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

This Service Manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual/Service Literature Question'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.

Publication Printed July, 2014 (PN 9924401)

© Copyright 2014 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to
constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information
presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or
inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS
Throughout this manual, important information is brought to your attention by the following symbols:

WARNING

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

CAUTION

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

CAUTION

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

NOTE:

NOTE provides key information by clarifying instructions.

IMPORTANT:

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

TRADEMARKS
POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:

Loctite, Registered Trademark of the Loctite Corporation

Nyogel, Trademark of Wm. F. Nye Co.

Fluke, Registered Trademark of John Fluke Mfg. Co.

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

Torx, Registered Trademark of Textron

Some Polaris factory publications can be downloaded from www.polaris.com, purchased from www.purepolaris.com
or by contacting the nearest Polaris dealer.
GENERAL INFORMATION 1

MAINTENANCE 2

MAIN FRAME 3
GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION 1
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL......................MOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
STANDARD BOLT TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
METRIC BOLT TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

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© Copyright 2014 Polaris Industries Inc.
GENERAL INFORMATION

GENERAL SPECIFICATIONS
MODEL......................MOWER
MODEL NUMBER.............FM Mower 66

Category Dimension
Length 51.9 in. / 131.8 cm
Width 77 in. / 195.7 cm
Height 27.8 - 30.8 in. / 70.6-78.1 cm
Cutting Width 66 in. / 167.6 cm
Cutting Height Range 2.0 - 4.5 in (50.8 x 114.3 mm)
0.25 x 2.50 x 23.0 inch
Blade Size (6.4 x 36.5 x 584.2 mm)
Number of Blades 3
Weight 480 lbs. / 217 kg
10.2 oz. / 302 ml
Gear Box Oil Capacity
(ATV Angle Drive Fluid)
Gear Box Reduction 1 : 1.43

Publication Numbers

Model No. Owner's Manual PN Parts Manual PN

FM Mower 66 9924399 9924400

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.

Vehicle Identification Number Location

VIN

1.2 9924401 - Mower Service Manual
© Copyright 2014 Polaris Industries Inc.
GENERAL INFORMATION
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 97/130 110/150
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

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GENERAL INFORMATION
Conversion Table
Unit of Measure Multiplied by Converts to
ft-lbs x 12 = in-lbs

in-lbs x .0833 = ft-lbs

ft-lbs x 1.356 = Nm

in-lbs x .0115 = kg-m

Nm x .7376 = ft-lbs

kg-m x 7.233 = ft-lbs

kg-m x 86.796 = in-lbs

kg-m x 10 = Nm

in. x 25.4 = mm

mm x .03937 = in.

in. x 2.54 = cm

mile (mi.) x 1.6 = km

km x .6214 = mile (mi.)

Ounces (oz.) x 28.35 = Grams (g)

Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc)

Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.)

Grams (g) x 0.035 = Ounces (oz.)

lb. x .454 = kg

kg x 2.2046 = lb.

Cubic inches (cu. in) x 16.387 = Cubic centimeters (cc)

Cubic centimeters (cc) x 0.061 = Cubic inches (cu. in)

Imperial pints (Imp pt.) x 0.568 = Liters (l)

Liters (l) x 1.76 = Imperial pints (Imp pt.)

Imperial quarts (Imp qt.) x 1.137 = Liters (l)

Liters (l) x 0.88 = Imperial quarts (Imp qt.)

Imperial quarts (Imp qt.) x 1.201 = US quarts (US qt.)

US quarts (US qt.) x 0.833 = Imperial quarts (Imp qt.)

US quarts (US qt.) x 0.946 = Liters (l)
Liters (l) x 1.057 = US quarts (US qt.)

US gallons (US gal) x 3.785 = Liters (l)

Liters (l) x 0.264 = US gallons (US gal)
Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa)

Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi)

Kilopascals (kPa) x 0.01 = Kilograms - force per square cm
Kilograms - force per square cm x 98.1 = Kilopascals (kPa)

p(3.14)xR2x H (height) = Cylinder Volume

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

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© Copyright 2014 Polaris Industries Inc.
GENERAL INFORMATION
SAE Tap Drill Sizes Decimal Equivalents
Thread Size / Drill Size
#0-80 3/64
Thread Size / Drill Size
1/2-13 27/64 1
#1-64 53 1/2-20 29/64
#1-72 53 9/16-12 31/64
#2-56 51 9/16-18 33/64
#2-64 50 5/8-11 17/32
#3-48 5/64 5/8-18 37/64
#3-56 45 3/4-10 21/32
#4-40 43 3/4-16 11/16
#4-48 42 7/8-9 49/64
#5-40 38 7/8-14 13/16
#5-44 37 1-8 7/8
#6-32 36 1-12 59/64
#6-40 33 1 1/8-7 63/64
#8-32 29 1 1/8-12 1 3/64
#8-36 29 1 1/4-7 1 7/64
#10-24 24 1 1/4-12 1 11/64
#10-32 21 1 1/2-6 1 11/32
#12-24 17 1 1/2-12 1 27/64
#12-28 4.6mm 1 3/4-5 1 9/16
1/4-20 7 1 3/4-12 1 43/64
1/4-28 3 2-4 1/2 1 25/32
5/16-18 F 2-12 1 59/64
5/16-24 I 2 1/4-4 1/2 2 1/32
3/8-16 O 2 1/2-4 2 1/4
3/8-24 Q 2 3/4-4 2 1/2
7/16-14 U 3-4 2 3/4
7/16-20 25/64

Metric Tap Drill Sizes
Tap Size Drill Size Decimal Nearest
Equivalent Fraction
3x.50 #39 0.0995 3/32
3x.60 3/32 0.0937 3/32
4x.70 #30 0.1285 1/8
4x.75 1/8 0.125 1/8
5x.80 #19 0.166 11/64
5x.90 #20 0.161 5/32
6x1.00 #9 0.196 13/64
7x1.00 16/64 0.234 15/64
8x1.00 J 0.277 9/32
8x1.25 17/64 0.265 17/64
9x1.00 5/16 0.3125 5/16
9x1.25 5/16 0.3125 5/16
10x1.25 11/32 0.3437 11/32
10x1.50 R 0.339 11/32
11x1.50 3/8 0.375 3/8
12x1.50 13/32 0.406 13/32
12x1.75 13/32 0.406 13/32

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GENERAL INFORMATION

NOTES

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MAINTENANCE
CHAPTER 2
MAINTENANCE
PERIODIC MAINTENANCE CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
PERIODIC MAINTENANCE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2
POLARIS LUBRICANTS AND SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
LUBRICANTS AND SERVICE PRODUCTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
MAINTENANCE REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
GENERAL VEHICLE INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 2.6
FRAME, NUTS, BOLTS AND FASTENER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 2.6
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
ADJUSTING BELT TENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
GEAR BOX FLUID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
CHECKING GEAR BOX FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
CHANGING GEAR BOX FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
SHEAR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
REPLACING GEAR BOX SHEAR BOLT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
REPLACING THE BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
SHARPENING BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
LUBRICATING THE PTO DRIVELINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
LUBRICATING THE BELT TENSION PIVOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

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© Copyright 2014 Polaris Industries Inc.
MAINTENANCE
PERIODIC MAINTENANCE CHART
Periodic Maintenance Overview
Careful periodic maintenance will help keep your vehicle / attachment in the safest, most reliable condition. Inspection,
adjustment and lubrication of important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement
parts, use genuine Polaris parts available from your Polaris dealer.
NOTE: Service and adjustments are critical. If you're not familiar with safe service and adjustment procedures, have a
qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average conditions. Attachments subjected to severe use
must be inspected and serviced more frequently.

Severe Use Definition

· Thick, wet grass
· Over grown, heavy grow

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 Above

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

WARNING

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

2.2 9924401 - Mower Service Manual
© Copyright 2014 Polaris Industries Inc.
MAINTENANCE
Maintenance Interval

Maintenance Interval
Item (whichever comes first) Remarks
Hours Calendar
Attachment Frame Inspection - Pre-Ride Inspect for cracks or damage.
Discharge Chute Inspection - Pre-Ride Inspect for cracks or damage.
Inspect for excess wear, cracks, damage and loose
2
Blade Inspection - Pre-Ride
hardware.
Adjust Belt 10 H Adjust belt as needed.
Grease PTO Shaft 10 H Grease PTO shaft and u-joints.
Check Gear Box Lube 50 H Check fluid level, add as needed.
Drain and replace fluid (Approx. 10.2 fl oz (302 ml) of
Replace Gear Box Lube 250 H
ATV Angle Drive Fluid

Perform these procedures more often for vehicles subjected to severe use.
* Replace the gear box fluid at the first 50 hours of operation and thereafter as scheduled.

Troubleshooting

WARNING

Instructions are necessary before operating or servicing machine. Read and understand the owner's manual,
operator's handbook, and signs (decals) on machine. Follow warnings and instructions in the manuals when making
repairs, adjustments or service. Check for correct function after adjustments, repairs or service. Untrained operators
and failure to follow instructions can cause injury or death.

PROBLEM CAUSE CORRECTION
Travel speed too fast. Reduce travel speed.
Damaged gearbox. Repair or replace gearbox.
Poor Cutting. Low blade RPM. Increase RPM.
Blade belt slipping. Adjust belt to correct tension.
Dull blades. Sharpen or replace the blades.
Worn or broken blade belt. Replace belt.
Blades will not rotate.
PTO driveline disconnected Check PTO driveline.
Vibration. Build up of material on the bottom of the mower deck. Clean the bottom of the mower deck.

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© Copyright 2014 Polaris Industries Inc.
MAINTENANCE
POLARIS LUBRICANTS AND SERVICE PRODUCTS
Lubricants and Service Products
Part No. Description

Grease / Specialized Lubricants
Premium All Season Grease
2871322
(3 oz. cartridge) (24 Count)
Premium All Season Grease
2871423
(14 oz. cartridge) (10 Count)
2876160 ATV Angle Drive Fluid (32 oz./0.95 l)
2872276 ATV Angle Drive Fluid (2.5 gal.)
2871950 Loctite 242 (6 ml.) (12 Count)
2871557 Crankcase Sealant, 3-Bond 1215 (5oz.)
NOTE: The number count supplied in the table indicates the number of units that are shipped with each
order.

2.4 9924401 - Mower Service Manual
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MAINTENANCE
MAINTENANCE REFERENCES

2

#1 Adjust Belt

#3 Check Plug
#2 Lubricate Grease Fittings

# Item Lubrication Method Frequency*
1. Drive Belt Adjust belt Every 10 hours.
Polaris Premium All Season
2. PTO Driveline Grease zerks Lubricate every 10 hours.
Grease**
Check level, add or Check every 50 hours. Change
3. Mower Gear Box Polaris ATV Angle Drive Fluid
change lube fluid at 250 hours.

* More often under severe use, such as operating under severe loads.
**Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or Mobilegrease
Special.

9924401 - Mower Service Manual
2.5
© Copyright 2014 Polaris Industries Inc.
MAINTENANCE
GENERAL VEHICLE INSPECTION AND MAINTENANCE
Frame, Nuts, Bolts and Fastener Inspection
Periodically inspect the torque of all fasteners in accordance with the maintenance schedule. Check that all cotter pins
are in place. Refer to specific fastener torques listed in each chapter.

2.6 9924401 - Mower Service Manual
© Copyright 2014 Polaris Industries Inc.
MAINTENANCE
DRIVE BELT
Adjusting Belt Tension
Adjust the belt tension as required.

WARNING

AVOID SERIOUS INJURY OR DEATH
2
Before leaving the operator seat:
·Park on flat level ground. 3
·Lower the attachment arm, put the attachment flat 4
on the ground.
·Press the brake and put the gear selector lever in
PARK.
·Stop the engine and remove the key.
6. Loosen the jam nut (Item 3), tighten or loosen the
·Make sure PTO driveline and all rotating parts have
tension nut (Item 4) to the desired belt tension.
come to a complete stop.
7. Check the belt tension by pressing forcefully on the
belt at the area indicated in the photo.

8. The belt should move between 0.2-0.4 inch (5-10 mm)
when adjusted correctly.

9. After tension is correct, tighten the jam nut (Item 3).
2
10. Reinstall the belt guard (Item 2) and bolt (Item 1).

WARNING
1 AVOID SERIOUS INJURY OR DEATH
· Never operate with covers or guards removed.

1. Position the vehicle on a level surface and fully lower
the attachment to the ground.

2. Move the gear selector lever to Park.

3. Make sure all rotating components have come to a
complete stop before exiting vehicle.

4. Stop the engine and exit the vehicle.

5. Remove the bolt (Item 1) and remove the belt guard
(Item 2).

9924401 - Mower Service Manual
© Copyright 2014 Polaris Industries Inc. 2.7
MAINTENANCE
DRIVE BELT
Removal And Installation
4
WARNING

AVOID SERIOUS INJURY OR DEATH
Before leaving the operator seat:
·Park on flat level ground.
·Lower the attachment arm, put the attachment flat
on the ground.
·Press the brake and put the gear selector lever in
PARK.
·Stop the engine and remove the key. 3
·Make sure PTO driveline and all rotating parts have
come to a complete stop.
6. Loosen or remove the tension bolt (Item 3) and
1. Position the vehicle on a level surface and fully lower remove the belt (Item 4) from the pulleys.
the attachment to the ground.

2. Move the gear selector lever to Park.
5
3. Make sure all rotating components have come to a
complete stop before exiting vehicle.

4. Stop the engine and exit the vehicle.

6

2 7. Position the new belt (Item 5) around the pulleys as
shown.

8. Install the tension bolt (Item 6) and nuts.

9. Adjust the tension. (see "Adjusting Belt Tension" for
1 specification).

10. Reinstall the belt guard (Item 2) and install the bolt
(Item 1).
5. Remove the bolt (Item 1) and remove the belt guard
(Item 2).

WARNING

AVOID SERIOUS INJURY OR DEATH
· Never operate with covers or guards removed.

9924401 - Mower Service Manual
2.8 © Copyright 2014 Polaris Industries Inc.
MAINTENANCE
GEAR BOX FLUID
Checking Gear Box Fluid
Inspect the gear box fluid as scheduled.

WARNING
2
AVOID SERIOUS INJURY OR DEATH
Before leaving the operator seat:
·Park on flat level ground.
·Lower the attachment arm, put the attachment flat
on the ground.
·Press the brake and put the gear selector lever in
PARK.
·Stop the engine and remove the key.
3
·Make sure PTO driveline and all rotating parts have
come to a complete stop.

NOTE: Fluid such as engine oil, hydraulic fluid,
coolants, grease, etc. must be disposed of in an
environmentally safe manner. Some regulations
require that certain spills and leaks on the ground 6. Remove the fill / check plug (Item 3).
must be cleaned in a specific manner. See local,
state and federal regulations for the correct 7. The fluid level should be at the bottom edge of the plug
disposal. hole.

8. If fluid level is low, add Polaris ATV Angle Drive Fluid
until the fluid flows from the plug hole.

9. Allow any extra fluid to drain from the fill hole before
reinstalling the plug.

2 10. Reinstall the plug (Item 3) and tighten.

1 WARNING

AVOID SERIOUS INJURY OR DEATH
· Never operate with covers or guards removed.
1. Position the vehicle on a level surface and fully lower
the attachment to the ground.
Changing Gear Box Fluid
2. Move the gear selector lever to Park.
Change the gear box fluid as scheduled.
3. Make sure all rotating components have come to a
complete stop before exiting vehicle. NOTE: To change the gear box fluid, the gear box
must be removed. There is no access to a drain plug
4. Stop the engine and exit the vehicle. when the gearbox is installed. See Gear box removal
section.
5. Remove the bolt (Item 1) and remove the belt guard
(Item 2).

9924401 - Mower Service Manual
© Copyright 2014 Polaris Industries Inc. 2.9
MAINTENANCE
SHEAR BOLTS
Replacing Gear Box Shear Bolt
4

WARNING

AVOID SERIOUS INJURY OR DEATH
Before leaving the operator seat: 3
·Park on flat level ground.
·Lower the attachment arm, put the attachment flat
on the ground.
·Press the brake and put the gear selector lever in
PARK.
·Stop the engine and remove the key.
·Make sure PTO driveline and all rotating parts have
6. Remove the nut (Item 3).
come to a complete stop.
7. Rotate the drive shaft (if necessary) and remove the
shear bolt (Item 4).
8. Remove any remaining portion of the old shear bolt
(Item 4) from the shaft.
NOTE: Use only shear bolts recommended by
Polaris.
2 9. Realign holes, install the new shear bolt (Item 4) and
nut (Item 3). Tighten the nut to specification.

=T
1 Shear Bolt:
16 ft-lbs (22 Nm)

1. Position the vehicle on a level surface and fully lower 10. Reinstall the belt guard (Item 2) and bolt (Item 1).
the attachment to the ground.

2. Move the gear selector lever to Park.

3. Make sure all rotating components have come to a WARNING
complete stop before exiting vehicle.
AVOID SERIOUS INJURY OR DEATH
4. Stop the engine and exit the vehicle.
· Never operate with covers or guards removed.
5. Remove the bolt (Item 1) and remove the belt guard
(Item 2).

9924401 - Mower Service Manual
2.10 © Copyright 2014 Polaris Industries Inc.
MAINTENANCE
BLADE 6. Install the blade (Item 2), washer and bolt (Item 1).
7. Torque the bolt to specifications.
Replacing The Blade
=T
WARNING
Blade Mount Bolt:
AVOID SERIOUS INJURY OR DEATH 65-70 ft-lbs (88-95 Nm)
Before leaving the operator seat:
·Park on flat level ground.
Sharpening Blade
2
·Lower the attachment arm, put the attachment flat
on the ground.
·Press the brake and put the gear selector lever in
PARK. WARNING
·Stop the engine and remove the key.
·Make sure PTO driveline and all rotating parts have AVOID SERIOUS INJURY OR DEATH
come to a complete stop. Wear safety glasses to prevent eye injury when any of
the following conditions exist:
·When fluids are under pressure.
CAUTION ·Flying debris or loose material is present.

Use care when supporting the attachment on blocks so ·Engine is running.
that it does not tip or fall. Serious injury may occur if ·Tools are being used.
attachment tips or falls.

WARNING

ROTATING BLADES CAN CAUSE SERIOUS
INJURY OR DEATH
·Never put hands, feet or objects into or under Cutting Edge
mower when engine is running.
·Keep bystanders away.
·No riders. 2.5 in.
New (63.5 mm)
·Stop engine before servicing.

2.25 in.
Replace (57.2 mm)

2 When the cutting edges of the blade become dull, remove
1
the blades.

1. Position the vehicle on a level surface and lower the Sharpen the blades at a 28° angle and balance the blades.
attachment securely onto blocks. Replace the blades when thy reach a width of 2.25 in (57.2
mm).
2. Move the gear selector lever to Park.
3. Make sure all rotating components have come to a Always replace all three blades that are equal in weight to
complete stop before exiting vehicle. prevent vibration. Use only Polaris replacement blades.
4. Stop the engine and exit the vehicle. If any vibration in the mower is felt, the blades must be
5. Secure the blade from rotating and remove the bolt balanced or replaced.
and washer (Item 1) and the blade (Item 2).

9924401 - Mower Service Manual
© Copyright 2014 Polaris Industries Inc. 2.11
MAINTENANCE
LUBRICATION
Lubricating The PTO Driveline
WARNING
Lubricate the mower as scheduled.
AVOID SERIOUS INJURY OR DEATH
Grease Fittings Before leaving the operator seat:
·Park on flat level ground.
·Lower the attachment arm, put the attachment flat
on the ground.
·Press the brake and put the gear selector lever in
PARK.
·Stop the engine and remove the key.
·Make sure PTO driveline and all rotating parts have
come to a complete stop.

NOTE: Fluid such as engine oil, hydraulic fluid,
coolants, grease, etc. must be disposed of in an
environmentally safe manner. Some regulations
require that certain spills and leaks on the ground
must be cleaned in a specific manner. See local,
state and federal regulations for the correct
disposal.
1. Position the vehicle on a level surface and fully lower
the attachment to the ground.
2. Move the gear selector lever to Park.
3. Stop the engine and exit the vehicle.

Lubricating The Belt Tension Pivot 4. Make sure PTO driveline and all rotating parts have
come to a complete stop.
NOTE: The belt guard will need to be removed to
access the driveline u-joint grease fitting at the gear
box and the belt tension pivot grease fitting.

5. Lubricate the grease fittings with Polaris Premium All
Season Grease or equivalent.

WARNING

AVOID SERIOUS INJURY OR DEATH
· Never operate with covers or guards removed.

Grease Fitting

9924401 - Mower Service Manual
2.12 © Copyright 2014 Polaris Industries Inc.
MAINFRAME
CHAPTER 3
MAINFRAME
ANTI-SCALP WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2
GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3
PARTS IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.5
DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6
DRIVELINE TO GEAR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
DISCHARGE CHUTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11
BLADE SPINDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
3
REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.12
PARTS IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.13
DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.14
BELT TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16

9924401 - Mower Service Manual
3.1
© Copyright 2014 Polaris Industries Inc.
MAINFRAME
ANTI-SCALP WHEELS
Removal And Installation

WARNING

AVOID SERIOUS INJURY OR DEATH
Before leaving the operator seat:
·Park on flat level ground.
·Lower the attachment arm, put the attachment flat 2
on the ground. 1
·Press the brake and put the gear selector lever in
PARK. 3
·Stop the engine and remove the key.
·Make sure PTO driveline and all rotating parts have 5. Remove the nut (Item 1).
come to a complete stop. 6. Remove the bolt (Item 2) and the two wheels (Item 3).

Installation
WARNING
1. Install the two wheels (Item 3) and the bolt (Item 2).
AVOID INJURY OR DEATH 2. Install the nut (Item 1) and tighten to specification.
Wear safety glasses to prevent eye injury when any of
the following conditions exist:
· When fluids are under pressure.
· Flying debris or loose material is present.
· Engine is running. =T
· Tools are being used.
Anti-Scalp Wheel Nut:
1. Position the vehicle on a level surface and fully lower 25-28 ft-lbs (34-38 Nm)
the attachment to the ground.
2. Move the gear selector lever to Park.
3. Make sure all rotating components have come to a
complete stop before exiting vehicle.
4. Stop the engine and exit the vehicle.

3.2 9924401 - Mower Service Manual
© Copyright 2014 Polaris Industries Inc.
MAINFRAME
GEARBOX
Removal And Installation

WARNING 3
AVOID SERIOUS INJURY OR DEATH 4
Before leaving the operator seat:
·Park on flat level ground.
·Lower the attachment arm, put the attachment flat
on the ground.
·Press the brake and put the gear selector lever in
PARK. 3
·Stop the engine and remove the key.
·Make sure PTO driveline and all rotating parts have
come to a complete stop. 6. Remove the snap ring (Item 3).
7. Remove the driveline (Item 4).
WARNING
6
5
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any of
the following conditions exist:
· When fluids are under pressure.
· Flying debris or loose material is present.
· Engine is running.
· Tools are being used.
5
1. Position the vehicle on a level surface and fully lower
the attachment to the ground.
2. Move the gear selector lever to Park.
3. Make sure all rotating components have come to a
complete stop before exiting vehicle. 8. Remove the belt. See "DRIVE BELT" on page 2.8.
4. Stop the engine and exit the vehicle. 9. Remove the four bolts (Item 5) and remove the
gearbox (Item 6).

2 7

1
8

5. Remove the nut (Item 1) and the shear bolt (Item 2).
10. Remove the eight bolts (Item 7) and remove the two
gear box mounts (Item 8).

9924401 - Mower Service Manual
3.3
© Copyright 2014 Polaris Industries Inc.
MAINFRAME
Removal And Installation Installation

9
11

9

9

10

1. Place the pulley (Item 11) on the gear box shaft.
2. Align and install the collar (Item 10) on the gear box
11. Remove the two bolts (Item 9).
shaft.
3. Rotate the pulley until the holes of the pulley and the
collar are aligned.
7 11 4. Install the two bolts (Item 9) through the collar (Item
10) and into the pulley (Item 11).
5. Tighten the bolts evenly until the collar and the pulley
are securely fastened on the shaft.
6. Install the two mounts (Item 8) on the gear box and
install the eight bolts (Item 7) and tighten.

10 =T
Gear Box Mount Bolts:
25-28 ft-lbs (34-38 Nm)
12. Using two of the existing bolts (Item 7), install the two
bolts into the collar (Item 10). 7. Install the gear box / mount assembly (Item 6) with the
13. Tighten the two bolts (Item 7) evenly until the collar four bolts (Item 5) and tighten.
(Item 10) is removed from the shaft.
14. Remove the pulley (Item 11). =T
15. Remove the two bolts (Item 7) from the collar.
Gear Box Mount Bolts:
25-28 ft-lbs (34-38 Nm)

8. Install the driveline (Item 4) and the snap ring (Item 3).
9. Align the driveline to the gear box. Install the shear
bolt (Item 2) and the nut (Item 1) and tighten.

=T
Shear Bolt:
16 ft-lbs (22 Nm)

NOTE: Use only shear bolts recommended by
Polaris.

3.4 9924401 - Mower Service Manual
© Copyright 2014 Polaris Industries Inc.
MAINFRAME
Parts Identification

Gear Box Exploded View
17 - 21 ft-lbs 13
(23 - 28 Nm)
14 12
13

13
Replace all seals upon assembly

1
3
10
4 13
6 2

5
3 7
7
6

9
10

8
7
6 14 12 11
7

REF. QTY. DESCRIPTION REF. QTY. DESCRIPTION

1 1 Housing 8 1 Key
2 1 Housing 9 1 Retaining Ring
3 1 Input Shaft 10 1 Seal
4 1 Output Shaft 11 1 End Cap
5 1 Pinion Gear 12 2 Plug
6 4 Bearing Cup 13 8 Bolt
7 4 Roller Bearing 14 2 Plug

9924401 - Mower Service Manual
3.5
© Copyright 2014 Polaris Industries Inc.
MAINFRAME
Disassembly And Assembly

WARNING
5
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any of
the following conditions exist:
· When fluids are under pressure.
· Flying debris or loose material is present.
· Engine is running.
· Tools are being used.

NOTE: Fluid such as engine oil, hydraulic fluid,
4. With the top housing removed, hold the input shaft
coolants, grease, etc. must be disposed of in an
environmentally safe manner. Some regulations (Item 5) and tap th