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Maintenance
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MAINTENANCE
CHAPTER 2 MAINTENANCE
PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
BREAK-IN PERIOD / MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 PRE-RIDE - DAILY MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 25 - 100 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 100 - 2000 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 POLARIS LUBRICANTS & MAINTENANCE PRODUCTS. . . . . . . . . . . . . . . . . . . . . . . . 2.7 GREASE LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 GREASE LUBRICATION POINTS, CONTINUED..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 MAINTENANCE QUICK REFERENCE (ALL MODELS) . . . . . . . . . . . . . . . . . . . . . . . . 2.10 MAINTENANCE QUICK REFERENCE (ALL MODELS), CONTINUED..... . . . . . . . . . . 2.11 MAINTENANCE QUICK REFERENCE (HD / HDPTO MODELS) . . . . . . . . . . . . . . . . . 2.12
2
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 PEDAL REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 CABLE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
HYDROSTATIC / TREADLE PEDAL ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
HYDROSTATIC TRAVEL CONTROL ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . 2.14 NEUTRAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15 TRAVEL CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16 FORWARD SPEED CONTROL CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 2.17 REVERSE SPEED CONTROL CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 2.18 ENGINE SPEED CONTROL CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
ENGINE SPEED CONTROL LEVER (HD / HDPTO MODELS) . . . . . . . . . . . . . . . . . . . 2.19 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
FUEL SYSTEM SAFETY PRECAUTIONS / GENERAL INFORMATION. . . . . . . . . . . . 2.20 FUEL FILTER / WATER SEPARATOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20 FUEL FILTER / WATER SEPARATOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 2.21 FUEL PICK-UP SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 FUEL LINES / VENT LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25 ENGINE OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26 ENGINE CRANKCASE BREATHER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28 ENGINE COMPRESSION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29 ENGINE LEAKDOWN TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30 ALTERNATOR / FAN / WATER PUMP DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30 VALVE CLEARANCE INSPECTION / ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32 EXHAUST CLEAN OUT PLUG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33 SPECIFICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34 SHIFT CABLE INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34 TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35 FRONT GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36
PR
EL
TRANSMISSION AND FRONT GEARCASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
IM
ENGINE INTAKE PRE-FILTER SCREEN SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22 AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23 AIR INTAKE EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
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GENERAL VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 TRAVEL CONTROL (TREADLE) PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
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9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
MAINTENANCE
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38
COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38 COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38 COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39 RADIATOR INSPECTION / CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39 COOLANT DRAIN / FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.39
HVAC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.40
HYDRAULIC / HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.42
HYDRAULIC / HYDROSTATIC HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2.42 HYDRAULIC FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.43 HYDRAULIC FLUID AND FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.43 PTO GEARBOX OIL LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.46 PTO GEARBOX OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.47 PTO DRIVE BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.49 PTO U-JOINT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.49 PTO CLUTCH BRAKE INSPECTION / ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 2.50
POWER TAKE-OFF SYSTEM (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.46
FINAL DRIVE / WHEEL AND TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.51
DRIVE SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.51 FRONT WHEEL BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.51 WHEEL AND HUB TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.52 WHEEL REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.52 TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.52 TIRE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.53 BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.54 BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.54 BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.55 BATTERY CHARGING / OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.55 CHASSIS / ENGINE ELECTRICAL GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.55
ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.54
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.56
SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.58 SPRING PRE-LOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.58
BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.59
PR
2.2
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
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BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.59 BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.59 BRAKE PAD / DISC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.59
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SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.58
IN
STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.56 TIE ROD END / WHEEL HUB INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.56 WHEEL TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.57 WHEEL TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.57
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A/C CONDENSER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.40 HVAC FILTER INSPECTION / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.40 AIR CONDITIONING DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.40
MAINTENANCE
PERIODIC MAINTENANCE CHART
Periodic Maintenance Overview
Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Pure Polaris parts available from your Polaris dealer.
2
Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently. Severe Use Definition · Frequent immersion in mud, water or sand · Racing or race-style high RPM use · Prolonged low speed, heavy load operation · Extended idle · Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.
Break-In Period
The break-in period consists of the first 50 hours of operation. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components. · Drive vehicle slowly at first while varying the throttle position. Do not operate at sustained idle. · Perform regular checks on fluid levels and other areas outlined on the daily pre-ride inspection checklist. · Change both the engine oil and filter after initial 50 hours of operation. · See "Owner's Manual" for additional break-in information. · Check and adjust alternator V-belt after initial 50 hours of operation. · Pull only light loads.
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.
PR
= SEVERE USE ITEM: See information provided above.
E = Emission Control System Service (California).
NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.
Improperly performing the procedures marked could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.
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Maintenance Chart Key
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WARNING
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NOTE: Service and adjustments are critical. If you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.
2.3
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
MAINTENANCE
Pre-Ride - Daily Maintenance Interval
Item Hours Brake Fluid Level Diesel Fuel Level Maintenance Interval (whichever comes first) Calendar Miles (KM) Remarks
Coolant Level Engine Oil Level E Hydraulic Fluid Level Engine Speed Control Lever Travel Control Pedal Head Lights / Tail Lights Indicator Lights / Switches E E Air Filter Air Intake Sediment Drains Daily Daily Daily Daily Daily Daily Brake System / Pedal Travel
Ensure proper operation
Check for proper operation
Cooling System Drive Shaft Boots E Engine Intake Pre-Filter Screen (LH side) Frame Fasteners E Fuel Filter / Water Separator Heater / A/C Filter (if equipped) PTO (if equipped) ROPS/OPS
AR Y
Daily Daily Daily Daily Daily Daily Daily Daily Daily Daily Daily -
IN
IM
EL
Safety Signs / Decals Seat Belts
-
PR
Steering / Suspension Tires
Wheels / Fasteners
-
Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.
2.4
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
VE R
Inspect; clean often
Inspect filter element; replace as needed or every 150 hours
Inspect drain on bottom of engine air intake duct and air filter housing for obstructions
Inspect oil cooler, radiator, A/C condenser (if equipped) and grills for debris; remove debris if needed Inspect boots for damage, tears, wear or leaking grease
Inspect and ensure tightness Drain daily (severe conditions with poor fuel quality) or every 50 hours (normal conditions with quality fuel) Clean or replace filter as needed during heating and cooling seasons Inspect the splines, guards and shields and mounting hardware; tighten loose hardware or replace damaged parts Check the condition of the ROPS/OPS and mounting hardware Check for damaged signs (decals); replace any that are damaged Check the condition of seat belts; clean or replace seat belt retractors as needed Inspect for broken parts, loose hardware and free operation Check for wear, damage and correct air pressure Check for loose wheel nuts and tighten to correct torque value; retorque wheel nuts after 8 hours of use any time the nuts are removed for servicing
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Daily
-
Check the levels and add as needed
MAINTENANCE
25 - 100 Hour Maintenance Interval
Item Hours Front Gearcase Lubricant (Demand Drive Plus) Transmission Lubricant (AGL Gearcase Lubricant) Attachment Interface Mounting Hardware (HD / HDPTO) Brake Pad Wear Air Conditioner Drive Belt (if equipped) Alternator / Fan / Water Pump Drive Belt Engine Oil & Filter Change 25 H 25 H 25 H 50 H Maintenance Interval (whichever comes first) Calendar 1M 1M 1M Miles (KM) 250 (400) 250 (400) 250 (400) Remarks
Initial fluid level inspection; add lubricant if needed
2
Retorque to lower mounting bolts to 95 ft-lbs Inspect; replace if necessary
Check and adjust the V-belt after initial 50 hours of operation; perform every 200 hours thereafter Check and adjust the V-belt after initial 50 hours of operation; perform every 200 hours thereafter Perform an oil and filter change after initial 50 hours of operation; perform every 100 hours or 6 months thereafter Replace hydraulic filter only after initial 50 hours of operation; replace hydraulic fluid and filter every 400 hours thereafter
E
50 H
-
50 H
-
Hydraulic / Hydrostatic System Battery E E Fuel Filter / Water Separator General Grease Lubrication Air Intake Ducts / Adaptors Attachment Interface Mounting Hardware (HD / HDPTO) PTO Gearbox (if equipped) Engine Oil & Filter Change E Front / Rear Suspension Shift Cable / Linkage
50 H 50 H 50 H
1M
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3M 3M 6M 6M 6M 6M 6M 6M 12 M 12 M 12 M 12 M 12 M -
50 H 50 H
IN
100 H
100 H
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100 H
100 H 100 H 100 H 100 H
Steering E
EL
Travel Control and Engine Speed Control Systems
PR
Cooling Hoses
100 H 100 H 100 H 100 H 100 H
Engine Mounts Exhaust Silencer / Pipe
E
Fuel System
Front Wheel Bearings
Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.
VE R
500 (800) 1000 (1600) 1000 (1600) 1000 (1600) 1000 (1600) Inspect 1000 (1600)
Check terminals; clean; test Drain every 50 hours (normal conditions with quality fuel) or daily (severe conditions with poor fuel quality) Lubricate all grease fittings, pivots, etc. Inspect ducts for proper sealing/air leaks Retorque to lower mounting bolts to 95 ft-lbs Inspect for leaks Perform an oil and filter change after initial 50 hours of operation; perform every 100 hours or 6 months thereafter Inspect for wear Inspect, lubricate, adjust Inspect steering freeplay Inspect for proper operation and adjustment if necessary Inspect for leaks; replace if necessary Inspect, torque to specification Check for leaks at fill cap, fuel lines and fuel pump Inspect; replace as needed
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Initial fluid level inspection; add lubricant if needed
2.5
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MAINTENANCE
100 - 2000 Hour Maintenance Interval
Item Hours Front Gearcase Lubricant (Demand Drive Plus) Transmission Lubricant (AGL Gearcase Lubricant) Hydraulic, Hydrostatic and Power Steering Hoses Radiator Wiring Cooling System Air Filter E E Fuel Filter / Water Separator Air Conditioner Drive Belt (if equipped) Alternator / Fan / Water Pump Drive Belt PTO Drive Belt (if equipped) 100 H 100 H 100 H 100 H 100 H 150 H 150 H 100 H Maintenance Interval (whichever comes first) Calendar 12 M 12 M 12 M 12 M 12 M 12 M 12 M Miles (KM) 1000 (1600) 1000 (1600) 1000 (1600) 1000 (1600) 1000 (1600) Change lubricant Remarks
Inspect; clean external surfaces
Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc. Test coolant strength and pressure test system Replace air filter; replace more often if vehicle is subject to severe use
100 H 200 H 200 H 200 H 300 H 400 H
-
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24 M 2000 (3200) 24 M 2000 (3200) 36 M 12 M 12 M 12 M 24 M 24 M 24 M -
Toe Adjustment Brake Fluid Exhaust Clean Out Hydraulic / Hydrostatic System PTO Gearbox Lubricant (if equipped) PTO Shaft U-Joints (if equipped) PTO Clutch Brake (if equipped) E E Valve Clearance Coolant
IN
400 H
IM
400 H
400 H
EL
1000 H 1000 H 1500 H 1500 H 2000 H 2000 H
Fuel Injectors
PR
E
Engine Crankcase Breather System Fuel Hoses Cooling Hoses Headlight Aim
Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.
2.6
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
VE R
Change lubricant Adjust Tension Replace coolant Adjust as needed
Replace fuel filter / water separator Check and adjust the V-belt after initial 50 hours of operation; perform every 100 hours thereafter; replace as needed Check and adjust the V-belt after initial 50 hours of operation; perform every 100 hours thereafter; replace as needed Inspect for damage; replace as needed Inspect; adjust if necessary or when parts are replaced
Change every two years (DOT 4) Remove plug and clean out Replace hydraulic fluid and filter
Inspect for wear; replace as needed
Inspect; adjust as needed
Inspect, clean and test fuel injectors, if necessary (see Engine Chapter) Inspect crankcase breather system Replace rubberized fuel hoses Replace coolant hoses
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Inspect for damage and leaks; repair or replace as needed
N
Change lubricant
MAINTENANCE
Polaris Lubricants & Maintenance Products
Part No. Description Engine Lubricant 2878473 2878474 2879832 3070131 Polaris Diesel Engine Oil 15W-40 (Summer) (2 Qts.) (8 Count) Polaris Diesel Engine Oil 10W-30 (Winter) (2 Qts.) (8 Count) Polaris Synthetic Diesel Engine Oil 5W-40 (All-Season) (2 Qts.) (8 Count) Diesel Engine Oil Filter Demand Drive Plus (1 Qt.) (12 Count) Demand Drive Plus (2.5 Gal.) (2 Count) AGL Plus Gearcase Lubricant (1 Qt.) (12 Count) AGL Plus Gearcase Lubricant (1 Gal.) (4 Count) AGL Plus Gearcase Lubricant (2.5 Gal.) (2 Count) Part No. Description LoctiteTM Threadlock 242 (6 ml.) (12 count) Additives / Sealants / Thread Locking Agents / Misc. 2871950 2872189 2871557
NOTE: Each item can be purchased separately at your local Polaris dealer.
2
Crankcase Sealant, 3-Bond 1215 (5 oz.)
Front Gearcase / Transmission / Gearbox Lubricants 2877922 2877923 2878068 2878069 2878070 2879748 2879747 2870465
NOTE: The number count indicated by each part number in the table above indicates the number of units that are shipped with each order.
PTO Gearbox Oil (if equipped) (6 oz.) Angle Broom Oil (if equipped) (14 oz.) Oil Pump for 1 Gallon Jug
2871312 2871322 2871423 2871460 2871515 2871551 2871329
Grease Gun Kit
Premium All Season Grease (14 oz. cartridge) (10 Count) Starter Drive Grease (12 Count) Premium U-Joint Lube (3 oz.) (24 Count) Premium U-Joint Lube (14 oz.) (10 Count) Dielectric Grease (NyogelTM) Hydraulic / Hydrostatic Fluid
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2879746 3120212
2871323 2871534
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Polaris Hydraulic Fluid (1 Gal.) Hydraulic/Hydrostatic Filter Coolant
60/40 Coolant (Gallon) (6 Count) 60/40 Coolant (Quart) (12 Count)
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Premium All Season Grease (3 oz. cartridge) (24 Count)
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Grease / Specialized Lubricants
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DOT 4 Brake Fluid (12 count)
MAINTENANCE
Grease Lubrication Points
Apply Polaris All Season Grease to each component until all traces of water have been purged out at each of these areas. Item A B C Front A-arm Pivot Bushings Rear Suspension Pivot Bushings Front Propshaft Yoke Method Grease all fittings on each side of the vehicle Grease the fitting (3 pumps maximum) Recommended Lube Frequency Grease fittings every 500 miles (800 km); Grease before long periods of storage, and after thoroughly washing or submerging the vehicle
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FRONT SUSPENSION
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REAR SUSPENSION
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Polaris All Season Grease
MAINTENANCE
Grease Lubrication Points, Continued.....
Apply Polaris All Season Grease to each component until all traces of water have been purged out at each of these areas. Item D Method Recommended Lube Frequency Grease fittings every 500 miles (800 km); Grease before long periods of storage, and after thoroughly washing or submerging the vehicle
Grease all fittings at PRO-TACH System Attachment Arm Fittings attachment arm pivot locations (HD / HDPTO Models) PTO Shaft Yoke (HDPTO Models Only) Grease the fitting (3 pumps maximum)
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Polaris All Season Grease
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PRO-TACH ATTACHMENT SYSTEM
(HD / HDPTO Models)
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PTO SHAFT
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Maintenance Quick Reference (All Models)
III. # 1 Item Engine Oil Recommended Lube / Fluid Polaris Diesel Engine Oil Reference "Engine Oil Recommendations" Polaris 60/40 Coolant Method Add oil to proper level on dipstick Maintain coolant level in coolant reservoir bottle. Frequency* Perform an oil and filter change after initial 50 hours; every 100 hours or 6 months thereafter
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* More often under severe use, such as operated in water or under severe loads.
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Engine Coolant
Check level daily; change coolant every two years
MAINTENANCE
Maintenance Quick Reference (All Models), Continued.....
III. # 3 4 5 Item Brake Fluid Recommended Lube / Fluid Polaris DOT 4 Brake Fluid Method Frequency*
Maintain fluid level between Check level daily; change fluid "MAX and "MIN" lines on the every two years master cylinder reservoir Initial level check at 25 hours or 1 month; Change lubricant Add lubricant until it is visible at the fill hole threads every 100 hours or 12 months thereafter
Front Gearcase Polaris Demand Drive Plus Transmission Polaris AGL Plus Gearcase Lubricant
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* More often under severe use, such as operated in water or under severe loads.
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Maintenance Quick Reference (HD / HDPTO Models)
III. # Item Recommended Lube / Fluid Method Maintain fluid level within sight glass Completely drain lubricant and refill to recommended capacity. Frequency* Replace hydraulic filter after initial 50 hours; replace hydraulic fluid and filter every 400 hours thereafter Perform oil change every 400 hours or 12 months; whichever comes first
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Hydraulic Fluid Polaris Hydraulic Fluid Reservoir / Filter
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PTO Gearbox (HDPTO Only)
Polaris PTO Gearbox Oil
* More often under severe use, such as operated in water or under severe loads.
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GENERAL VEHICLE INSPECTION
Frame, Nuts, Bolts, and Fasteners
Periodically inspect the torque of all fasteners in accordance with the maintenance schedule. Check that all cotter pins are in place. Refer to specific fastener torque values listed in each chapter.
Inspection
1. Position the vehicle on a flat level surface. Position the gear selector lever in Park and stop the engine. 2. Inspect the travel control pedal (Item 1) for free movement. Be sure the pedal returns to the neutral position normally when released.
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TRAVEL CONTROL (TREADLE) PEDAL
Description
The travel control (treadle) pedal is used to control the forward and backward movement of the vehicle. The farther the pedal is pressed, the faster the travel speed. The travel direction control system requires regular inspection. Inspect the travel direction control system to ensure proper operation. Incorrect adjustment may cause erratic travel speed conditions.
WARNING
Failure to check or maintain proper operation of the travel control system can result in an accident and lead to serious injury or death if the travel control pedal or the engine speed control lever sticks during operation. Always inspect the travel control pedal for free movement and return to neutral before starting the engine and occasionally during operation. Never start or operate this vehicle if it has a sticking or improperly operating travel control pedal.
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3. Check the travel control pedal (Item 2) for excessive freeplay. 2 4. The correct amount of total free travel on the travel control pedal is 0.30 in. (7.6mm). 5. While on flat level ground, with the gear selector lever in Park, press the travel control pedal to full forward, the engine speed should be 3650 - 3750 RPM. Repeat with travel control pedal fully in reverse, the engine speed should be 3650 - 3750 RPM. If the specified RPM is not observed or if the travel control pedal does not return to neutral unassisted, reference the "Hydrostatic / Treadle Pedal Adjustments".
Pedal Removal and Installation
Reference Chapter 10 - Hydrostatic Drive.
Cable Removal and Installation
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Reference Chapter 10 - Hydrostatic Drive.
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HYDROSTATIC / TREADLE PEDAL ADJUSTMENTS
Hydrostatic Travel Control Adjustments
NOTE: The travel control adjustments are listed in the order in which they MUST be performed. Failure to do so will result in poor vehicle performance. 1. Raise the vehicle so all four wheels are off the ground and place on jack stands. 3. Disconnect the neutral safety switch connector (Item 2) and remove the controls cover (Item 3).
WARNING
Be certain that ALL four wheels are safely elevated off the ground before attempting to perform any adjustment procedures. 2. Remove the bolts (Item 1) retaining the controls cover. 3
4. Verify that the speed control cable (Item 4) is attached to the top hole of the engine speed control lever.
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Neutral Adjustment
1. Install a tie strap (Item 1) on the hydraulic hose shown to serve as a pointer on the pump plate. 4. Slowly rotate the pump plate clockwise until the rear wheel starts to rotate. Mark the location of the tie strap on the pump plate (Item 3), using a fine tipped marker.
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2. Start the engine, place the AWD / 2WD / TURF Switch in the TURF mode, the gear selector in HIGH and engine speed at high idle. 3. Loosen the four pump plate mounting bolts (Item 2).
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5. Slowly rotate the pump plate counterclockwise until the wheel stops rotating and then starts to rotate in the opposite direction. Mark the location of the tie strap on the pump plate (Item 4).
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6. Rotate the pump plate clockwise until the end of the tie strap rests approximately half way between the two marks. By centering the pump plate between clockwise and counterclockwise wheel rotation start points, the pump is now centered in a neutral position. 7. The wheels should not be turning.
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8. Torque the four bolts (Item 5) to specification. 2. Locate PU-51261 - Drive Control Adjustment Wrench (Item 2) and install it as shown.
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Pump Plate Mounting Bolts: 22 ft-lbs (30 Nm) 9. Return the engine to slow idle and shut the engine off. Place the gear selector lever in Park. Proceed to "Travel Cable Adjustment".
Travel Cable Adjustment
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2 3. The Drive Control Adjustment Wrench is used to rotate the pintle lever while maintaining proper spacing between command and pintle levers. 4. Loosen the jam nuts (Item 3) on the travel control cable. 3
1. Secure the travel pedal in the full forward position by placing wood blocks (Item 1) under the rear of the pedal. The travel pedal should remain in contact with the pedal stop on the frame.
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5. The travel control cable (Item 4) will pull the command lever (Item 5) counterclockwise and the HP control spring (Item 6) will pull the pintle lever along with the command lever. 5 4 8. While holding the outer jam nut, torque the inner jam nut (Item 8) to specification.
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Travel Control Cable Jam Nuts: 12 ft-lbs (16 Nm) NOTE: Over tightening the outer jam nut results in overstroking the command lever causing the HP control spring to function improperly.
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9. Remove the wood blocks (Item 9) from under the foot pedal. Proceed to "Forward Speed Control Cable Adjustment".
6. Apply pressure on the tool in a counterclockwise direction until the pintle lever is held against the internal stop.
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7. Tighten the outer jam nut (Item 7) until it is tight against the bracket.
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Forward Speed Control Cable Adjustment
1. Adjust the jam nuts (Item 1) to remove any slack in the speed control cable (Item 2).
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2. After adjustments are made, the protective boot (Item 3) must be in place to prevent cable damage. Proceed to "Reverse Speed Control Cable Adjustment".
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MAINTENANCE
Reverse Speed Control Cable Adjustment
1. Adjust the jam nuts (Item 1) to remove any slack in the travel control cable (Item 2).
Engine Speed Control Cable Adjustment
1. Adjust the jam nuts (Item 1) to remove any slack in the speed control cable (Item 2).
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2. After adjustments have been made, the protective boot (Item 3) must be in place to prevent damage to the cable. Proceed to "Engine Speed Control Cable Adjustment".
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MAINTENANCE
ENGINE SPEED CONTROL LEVER (HD / HDPTO MODELS)
Description
The engine speed control lever controls engine RPM. This is used to set engine RPM separately from the travel speed when using hydraulic attachments. The engine speed control lever requires regular inspection. Inspect the engine speed control system to ensure proper operation. Incorrect adjustment may cause erratic engine speed conditions.
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Inspection
1. While on flat level ground, with the travel control pedal in neutral, move the gear select lever to low and move the engine speed control lever (Item 1) to high idle. If any vehicle movement is detected, travel control adjustments must be made (see "Hydrostatic / Treadle Pedal Adjustments").
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2. While on flat level ground, with the gear selector lever in Park, move the engine speed control lever (Item 1) to high idle position. The engine speed should be 3650 - 3750 RPM. If the specified RPM is not observed, reference the "Engine Speed Control Cable Adjustment" only if NO vehicle movement was detected during Step 1. If vehicle movement was detected, reference "Hydrostatic / Treadle Pedal Adjustments".
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FUEL SYSTEM
Fuel System Safety Precautions WARNING
Diesel fuel is flammable and explosive under certain conditions. Fuel injection components are under high pressure. Verify system pressure has been relieved before system disassembly. NEVER start the engine or let it run in an enclosed area. Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Before you operate the engine, check for fuel leaks. NEVER drain the fuel system when the engine is hot. Severe burns may result. When you prime the fuel system, turn the key switch to the ON position for 10 to 15 seconds to allow the electric fuel transfer pump to prime the fuel system. Only use the key switch to start the engine. NEVER jump-start the engine. Sparks caused by shorting the battery to the starter motor terminals may cause a fire or explosion.
General Information
The fuel filter / water separator is located behind the driver's seat and can be accessed by tilting the rear cargo box. The filter should be: · Inspected daily. · Drained every 50 hours (normal conditions with quality fuel) OR drained daily (severe conditions / poor fuel quality).
Fuel Filter / Water Separator Draining
Both fuel and water will drain from the separator during the following procedure. Use caution and observe all fuel safety precautions when handling fuel. 1. Be sure engine is cool and the battery is disconnected. 2. Tilt the cargo box to access the fuel filter / water separator. 3. Place an approved container under the fuel filter / water separator (Item 1) to collect the contaminants. Locate the black drain valve at the bottom (Item 2).
NEVER use diesel fuel as a cleaning agent. Always turn off the engine before refueling. Always refuel outdoors or in a well-ventilated area. Do not overfill the tank. The tank is at full capacity when the fuel reaches the bottom of the filler neck. Leave room for expansion.
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NEVER use a shop rag to catch diesel fuel. Vapors from the rag are flammable and explosive. Wipe up any fuel spills immediately.
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Do not smoke or allow open flames or sparks in or near the area where refueling is being performed or where fuel is stored.
If you get fuel in your eyes or if you should swallow fuel, seek medical attention immediately. If you spill on your skin or clothing, immediately wash it off with soap and water and change clothing.
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· Replaced every 150 hours OR 12 months OR 2000 miles (3200KM). WHICHEVER COMES FIRST.
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4. Reach under the fuel filter / water separator and unscrew or open the black drain valve (large arrow) until fuel starts to drain out of the bottom of the valve (1/2 to 1 turn). Do not unscrew the drain valve completely.
Fuel Filter / Water Separator Replacement
1. Follow Steps 1-6 from the "Fuel Filter / Water Separator Draining" procedure. 2. Unscrew fuel filter / water separator from the filter mount using a commercially available filter wrench if it is not removable by hand. The filter has standard rotation threads. 3. Properly drain and dispose of fuel filter / water separator. 4. Lightly lubricate the rubber gasket of the new fuel filter / water separator with fresh engine oil. 5. Thread the new filter onto the filter mount until the gasket lightly touches the filter housing. Tighten filter 1/2-3/4 of a turn after initial contact of the rubber gasket to the filter mount. IMPORTANT: Be sure that the drain valve on the bottom of the filter is snug and did not loosen up during filter installation. 6. Clean up any excess fuel properly. 7. Reconnect the battery. 8. Turn key switch ON for 10-15 seconds to prime the fuel system. 9. Start engine and verify that no fuel leaks are present.
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5. Allow any contaminants to completely drain from the valve until clear fuel is visible. Firmly tighten or close the valve hand-tight only (small arrow). 6. Dispose of contaminants and excess fuel properly. 7. Reconnect the battery.
8. Turn key switch ON for 10-15 seconds to prime the fuel system. Doing so will force air out of the fuel system.
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NOTE: At times it may be necessary to open the bleed screw on the fuel filter housing until fuel comes from the valve with no air bubbles. 9. Start engine and verify that no fuel leaks are present.
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Fuel Pick-up Screen
4
The fuel pick-up screen (Item 3) is located in the fuel tank at the bottom of the fuel pick-up. The screen can be cleaned, but is not serviceable. The fuel pick-up / sender assembly (Item 4) must be replaced if required.
If the fuel pick-up screen requires service, reference Chapter 4 "Fuel System" for service procedure.
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Fuel Lines / Vent Line
1. Remove the drivers seat base and storage container. Tilt the rear cargo box. 2. Check the fuel supply lines (Item 1) and return line (Item 2) at the fuel tank and fuel pump for signs of wear, deterioration, damage or leakage. Replace line(s) if necessary. 1 3 1
AIR INTAKE SYSTEM
Engine Intake Pre-Filter Screen Service
It is recommended that the engine intake pre-filter be inspected daily. The filter should be inspected using the following procedure:
2. Press in (towards the front of the unit) on intake prefilter tab (Item 2) to remove it. 1
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4. Check the fuel supply line (Item 4) and return line (Item 5) at the engine for signs of wear, deterioration, damage or leakage. Replace line(s) if necessary.
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4 4. If any damage is found, replace the pre-filter assembly.
5. Be sure fuel lines and vent line are routed and retained properly. IMPORTANT: Make sure lines are not kinked or pinched.
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3. Check the fuel tank vent line (Item 3) for signs of wear, deterioration, damage or leakage. Replace vent line every two years.
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3. Inspect the pre-filter. If necessary, clean with soapy water and dry with low pressure compressed air.
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1. The engine intake pre-filter (Item 1) is located just behind the driver hip bolster on the left side of the vehicle.
MAINTENANCE
Air Filter Service
Inspect the air filter at the intervals outlined in the Periodic Maintenance Chart. In extremely dusty conditions, air filter replacement will be required more often. 1. Tilt the rear cargo box to access the airbox. 2. Release the (2) airbox cover latches (Item 3) and remove the cover (Item 4). 7. Install the airbox cover and engage the 2 clips onto the airbox.
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5
4. Inspect the air filter and replace if necessary.
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IMPORTANT: If the filter has been soaked with fuel or oil it must be replaced. DO NOT attempt to clean the air filter. If cleaning is required, replace the filter. 5. Inspect the airbox for oil or water deposits. Wipe away any deposits with a clean shop towel. 6. Reinstall the air filter into the airbox housing. Be sure the filter fits tightly in the air box.
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3. Remove the air filter assembly (Item 5) by using a pulling/twisting motion. Be sure not to damage the filter element if you plan to reinstall it.
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NOTE: Be sure airbox cover "TOP" is positioned at the top to allow the drain valve (Item 6) to function properly.
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Air Intake Exploded View
Mount Bracket 8 ft-lbs (11 Nm)
8 ft-lbs (11 Nm)
Airbox Lid
Main Airbox
Valve Air Filter
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Intake Duct Boot
35 in-lbs (4 Nm)
Intake Duct
Plug
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35 in-lbs (4 Nm)
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Intake Hose
8 ft-lbs (11 Nm) Drain
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To Engine Intake Hose
48 in-lbs (5.4 Nm)
Clamp Intake Resonator Box
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Intake Fender 24 in-lbs (2.7 Nm) Boot 35 in-lbs (4 Nm) 35 in-lbs (4 Nm)
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ENGINE
Engine Oil Recommendations
IMPORTANT: Use of a non-recommended engine oil may cause serious engine damage. Polaris recommends the use of Polaris Diesel Oil (SAE CI4) for this vehicle. Always use the correct viscosity grade based on the ambient temperature expected during operation. See the chart below. Oil Viscosity / Ambient Air Temperature Chart
Engine Oil Level
Always check the engine oil level daily. Change the engine oil at the intervals outlined in the Periodic Maintenance Chart. Access the oil dipstick and oil fill cap by tilting the rear cargo box.
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SAE 10W-30 SAE 15W-40 Synthetic 5W-40 -25°F (-31°C) +5°F (-15°C) +80°F +104°F (+27°C) (+40°C)
Always remove all cargo from the cargo box before lifting the box to access the engine. 2. Position the vehicle on a level surface and place the transmission in PARK.
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Recommended Engine Oil:
Polaris Synthetic Diesel Engine Oil 5W-40 All-Season (PN 2879832) Ambient Temp Range: -25° F to 104° F Polaris Diesel Engine Oil 15W-40 Summer (PN 2878473) Ambient Temp Range: +5° F to 104° F Polaris Diesel Engine Oil 10W-30 Winter (PN 2878474) Ambient Temp Range: -25° F to 80° F
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3. Stop the engine and allow the oil level to settle for 3 minutes before removing the dipstick.
IMPORTANT: Do not check oil immediately after engine operation. 4. Tilt the rear cargo box to access the dipstick. 5. Remove the dipstick (Item 1) and wipe dry with a clean cloth. 1
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Diesel Engine Oil Filter (3070131) Capacity: 2.75 Quarts (2.6 L) 6. Reinstall the dipstick and ensure it seats completely. NOTE: Make certain the dipstick is inserted all the way into the dipstick tube to keep the depth of the dipstick consistent. 7. Remove the dipstick and check the oil level.
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1. Remove all cargo from the cargo box.
MAINTENANCE
NOTE: A rising oil level between checks during cold weather operation can indicate contaminants such as fuel or moisture collecting in the crankcase. If the oil level is over the upper mark, change the oil immediately. 8. Add the recommended oil as necessary to bring the oil level within the SAFE range on dipstick. Do not overfill.
Engine Oil and Filter Change
Always change engine oil and filter at the intervals outlined in the Periodic Maintenance Chart. Always change the oil filter whenever changing the engine oil. Access the oil dipstick and oil fill cap by tilting the rear cargo box. The engine oil drain plug is located on the bottom of the engine crankcase. Access the drain plug through the skid plate access hole located directly under the crankcase. It is important to use oil viscosities that will work efficiently in the ambient temperature the vehicle will be operated in for extended periods. Reference the "Engine Oil Recommendations" section for proper engine oil usage.
Maintain Oil Level In SAFE Range DO NOT Overfill the Engine
NOTE: Use only the recommended engine oil (see "Engine Oil Recommendations"). 9. Add engine oil through the oil fill cap (Item 2) located on top of the valve cover. 2
2. Stop the engine, position the vehicle on a level surface and place the transmission in PARK. 3. Clean the area around the crankcase drain plug.
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10. When finished, reinstall the oil fill cap and oil dipstick.
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4. Place a drain pan under the engine crankcase and remove the drain plug (Item 3). Allow the engine oil to drain completely.
5. Clean sealing area of drain plug and oil pan. Replace the sealing washer on drain plug. NOTE: The sealing surface on the drain plug should be clean and free of burrs, nicks or scratches.
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1. Run the engine for two to three minutes or until warmed up.
Use caution when performing this procedure. Do not allow hot engine oil to come into contact with skin, as serious burns may result.
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6. Remove all cargo from the cargo box. 12. Install and tighten the oil filter to specification.
CAUTION
Always remove all cargo from the cargo box before lifting the box to access the engine. 7. Tilt the cargo box up. 8. Remove the oil fill cap (Item 4) to vent the engine crankcase and allow the oil to drain more easily. 4
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Oil Filter: Turn by hand until filter gasket contacts sealing surface, then turn an additional 1/2 - 3/4 turn. 13. Reinstall the engine crankcase drain plug. Torque drain plug to specification.
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9. Place shop towels beneath oil filter (Item 5). Using Oil Filter Wrench (PU-50105), turn the filter counterclockwise to remove it.
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Oil Filter Wrench: PU-50105: 2.5" (64 mm)
10. Using a clean dry cloth, clean the filter sealing surface on the engine crankcase. 11. Lubricate the gasket on the new oil filter with a film of fresh engine oil. Check to make sure the gasket is in good condition.
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15. Install the oil fill cap.
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Engine Crankcase Drain Plug: 25 ft-lbs (34 Nm)
14. Fill the engine with 2.75 quarts (2.6 L) of the recommended engine oil (see "Engine Oil Recommendations").
Recommended Engine Oil:
Polaris Synthetic Diesel Engine Oil 5W-40 All-Season (PN 2879832) Ambient Temp Range: -25° F to 104° F Polaris Diesel Engine Oil 15W-40 Summer (PN 2878473) Ambient Temp Range: +5° F to 104° F Polaris Diesel Engine Oil 10W-30 Winter (PN 2878474) Ambient Temp Range: -25° F to 80° F Diesel Engine Oil Filter (3070131) Capacity: 2.75 Quarts (2.6 L)
16. Verify the transmission is still in PARK and start the engine. Allow it to idle for one to two minutes. 17. Stop the engine, inspect for leaks and allow the oil level to settle for 3 minutes before removing the dipstick. IMPORTANT: Do not check oil immediately after engine operation.
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18. Remove the dipstick (Item 6) and wipe dry with a clean cloth. 6
Engine Crankcase Breather Inspection
Proper operation of the crankcase breather system is required to maintain the emission requirements of the engine. The EPA / ARB requires that the crankcase breather system is inspected every 1500 hours. The Yanmar TNM engine uses a crankcase breather system that has a spring-backed diaphragm (Item 1) in the valve cover (Item 2). When the crankcase pressure reaches a predetermined value, the diaphragm opens a passage that allows crankcase fumes to be routed to the intake manifold.
19. Reinstall the dipstick and ensure it seats completely. NOTE: Make certain the dipstick is inserted all the way into the dipstick tube to keep the depth of the dipstick consistent. 20. Remove the dipstick and check the oil level. 21. Add oil as necessary to bring the oil level within the SAFE range on dipstick. Do not overfill.
Maintain Oil Level In SAFE Range DO NOT Overfill the Engine
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To inspect the diaphragm and spring (Item 3): 1. Remove the bolts retaining the diaphragm cover (Item 4). 2. Remove the diaphragm cover, spring, diaphragm plate (Item 5) and diaphragm. 3. Inspect the diaphragm for tears. Inspect the spring for distortion. Replace components if necessary. 4. Reinstall the diaphragm, diaphragm plate, spring and diaphragm cover. Tighten the diaphragm bolts. IMPORTANT: Failure of the diaphragm and / or spring will cause the loss of pressure control and allow an excessive amount of crankcase fumes to be routed to the intake manifold. This could result in excessive deposits in the intake system, high engine exhaust smoke levels, excessive engine oil consumption and / or engine run-on due to the burning of the engine oil.
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MAINTENANCE
Engine Compression Test
NOTE: This engine does NOT have decompression components. Compression readings will vary in proportion to cranking speed during the test. Compression pressure drop is one of major causes of increasing blow-by gas or starting failure. The compression pressure is affected by the following factors: · Degree of clearance between piston and cylinder · Degree of clearance at intake / exhaust valve seat · Gas leak from nozzle gasket or cylinder head gasket The pressure will drop due to increased parts wear. Pressure drop reduces the durability of the engine. A pressure drop may also be caused by scratched cylinder or piston by dust entrance from the dirty air cleaner element or worn or broken piston ring. Measure the compression pressure to determine the condition of the engine. 1. Warm up the engine. 2. Stop the engine. Remove the high-pressure fuel injection lines (Item 1) as an assembly from the engine (see "Removing the High-Pressure Injection Lines" in Chapter 4). 1 3. Remove the fuel injector (Item 2) from the cylinder to be measured (see "Removing the Fuel Injectors" in Chapter 4).
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IMPORTANT: Remove and install the high-pressure fuel injection lines as an assembly whenever possible. Disassembling the high-pressure fuel injection lines from the retainers or bending any of the fuel lines will make it difficult to reinstall the fuel lines. 5. Crank the engine for a few seconds with the fuel solenoid disconnected (no injection state) before installing the compression gauge and adapter, this will expel any residual fuel from the cylinder.
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4. Disconnect the fuel solenoid at the connector (Item 3). 3
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6. Install one injector gasket at the tip end of the compression gauge adapter (PU-50529). Install the compression gauge and the compression gauge adapter at the cylinder to be measured. PU-50529
Alternator / Fan / Water Pump Drive Belt
The V-belt will slip if it does not have the proper tension. This will prevent the alternator from generating sufficient power. Also, the engine will overheat due to the engine coolant pump pulley slipping. IMPORTANT: NEVER get any oil on the belt. Oil on the belt causes slipping and stretching. Replace the belt if damaged.
1. Position the vehicle on a level surface, place the transmission in PARK and stop the engine. 2. Tilt the rear cargo box.
Diesel Compression Tester: PU-50529 7. Crank the engine until the compression gauge reading is stabilized. Cylinder Compression Standard: 470 ± 15 PSI Limit: 370 ± 15 PSI
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3. Remove the three bolts (Item 1) and belt shield (Item 2) from the vehicle. 1
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8. After performing the compression check, remove the compression gauge and compression gauge adapter from the cylinder. Reinstall the fuel injector, highpressure fuel injection lines and reconnect the fuel solenoid (see Chapter 4 "Fuel System").
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4. Check the V-belt for cracks, oil or wear. If any of these conditions exist, replace the V-belt. IMPORTANT: ALWAYS use the specified V-belt. Using a non-specified V-belt will cause inadequate charging and shorten the belt life.
9. Prime the fuel system. Check for leaks. Test the engine.
Engine Leakdown Test
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A cylinder leakdown test is the best indication of engine condition. Follow the manufacturer's instructions to perform a cylinder leak-down test. Cylinder Leakdown Service Limit 15%
(Inspect for cause if test exceeds 15%)
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Check and adjust the V-belt tension (deflection) as follows:
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5. At the mid span location shown, press down on the Vbelt with approximately 20 lbs. (89 N) of applied force to check the belt deflection. 8. Torque the adjustment bolt (Item 4) to specification.
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Upper Alternator Adjustment Bolt: 28 ft-lbs (38 Nm)
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Alternator/Fan/Water Pump Belt Tension Applied Force: 20 lbs. (89 N) Belt Defection: 1/4 - 3/8 in. (7-10 mm) 6. If adjustment is necessary, loosen the mounting bolt (Item 3) and adjustment bolt (Item 4). Move the top of the alternator (Item 5) with a pry bar to tighten the Vbelt to the desired tension and then tighten the adjustment bolt (Item 4). 4 5
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7. Torque the mounting bolt (Item 3) to specification.
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Lower Alternator Mounting Bolt: 15 ft-lbs (20 Nm)
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10. After adjusting, run the engine for 5 minutes or more. Check the tension again referencing the previous specification.
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9. Install the belt shield and three retaining bolts.
MAINTENANCE
Valve Clearance Inspection / Adjustment
IMPORTANT: Valve clearance inspection should be performed on a cold engine, at room temperature. NOTE: When a piston is at TDC of the compression stroke, both rocker arms will be loose and the cylinder TDC mark on the flywheel will be visible in the timing port (Item 1). 4. If adjustment is required, proceed to the next step. NOTE: No valve clearance when the piston is at TDC of the compression stroke indicates extreme wear or damage to the cylinder head or valves. 5. Loosen the valve adjusting screw lock nut (Item 2) and valve adjusting screw (Item 3) on the rocker arm. Check the valve for inclination of the valve cap, entrance of dirt or wear.
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1. Remove the intake manifold / valve cover.
2. Bring No. 1 piston to TDC of the compression stroke.
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3. Insert a feeler gauge between rocker arm and valve cap and record the measured valve clearance.
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= In. / mm.
Valve Clearance 0.006 - 0.010" (0.15 - 0.25 mm)
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NOTE: The No. 1 piston is on the flywheel end of the engine. The firing order is 1-3-2.
6. Insert a feeler gauge of the correct thickness between rocker arm and valve cap. Turn the valve adjustment screw to adjust the valve clearance so there is a slight "drag" on the feeler gauge when sliding it between the rocker arm and valve cap. Tighten the valve adjusting screw lock nut. Recheck the clearance. NOTE: Valve clearance will decrease slightly when the lock nut is tightened. Initial clearance adjustment should be made slightly on the "loose" side before tightening the lock nut. 7. Apply oil to the contact surface between adjusting screw and push rod. 8. Rotate the crankshaft and measure the next cylinder. Continue until all valves are adjusted.
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Exhaust Clean Out Plug WARNING
Failure to heed these warnings could result in serious personal injury or death. Do not perform service on the spark arrester while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding. Remove any combustible materials from the area. Wear eye protection and gloves. Do not stand behind or in front of the vehicle while purging the exhaust system. Never run the engine in an enclosed area. Exhaust can cause loss of consciousness or death in a very short time. Never go under the vehicle while it's inclined. Use the following procedure to periodically purge accumulated carbon from the exhaust pipe: 4. If carbon is expelled, partially cover the exhaust outlet and rap on the pipe around the clean-out plug while revving the engine several more times. 5. If particles are still suspected to be in the silencer, elevate the rear of the vehicle one foot higher than the front. Block the wheels.
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8. Reinstall the clean-out plug (Item 1).
1. Remove the exhaust clean-out plug (Item 1) located on the bottom of the silencer.
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2. Place the transmission in Park. Start the engine. 3. Press the brake pedal and then press the travel control pedal to increase engine RPM. Purge accumulated carbon from the system by momentarily revving the engine several times.
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7. Stop the engine. Allow the exhaust silencer to cool.
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6. Repeat steps 3 and 4 until no more particles are expelled when the engine is revved.
MAINTENANCE
TRANSMISSION AND FRONT GEARCASE
Specification Chart
Gearcase Transmission Front Gearcase Lubricant AGL Plus Gearcase Lubricant Demand Drive Plus Capacity 41 oz. (1200 ml) 6.75 oz. (200 ml) Fill / Drain Plug Torque 10-14 ft-lbs. (14-19 Nm) 8-10 ft-lbs. (11-14 Nm)
Shift cable adjustment may be necessary if symptoms include: · No gear position or AWD display on instrument cluster · Ratcheting noise on deceleration · Inability to engage into a gear · Excessive gear lash (noise) · Gear selector moving out of desired range 1. Locate the shift cable (Item 1) attached to the mount bracket (Item 2) and transmission in the right rear wheel well area.
3. If shift cable adjustment is required, loosen the lower jam nut (Item 5) and pull the cable out of the mount bracket to move the upper jam nut (Item 6). 6
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2. Inspect shift cable dust boot (Item 3) and the clevis pin and pivot bushings (Item 4). Replace if worn or damaged. 4 3
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4. Adjust the shift cable so there is the same amount of cable travel when shifting slightly past HIGH gear and PARK.
5. Thread the upper or lower jam nut as required to obtain proper cable adjustment. NOTE: This procedure may require a few attempts to obtain the proper adjustment. 6. Once the proper adjustment is obtained, place the shift cable and upper jam nut into the mount. Tighten the lower jam nut (Item 5) against the mount. 7. Start engine and shift through all gears to ensure the shift cable is properly adjusted. If transmission still ratchets after cable adjustment, the transmission will require service.
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Shift Cable Inspection / Adjustment
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Transmission Lubrication
NOTE: It is important to follow the transmission maintenance intervals described in the Periodic Maintenance Chart. The transmission lubricant level should be checked and changed in accordance with the maintenance schedule. · Be sure vehicle is positioned on a level surface when checking or changing the lubricant. · Check vent hose to be sure it is routed properly and unobstructed. Transmission Lubricant Level Check The fill plug is located on the right rear portion of the transmission gearcase. Access the fill plug through the right rear wheel well of the vehicle. Maintain lubricant level even with the bottom of the fill plug hole. 1. Position vehicle on a level surface. 2. Remove the fill plug and check the lubricant level. Transmission Lubricant Change The drain plug is located on the bottom of the transmission gearcase. Access the drain plug through the drain hole in the skid plate. 1. Remove the fill plug (refer to "Transmission Lubricant Level Check").
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3. If lubricant level is not even with bottom threads, add recommended lubricant as needed. Do not overfill. 4. Reinstall the fill plug and torque to specification.
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4. Clean the drain plug magnetic surface. Reinstall drain plug with a new O-ring and torque to specification. 5. Add the recommended amount of lubricant through the fill plug hole. Maintain the lubricant level at the bottom of the fill plug hole when filling the transmission. Do not overfill.
Recommended Transmission Lubricant: AGL Plus Gearcase Lubricant (PN 2878068) (Quart) Capacity: 41 oz. (1200 ml) 6. Reinstall fill plug with a new O-ring and torque to specification.
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Fill / Drain Plug: 10-14 ft-lbs (14-19 Nm)
Fill / Drain Plug: 10-14 ft-lbs (14-19 Nm) 7. Check for leaks. Dispose of used lubricant properly.
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3. Remove drain plug and allow lubricant to drain completely.
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2. Place a drain pan under the transmission drain plug.
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Front Gearcase Lubrication
NOTE: It is important to follow the front gearcase maintenance intervals described in the Periodic Maintenance Chart. The front gearcase fluid level should be checked and changed in accordance with the maintenance schedule. 3. Remove the fill plug and check the fluid level.
Front Gearcase Fluid Level Check The fill plug is located on the bottom right side of the front gearcase. Access the fill plug through the right front wheel well. Maintain fluid level even with the bottom of the fill plug hole. 1. Position vehicle on a level surface. 2. Locate the gearcase fill plug (Item 1) through the right front wheel well area.
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4. If fluid level is not even with the bottom threads, add the recommended fluid as needed. Do not overfill. 5. Reinstall the fill plug and torque to specification.
Front Gearcase Fluid Change: The drain plug is located on the bottom of the front gearcase. Access the drain plug through the access hole in the frame underneath the front gearcase. 1. Remove the fill plug (refer to "Front Gearcase Fluid Level Check"). 2. Place a drain pan under the front gearcase drain plug.
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Fill / Drain Plug: 8-10 ft-lbs (11-14 Nm)
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· Check vent hose to be sure it is routed properly and unobstructed.
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· Be sure vehicle is positioned on a level surface when checking or changing the fluid.
MAINTENANCE
3. Remove the drain plug and allow fluid to drain completely.
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5. Reinstall drain plug with a new O-ring and torque to specification.
6. Add the recommended amount of fluid through the fill hole. Maintain the fluid level even with the bottom threads of the fill plug hole.
Recommended Front Gearcase Fluid: Polaris Demand Drive Plus (PN 2877922) (Quart)
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7. Reinstall fill plug with a new O-ring and torque to specification.
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Capacity: 6.75 oz. (200 ml)
8. Check for leaks. Dispose of used fluid properly.
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Fill / Drain Plug: 8-10 ft-lbs (11-14 Nm)
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4. Clean the drain plug magnetic surface.
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COOLING SYSTEM
Liquid Cooling System Overview
NOTE: Use ethylene