1506
SECONDARY AIR INJECTION SYSTEM ....1507
TROUBLESHOOTING ....1508
FUEL STARVATION / LEAN MIXTURE ....1508
RICH MIXTURE ....1508
POOR IDLE ....1508
GENERAL INFORMATION ....1512
SPECIAL TOOLS ....1512
TORQUE SPECIFICATIONS ....1512
BODY REMOVAL - OUTLAW 50 ....1512
BODY REMOVAL ....1512
FOOTWELL REMOVAL ....1514
FRONT BUMPER REMOVAL / INSTALLATION ....1514
OUTLAW 50 - BODY EXPLODED VIEW ....1515
BODY REMOVAL - OUTLAW 90 ....1516
REAR CAB REMOVAL ....1516
SIDE PANEL REMOVAL ....1516
FOOTWELL REMOVAL ....1517
FRONT CAB REMOVAL ....1517
FRONT BUMPER REMOVAL / INSTALLATION ....1518
OUTLAW 90 - BODY EXPLODED VIEW ....1519
BODY REMOVAL - SPORTSMAN 90 ....1520
REAR CAB REMOVAL ....1520
SIDE PANEL REMOVAL ....1520
FOOTWELL REMOVAL ....1521
FRONT CAB REMOVAL ....1521
BUMPER AND RACK REMOVAL ....1523
SPORTSMAN 90 - BODY EXPLODED VIEW ....1523
INDICATOR LIGHT / IGNITION SWITCH REPLACEMENT ....1524
SUSPENSION ....1525
50CC SHOCKS AND SPRINGS ....1525
90CC SHOCKS AND SPRINGS ....1525
FRONT SHOCK REMOVAL ....1525
REAR SHOCK REMOVAL ....1525
FRONT CONTROL ARM - 50CC ....1526
CONTROL ARM EXPLODED VIEW ....1526
CONTROL ARM REPLACEMENT ....1526
FRONT A-ARM - 90CC ....1528
A-ARM EXPLODED VIEW ....1528
A-ARM REPLACEMENT ....1528
SWING ARM ....1529
REMOVAL ....1529
STEERING - 50CC ....1532
STEERING ASSEMBLY EXPLODED VIEW ....1532
STEERING POST REMOVAL ....1532
STEERING - 90CC ....1533
STEERING ASSEMBLY EXPLODED VIEW ....1533
STEERING POST REMOVAL ....1533
TIE ROD ....1534
REMOVAL / ADJUSTMENT ....1534
HANDLEBAR ....1534
OUTLAW 50 EXPLODED VIEW ....1534
OUTLAW 90 EXPLODED VIEW ....1534
SPORTSMAN 90 EXPLODED VIEW ....1535
DECAL REPLACEMENT ....1535
SPECIFICATIONS ....1537
GENERAL SPECIFICATIONS ....1537
TORQUE SPECIFICATIONS ....1537
FRONT BRAKES ....1538
EXPLODED VIEW ....1538
FRONT BRAKE SERVICE ....1538
REAR BRAKE ....1543
EXPLODED VIEW ....1543
REAR BRAKE SERVICE ....1544
BRAKE LEVER ADJUSTMENTS ....1546
CVT SYSTEM ....1549
CVT MAINTENANCE / INSPECTION ....1549
DRIVE CLUTCH OPERATION ....1549
DRIVEN CLUTCH OPERATION ....1549
CVT SYSTEM DRYING ....1550
CVT OVERHEATING / DIAGNOSIS ....1551
CLUTCH COVER REMOVAL ....1552
DRIVE BELT REMOVAL ....1552
DRIVE CLUTCH SERVICE ....1553
DRIVE CLUTCH DISASSEMBLY AND INSPECTION ....1553
DRIVE CLUTCH ASSEMBLY ....1554
DRIVEN CLUTCH SERVICE ....1556
DRIVEN CLUTCH DISASSEMBLY AND INSPECTION ....1556
DRIVEN CLUTCH ASSEMBLY ....1558
GENERAL INFORMATION ....1562
SPECIAL TOOLS ....1562
ELECTRICAL SYSTEM SERVICE NOTES ....1562
SWITCHES AND CONTROLS ....1562
BRAKE LEVER SWITCHES ....1562
TETHER SWITCH TEST ....1563
THROTTLE RELEASE SWITCH (TRS) ....1563
TRS OPERATION ....1563
TRS SWITCH ADJUSTMENT ....1564
KEY SWITCH ....1564
LEFT HAND SWITCH ASSEMBLY ....1564
DAYTIME RUNNING LIGHTS ....1565
“DRL” TEST ....1565
“DRL” LAMP REPLACEMENT ....1565
TAIL LIGHT ....1566
TAIL LIGHT LAMP REPLACEMENT ....1566
INDICATOR LAMPS (90CC MODELS) ....1566
INDICATOR LAMP REPLACEMENT ....1566
TRANSMISSION SWITCH ....1568
TRANSMISSION SWITCH - CIRCUIT BREAKOUT ....1568
TESTING ....1568
REMOVAL ....1569
INSTALLATION ....1569
IGNITION SYSTEM ....1570
OVERVIEW ....1570
IGNITION SYSTEM TROUBLESHOOTING ....1570
IGNITION SYSTEM TESTING ....1571
RPM IGNITION LIMITER FUNCTIONS ....1572
RPM LIMITER SPECIFICATIONS ....1572
IGNITION COIL TEST ....1572
CDI OUTPUT TEST USING PEAK READING ADAPTOR ....1572
PULSER COIL OUTPUT / RESISTANCE TESTS ....1573
CHARGING SYSTEM ....1574
CHARGING SYSTEM TESTING ....1574
MAIN FUSE / FUSIBLE LINK LOCATION ....1575
VOLTAGE REGULATOR / RECTIFIER ....1575
STATOR / ALTERNATOR TESTS ....1576
BATTERY ....1577
BATTERY MAINTENANCE SERVICE NOTES ....1577
NEW BATTERY ACTIVATION ....1577
BATTERY REMOVAL - 50CC ....1578
BATTERY REMOVAL - 90CC ....1578
BATTERY CLEANING ....1579
BATTERY INSTALLATION ....1579
BATTERY VOLTAGE TEST ....1579
BATTERY LOAD TEST ....1579
BATTERY CHARGING PROCEDURE ....1580
BATTERY STORAGE ....1580
STARTER SYSTEM ....1581
STARTER RELAY ....1581
STARTER MOTOR SERVICE ....1581
STARTER DISASSEMBLY ....1581
STARTER BRUSH INSPECTION / REPLACEMENT ....1582
ARMATURE TEST ....1582
STARTER REASSEMBLY ....1583
VOLTAGE DROP TEST ....1583
STARTER SYSTEM TROUBLESHOOTING ....1583
STARTER SYSTEM TESTING ....1584
2014 Youth WD.pdf....0
9923970_Youth_4-Stroke 193....1590
9923970_Youth_4-Stroke 194....1591
appout.pdf....0
2013–2014 Youth 4–Stroke ....1382
VEHICLE IDENTIFICATION ....1383
MODEL NUMBER DESIGNATION ....1383
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION ....1383
ENGINE NUMBER DESIGNATION ....1384
VEHICLE IDENTIFICATION NUMBER AND ENGINE SERIAL NUMBER LOCATION ....1384
GENERAL SPECIFICATIONS ....1385
MODEL OVERVIEW: OUTLAW 50 ....1385
MODEL OVERVIEW: OUTLAW 90 ....1385
MODEL OVERVIEW: SPORTSMAN 90 ....1385
MODEL: OUTLAW 50 ....1386
MODEL: OUTLAW 90 / SPORTSMAN 90 ....1387
GENERAL INFORMATION ....1388
PUBLICATION NUMBERS ....1388
PAINT CODES ....1388
REPLACEMENT KEYS ....1388
SPECIAL TOOLS - WHERE USED ....1389
CONVERSION TABLE ....1390
STANDARD BOLT TORQUE SPECIFICATION ....1391
METRIC BOLT TORQUE SPECIFICATION ....1391
SAE TAP / DRILL SIZES ....1392
METRIC TAP / DRILL SIZES ....1392
DECIMAL EQUIVALENTS ....1393
Polaris Outlaw 500 '06-'07 Service Repair Manual....1592
TABLE....1592
GENERAL INFORMATION....1594
Vehicle Identification....1595
Model Identification....1595
Engine Designation Number....1595
VIN Identification....1595
Unit Serial Number (VIN) Location....1595
Engine Serial Number Location....1595
Vehicle Information....1595
Paint Codes....1595
Replacement Keys....1595
Publication Numbers....1596
Standard Torque Specifications....1596
Specifications....1597
MODEL: 2007 OUTLAW 500....1597
2007 OUTLAW 500....1598
Special Tools....1599
‘Where Used’ Table....1599
Special Tool Listing....1600
Misc. Numbers / Charts....1603
SAE Tap / Drill Sizes....1603
Metric Tap / Drill Sizes....1603
Decimal Equivalents....1603
Coversion Table....1604
Glossary of Terms....1605
MAINTENANCE....1606
Periodic Maintenance Chart....1608
Periodic Maintenance Overview....1608
Maintenance Chart Key....1608
Pre-Ride Maintenance Interval....1609
Recommended Pre-Ride Fluid Level Checks....1609
0 - 50 Hour Maintenance Interval....1610
50 - 100 Hour Maintenance Interval....1611
100 - 300 Hour Maintenance Interval....1612
Maintenance References....1613
Lubricants and Service Products....1614
Polaris Lubricants, Maintenance and Service Products....1614
General Vehicle Inspection and Maintenance....1615
Pre-Ride / Daily Inspection....1615
Frame, Nuts, Bolts, and Fasteners....1615
Fuel System and Air Intake....1615
Fuel System....1615
Fuel Lines....1615
Vent Lines....1616
Fuel Valve....1616
Carburetor Draining....1616
Carburetor Pilot Screw Adjustment....1617
Idle Speed Adjustment....1617
Throttle Inspection....1617
Throttle Cable / Electronic Throttle Control (ETC) Adjustment....1618
Choke Adjustment....1618
Air Filter and Pre-filter Service....1618
Air Box Drain Tube....1619
Crankcase Breather Filter Inspection....1619
Engine and Transmission....1619
Engine Oil Level Check....1619
Engine Oil and Filter Service....1620
Oil Pump Priming Procedure....1621
Compression Test....1621
Exhaust Pipe / Spark Arrestor....1621
Engine Mount Locations....1622
Liquid Cooling System....1622
Cooling System Overview....1622
Coolant Strength / Type....1623
Cooling System Hoses....1623
Radiator....1623
Recovery Bottle Coolant Level Inspection....1623
Cooling System Pressure Test....1624
Radiator Screen Removal....1624
Final Drive....1624
Clutch Adjustment....1624
Reverse Lock-Out Lever Inspection and Cable Adjustment....1624
Sprocket Inspection....1624
Drive Chain Inspection / Replacement....1625
Drive Chain Tension....1625
Drive Chain Adjustment....1626
Rear Driveshaft Boot Inspection....1626
Rear Driveshaft Boot “Pressure Equalizing”....1627
Electrical and Ignition System....1627
Battery Maintenance....1627
Battery Inspection / Removal....1628
Battery Terminals / Bolts....1628
Off Season Storage....1628
Engine- To- Frame Ground....1628
Charging Procedure....1628
Spark Plug Inspection....1629
Ignition Timing....1629
Steering and Suspension....1629
Steering....1629
Controls....1630
Wheel Alignment....1630
Steering Inspection / Tie Rod Ends and Hubs ....1631
Toe Alignment Adjustment....1632
Camber and Caster....1632
Suspension Spring Preload Adjustment....1632
Rear Shock Compression Adjustment....1634
Brake System....1634
Brake System Inspection....1634
Hose / Fitting Inspection....1635
Brake Pad Inspection....1635
Brake Testing....1635
Wheels and Tires....1635
Wheels....1635
Wheel, Hub, and Spindle Torque Table....1635
Wheel Removal: Front or Rear....1635
Tire Pressure....1636
Tire Inspection....1636
ENGINE....1638
Specifications....1640
Torque Specifications....1640
ES50PL Engine Service Data....1641
ES50PL Engine Service Data....1642
Special Tools....1643
Engine Fastener Torque Patterns....1643
General Engine Service....1643
Piston Identification....1643
Compression Test....1643
Coolant Temperature Sensor (Thermistor)....1644
Cooling System....1644
Radiator Cap / System Pressure Test....1644
Cooling System Specifications....1644
Accessible Components....1645
Engine Removal....1645
Engine Installation Notes....1646
Crankshaft Straightening....1647
ES50PL Engine Lubrication....1647
Oil Pressure Test....1647
Oil Pump Priming Procedure....1648
Oil Flow - ES50PL....1648
ES50PL Oil Flow Chart....1649
ES50PL Engine Exploded Views....1650
Upper Engine Disassembly....1651
Disassembly....1651
Cam Chain Tensioner Removal....1651
Cam Chain Tensioner Inspection and Reassembly....1651
Camshaft Removal....1652
Automatic Compression Release Inspection....1652
Camshaft Inspection....1653
Cylinder Head Removal....1653
Cylinder and Piston Removal....1654
Piston Removal....1654
Piston and Rod Inspection....1655
Lower Engine Disassembly....1656
Crankcase Disassembly and Inspection....1656
Starter Drive Gears Removal and Inspection....1656
Flywheel / One-Way Starter Clutch Removal and Inspection....1656
Crankshaft Nut Removal....1657
Clutch Cover / Clutch Removal and Inspection....1657
Shifter Component Removal and Inspection....1659
Oil Pump Removal and Inspection....1660
Crankshaft Drive and Cam Gear Removal....1660
Cam Chain / Tensioner Blade Removal....1661
Crankcase Separation....1661
Crankcase Inspection....1662
Crankcase Bearing Inspection / Removal / Installation....1662
Transmission and Crankshaft Service....1663
Transmission Removal and Inspection....1663
Transmission Main Shaft Disassembly / Assembly....1663
Transmission Reassembly....1664
Crankshaft Removal / Installation....1666
Crankshaft Inspection....1666
Engine Reassembly....1667
Crankcase Reassembly....1667
Piston Installation....1668
Piston Ring Installation....1668
Cylinder Installation....1669
Cam Chain Installation....1669
Camshaft Timing....1669
Primary Drive Gear Installation....1670
Outlaw Cam Timing Exploded View....1671
Cylinder Head Service....1672
Cylinder Head Inspection....1672
Cylinder Head Warp....1672
Cylinder Head Disassembly....1672
Cylinder Head Valve Guide / Valve Seat Inspection....1673
Valve Guide Removal / Installation / Ream....1673
Valve Seat Reconditioning....1674
Valve Inspection....1676
ES50PL Adjusting Pad Selection Matrix....1677
Cylinder Head Assembly....1678
Cylinder Head Installation....1679
Cylinder Service....1679
Cylinder Inspection....1679
Piston-to-Cylinder Clearance....1680
Cylinder Hone Selection and Honing Procedure....1680
Honing To Deglaze....1680
Piston Ring Installed Gap....1681
Water Pump Service....1681
Oil Seal / Mechanical Seal Removal (Engine Disassembled)....1681
Water Pump Mechanical Seal Installation....1681
Mechanical Seal Removal and Installation (Engine Assembled)....1682
Troubleshooting....1683
Engine....1683
Spark Plug Fouling....1685
Cooling System....1685
FUEL SYSTEM / CARBURETION....1686
Fuel System and Carburetion....1687
BSR 42 Carburetor Exploded View....1687
Fuel Tank Assembly....1688
Special Tools....1689
Jetting Guidelines....1689
Carburetor Jetting....1689
Mikuni Jet Part Numbers....1689
CV Carburetor System....1690
Carburetor Function....1690
Vent Systems - CV Carburetor....1690
Mikuni CV Carburetor Operation....1690
Pilot (Idle and Slow) System ....1691
Starter System (Choke or Enrichment)....1692
Float System....1692
Main System....1693
Pilot Screw....1693
Carburetor Disassembly....1694
Carburetor Cleaning....1695
Carburetor Inspection....1695
Carburetor Assembly....1696
Float Height Adjustment....1696
Fuel Delivery....1697
Needle and Seat Leak Test....1697
Fuel Level test....1697
Fuel Pump....1698
Fuel Pump Disassembly....1698
Fuel Pump Inspection / Assembly....1698
Troubleshooting....1698
Fuel Starvation / Lean Mixture....1698
Rich Mixture....1699
Poor Idle / Idle Too High....1699
Idle Too Low....1699
Erratic Idle....1699
BODY / STEERING / SUSPENSION....1700
General Information....1702
Torque Specifications....1702
Special Tools....1702
Body Assembly....1703
Exploded View....1703
Body Component Removal....1704
Seat / Side Panel....1704
Front Cab....1704
Tank Cover....1704
Heel Pocket....1705
Rear Cab....1705
Steering Assembly Exploded View....1706
Steering Knuckle....1707
Removal....1707
Installation....1707
Ball Joint Service....1707
Removal....1707
Installation....1708
Front Hub....1709
Exploded View....1709
Hub Removal....1710
Hub Disassembly....1711
Hub Assembly....1711
Hub Installation....1712
Front Suspension Exploded View....1713
Front A-arm Replacement....1714
A-arm Removal and Inspection....1714
A-arm Installation....1714
Rear Suspension Exploded View....1715
Rear A-arm Replacement....1716
A-arm Removal....1716
A-arm Inspection....1716
A-arm Installation....1717
Rear Housing....1718
Exploded View....1718
Housing Removal....1719
Housing Disassembly / Service....1720
Assembly....1722
Installation....1723
Rear Bearing Carrier....1724
Carrier Removal....1724
Carrier Disassembly / Inspection....1724
Carrier Assembly....1725
Carrier Installation....1726
Rear Drive (CV) Joint....1727
CV Joint Removal....1727
CV Joint Service....1727
CV Boot Replacement....1728
CV Joint Installation....1729
Decals....1730
Replacement....1730
Front Shock Exploded View....1731
RydeFX™ FRONT SHOCK....1731
Rear Shock Exploded View....1732
RydeFX™ REAR SHOCK (Compression Adjustable)....1732
RydeFX™ Shock Service....1733
Shock Specification Chart....1733
Piston Orientation....1733
RydeFX™ Shock Rebuild Procedure....1734
BRAKES....1740
Brake Specifications....1741
General Specifications....1741
Torque Specifications....1741
Special Tools....1741
Brake Caliper Exploded Views....1742
Rear Brake Caliper Assembly....1742
Front Brake Caliper Assembly....1742
Brake System Overview....1743
Front Brake System - Exploded View....1743
Rear Brake System - Exploded View....1744
Service Notes....1745
Brake Noise Troubleshooting....1745
Hydraulic System Operation....1746
Brake Fluid Replacement and Bleeding Procedure....1747
Master Cylinder....1749
Removal....1749
Installation....1750
Front Caliper Service....1751
Caliper Removal and Disassembly ....1751
Caliper Inspection....1752
Caliper Reassembly....1753
Caliper Installation....1753
Front Brake Pads....1754
Pad Removal....1754
Pad Assembly....1755
Brake Burnishing Procedure....1755
Front Brake Disc....1756
Disc Inspection....1756
Disc Removal / Replacement....1756
Rear Caliper Service....1757
Caliper Removal....1757
Caliper Disassembly....1757
Caliper Inspection....1758
Caliper Assembly....1758
Rear Brake Pad....1759
Pad Removal....1759
Pad Installation....1760
Rear Brake Disc....1761
Disc Inspection....1761
Disc Removal....1762
Disc Replacement....1762
Troubleshooting....1763
Brakes Squeal....1763
Poor Brake Performance....1763
Lever Vibration....1763
Brakes Lock....1763
ELECTRICAL....1764
General Information....1765
Special Tools....1765
Electrical Service Notes....1765
Timing Check Procedure....1765
Lighting and Controls....1766
Neutral / Reverse Position Indicator Switch Test....1766
Headlight Lamp Replacement....1766
Headlamp Switch Test....1766
Headlight Housing Replacement....1766
Headlight Adjustment....1767
Taillight / Brakelight Lamp Replacement....1767
Brake Light Switch Tests....1768
Clutch Switch Test....1768
Indicator Lamp Replacement....1768
Tether Switch Test (Accessory Option)....1769
Electronic Throttle Control (ETC) Switch....1769
ETC Operation Test....1769
Ignition System....1770
Ignition System Troubleshooting....1770
Circuit Breakers....1770
Cranking Output Tests....1770
Flywheel Identification....1771
DC / CDI Ignition....1771
Ignition System Testing....1772
Components of DC / CDI Ignition....1773
Cooling System....1774
Fan Control Circuit Operation / Testing....1774
Coolant Temperature Sensor Test (Hot Light)....1774
Fan Control Switch Bypass Test....1774
Coolant Fan Control Switch Operation Test....1775
Fan Motor Current Draw....1775
Charging System....1775
Current Draw - Key Off....1775
Charging System “Break Even” Test....1776
Alternator Tests (Charging System)....1776
Charging System Testing Flow Chart....1777
Battery Service....1778
Battery Maintenance....1778
Battery Inspection / Removal....1778
Battery Terminals / Bolts....1779
Battery Testing....1779
OCV - Open Circuit Voltage Test....1779
Load Test....1779
Off Season Storage....1779
Charging Procedure....1780
Starting System....1780
Starter System Troubleshooting....1780
Clutch Switch Test....1781
Neutral Start Diode Test ....1781
Starter Voltage Drop Testing....1781
Starter Motor Disassembly....1781
Brush Inspection / Replacement....1782
Armature Testing....1782
Starter Reassembly....1783
Starter One-Way Clutch Inspection....1783
Starter System Testing Flow Chart ....1784
INDEX....1786
WIRE DIAGRAM (Main)....1790
WIRE DIAGRAM (Breakouts)....1792
Polaris Outlaw 525 IRS '07 Service Repair Manual (9921126)....1793
9921126_CHAPTER_1....1794
GENERAL INFORMATION....1794
VEHICLE IDENTIFICATION....1795
Model Identification....1795
Engine Designation Number....1795
VIN Identification....1795
Vehicle Identification Number (VIN) Location....1795
Engine Serial Number Location....1795
VEHICLE INFORMATION....1795
Paint Codes....1795
Replacement Keys....1795
Publication Numbers....1796
Standard Torque Specifications....1796
SPECIFICATIONS....1797
MODEL: 2007 OUTLAW 525....1797
2007 OUTLAW 525....1798
MISC. NUMBERS / CHARTS....1801
SAE Tap / Drill Sizes....1801
Metric Tap / Drill Sizes....1801
Decimal Equivalents....1801
Coversion Table....1802
Glossary of Terms....1803
9921126_CHAPTER_2....1804
MAINTENANCE....1804
PERIODIC MAINTENANCE CHART....1806
Periodic Maintenance Overview....1806
Break-In Period....1806
Maintenance Chart Key....1806
Pre-Ride Maintenance Interval....1807
Recommended Pre-Ride Fluid Level Checks....1807
10 - 60 Hour Maintenance Interval....1808
Grease Lubrication Maintenance Interval (45 - 90 Hour)....1809
90 - 300 Hour Maintenance Interval....1810
Maintenance References....1811
LUBRICANTS AND SERVICE PRODUCTS....1812
Polaris Lubricants, Maintenance and Service Products....1812
GENERAL VEHICLE INSPECTION AND MAINTENANCE....1813
Pre-Ride / Daily Inspection....1813
Frame, Nuts, Bolts, and Fasteners....1813
FUEL SYSTEM AND AIR INTAKE....1813
Fuel System....1813
Fuel Lines....1813
Vent Lines....1814
Fuel Valve....1814
Carburetor General Maintenance....1814
Carburetor Draining....1814
Idle Speed Adjustment....1815
Throttle Inspection....1815
Throttle Cable / Electronic Throttle Control (ETC) Adjustment....1815
Choke Operation....1816
Air Filter Service....1816
Air Box Drain Tube....1817
ENGINE AND TRANSMISSION....1817
Engine Oil Level....1817
Engine Oil and Filter Service....1818
Cylinder Leakdown Test....1820
Valve Clearance Adjustment....1820
Exhaust Pipe / Spark Arrestor....1820
Engine Mount Locations....1821
LIQUID COOLING SYSTEM....1821
Cooling System Overview....1821
Coolant Strength / Type....1821
Cooling System Hoses....1822
Recovery Bottle / Coolant Level Inspection....1822
Radiator / Coolant Level Inspection....1823
Cooling System Bleeding....1823
Radiator Screen Removal....1823
FINAL DRIVE....1824
Hydraulic Clutch Lever Adjustment....1824
Hydraulic Clutch Oil level Inspection....1824
Hydraulic Clutch System Bleeding....1824
Reverse Lock-Out Lever Inspection and Cable Adjustment....1825
Sprocket Inspection....1825
Drive Chain Inspection / Replacement....1826
Drive Chain Tension....1826
Drive Chain Adjustment....1827
Rear Driveshaft Boot Inspection....1827
Rear Driveshaft Boot “Pressure Equalizing”....1828
ELECTRICAL AND IGNITION SYSTEM....1828
Battery Maintenance....1828
Battery Inspection / Removal....1829
Battery Terminals / Bolts....1829
Off Season Storage....1829
Engine- To- Frame Ground....1829
Spark Plug Removal / Inspection....1829
Charging Procedure....1830
STEERING AND SUSPENSION....1831
Steering....1831
Controls / Handlebar....1831
Steering Inspection / Tie Rod Ends and Hubs ....1831
Toe Alignment Inspection....1832
Toe Adjustment....1833
Camber and Caster....1833
Suspension Spring Preload Adjustment....1833
Rear Shock Compression Adjustment....1835
BRAKE SYSTEM....1836
Brake System Inspection....1836
Hose / Fitting Inspection....1836
Brake Pad Inspection....1836
Brake Testing....1836
WHEELS AND TIRES....1837
Wheels....1837
Wheel, Hub, and Spindle Torque Table....1837
Wheel Removal: Front or Rear....1837
Tire Pressure....1837
Tire Inspection....1837
9921126_CHAPTER_3....1838
ENGINE....1838
ENGINE SERVICE....1839
KTM 525 Engine....1839
GENERAL ENGINE INFORMATION....1839
Special Tools....1839
Accessible Components....1839
Engine Removal....1839
Engine Installation Notes....1843
Engine Break-In Period....1844
ES51KL Engine Lubrication....1844
ENGINE COOLING SYSTEM....1844
Coolant Temperature Sensor (Dual Temp Thermal Sensor)....1844
Cooling System Flow Chart....1844
Radiator Cap / System Pressure Test....1845
Cooling System Specifications....1845
9921126_CHAPTER_4....1846
FUEL SYSTEM....1846
CARBURETOR SERVICE....1847
Keihin FCR-MX 39 mm Carburetor....1847
GENERAL INFORMATION....1847
Jetting Guidelines....1847
Carburetor Jetting....1847
Keihin Optional Jet Part Numbers....1847
KEIHIN FCR-MX 3900 CARBURETOR....1848
Exploded View....1848
FUEL TANK....1849
Exploded View....1849
9921126_CHAPTER_5....1850
BODY / STEERING / SUSPENSION....1850
GENERAL INFORMATION....1851
Torque Specifications....1851
Special Tools....1851
BODY ASSEMBLY....1852
Exploded View....1852
BODY COMPONENT REMOVAL....1853
Seat / Side Panel....1853
Front Cab....1853
Tank Cover....1853
Heel Pocket....1854
Rear Cab....1854
STEERING ASSEMBLY EXPLODED VIEW....1855
STEERING KNUCKLE....1856
Removal....1856
Installation....1856
BALL JOINT SERVICE....1856
Removal....1856
Installation....1857
FRONT HUB....1858
Exploded View....1858
Hub Removal....1859
Hub Disassembly....1860
Hub Assembly....1860
Hub Installation....1861
FRONT SUSPENSION EXPLODED VIEW....1862
FRONT A-ARM REPLACEMENT....1863
A-arm Removal and Inspection....1863
A-arm Installation....1863
REAR SUSPENSION EXPLODED VIEW....1864
REAR A-ARM REPLACEMENT....1865
A-arm Removal....1865
A-arm Inspection....1865
A-arm Installation....1866
REAR HOUSING....1867
Exploded View....1867
Housing Removal....1868
Housing Disassembly / Service....1869
Assembly....1871
Installation....1872
REAT BEARING CARRIER....1873
Carrier Removal....1873
Carrier Disassembly / Inspection....1873
Carrier Assembly....1874
Carrier Installation....1875
REAR DRIVE (CV) JOINT....1876
CV Joint Removal....1876
CV Joint Service....1876
CV Boot Replacement....1877
CV Joint Installation....1878
DECAL REPLACEMENT....1879
FRONT SHOCK EXPLODED VIEW....1880
RydeFX™ FRONT SHOCK....1880
REAR SHOCK EXPLODED VIEW....1881
RydeFX™ REAR SHOCK (Compression Adjustable)....1881
RYDE FX™ SHOCK SERVICE....1882
Shock Specification Chart....1882
Piston Orientation....1882
RydeFX™ Shock Rebuild Procedure....1883
9921126_CHAPTER_6....1888
BRAKES....1888
BRAKE SPECIFICATIONS....1889
General Specifications....1889
Torque Specifications....1889
Special Tools....1889
BRAKE CALIPER EXPLODED VIEWS....1890
Rear Brake Caliper Assembly....1890
Front Brake Caliper Assembly....1890
BRAKE SYSTEM OVERVIEW....1891
Front Brake System - Exploded View....1891
Rear Brake System - Exploded View....1892
Service Notes....1893
Brake Noise Troubleshooting....1893
Hydraulic System Operation....1894
Brake Fluid Replacement and Bleeding Procedure....1895
MASTER CYLINDER....1897
Removal....1897
Disassembly....1898
Installation....1898
FRONT CALIPER SERVICE....1899
Caliper Removal and Disassembly ....1899
Caliper Inspection....1901
Caliper Assembly....1901
Caliper Installation....1902
FRONT BRAKE PADS....1902
Pad Removal....1902
Pad Assembly....1903
Brake Burnishing Procedure....1904
FRONT BRAKE DISC....1904
Disc Inspection....1904
Disc Removal / Replacement....1905
REAR CALIPER SERVICE....1905
Caliper Removal....1905
Caliper Disassembly....1905
Caliper Inspection....1906
Caliper Assembly....1907
REAR BRAKE PAD....1907
Pad Removal....1907
Pad Installation....1909
REAR BRAKE DISC....1910
Disc Inspection....1910
Disc Removal....1910
Disc Installation....1911
TROUBLESHOOTING....1911
Brakes Squeal....1911
Poor Brake Performance....1911
Lever Vibration....1911
Brakes Lock....1911
9921126_CHAPTER_7....1912
ELECTRICAL....1912
GENERAL INFORMATION....1913
Special Tools....1913
Electrical Service Notes....1913
LIGHTING AND CONTROLS....1913
Transmission Switch Test....1913
Headlight Lamp Replacement....1913
Headlamp Switch Test....1914
Headlight Housing Replacement....1914
Headlight Adjustment....1914
Taillight / Brakelight Lamp Replacement....1915
Brake Light Switch Tests....1915
Clutch Switch Test....1916
Indicator Lamp Replacement....1916
Tether Switch Test (Accessory Option)....1916
Electronic Throttle Control (ETC) Switch....1916
ETC Operation Test....1917
IGNITION SYSTEM....1917
Ignition System Troubleshooting....1917
DC / CDI Ignition....1918
Circuit Breakers....1918
Cranking Output Tests....1918
Ignition System Breakout Diagram....1919
Ignition System Testing....1920
Components of DC / CDI Ignition....1921
COOLING SYSTEM....1922
Fan Control Circuit Operation / Testing....1922
Fan Switch Bypass Tests....1922
Fan Switch “Hot Light” Operation....1923
CHARGING SYSTEM....1923
Current Draw - Key Off....1923
Charging System “Break Even” Test....1923
Alternator Tests (Charging System)....1924
Charging System Testing Flow Chart....1925
BATTERY SERVICE....1926
Battery Maintenance....1926
Battery Inspection / Removal....1926
Battery Terminals / Bolts....1927
Battery Testing....1927
OCV - Open Circuit Voltage Test....1927
Load Test....1927
Off Season Storage....1927
Charging Procedure....1928
STARTING SYSTEM....1928
Starter System Troubleshooting....1928
Starting System Circuit....1929
Clutch Switch Test....1930
Neutral Start Diode Test ....1930
Starter Voltage Drop Testing....1930
Starter Motor Removal....1930
Starter Motor Exploded View....1931
Starter Motor Disassembly....1932
Brush Inspection / Replacement....1932
Armature Testing....1933
Starter Reassembly....1933
Starter Motor Installation....1934
Starter One-Way Clutch Inspection....1934
Starter System Testing Flow Chart ....1935
9921126_CHAPTER_KTM 2....1936
9921126_CHAPTER_KTM....1979
9921126_WIRE_DIAGRAM....2033
Polaris Predator '03 Service Repair Manual....2035
Index....2038
Chapter 1 General Information....2040
Chapter 2 Maintenance....2050
Chapter 3 Engine....2078
Chapter 4 Fuel System/Carburetion....2124
Chapter 5 Body And Steering....2136
Chapter 6 Brakes....2180
Chapter 7 Electrical....2202
Polaris Predator 500 '03 Service Repair Manual (9918062)....2228
Index....2231
Chapter 1 General Information....2233
Chapter 2 Maintenance....2243
Chapter 3 Engine....2271
Chapter 4 Fuel System/Carburetion....2317
Chapter 5 Body And Steering....2329
Chapter 6 Brakes....2373
Chapter 7 Electrical....2395
Polaris RZR XP, XP 4 1000 '14 Service Repair Manual (PN 9924874 R02)....2421
9924874_RZR_XP_XP4_1000.pdf....2421
2014 RZR XP / XP 4 1000 ....2421
Trademarks ....2423
VEHICLE IDENTIFICATION ....2427
MODEL NUMBER DESIGNATION ....2427
ENGINE DESIGNATION NUMBER ....2427
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION ....2427
VEHICLE AND ENGINE SERIAL NUMBER LOCATION ....2428
VEHICLE INFORMATION ....2428
PUBLICATION NUMBERS ....2428
REPLACEMENT KEYS ....2429
SPECIAL TOOLS ....2430
GENERAL SPECIFICATIONS ....2431
MODEL: 2014 RZR XP 1000 / EPS / INT’L ....2431
2014 RZR XP 1000 / EPS / INT’L ....2432
MODEL: 2014 RZR XP 4 1000 ....2433
2014 RZR XP 4 1000 ....2434
2014 RZR XP / XP 4 1000 CLUTCH CHARTS ....2435
MISC. SPECIFICATIONS AND CHARTS ....2436
MASTER TORQUE TABLE ....2436
CONVERSION TABLE ....2439
STANDARD BOLT TORQUE SPECIFICATION ....2440
METRIC BOLT TORQUE SPECIFICATION ....2440
SAE TAP / DRILL SIZES ....2441
METRIC TAP / DRILL SIZES ....2441
DECIMAL EQUIVALENTS ....2442
PERIODIC MAINTENANCE CHART ....2446
PERIODIC MAINTENANCE OVERVIEW ....2446
BREAK-IN PERIOD ....2446
MAINTENANCE CHART KEY ....2446
PRE-RIDE - 50 HOUR MAINTENANCE INTERVAL ....2447
50 - 500 HOUR MAINTENANCE INTERVAL ....2448
MAINTENANCE QUICK REFERENCE ....2449
MAINTENANCE QUICK REFERENCE, CONTINUED... ....2450
GREASE LUBRICATION POINTS ....2451
LUBRICANTS / SERVICE PRODUCTS ....2452
POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS ....2452
GENERAL VEHICLE INSPECTION AND MAINTENANCE ....2453
PRE-RIDE / DAILY INSPECTION ....2453
SHIFT CABLE INSPECTION / ADJUSTMENT ....2453
FUEL SYSTEM AND AIR INTAKE ....2454
FUEL SYSTEM ....2454
FUEL TANK VENT LINE ....2454
FUEL PUMP / FUEL FILTERS ....2454
FUEL LINES ....2455
THROTTLE PEDAL INSPECTION ....2455
ENGINE INTAKE PRE-FILTER SERVICE ....2456
AIR FILTER SERVICE ....2456
INTAKE DUCT DRAIN INSPECTION ....2457
AIR BOX / AIR FILTER ASSEMBLY VIEW ....2458
ENGINE ....2459
ENGINE OIL LEVEL ....2459
ENGINE OIL AND FILTER CHANGE ....2460
ENGINE CRANKCASE BREATHER HOSE INSPECTION ....2461
ENGINE CYLINDER LEAKDOWN TEST ....2461
VALVE CLEARANCE INSPECTION ....2462
TRANSMISSION AND FRONT GEARCASE ....2464
SPECIFICATION CHART ....2464
TRANSMISSION LUBRICATION ....2464
FRONT GEARCASE LUBRICATION ....2465
COOLING SYSTEM ....2466
COOLING SYSTEM OVERVIEW ....2466
COOLANT STRENGTH ....2466
COOLANT LEVEL INSPECTION ....2467
COOLING SYSTEM PRESSURE TEST ....2468
COOLING SYSTEM HOSES ....2468
RADIATOR INSPECTION / CLEANING ....2469
COOLANT DRAIN / FILL ....2469
PVT / FINAL DRIVE / WHEEL AND TIRE ....2470
DRIVE CLUTCH / DRIVEN CLUTCH / BELT SERVICE ....2470
PVT INTAKE PRE-FILTER SERVICE ....2470
PVT DRYING ....2470
DRIVE SHAFT BOOT INSPECTION ....2471
WHEEL AND HUB TORQUE TABLE ....2471
WHEEL REMOVAL ....2471
WHEEL INSTALLATION ....2471
TIRE INSPECTION ....2471
TIRE PRESSURE ....2472
ELECTRICAL AND IGNITION SYSTEM ....2472
BATTERY MAINTENANCE ....2472
BATTERY CHARGING / OFF SEASON STORAGE ....2473
BATTERY REMOVAL ....2473
BATTERY INSTALLATION ....2473
ENGINE / CHASSIS ELECTRICAL GROUND ....2474
SPARK PLUG SERVICE ....2474
STEERING ....2475
STEERING INSPECTION ....2475
STEERING WHEEL FREEPLAY ....2475
TIE ROD END / WHEEL HUB INSPECTION ....2476
WHEEL TOE ALIGNMENT INSPECTION ....2476
WHEEL TOE ADJUSTMENT ....2477
SUSPENSION (WALKER EVANS™) ....2478
SPRING ADJUSTMENT ....2478
SHOCK COMPRESSION ADJUSTMENT ....2479
BRAKE SYSTEM ....2480
BRAKE FLUID INSPECTION ....2480
BRAKE PAD / DISC INSPECTION ....2480
BRAKE HOSE AND FITTING INSPECTION ....2480
GENERAL INFORMATION ....2484
SPECIAL TOOLS ....2484
ENGINE LUBRICATION SPECIFICATIONS ....2484
OIL PRESSURE TEST ....2485
ENGINE OIL FLOW CHART ....2486
ENGINE SERVICE SPECIFICATIONS ....2487
ENGINE SPECIFICATIONS ....2487
ENGINE DETAIL - TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES ....2489
MAIN ENGINE COMPONENTS - TORQUE SPECIFICATION AND SEQUENCE ....2489
BALANCE SHAFT / CONNECTING RODS / CRANKCASE / CRANKSHAFT / PISTONS ....2490
CYLINDER / OIL COOLER / OIL FILTER / OIL PUMP / OIL SUMP / WATER PUMP ....2491
CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / IDLER GEARS / STATOR COVER ....2492
SPARK PLUGS / STARTER / THERMOSTAT HOUSING / THROTTLE BODY / VALVE COVER ....2493
ENGINE COOLING SYSTEM ....2494
COOLING SYSTEM PRESSURE TEST ....2494
PRESSURE CAP TEST ....2494
RADIATOR REMOVAL / INSTALLATION ....2495
THERMOSTAT REPLACEMENT ....2496
COOLING SYSTEM ASSEMBLY VIEW ....2498
COOLING SYSTEM BLEEDING PROCEDURE ....2499
WATER PUMP REMOVAL ....2500
WATER PUMP INSTALLATION ....2500
WATER PUMP SERVICE ....2502
ENGINE SERVICE ....2505
ACCESSIBLE ENGINE COMPONENTS ....2505
TOP-END SERVICE (ENGINE IN CHASSIS) ....2505
ENGINE REMOVAL ....2505
ENGINE INSTALLATION ....2509
ENGINE MOUNTING AND TORQUE VALUES ....2512
ENGINE BREAK-IN PERIOD ....2513
ENGINE LUBRICATION SPECIFICATIONS ....2513
ENGINE DISASSEMBLY / INSPECTION - TOP END ....2514
VALVE COVER REMOVAL ....2514
CAMSHAFT REMOVAL ....2514
CAMSHAFT SPROCKET INSPECTION ....2515
CAMSHAFT / CAMSHAFT BORE INSPECTION ....2515
CYLINDER HEAD REMOVAL ....2517
CYLINDER HEAD WARP INSPECTION ....2518
CYLINDER HEAD DISASSEMBLY ....2518
VALVE INSPECTION ....2519
COMBUSTION CHAMBER CLEANING ....2520
VALVE SEALING TEST ....2520
VALVE SEAT RECONDITIONING ....2521
ENGINE DISASSEMBLY / INSPECTION - LOWER END ....2524
STATOR COVER REMOVAL / INSPECTION ....2524
WATER PUMP HOUSING REMOVAL ....2525
FLYWHEEL REMOVAL ....2525
STARTER ONE-WAY CLUTCH DISASSEMBLY ....2526
CRANKCASE DISASSEMBLY / INSPECTION ....2527
BALANCE SHAFT REMOVAL / INSPECTION ....2530
CRANKSHAFT REMOVAL / INSPECTION ....2531
CRANKCASE INSPECTION ....2533
CYLINDER INSPECTION ....2534
CYLINDER / PISTON REMOVAL ....2535
PISTON DISASSEMBLY / INSPECTION ....2536
PISTON RING REMOVAL ....2537
PISTON RING TO GROOVE CLEARANCE INSPECTION ....2538
PISTON RING INSTALLED GAP ....2538
PISTON-TO-CYLINDER CLEARANCE ....2538
CONNECTING ROD INSPECTION ....2539
ENGINE ASSEMBLY - LOWER END ....2541
BEARING SELECTION IDENTIFICATION LETTERS AND NUMBERS ....2541
CONNECTING ROD BEARING SELECTION ....2542
CRANKSHAFT MAIN BEARING SELECTION ....2542
UPPER CRANKCASE PREPARATION ....2542
PISTON RING INSTALLATION ....2543
PISTON / CONNECTING ROD ASSEMBLY ....2544
CYLINDER / PISTON INSTALLATION ....2545
CRANKSHAFT INSTALLATION ....2546
BALANCE SHAFT INSTALLATION ....2548
LOWER CRANKCASE PREPARATION ....2548
CRANKCASE ASSEMBLY ....2549
STARTER ONE-WAY CLUTCH ASSEMBLY ....2553
FLYWHEEL INSTALLATION ....2554
STATOR COVER INSTALLATION ....2554
ENGINE ASSEMBLY - TOP END ....2555
CYLINDER HEAD ASSEMBLY ....2555
CYLINDER HEAD INSTALLATION ....2556
CAMSHAFT INSTALLATION / TIMING ....2557
CAMSHAFT TIMING - QUICK REFERENCE ....2561
VALVE CLEARANCE ADJUSTMENT ....2562
INTAKE VALVE LASH - TAPPET SELECTION MATRIX ....2564
EXHAUST VALVE LASH - TAPPET SELECTION MATRIX ....2565
VALVE COVER INSTALLATION ....2566
TROUBLESHOOTING ....2567
ENGINE ....2567
COOLING SYSTEM ....2568
GENERAL INFORMATION ....2572
SPECIAL TOOLS ....2572
EFI SERVICE NOTES ....2574
EFI SYSTEM ASSEMBLY VIEW ....2575
EFI SYSTEM COMPONENT LOCATIONS ....2576
FUEL TANK ....2578
ASSEMBLY VIEW ....2578
FUEL LINE REMOVAL / INSTALLATION ....2579
FUEL TANK REMOVAL ....2579
FUEL TANK INSTALLATION ....2581
FUEL TANK REMOVAL RZR XP 4 1000 ....2583
FUEL TANK INSTALLATION RZR XP 4 1000 ....2584
ELECTRONIC FUEL INJECTION ....2585
PRINCIPAL COMPONENTS ....2585
EFI OPERATION OVERVIEW ....2585
INITIAL PRIMING / STARTING PROCEDURE ....2586
ELECTRONIC CONTROL UNIT (ECU) ....2586
OPERATION OVERVIEW ....2586
ECU SERVICE ....2587
ECU REPLACEMENT ....2587
FUEL INJECTORS ....2588
OPERATION OVERVIEW ....2588
FUEL INJECTOR TROUBLESHOOTING ....2588
FUEL INJECTOR TEST ....2589
FUEL INJECTOR REPLACEMENT ....2589
FUEL PUMP ....2592
OPERATION OVERVIEW ....2592
FUEL SENDER TEST ....2593
FUEL PUMP TEST ....2593
FUEL PUMP REPLACEMENT ....2594
TEMPERATURE / MANIFOLD ABSOLUTE PRESSURE (T-MAP) SENSOR ....2598
OPERATION OVERVIEW ....2598
T-MAP TEST / REPLACEMENT ....2598
CRANKSHAFT POSITION SENSOR (CPS) ....2598
OPERATION OVERVIEW ....2598
CPS TEST ....2599
CPS REPLACEMENT ....2599
THROTTLE BODY ASSEMBLY ....2600
OPERATION OVERVIEW ....2600
THROTTLE BODY SERVICE ....2600
THROTTLE BODY REMOVAL ....2600
ELECTRONIC THROTTLE CONTROL (ETC) ....2601
OPERATION OVERVIEW ....2601
ETC TEST ....2601
ETC REPLACEMENT ....2602
PEDAL POSITION SENSOR (PPS) ....2602
OPERATION OVERVIEW ....2602
LOCATION ....2602
PPS TEST ....2602
PPS REPLACEMENT ....2603
EFI DIAGNOSTICS ....2604
INSTRUMENT CLUSTER TROUBLE CODE DISPLAY ....2604
EFI TROUBLESHOOTING ....2608
DIGITAL WRENCH® OPERATION ....2609
DIGITAL WRENCH® DIAGNOSTIC SOFTWARE OVERVIEW ....2609
SPECIAL TOOLS (ALSO REFER TO THE BEGINNING OF THIS CHAPTER) ....2609
DIAGNOSTIC SOFTWARE VERSION ....2610
GUIDED DIAGNOSTIC AVAILABLE ....2610
DIGITAL WRENCH® COMMUNICATION ERRORS ....2610
DIGITAL WRENCH® - DIAGNOSTIC CONNECTOR ....2610
DIGITAL WRENCH® SERIAL NUMBER LOCATION ....2610
DIGITAL WRENCH® VERSION AND UPDATE ID ....2611
DIGITAL WRENCH® UPDATES ....2611
DIGITAL WRENCH® FEATURE MAP ....2613
ECU REPLACEMENT ....2614
ENGINE CONTROLLER REPROGRAMMING (REFLASH) ....2614
GENERAL INFORMATION ....2620
SPECIAL TOOLS ....2620
MULTI-FUNCTION PLIERS ....2620
TORQUE SPECIFICATIONS ....2621
BODY ASSEMBLY VIEWS ....2622
CAB FRAME ASSEMBLY XP ....2622
CAB FRAME ASSEMBLY XP 4 ....2623
DOORS XP ....2624
DOORS XP 4 ....2625
DASH INSTRUMENTS / CONTROLS ....2626
HOOD / FRONT BODY WORK ....2627
CHASSIS / MAIN FRAME XP ....2628
CHASSIS / MAIN FRAME XP 4 ....2629
SEAT ASSEMBLY FRONT ....2630
SEAT ASSEMBLY REAR ....2631
FLOOR / ROCKER PANELS XP ....2632
FLOOR / ROCKER PANELS XP 4 ....2633
REAR CARGO BOX / FENDERS ....2634
REAR BUMPER ....2635
BODY COMPONENT REMOVAL ....2636
SEATS ....2636
ENGINE SERVICE PANEL ....2636
FRONT BUMPER XP ....2636
REAR BUMPER ....2636
HOOD AND FRONT BODY WORK ....2637
REAR FENDER / FENDER FLARE REMOVAL ....2638
REAR FENDER FLARE / REAR FENDER REMOVAL XP 4 ....2638
CARGO BOX ASSEMBLY REMOVAL ....2638
ROCKER PANELS, CONSOLE AND FLOOR XP ....2639
ROCKER PANELS, REAR CONSOLE AND FLOOR XP 4 ....2640
DECAL REPLACEMENT ....2643
STEERING ASSEMBLY ....2644
ASSEMBLY VIEW (NON-EPS MODELS) ....2644
STEERING WHEEL REMOVAL (NON-EPS MODELS) ....2645
STEERING SHAFT REMOVAL (NON-EPS MODELS) ....2645
STEERING SHAFT BEARING REPLACEMENT ....2645
ELECTRONIC POWER STEERING ASSEMBLY ....2647
ASSEMBLY VIEW (EPS MODELS) ....2647
UPPER STEERING SHAFT REMOVAL (EPS MODELS) ....2648
STEERING WHEEL REMOVAL (EPS MODELS) ....2648
POWER STEERING UNIT REMOVAL ....2649
LOWER STEERING SHAFT REMOVAL (EPS MODELS) ....2650
LOWER STEERING SHAFT INSTALLATION (EPS MODELS) ....2650
POWER STEERING UNIT INSTALLATION ....2651
UPPER STEERING SHAFT INSTALLATION (EPS MODELS) ....2651
FRONT A-ARMS ....2653
REMOVAL / REPLACEMENT ....2653
BALL JOINT SERVICE ....2656
SERVICE PREPARATION ....2656
BALL JOINT REMOVAL ....2656
BALL JOINT INSTALLATION ....2656
REAR RADIUS RODS ....2657
REMOVAL / INSTALLATION ....2657
REAR TRAILING ARM ....2658
TRAILING ARM REMOVAL / INSTALLATION ....2658
TRAILING ARM SPHERICAL BEARING REPLACEMENT ....2660
REAR SUSPENSION ASSEMBLY VIEW ....2661
REAR STABILIZER BAR ....2662
STABILIZER BAR REMOVAL ....2662
STABILIZER BAR INSTALLATION ....2662
SHOCKS / SPRINGS / FASTENERS ....2663
FRONT SHOCK ASSEMBLY VIEW ....2663
REAR SHOCK ASSEMBLY VIEW ....2663
SHOCK REMOVAL / INSTALLATION ....2664
SHOCK REPLACEMENT ....2664
WALKER EVANS™SHOCK ASSEMBLY VIEWS ....2665
WALKER EVANS™ 2.0" FRONT SHOCK ....2665
WALKER EVANS™ 2.5" REAR SHOCK ....2666
WALKER EVANS™ SHOCK SERVICE ....2667
GENERAL SERVICE INFORMATION ....2667
FRONT SHOCK SERVICE INFORMATION ....2667
REAR SHOCK SERVICE INFORMATION ....2668
WALKER EVANS™ SHOCK REBUILD INFORMATION ....2669
SPECIAL TOOLS ....2669
VALVE SHIM ARRANGEMENT ....2669
PISTON ORIENTATION ....2669
WALKER EVANS™ SHOCK DISASSEMBLY ....2670
WALKER EVANS™ SHOCK ASSEMBLY ....2672
GENERAL INFORMATION ....2679
SPECIAL TOOLS AND SUPPLIES ....2679
PVT SYSTEM TORQUE SPECIFICATIONS ....2679
2014 RZR XP / XP 4 1000 CLUTCH CHARTS ....2679
PVT SYSTEM OVERVIEW ....2680
GENERAL OPERATION ....2680
DRIVE CLUTCH OPERATION ....2680
DRIVEN CLUTCH OPERATION ....2680
PVT BREAK-IN (DRIVE BELT / CLUTCHES) ....2680
MAINTENANCE / INSPECTION ....2681
OVERHEATING / DIAGNOSIS ....2682
PVT SYSTEM SERVICE ....2683
PVT COVERS AND DUCT COMPONENTS ....2683
PVT DISASSEMBLY ....2684
PVT ASSEMBLY ....2685
DRIVE BELT ....2687
BELT REMOVAL ....2687
BELT INSPECTION ....2688
BELT INSTALLATION ....2688
PVT BREAK-IN (DRIVE BELT / CLUTCHES) ....2688
DRIVE CLUTCH SERVICE ....2689
DRIVE CLUTCH ASSEMBLY VIEW ....2689
DRIVE CLUTCH DISASSEMBLY / INSPECTION ....2690
NEEDLE BEARING INSPECTION ....2691
SHIFT WEIGHT INSPECTION ....2691
BUTTON TO TOWER CLEARANCE INSPECTION ....2692
SPIDER REMOVAL ....2692
ROLLER, PIN, AND THRUST WASHER INSPECTION ....2692
CLUTCH INSPECTION ....2693
MOVEABLE SHEAVE BUSHING INSPECTION ....2693
BUSHING SERVICE ....2694
DRIVE CLUTCH ASSEMBLY ....2696
DRIVEN CLUTCH SERVICE ....2699
CLUTCH DISASSEMBLY ....2699
BUSHING SERVICE ....2701
CLUTCH ASSEMBLY ....2703
ASSEMBLY VIEW ....2707
TROUBLESHOOTING ....2708
GENERAL INFORMATION ....2711
SPECIAL TOOLS ....2711
FINAL DRIVE TORQUE SPECIFICATIONS ....2711
FRONT BEARING CARRIER ....2712
BEARING CARRIER INSPECTION / REMOVAL ....2712
BEARING REPLACEMENT ....2713
BEARING CARRIER INSTALLATION ....2713
FRONT DRIVE SHAFT ....2715
DRIVE SHAFT REMOVAL ....2715
DRIVE SHAFT INSTALLATION ....2716
FRONT PROPSHAFT SERVICE ....2717
FRONT PROPSHAFT REMOVAL ....2717
FRONT PROP SHAFT INSTALLATION ....2718
REAR PROP SHAFT REMOVAL ....2719
REAR PROP SHAFT INSTALLATION ....2719
REAR PROP SHAFT REMOVAL XP 4 ....2721
REAR PROP SHAFT INSTALLATION XP 4 ....2721
SUPPORT BEARING REPLACEMENT ....2722
PROP SHAFT U-JOINT SERVICE ....2724
FRONT GEARCASE / CENTRALIZED HILLIARD ....2725
CENTRALIZED HILLIARD ASSEMBLY VIEW ....2725
ALL WHEEL DRIVE OPERATION ....2726
AWD DIAGNOSIS ....2726
FRONT GEARCASE REMOVAL ....2727
FRONT GEARCASE DISASSEMBLY / INSPECTION ....2728
FRONT GEARCASE ASSEMBLY ....2731
FRONT GEARCASE INSTALLATION ....2734
REAR BEARING CARRIER ....2735
BEARING CARRIER INSPECTION / REMOVAL ....2735
BEARING REPLACEMENT ....2736
BEARING CARRIER INSTALLATION ....2737
REAR DRIVE SHAFT ....2739
DRIVE SHAFT REMOVAL ....2739
DRIVE SHAFT INSTALLATION ....2740
DRIVE SHAFT CV JOINT / BOOT REPLACEMENT ....2742
DRIVE SHAFT / CV JOINT HANDLING TIPS ....2742
OUTER CV JOINT / BOOT REPLACEMENT ....2742
INNER PLUNGING JOINT / BOOT REPLACEMENT ....2744
DRIVE SHAFT ASSEMBLY VIEW ....2747
WHEEL HUBS ....2748
FRONT HUB ASSEMBLY VIEW ....2748
REAR HUB ASSEMBLY VIEW ....2748
SPECIFICATIONS ....2751
SPECIAL TOOLS ....2751
TORQUE SPECIFICATIONS ....2751
LUBRICATION ....2751
TRANSMISSION MOUNTING AND TORQUE VALUES ....2752
SHIFT LEVER ....2752
REMOVAL ....2752
INSTALLATION ....2753
SHIFT CABLE ....2753
INSPECTION ....2753
ADJUSTMENT ....2753
TRANSMISSION REMOVAL ....2754
TRANSMISSION INSTALLATION ....2757
TRANSMISSION SERVICE ....2761
TRANSMISSION DISASSEMBLY ....2761
GEAR / SHAFT / BEARING INSPECTION ....2766
SNORKEL GEAR BACKLASH PROCEDURE ....2767
TRANSMISSION SERVICE (INT’L) ....2774
DIFFERENTIAL OPERATION ....2774
TRANSMISSION DISASSEMBLY ....2775
PLANETARY DIFFERENTIAL DISASSEMBLY ....2780
PLANETARY DIFFERENTIAL BUSHING REPLACEMENT ....2781
PLANETARY DIFFERENTIAL ASSEMBLY ....2784
GEAR / SHAFT / BEARING INSPECTION ....2785
SNORKEL GEAR BACKLASH PROCEDURE ....2786
TROUBLESHOOTING ....2794
TROUBLESHOOTING CHECKLIST ....2794
TRANSMISSION ASSEMBLY VIEW ....2795
TRANSMISSION ASSEMBLY VIEW (INT’L) ....2797
GENERAL INFORMATION ....2802
SPECIAL TOOLS ....2802
GENERAL SPECIFICATIONS ....2802
TORQUE SPECIFICATIONS ....2802
BRAKE SYSTEM SERVICE NOTES ....2802
BRAKE NOISE TROUBLESHOOTING ....2803
HYDRAULIC BRAKE SYSTEM OPERATION ....2803
BRAKE SYSTEM ....2806
ASSEMBLY VIEW ....2806
MASTER CYLINDER ....2807
REMOVAL ....2807
INSTALLATION ....2807
BRAKE PEDAL LEVER ....2808
PEDAL REMOVAL ....2808
PEDAL INSTALLATION ....2808
BRAKE BLEEDING / FLUID CHANGE ....2808
PARKING BRAKE (INT’L MODEL) ....2810
ASSEMBLY VIEW ....2810
PARKING BRAKE INSPECTION ....2811
PARKING BRAKE CABLE ADJUSTMENT ....2811
PARKING BRAKE CALIPER SERVICE (INT’L MODEL) ....2812
CALIPER ASSEMBLY VIEW ....2812
CALIPER REMOVAL ....2813
CALIPER DISASSEMBLY / INSPECTION ....2813
NEW BRAKE PAD INSTALLATION ....2814
CALIPER INSTALLATION ....2815
PARKING BRAKE DISC (INT’L MODEL) ....2815
DISC INSPECTION ....2815
DISC REPLACEMENT ....2816
FRONT BRAKE PADS ....2816
PAD REMOVAL ....2816
PAD INSPECTION ....2817
PAD ASSEMBLY / INSTALLATION ....2818
BRAKE BURNISHING PROCEDURE ....2818
FRONT CALIPER SERVICE ....2819
CALIPER ASSEMBLY VIEW ....2819
CALIPER REMOVAL ....2819
CALIPER DISASSEMBLY ....2820
CALIPER INSPECTION ....2821
CALIPER ASSEMBLY ....2822
CALIPER INSTALLATION ....2822
FRONT BRAKE DISC ....2823
DISC RUNOUT ....2823
DISC INSPECTION ....2824
DISC REPLACEMENT ....2824
REAR BRAKE PADS ....2825
PAD REMOVAL ....2825
PAD INSPECTION ....2826
PAD ASSEMBLY / INSTALLATION ....2827
BRAKE BURNISHING PROCEDURE ....2828
REAR CALIPER SERVICE ....2829
CALIPER ASSEMBLY VIEW ....2829
CALIPER REMOVAL ....2829
CALIPER DISASSEMBLY ....2830
CALIPER INSPECTION ....2831
CALIPER ASSEMBLY ....2831
CALIPER INSTALLATION ....2832
REAR BRAKE DISC ....2833
DISC INSPECTION ....2833
DISC REPLACEMENT ....2833
TROUBLESHOOTING ....2834
BRAKES SQUEAL / POOR BRAKE PERFORMANCE ....2834
PEDAL VIBRATION ....2834
CALIPER OVERHEATS (BRAKES DRAG) ....2834
BRAKES LOCK ....2834
GENERAL INFORMATION ....2839
SPECIAL TOOLS ....2839
TORQUE SPECIFICATIONS ....2839
ELECTRICAL SERVICE NOTES ....2839
UNDER-DASH COMPONENTS ....2839
EFI DIAGNOSTICS ....2840
EFI COMPONENT TESTING ....2840
INSTRUMENT CLUSTER ....2841
OVERVIEW ....2841
RIDER INFORMATION DISPLAY ....2842
INFORMATION DISPLAY AREA ....2843
DIAGNOSTIC MODE ....2846
INSTRUMENT CLUSTER PINOUTS ....2847
INSTRUMENT CLUSTER REMOVAL ....2847
INSTRUMENT CLUSTER INSTALLATION ....2847
SWITCHES / CONTROLS ....2848
BRAKE LIGHT SWITCH ....2848
HEADLAMP SWITCH ....2848
IGNITION (KEY) SWITCH ....2849
IGNITION (KEY) SWITCH (INT’L) ....2849
AWD / 2WD SWITCH ....2850
AWD / 2WD / TURF SWITCH (INT’L) ....2850
TURN SIGNAL SWITCH (INT’L) ....2851
HAZARD SWITCH (INT’L) ....2851
TRANSMISSION (GEAR POSITION) SWITCH ....2851
PARKING BRAKE SWITCH (INT’L MODEL) ....2852
REAR DIFF SOLENOID (INT’L) ....2853
DIFFERENTIAL SOLENOID OVERVIEW ....2853
DIFFERENTIAL SOLENOID CIRCUIT OPERATION ....2853
ALL WHEEL DRIVE COIL ....2854
OPERATION OVERVIEW ....2854
DIAGNOSING SYSTEM FAILURES ....2854
VEHICLE SPEED SENSOR ....2855
SPEED SENSOR LOCATION ....2855
SPEED SENSOR TESTING ....2855
IGNITION COIL ....2855
OPERATION OVERVIEW ....2855
IGNITION COIL / HT LEAD REPLACEMENT ....2855
IGNITION COIL TESTS ....2856
HEAD LIGHTS ....2856
HEADLIGHT ADJUSTMENT ....2856
HEADLAMP REPLACEMENT ....2857
HEADLAMP INSTALLATION ....2858
TAIL / BRAKE LIGHTS ....2858
TAILLIGHT REPLACEMENT ....2858
COOLING SYSTEM ....2859
FAN CONTROL CIRCUIT OPERATION / TESTING ....2859
FAN CONTROL CIRCUIT BYPASS TEST ....2859
ENGINE COOLANT TEMPERATURE SENSOR (ECT) OVERVIEW ....2859
ECT SENSOR TEST ....2860
ECT SENSOR REPLACEMENT ....2860
FUEL SENDER ....2861
TESTING ....2861
FUSE BOX: FUSES / RELAYS / CIRCUIT BREAKER ....2862
OVERVIEW / OPERATION ....2862
FUSE BOX DETAIL ....2863
RELAY OPERATION ....2864
CHARGING SYSTEM ....2865
CURRENT DRAW - KEY OFF ....2865
CHARGING SYSTEM “BREAK EVEN” TEST ....2865
CHARGING SYSTEM STATOR (ALTERNATOR) TESTS ....2866
STATOR (ALTERNATOR) REPLACEMENT ....2867
REGULATOR / RECTIFIER ....2867
CHARGING SYSTEM TESTING FLOW CHART ....2868
BATTERY SERVICE ....2869
BATTERY SPECIFICATIONS ....2869
GENERAL BATTERY INFORMATION ....2869
BATTERY REMOVAL / INSTALLATION ....2870
BATTERY OFF SEASON STORAGE ....2870
BATTERY TESTING ....2870
OCV - OPEN CIRCUIT VOLTAGE TEST ....2870
LOAD TEST ....2870
BATTERY CONDUCTANCE ANALYZER ....2870
CHARGING PROCEDURE ....2871
STARTING SYSTEM ....2871
TROUBLESHOOTING ....2871
VOLTAGE DROP TEST ....2871
STARTER MOTOR REMOVAL ....2872
STARTER MOTOR INSTALLATION ....2872
STARTER SOLENOID BENCH TEST ....2872
STARTER SOLENOID OPERATION ....2872
STARTING SYSTEM TESTING FLOW CHART ....2873
CONDITION: STARTER FAILS TO TURN OVER THE ENGINE. ....2873
ELECTRONIC POWER STEERING (EPS) ....2874
EPS OPERATION ....2874
PROPER EPS SYSTEM DIAGNOSING ....2874
EPS SYSTEM BREAKOUT ....2875
EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL ON) ....2876
EPS TROUBLESHOOTING (POWER STEERING NON-FUNCTIONAL WITH MIL OFF) ....2877
EPS TROUBLESHOOTING (USING DIGITAL WRENCH®) ....2878
ELECTRICAL SYSTEM BREAKOUTS ....2879
AWD ....2879
VEHICLE SPEED SENSOR ....2880
COOLING SYSTEM ....2881
UNSWITCHED CHASSIS POWER ....2882
KEY-ON BATTERY POWER ....2883
LIGHTS ....2884
CHARGING SYSTEM ....2885
2014 RZR 1000 Wiring Harnesses....2892
2014 RANGER RZR XP 1000 (Chassis)....2892
2014 RANGER RZR XP 1000 (Box).pdf....2894
Polaris Scrambler 50-90, Sportsman 90, Predator 90 '03 Service Repair Manual (Sportsman Youth PN 9918068)....2895
Table of Contents....2898
Chapter 1 General Information Maintenance....2899
Chapter 2 Engine/Transmission/CVT....2923
Chapter 3 Carberation....2949
Chapter 4 Body/Steering/Suspension....2963
Chapter 5 Electrical....2979
Polaris Scrambler 500 2x2, 4x4 ATV '09 Service Repair Manual....3004
9921780_CH_01....3004
9921780_CH_02....3014
9921780_CH_03....3054
9921780_CH_04....3108
9921780_CH_05....3124
9921780_CH_06....3136
9921780_CH_07....3162
9921780_CH_08....3188
9921780_CH_09....3196
9921780_CH_10....3220
9921780_CH_Wire Diagrams....3258
Polaris Trail Boss 330 '03 Service Repair Manual....3260
Chapter 1 - General....3265
Chapter 2 - Maintenance....3277
Chapter 3 - Engine....3305
Chapter 4 - Fuel System....3351
Chapter 5 - Body/Suspension....3365
Chapter 6 - PVT System....3377
Chapter 7 - Final Drive....3401
Chapter 8 - Transmission....3413
Chapter 9 - Brakes....3421
Chapter 10 - Electrical....3443
Wiring Diagram....3472
Polaris Trail Boss330, Trail Blazer330 '09 Service Repair Manual....3473
9921775_CH_01.pdf....3473
9921775_CH_02....3485
9921775_CH_03....3519
9921775_CH_04....3567
9921775_CH_05....3583
9921775_CH_06....3597
9921775_CH_07....3621
9921775_CH_08....3633
9921775_CH_09....3641
9921775_CH_10....3665
9921775_CH_Wire Diagrams....3699
Polaris ATV & LUV Repair Service Manual
