Brutus Service Manual

2013 - 2014 BRUTUS
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 January 2014 (PN 9925342)

Copyright 2014 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 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.
GENERAL INFORMATION
MAINTENANCE
ENGINE
FUEL SYSTEM
ENGINE COOLING SYSTEM
HVAC
BODY / CAB / FRAME
STEERING / SUSPENSION
TRANSMISSION
HYDROSTATIC DRIVE
10
FINAL DRIVE
11
PTO
12
HYDRAULICS
13
BRAKES
14
ELECTRICAL
15
TRADEMARKS
POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCT(S) 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
Hilliard, Trademark of the Hilliard Corporation
Warn, Trademark of Warn Industries
FOX, Registered Trademark of FOX RACING SHOX
RydeFX, Registered Trademark of ArvinMeritor
Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from
www.purepolaris.com or by contacting the nearest Polaris dealer.
GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
REPLACEMENT KEYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
VEHICLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
GENERAL : 2013 - 2014 BRUTUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
DETAILED: 2013 - 2014 BRUTUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
GENERAL: 2013 - 2014 BRUTUS HD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10
DETAILED: 2013 - 2014 BRUTUS HD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
GENERAL: 2013 - 2014 BRUTUS CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13
DETAILED: 2013 - 2014 BRUTUS CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14
GENERAL: 2013 - 2014 BRUTUS HDPTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.16
DETAILED: 2013 - 2014 BRUTUS HDPTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.17
FUEL INFORMATION, USAGE AND RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.19
FUEL INFORMATION / RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.19
BIO-DIESEL FUELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.19
B5 DIESEL FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.19
BIO-FUEL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.19
B6 TO B20 BIO-DIESEL FUEL BLEND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.20
ENGINE WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.20
COLD WEATHER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.20
BLOCK HEATER USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.20
COLD START GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.21
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.22
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.22
STANDARD BOLT TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.23
METRIC BOLT TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.23
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.24
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.24
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.25
1.1
9925342 - 2013 - 2014 BRUTUS Service Manual
Copyright 2014
GENERAL INFORMATION
VEHICLE IDENTIFICATION
Model Number Designation
Example: D131D9JDJ
GROUP
MODEL
YEAR
CHASSIS
DRIVELINE
ENGINE
1st digit
2/3rd
digit
4th digit*
5th digit*
6th digit*
11
12
13
14
C = Sportsman
6x6
D = Sportsman
Tour
E = Trail Boss
F = Sportsman
Youth
G = Sport
H = RANGER 6x6
J = RZR XP
K = Sport Youth
M = Sportsman
N = Trail Blazer
P = Phoenix
R = RANGER
Midsize
S = RZR
T = Sportsman X2
U = RANGER
Fullsize
V = RZR
W = Multi-pass
RGR
X = Multi-pass
RZR
Z = Sportsman XP
1 = BRUTUS (No
Cab)
2 = BRUTUS (w/
Cab)
A = ATV
D=
BRUTUS
R=
RANGER
A = 2x4 Chain
B = 2x4 Shaft
C = 4x4 AC Drive
D = 4x4 Shaft, DeDion
E = 4x4 Shaft / IRS
G = 4x4 Chain rear /
shaft front
H = 4x4 Shaft / IRS
J = 2x4 Swing arm
Manual
L = DeDion w/Non
Powered
Attach - Lifter
M = DeDion w/
Powered
Attach - Mower
N = 4x4 Shaft ADC
P = 2x4 / IRS Manual
R = 6x6 Shaft / IRS
T = 4x4 Shaft / Trailing
Arm
X = 4x4 Shaft EBS
7th digit*
CATEGORY
OPTION
REGION
8th digit
9th
digit**
10th
digit
Displacement in cc
divided by 10 and
rounded to two digits
(i.e. 50 = 498cc)
-----------For electric vehicles
08 = 48 Volt
12 = 72 Volt
- - OR - -
5 = 550
6 = 570
7 = 760
8 = 850
9 = 875
or 904
E = EPS
D=
Diesel
F=D+E
G=
Gauge
Option
#1
J=F+G
A = ORV
D = Diesel
E = EU Onroad
F = INTL
G = EV
L = LSV
M = Military
S=
Scandinavian
V = EU Onroad
* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively
** = 9th digit will be used on color/featured versions of models (not including the base)
First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN.
1.2
Copyright 2014
C=
Calif.
GENERAL INFORMATION
Engine Designation Number
3TNM72-APB1 3-Cylinder, Liquid Cooled, Diesel, Electric Start
Vehicle Identification Number (VIN) Designation

Example: 4XA1D9JD3D2000000
Vehicle Descriptors
World Mfg. ID
Vehicle Identifiers
Chassis
Driveline
Engine
Size
Engine
Modifier
Category
Check
Digit
Model
Year
*
Mfg.
Location
Individual Serial No.
10
11
12
13
14
15
16
17
* Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014
1.3
Copyright 2014
GENERAL INFORMATION
Vehicle and Engine Serial Number Locations
Whenever corresponding about a Polaris BRUTUS utility vehicle, be sure to refer to the vehicle identification number
(VIN) and the engine model and serial number.
The VIN can be found stamped on the lower frame rail on the front LH side of the vehicle.
The engine model and serial number can be found on a nameplate located on top of the engine. These numbers are
also stamped on flat pads on the left side of the crankcase.
1.4
Copyright 2014
GENERAL INFORMATION
VEHICLE INFORMATION
Publication Numbers
MODEL
MODEL NO.
OWNERS
MANUAL
PARTS MANUAL
2013-2014 BRUTUS
2013 - D131D9JDJ, 2014 D141D9JDJ
9924341
9924343
2013-2014 BRUTUS HD
2013 - D131L9JDJ, 2014 D141L9JDJ
9924341
9924343
2013-2014 BRUTUS CAB
2013 - D132D9JDJ, 2014 D142D9JDJ
9924341
9924343
2013-2014 BRUTUS HDPTO
2013 - D132M9JDJ, 2014 D142M9JDJ
9924341
9924343
NOTE: When ordering service parts be sure to use the correct parts manual.
Polaris factory publications can be found at www.polarisindustries.com or purchased from www.purepolaris.
com.
Replacement Keys
Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the
original key and refer to the chart to the right for the proper part number.
Series#
Part Number
20
4010278
21
4010278
22
4010321
23
4010321
27
4010321
28
4010321
31
4110141
32
4110148
67
4010278
68
4010278
1.5
Copyright 2014
GENERAL INFORMATION
SPECIAL TOOLS
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while
other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools
when servicing any Polaris product. Dealers may order special tools through Polaris official tool supplier, Bosch
Automotive Service Solutions, by phone at 1-800-345-2233.
or on-line at http://polaris.service-solutions.com/.
1.6
Copyright 2014
GENERAL INFORMATION
VEHICLE SPECIFICATIONS
CATEGORY
DIMENSION / CAPACITY
GENERAL : 2013 - 2014 BRUTUS
Hitch Tongue Capacity
150 lbs. / 68 kg
MODEL NUMBER 2013: D131D9JDJ
Rated Vehicle Payload

(includes weight of
operator, passenger
and cargo)
1750 lbs. / 794 kg
Rated Vehicle Capacity

(GVWR)
3450 lbs. / 1565 kg
Hitch Towing Capacity
2000 lbs. / 907 kg

ENGINE NUMBER: 3TNM72-APB
CATEGORY
Length
123.5 in. / 310.4 cm
Width (tires)
63.2 in. / 160.5 cm
Height
73 in. / 185.4 cm
Wheel Base
84 in. / 213.4 cm
Ground Clearance
10 in. / 25.4 cm
Min. Turning Radius

(Unlocked Turf Mode)
90 in. / 229 cm
Cargo Box Dimensions

(inside dimensions)
43.5 x 54 x 11.5 in.

(108 x 137 x 29 cm)
Dry Weight
1643 lbs. / 745.3 kg
Curb Weight
1741 lbs. / 790 kg
Operator / Passenger
Capacity
500 lbs. / 227 kg
Cargo Box Capacity
1250 lbs. / 567 kg
1.7
Copyright 2014
GENERAL INFORMATION
DETAILED: 2013 - 2014 BRUTUS
STD MODELS: 2013 - D131D9JDJ
Fuel Pump Pressure
1-5 psi (7-34 kPa)
Fuel Tank Capacity
10 gal. (37.8 L)
Fuel Requirement
Low Sulfur or Ultra Low

Sulfur
STD MODELS: 2014 - D141D9JDJ

Engine
Hydrostatic Drive / Hydraulics / Drivetrain
Platform
Yanmar 3-Cylinder,
Liquid Cooled, Diesel
Engine Number
3TNM72-APB1
Engine Displacement
Transmission Type
Hydrostatic Driven
Shift Type
In Line Shift - H / L / N / P
904 cc
Travel Control
Pedal Drive Hydrostatic

Drive Forward / Reverse
Number of Cylinders
Hydraulic Pump
Engine Driven Gear Type
Bore & Stroke
72 x 74 mm
Compression Ratio
23.5:1
Hydraulic Pump
Capacity
7.6 gpm (28.8 L) @ 3600

RPM
Compression Pressure
470 15 PSI
Steering Flow
2.2 gpm (8.3 L) @ 3600

RPM
High Idle
3700 100 RPM
Steering Relief Valve
850 psi (58.6 bar)
Low Idle
1350 100 RPM
Charge Relief Valve
87 psi (6 bar)
Lubrication
Pressurized Wet Sump

Hydraulic Filtration
Full flow with 50 psi (3.4 bar)

cold weather bypass valve
Hydraulic Fluid
Capacity (Reservoir
Only)
2.75 qts. (2.6 L)
Hydraulic Fluid
Capacity (Full System)
7.2 qts. (6.8 L)
Front Gearcase
Lubricant
Requirements
Demand Drive Fluid

6.75 oz. (200 ml)
Transmission
Lubricant
Requirements
AGL Gearcase Lubricant

41 oz. (1200 ml)
Oil Requirements
Polaris DIESEL Oil
Oil Capacity
2.75 qts. (2.6 L)
Coolant Capacity
6.6 qts. (6.2 L)
Overheat Warning
Instrument Cluster Indicator
Exhaust System
Canister Style
Starting Aid
Glow Plugs / Opt. Block

Heater
Fuel System
Fuel Injection Unit
(non-serviceable)
Yanmar MC Fuel Injection

Pump Indirect Injection
Fuel Transfer System
Electronic Fuel Pump (inline)
1.8
Copyright 2014
GENERAL INFORMATION
Electrical
Steering Type
Hydraulic Power Steering
Toe Out
1/8 - 1/4 in. (3.2 - 6.35 mm)
Front Suspension
Dual A-arm
Front Travel
6 in. (15.2 cm)
Alternator Rated
Output
90A / 1215 Watts @ 3000

RPM
Headlights
Halogen: Low 55W / High

60W x 2
Tail Lights
L.E.D. (10): 0.2 Watts x 2
Rear Suspension
Multi-Link Coil Over De-Dion
Brake Lights
L.E.D. (10): 2.9 Watts x 2
Rear Travel
6 in. (15.2 cm)
Starting System
Electric Start
Cam Adjustment
Battery
Flooded-Filled / 32 Amp Hr.

575 CCA / 12 Volt
Shock Preload
Adjustment
DC Outlets
(2) - Standard 12 Volt
Relays
Located in Fuse/Relay
Boxes:
Chassis - ECM - Fuel Hold Fuel Pull - Glow Plug Starter
Externally Mounted Relays:
- Rear Differential - Cooling
Fan
Circuit Breakers
Fuses
40 Amp:
- Cooling Fan Motor
20 Amp:
- Accessory - Drive - ECU Fuel Hold Solenoid - Hydro Lights
30 Amp:
- Chassis - Fuel Pull
Solenoid - Glow Plug
Wheels / Brakes
Front Wheel Size /
Type
12 x 6 / Steel
Rear Wheel Size /

Type
12 x 8 / Steel
Front Tire
Make / Model / Size
Carlisle / AT489 / 25 x 10
R12
Rear Tire
Make / Model / Size
Carlisle / AT489 / 25 x 11
R12
Front: 10 psi (69 kPa)
Tire Air Pressure
Rear: 20 psi (138 kPa)
Brake System
4 Wheel Hydraulic Disc
Brake Fluid
DOT 4
Steering / Suspension
1.9
Copyright 2014
GENERAL INFORMATION
GENERAL: 2013 - 2014 BRUTUS HD
CATEGORY
2013 MODEL NUMBER: D131L9JDJ

2014 MODEL NUMBER: D141L9JDJ
Attachment Arm Rated

Operating Capacity
500 lbs. / 227 kg
150 lbs. / 68 kg

(includes weight of
operator, passenger,
cargo and attachment)
2000 lbs. / 907 kg

(GVWR)
4000 lbs. / 1814 kg
2000 lbs. / 907 kg
CATEGORY
Length (with bucket)
157.9 in. / 401 cm
Width (tires)
63.2 in. / 160.5 cm
Height
73 in. / 185.4 cm
Wheel Base
84 in. / 213.4 cm
Ground Clearance
10 in. / 25.4 cm
Min. Turning Radius

90 in. / 229 cm

(inside dimensions)
43.5 x 54 x 11.5 in.

(108 x 137 x 29 cm)
Dry Weight
1830 lbs. / 830.1 kg
Curb Weight
1919 lbs. / 870 kg
Capacity
500 lbs. / 227 kg
Cargo Box Capacity
1250 lbs. / 567 kg
1.10
Copyright 2014
GENERAL INFORMATION
DETAILED: 2013 - 2014 BRUTUS HD
Travel Control

2014 STD MODELS: D141L9JDJ
Hydraulic Pump
Hydraulic Pump
Capacity
7.6 gpm (28.8 L) @ 3600

RPM
Steering Flow
2.2 gpm (8.3 L) @ 3600

RPM
850 psi (58.6 bar)
Charge Relief Valve
87 psi (6 bar)
2013 STD MODELS: D131L9JDJ
Engine
Platform
Yanmar 3-Cylinder,
Engine Number
3TNM72-APB
Engine Displacement
904 cc
Number of Cylinders

Bore & Stroke
72 x 74 mm
Compression Ratio
23.5:1
Hydraulic Fluid
Capacity (Reservoir
Only)
2.75 qts. (2.6 L)
470 15 PSI
High Idle
8.4 qts. (7.9 L)
3700 100 RPM
Hydraulic Fluid
Low Idle
1350 100 RPM
Lubrication
Front Gearcase
Lubricant
Requirements
Demand Drive Fluid

6.75 oz. (200 ml)
Oil Requirements
Polaris DIESEL Oil
Oil Capacity
2.75 qts. (2.6 L)
Transmission
Lubricant
Requirements

41 oz. (1200 ml)
Coolant Capacity
6.6 qts. (6.2 L)
Overheat Warning
Exhaust System
Canister Style
Alternator Rated
Output
90A / 1215 Watts @ 3000

RPM
Starting Aid

Heater
Headlights

60W x 2
Tail Lights
L.E.D. (10): 0.2 Watts x 2
Brake Lights
L.E.D. (10): 2.9 Watts x 2
Starting System
Electric Start
Battery

575 CCA / 12 Volt
DC Outlets
Relays
Boxes:
Chassis - ECM - Fuel Hold Fuel Pull - Glow Plug Starter - Tilt Lock
Fan - Cargo Box Lift
Circuit Breakers
20 Amp:
- Cargo Box Lift
Fuel System
Fuel Injection Unit
(non-serviceable)

Fuel Pump Pressure
1-5 psi (7-34 kPa)
Fuel Tank Capacity
10 gal. (37.8 L)
Fuel Requirement

Sulfur

Transmission Type
Hydrostatic Driven
Shift Type
Electrical
1.11
Copyright 2014
GENERAL INFORMATION
40 Amp:
- Cooling Fan Motor
Fuses
20 Amp:
- Accessory - Drive - ECU Fuel Hold Solenoid - Hydro Lights
30 Amp:
Solenoid - Glow Plug
Steering Type
Wheels / Brakes
Front Wheel Size /
Type
12 x 6 / Steel
Rear Wheel Size /

Type
12 x 8 / Steel
Front Tire
Make / Model / Size
Carlisle / All Trail II / 25 x 9

R12
Rear Tire
Make / Model / Size

R12

Tire Air Pressure
Toe Out
1/8 - 1/4 in. (3.2 - 6.35 mm)
Front Suspension
Dual A-arm
Brake System
Front Travel
6 in. (15.2 cm)
Brake Fluid
DOT 4
Rear Suspension
Rear Travel
6 in. (15.2 cm)
Shock Preload
Adjustment
Cam Adjustment
1.12
Copyright 2014
GENERAL INFORMATION
GENERAL: 2013 - 2014 BRUTUS CAB
CATEGORY
150 lbs. / 68 kg

(includes weight of
1750 lbs. / 794 kg
4000 lbs. / 1814 kg

2000 lbs. / 907 kg

ENGINE NUMBER: 3TNM72APB
CATEGORY
Length
123.5 in. / 310.4 cm
Width (tires)
63.2 in. / 160.5 cm

(GVWR)
Height
74 in. / 188 cm
Wheel Base
84 in. / 213.4 cm
Ground Clearance
7 in. / 17.8 cm
Min. Turning Radius

90 in. / 229 cm

(inside dimensions)
43.5 x 54 x 11.5 in.

(108 x 137 x 29 cm)
Dry Weight
1915 lbs. / 869 kg
Curb Weight
2007 lbs. / 910 kg
Capacity
500 lbs. / 227 kg
Cargo Box Capacity
1250 lbs. / 567 kg
1.13
Copyright 2014
GENERAL INFORMATION
DETAILED: 2013 - 2014 BRUTUS CAB
Engine
Platform
Yanmar 3-Cylinder,
Engine Number
3TNM72-APB
Engine Displacement
904 cc
Number of Cylinders
Bore & Stroke
72 x 74 mm
Compression Ratio
23.5:1
470 15 PSI
High Idle
3700 100 RPM
Low Idle
1350 100 RPM
Lubrication
Oil Requirements
Polaris DIESEL Oil
Oil Capacity
2.75 qts. (2.6 L)
Coolant Capacity
6.9 qts. (6.5 L)
Overheat Warning
Exhaust System
Canister Style
Starting Aid

Heater
Hydraulic Pump
Capacity
7.6 gpm (28.8 L) @ 3600

RPM
Steering Flow
2.2 gpm (8.3 L) @ 3600

RPM
850 psi (58.6 bar)
Charge Relief Valve
87 psi (6 bar)

Hydraulic Fluid
Capacity (Reservoir
Only)
2.75 qts. (2.6 L)
Hydraulic Fluid
8.4 qts. (7.9 L)
Front Gearcase
Lubricant
Requirements
Demand Drive Fluid

6.75 oz. (200 ml)
Transmission
Lubricant
Requirements

41 oz. (1200 ml)
PTO
Lubricant
Requirements
PTO Gearbox Oil

6 oz. (177 ml)
Electrical
Alternator Rated
Output
90A / 1215 Watts @ 3000

RPM
Headlights

60W x 2
Fuel System
Fuel Injection Unit
(non-serviceable)

Tail Lights
L.E.D. (10): 0.2 Watts x 2
Brake Lights
L.E.D. (10): 2.9 Watts x 2
Fuel Pump Pressure
1-5 psi (7-34 kPa)
Starting System
Electric Start
Fuel Tank Capacity
10 gal. (37.8 L)
Battery

575 CCA / 12 Volt
Fuel Requirement

Sulfur
DC Outlets
Relays
Boxes:
Chassis - Condenser Fan ECM - Fuel Hold - Fuel Pull Glow Plug - PTO - Starter Tilt Lock
Fan - HVAC - Cargo Box Lift
Circuit Breakers
20 Amp:

Transmission Type
Hydrostatic Driven
Shift Type
Travel Control

Hydraulic Pump
1.14
Copyright 2014
GENERAL INFORMATION
Fuses
- Cargo Box Lift

- Condenser Fan Motor
40 Amp:
- Cooling Fan Motor
Shock Preload
Adjustment
20 Amp:
- Accessory - Drive - ECU Fuel Hold Solenoid - Hydro Lights - PTO
30 Amp:
Solenoid - Glow Plug HVAC*
* Located external from
Fuse/Relay Box
Front Wheel Size /

Type
12 x 6 / Steel
Rear Wheel Size /

Type
12 x 8 / Steel
Front Tire
Make / Model / Size

R12
Rear Tire
Make / Model / Size

R12
Wheels / Brakes
Air Conditioning
Tire Air Pressure
A/C Refrigerant
Cam Adjustment
R134A
Brake System

DOT 4
Steering Type
Brake Fluid
Toe Out
1/8 - 1/4 in. (3.2 - 6.35 mm)
HVAC
Front Suspension
Dual A-arm
Front Travel
6 in. (15.2 cm)
Rear Suspension
Rear Travel
6 in. (15.2 cm)
Refrigerant
1.8 lbs (.816 kg)
Air Conditioning Oil
5.1 - 5.7 fl oz (150170cc)
1.15
Copyright 2014
GENERAL INFORMATION
GENERAL: 2013 - 2014 BRUTUS HDPTO
CATEGORY
2013 MODEL NUMBER: D132M9JDJ
150 lbs. / 68 kg

(includes weight of
1750 lbs. / 794 kg
4000 lbs. / 1814 kg

2000 lbs. / 907 kg
2014 MODEL NUMBER: D142M9JDJ

CATEGORY
Length (with bucket)
157.9 in. / 401 cm
Width (tires)
63.2 in. / 160.5 cm

(GVWR)
Height
74 in. / 188 cm
Wheel Base
84 in. / 213.4 cm
Ground Clearance
7 in. / 17.8 cm
Min. Turning Radius

90 in. / 229 cm

(inside dimensions)
43.5 x 54 x 11.5 in.

(108 x 137 x 29 cm)
Dry Weight
2148 lbs. / 974.3 kg
Curb Weight
2232 lbs. / 1012 kg
Capacity
500 lbs. / 227 kg
Cargo Box Capacity
1250 lbs. / 567 kg
Attachment Arm Rated

Operating Capacity
500 lbs. / 227 kg
1.16
Copyright 2014
GENERAL INFORMATION
DETAILED: 2013 - 2014 BRUTUS HDPTO
Travel Control

2014 STD MODELS: D142M9JDJ
Hydraulic Pump
Hydraulic Pump
Capacity
7.6 gpm (28.8 L) @ 3600

RPM
Steering Flow
2.2 gpm (8.3 L) @ 3600

RPM
850 psi (58.6 bar)
Charge Relief Valve
87 psi (6 bar)
2013 STD MODELS: D132M9JDJ
Engine
Platform
Yanmar 3-Cylinder,
Engine Number
3TNM72-APB
Engine Displacement
904 cc
Number of Cylinders

Bore & Stroke
72 x 74 mm
Compression Ratio
23.5:1
Hydraulic Fluid
Capacity (Reservoir
Only)
2.75 qts. (2.6 L)
470 15 PSI
High Idle
8.4 qts. (7.9 L)
3700 100 RPM
Hydraulic Fluid
Low Idle
1350 100 RPM
Lubrication
Front Gearcase
Lubricant
Requirements
Demand Drive Fluid

6.75 oz. (200 ml)
Oil Requirements
Polaris DIESEL Oil
Oil Capacity
2.75 qts. (2.6 L)
Transmission
Lubricant
Requirements

41 oz. (1200 ml)
Coolant Capacity
6.9 qts. (6.5 L)
Overheat Warning
PTO
Lubricant
Requirements
PTO Gearbox Oil

6 oz. (177 ml)
Exhaust System
Canister Style
Starting Aid

Heater
Fuel System
Electrical
Alternator Rated
Output
90A / 1215 Watts @ 3000

RPM
Headlights

60W x 2
Tail Lights
L.E.D. (10): 0.2 Watts x 2
Brake Lights
L.E.D. (10): 2.9 Watts x 2
Fuel Injection Unit

(non-serviceable)

Fuel Pump Pressure
1-5 psi (7-34 kPa)
Starting System
Electric Start
Fuel Tank Capacity
10 gal. (37.8 L)
Battery
Fuel Requirement

Sulfur

575 CCA / 12 Volt
DC Outlets
Relays
Boxes:
Chassis - Condenser Fan ECM - Fuel Hold - Fuel Pull Glow Plug - PTO - Starter Tilt Lock

Transmission Type
Hydrostatic Driven
Shift Type
1.17
Copyright 2014
GENERAL INFORMATION
Fan - HVAC - Cargo Box Lift
Circuit Breakers
Fuses
20 Amp:
- Cargo Box Lift
- Condenser Fan Motor
40 Amp:
- Cooling Fan Motor
20 Amp:
- Accessory - Drive - ECU Fuel Hold Solenoid - Hydro Lights - PTO
30 Amp:
Solenoid - Glow Plug HVAC*
* Located external from
Fuse/Relay Box
Rear Travel
6 in. (15.2 cm)
Shock Preload
Adjustment
Cam Adjustment
Wheels / Brakes
Front Wheel Size /
Type
12 x 6 / Steel
Rear Wheel Size /

Type
12 x 8 / Steel
Front Tire
Make / Model / Size

R12
Rear Tire
Make / Model / Size

R12
Tire Air Pressure
Air Conditioning
A/C Refrigerant
R134A
Steering Type
Toe Out
1/8 - 1/4 in. (3.2 - 6.35 mm)
Front Suspension
Dual A-arm
Front Travel
6 in. (15.2 cm)
Rear Suspension
Brake System
Brake Fluid
DOT 4
HVAC
Refrigerant
1.8 lbs (.816 kg)
Air Conditioning Oil
5.1 - 5.7 fl oz (150170cc)
1.18
Copyright 2014
GENERAL INFORMATION
FUEL INFORMATION, USAGE AND
RECOMMENDATIONS
Fuel Information / Recommendations
Fuel additives are not recommended. Some fuel

additives may cause poor engine performance.
Ash content must not exceed 0.01% by volume.
Carbon residue content must not exceed 0.35% by
volume. Less than 0.1% is preferred.
CAUTION
Total aromatics content should not exceed 35% by

volume. Less than 30% is preferred.
NEVER use an engine starting aid such as ether.

Engine damage will result.
PAH (polycyclic aromatic hydrocarbons) content

should be below 10% by volume.
NOTE: For the best engine performance, to prevent

engine damage and to comply with EPA/ARB
warranty requirements, use ONLY the recommended
diesel fuels. Use only CLEAN Low Sulfur, Ultra Low
Sulfur #2 or #1 Diesel Fuel containing no more than
5% bio-diesel.
Diesel fuel should comply with the following world-wide
specifications:
Metal content of Na, Mg, Si and Al should be equal

to or lower than 1 mass ppm (test analysis method
JPI-5S-44-95).
Lubricity: Wear mark of WS1.4 should be Max.
0.018 in. (.460 m) at HFRR test.
Bio-Diesel Fuels
NOTE: Never use bio-diesel blended fuel containing
more than 5% bio-diesel in this vehicle.
DIESEL FUEL
SPECIFICATION
LOCATION
ASTM D975
No. 1D S15, S500
No. 2D S15, S500
USA
EN590:96
European Union
ISO 8217 DMX
International
BS 2869-A1 or A2
United Kingdom
JIS K2204 Grade No. 2
Japan
KSM-2610
Korea
B5 Diesel Fuel Requirements
GB252
China
1. The bio-fuels must meet the minimum specifications

for the country in which they are used.
Additional Technical Fuel Requirements

The fuel cetane number should be equal to 45 or
higher.
The sulfur content must not exceed 0.5% by
volume. Less than 0.5% is preferred. Especially in
the U. S. A. and Canada, Low Sulfur (300 to 500
ppm (mg/kg) or Ultra Low Sulfur fuel should be
used.
NEVER mix kerosene, used engine oil or residual
fuels with the diesel fuel.
Water and sediment in the fuel should not exceed
0.05% by volume.
Keep the fuel tank and fuel-handling equipment
clean at all times.
Poor quality fuel can reduce engine performance
and/or cause engine damage.
In Europe and in the United States, as well as some

other countries, non-mineral oil based fuel resources
such as RME (Rapeseed Methyl Ester) and SOME
(Soybean Methyl Ester), collectively known as FAME
(Fatty Acid Methyl Esters), are being used as extenders
for mineral oil derived diesel fuels.
YANMAR approves the use of bio-diesel fuels that do not
exceed a blend of 5% (by volume) of FAME with 95% (by
volume) of approved mineral oil derived diesel fuel. Such
bio-diesel fuels are known in the marketplace as B5
diesel fuels.
In Europe, bio-diesel fuels must comply with the

European Standard EN14214
In the United States, bio-diesel fuels must comply
with the American Standard ASTMD-6751.2
2. Bio-fuels should be purchased only from recognized
and authorized diesel fuel suppliers.
Bio-Fuel Precautions
1. Free methanol in FAME may result in corrosion of
aluminum and zinc FIE components.
2. Free water in FAME may result in plugging of fuel
filters and increased bacterial growth.
3. High viscosity at low temperatures may result in fuel
delivery problems, injection pump seizures, and poor
injection nozzle spray atomization.
1.19
Copyright 2014
GENERAL INFORMATION
4. FAME may have adverse effects on some
elastomers (seal materials) and may result in fuel
leakage and dilution of the engine lubricating oil.
5. Even bio-diesel fuels that comply with a suitable
standard as delivered, will require additional care
and attention to maintain the quality of the fuel in the
equipment or other fuel tanks. It is important to
maintain a supply of clean, fresh fuel. Regular
flushing of the fuel system, and/or fuel storage
containers, may be necessary.
6. The use of bio-diesel fuels that do not comply with
the standards as agreed to by the diesel engine
manufacturers and the diesel fuel injection
equipment manufacturers, or bio-diesel fuels that
have degraded as per the precautions and concerns
above, may affect the warranty coverage of your
engine.
Engine Warranty
Damages, performance or service concerns determined
to be caused by the use of bio-diesel fuel not meeting the
specifications outlined above are not considered to be
defects in material or factory workmanship and are not
covered under warranty. The same applies to damages
or other concerns induced by not complying with the
recommended operating conditions of YANMAR engines
with bio-diesel fuel.
Cold Weather Operation

Cold weather operation can result in fuel gelling if the
incorrect fuel type is used. Use the fuel blending
guideline table below to prevent this from occurring.
Cold Weather Fuel Blending Guideline:
B6 to B20 Bio-Diesel Fuel Blend
TEMPERATURE
B6 to B20 bio-diesel is NOT approved for this Polaris

vehicle application.
NO. 2
DIESEL
NO. 1
DIESEL
Above 15 F (9 C)
100%
0%
Approved Engines
Down to -20 F (-29 C)
50%
50%
Only the YANMAR TNM engine series (3TNM72) may

operate with bio-diesel fuel concentrations up to B5 for
Polaris vehicle applications.
Below -20 F (-29 C)
0%
100%
Approved Fuel
Block Heater Usage
NOTE: Raw pressed vegetable oils are not

considered bio-diesel, and are unacceptable for use
as fuel in any concentration in YANMAR engines.
Use of a block heater is recommend if this vehicle is

operated in temperatures in the +15 to +5 F (-9 to -15
C) range. A block heater is required at temperatures
below +5 F (-15 C). Please see your dealer to purchase
a block heater kit.
Bio-diesel fuel blends up to B5 must comply with the

following standards:
EN14214 (European standard) and/or ASTM D6751 (American standard)
All applicable engines may operate with bio-diesel
fuel up to a maximum B5 (5% bio-diesel blend)
concentration
1.20
Copyright 2014
GENERAL INFORMATION
Cold Start Guide
IMPORTANT: Before attempting to start the vehicle in freezing temperatures turn off lights, heater/air conditioning and
accessories. Turn the key switch to the ON position and wait for the glow plug indicator light to go out before
engaging the starter.
Engage starter for a maximum of five (5) seconds. If engine does not start, stop cranking and wait for five (5) seconds
then repeat.
If engine fails to start perform the following inspections:
1. Inspect the air filter and replace if restricted or contaminated.
2. Inspect the water/fuel separator and drain as required.
3. Inspect the fuel filter and replace if restricted.
4. Verify the correct fuel type is being used and is not contaminated.
5. Verify the hydrostatic drive neutral adjustment is correct.
*2878474 has been discontinued, use 2879832 as a replacement in the applicable temperature range. Avoid mixing oil
types. **Revised from previous publications.
1.21
Copyright 2014
GENERAL INFORMATION
MISC. SPECIFICATIONS AND CHARTS
Conversion Table
C to F: C x 9/5 + 32 = F F to C: F - 32 x 5/9 = C
1.22
Copyright 2014
GENERAL INFORMATION
Standard Bolt Torque Specification
BOLT SIZE
GRADE 2
FT-LBS (NM)
GRADE 5
FT-LBS (NM)
GRADE 8
FT-LBS (NM)
1/4-20
5 (7)
8 (11)
12 (16)
1/4-28
6 (8)
10 (14)
14 (19)
5/16-18
11 (15)
17 (23)
25 (35)
5/16-24
12 (16)
19 (26)
29 (40)
3/8-16
20 (27)
30 (40)
45 (62)
3/8-24
23 (32)
35 (48)
50 (69)
7/16-14
30 (40)
50 (69)
70 (97)
7/16-20
35 (48)
55 (76)
80 (110)
1/2-13
50 (69)
75 (104)
110 (152)
1/2-20
55 (76)
90 (124)
120 (166)
Metric Bolt Torque Specification
GRADE
BOLT
SIZE
4.6
4.8
8.8 / 8.9
10.9
12.9
FT-LBS (NM) DRY THREADS

M3
.3 (.5)
.5 (.7)
1 (1.3)
1.5 (2)
1.5 (2)
M4
.8 (1.1)
1 (1.5)
2 (3)
3 (4.5)
4 (5)
M5
1.5 (2.5)
2 (3)
4.5 (6)
6.5 (9)
7.5 (10)
M6
3 (4)
4 (5.5)
7.5 (10)
11 (15)
13 (18)
M8
7 (9.5)
10 (13)
18 (25)
26 (35)
33 (45)
M10
14 (19)
18 (25)
37 (50)
55 (75)
63 (85)
M12
26 (35)
33 (45)
63 (85)
97 (130)
11 (150)
M14
37 (50)
55 (75)
103 (140)
151 (205)
177 (240)
M16
59 (80)
85 (115)
159 (215)
232 (315)
273 (370)
M18
81 (110)
118 (160)
225 (305)
321 (435)
376 (510)
1.23
Copyright 2014
GENERAL INFORMATION
SAE Tap / Drill Sizes
Metric Tap / Drill Sizes
1.24
Copyright 2014
GENERAL INFORMATION
Decimal Equivalents
1.25
Copyright 2014
GENERAL INFORMATION
NOTES
1.26
Copyright 2014
MAINTENANCE
CHAPTER 2
MAINTENANCE
PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
PERIODIC MAINTENANCE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
PRE-RIDE - DAILY MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
25 - 100 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
100 - 2000 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
POLARIS LUBRICANTS & MAINTENANCE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10
GREASE LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
GREASE LUBRICATION POINTS, CONTINUED..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13
MAINTENANCE QUICK REFERENCE (ALL MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14
MAINTENANCE QUICK REFERENCE (ALL MODELS), CONTINUED..... . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15
MAINTENANCE QUICK REFERENCE (HD / HDPTO MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16
GENERAL VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
TRAVEL CONTROL (TREADLE) PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
PEDAL REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18
CABLE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18
HYDROSTATIC / TREADLE PEDAL ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19
HYDROSTATIC TRAVEL CONTROL ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19
NEUTRAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20
TRAVEL CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
FORWARD SPEED CONTROL CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23
REVERSE SPEED CONTROL CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
ENGINE SPEED CONTROL CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
ENGINE SPEED CONTROL LEVER (HD / HDPTO MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
FUEL SYSTEM SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26
FUEL FILTER / WATER SEPARATOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26
FUEL FILTER / WATER SEPARATOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26
FUEL PICK-UP SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27
FUEL LINES / VENT LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28
ENGINE INTAKE PRE-FILTER SCREEN SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28
AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28
AIR INTAKE EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31
2.1
Copyright 2014
MAINTENANCE
ENGINE OIL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31
ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31
ENGINE OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32
ENGINE CRANKCASE BREATHER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.34
ENGINE COMPRESSION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.35
ENGINE LEAKDOWN TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.36
ALTERNATOR / FAN / WATER PUMP DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.36
VALVE CLEARANCE INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38
EXHAUST CLEAN OUT PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.39
TRANSMISSION AND FRONT GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.40

SPECIFICATION CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.40
SHIFT CABLE INSPECTION / ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.40
TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.40
FRONT GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.42
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.44
LIQUID COOLING SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.44
COOLANT STRENGTH / TYPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.44
COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.45
COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.46
RADIATOR INSPECTION / CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.46
COOLANT DRAIN / FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.46
HVAC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.46
A/C CONDENSER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.46
HVAC FILTER INSPECTION / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.47
A/C DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.47
HYDRAULIC / HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.50
HYDRAULIC / HYDROSTATIC HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.50
HYDRAULIC / HYDROSTATIC HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.50
HYDRAULIC FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.50
HYDRAULIC FLUID AND FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.51
POWER TAKE-OFF SYSTEM (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.53
PTO GEARBOX OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.53
PTO GEARBOX OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.55
PTO DRIVE BELT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.56
PTO U-JOINT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.57
PTO CLUTCH BRAKE INSPECTION / ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.58
FINAL DRIVE / WHEEL AND TIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.59
DRIVE SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.59
FRONT WHEEL BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.59
WHEEL AND HUB TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.60
WHEEL REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.60
WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.60
TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.60
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.61
ELECTRICAL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.61
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.61
BATTERY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.61
2.2
Copyright 2014
MAINTENANCE
BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.62
BATTERY CHARGING / OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.62
CHASSIS / ENGINE ELECTRICAL GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.62
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.63
STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.63
TIE ROD END / WHEEL HUB INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.63
WHEEL TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.64
WHEEL TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.64
SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.65
SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.65
SPRING PRE-LOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.65
BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.66
BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.66
BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.66
BRAKE PAD / DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.66
2.3
Copyright 2014
MAINTENANCE
PERIODIC MAINTENANCE CHART
Break-In Period
Periodic Maintenance Overview
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.
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.
NOTE: Service and adjustments are critical. If
youre not familiar with safe service and adjustment
procedures, have a qualified dealer perform these
operations.
Maintenance intervals in the following chart are based
upon average riding conditions and an average vehicle
speed of approximately 10 miles per hour. Vehicles
subjected to severe use must be inspected and serviced
more frequently.
Drive vehicle slowly at first while varying the

throttle position. Do not operate at sustained idle.
Pull only light loads.
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.
Check and adjust alternator V-belt after initial 50
hours of operation.
See Owners Manual for additional break-in
information.
Maintenance Chart Key
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
The following symbols denote potential items to be

aware of during maintenance:
= CAUTION: Due to the nature of these
adjustments, it is recommended this service be
performed by an authorized Polaris dealer.
= SEVERE USE ITEM: See information provided
above.
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.
E = Emission Control System Service (California).

NOTE: Inspection may reveal the need for
replacement parts. Always use genuine Polaris
parts.
WARNING
Improperly performing the procedures marked could
result in component failure and lead to serious injury or
death. Have an authorized Polaris dealer perform these
services.
2.4
Copyright 2014
MAINTENANCE
Pre-Ride - Daily Maintenance Interval
ITEM
Brake Fluid Level
Coolant Level
Diesel Fuel Level
Engine Oil Level
Hydraulic Fluid Level
Brake System / Pedal

Travel
Engine Speed Control
Lever
MAINTENANCE INTERVAL
(WHICHEVER COMES FIRST)
REMARKS
HOURS
CALENDAR
MILES
(KM)
Daily
Check the levels and add as needed
Daily
Ensure proper operation
Daily
Check for proper operation
Travel Control Pedal

Head Lights / Tail Lights
Indicator Lights / Switches
Air Filter
Daily
Inspect filter element; replace as needed

or every 150 hours
Air Intake Sediment Drains
Daily
Inspect drain on bottom of engine air

intake duct and air filter housing for
obstructions
Cooling System
Daily
Inspect oil cooler, radiator, A/C

condenser (if equipped) and grills for
debris; remove debris if needed
Drive Shaft Boots
Daily
Inspect boots for damage, tears, wear or

leaking grease
Engine Intake Pre-Filter

Screen (LH side)
Daily
Inspect; clean often
Frame Fasteners
Daily
Inspect and ensure tightness
Fuel Filter / Water

Separator
Daily
Drain daily (severe conditions with poor

fuel quality) or every 50 hours (normal
conditions with quality fuel)
Heater / A/C Filter

(if equipped)
Daily
Clean or replace filter as needed during

heating and cooling seasons
PTO (if equipped)
Daily
Inspect the splines, guards and shields

and mounting hardware; tighten loose
hardware or replace damaged parts
ROPS/OPS
Daily
Check the condition of the ROPS/OPS

and mounting hardware
2.5
Copyright 2014
MAINTENANCE
ITEM
REMARKS
HOURS
CALENDAR
MILES
(KM)
Safety Signs / Decals
Daily
Check for damaged signs (decals);

replace any that are damaged
Seat Belts
Daily
Check the condition of seat belts; clean

or replace seat belt retractors as needed
Daily
Inspect for broken parts, loose hardware

and free operation
Tires
Daily
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
Wheels / Fasteners
Daily
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
Copyright 2014
MAINTENANCE
25 - 100 Hour Maintenance Interval
ITEM
HOURS
CALENDAR
MILES
(KM)
REMARKS
Front Gearcase Lubricant

(Demand Drive Fluid)
25 H
1M
250 (400)
Initial fluid level inspection; add lubricant

if needed
Transmission Lubricant
(AGL Gearcase Lubricant)
25 H
1M
250 (400)
Initial fluid level inspection; add lubricant

if needed
Attachment Interface
Mounting Hardware (HD /
HDPTO)
25 H
Retorque to lower mounting bolts to 95

ft-lbs
1M
250 (400)
Inspect; replace if necessary
4< Brake Pad Wear
Air Conditioner Drive Belt

(if equipped)
50 H
Check and adjust the V-belt after initial

50 hours of operation; perform every 200
hours thereafter
Alternator / Fan / Water

Pump Drive Belt
50 H

hours thereafter
Engine Oil & Filter Change
50 H
Perform an oil and filter change after

initial 50 hours of operation; perform
every 100 hours or 6 months thereafter
Hydraulic / Hydrostatic
System
50 H
Replace hydraulic filter only after initial

50 hours of operation; replace hydraulic
fluid and filter every 400 hours thereafter
Battery
50 H
1M
Check terminals; clean; test
Fuel Filter / Water

Separator
50 H
3M
Drain every 50 hours (normal conditions

with quality fuel) or daily (severe
conditions with poor fuel quality)
General Grease
Lubrication
50 H
3M
500 (800)
Lubricate all grease fittings, pivots, etc.
Air Intake Ducts / Adaptors
50 H
6M
Inspect ducts for proper sealing/air leaks
Attachment Interface
Mounting Hardware (HD /
HDPTO)
100 H
Retorque to lower mounting bolts to 95

ft-lbs
PTO Gearbox (if

equipped)
100 H
Inspect for leaks
Engine Oil & Filter Change
100 H
6M
Perform an oil and filter change after

initial 50 hours of operation; perform
every 100 hours or 6 months thereafter
Front / Rear Suspension
100 H
6M
1000 (1600)
Inspect for wear
Shift Cable / Linkage
100 H
6M
1000 (1600)
Inspect, lubricate, adjust
Steering
100 H
6M
1000 (1600)
Inspect steering freeplay
2.7
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MAINTENANCE
ITEM
HOURS
CALENDAR
MILES
(KM)
REMARKS
<E
Travel Control and Engine

Speed Control Systems
100 H
6M
1000 (1600)
Inspect for proper operation and

adjustment if necessary
Cooling Hoses
100 H
12 M
Inspect for leaks; replace if necessary
Engine Mounts
100 H
12 M
Inspect, torque to specification
Exhaust Silencer / Pipe
100 H
12 M
Inspect
Fuel System
100 H
12 M
Check for leaks at fill cap, fuel lines and

fuel pump
Front Wheel Bearings
100 H
12 M
1000 (1600)
Inspect; replace as needed
2.8
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MAINTENANCE
100 - 2000 Hour Maintenance Interval
ITEM
HOURS
CALENDAR
MILES
(KM)
REMARKS
Front Gearcase Lubricant

(Demand Drive Fluid)
100 H
12 M
1000 (1600)
Change lubricant
Transmission Lubricant
(AGL Gearcase Lubricant)
100 H
12 M
1000 (1600)
Change lubricant
Hydraulic, Hydrostatic and

Power Steering Hoses
100 H
12 M
1000 (1600)
Inspect for damage and leaks; repair or

replace as needed
Radiator
100 H
12 M
1000 (1600)
Inspect; clean external surfaces
Wiring
100 H
12 M
1000 (1600)
Inspect for wear, routing, security; apply

dielectric grease to connectors subjected
to water, mud, etc.
Cooling System
12 M
Test coolant strength and pressure test

system
Air Filter
150 H
Replace air filter; replace more often if

vehicle is subject to severe use
Fuel Filter / Water

Separator
150 H
12 M
Replace fuel filter / water separator
Air Conditioner Drive Belt

(if equipped)
100 H

hours thereafter; replace as needed
Alternator / Fan / Water

Pump Drive Belt
100 H

hours thereafter; replace as needed
PTO Drive Belt

(if equipped)
200 H
Inspect for damage; replace as needed
Toe Adjustment
200 H
24 M
2000 (3200)
Inspect; adjust if necessary or when

parts are replaced
Brake Fluid
200 H
24 M
2000 (3200)
Change every two years (DOT 4)
Exhaust Clean Out
300 H
36 M
Remove plug and clean out
Hydraulic / Hydrostatic
System
400 H
Replace hydraulic fluid and filter
PTO Gearbox Lubricant

(if equipped)
400 H
12 M
Change lubricant
PTO Shaft U-Joints

(if equipped)
400 H
12 M
Inspect for wear; replace as needed
PTO Clutch Brake

(if equipped)
400 H
12 M
Adjust Tension
2.9
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MAINTENANCE
ITEM
HOURS
CALENDAR
MILES
(KM)
REMARKS
Valve Clearance
1000
H
Inspect; adjust as needed
Coolant
1000
H
24 M
Replace coolant
Fuel Injectors
1500
H
Inspect, clean and test fuel injectors, if

necessary (see Engine Chapter)
Engine Crankcase
Breather System
1500
H
Inspect crankcase breather system
Fuel Hoses
2000
H
24 M
Replace rubberized fuel hoses
Cooling Hoses
2000
H
24 M
Replace coolant hoses
Headlight Aim
Adjust as needed
2.10
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MAINTENANCE
Polaris Lubricants & Maintenance Products
PART
NO.
DESCRIPTION
DESCRIPTION
(1 Gal.)
Engine Lubricant
2878473
PART
NO.
3120212
Polaris Diesel Engine Oil 15W-40

(Summer) (2 Qts.) (8 Count)
2878474

(Winter) (2 Qts.) (8 Count)
2879832
Polaris Synthetic Diesel Engine Oil 5W-40

(All-Season) (2 Qts.) (8 Count)
3070131
Diesel Engine Oil Filter
Front Gearcase / Transmission / Gearbox Lubricants
Hydraulic/Hydrostatic Filter
Coolant
2871323
60/40 Coolant (Gallon) (6 Count)
2871534
60/40 Coolant (Quart) (12 Count)
NOTE: Each item can be purchased separately at

your local Polaris dealer.
PART
NO.
DESCRIPTION
2877922
Demand Drive Fluid

(1 Qt.) (12 Count)
Additives / Sealants / Thread Locking Agents / Misc.
2877923
Demand Drive Fluid

(2.5 Gal.) (2 Count)
2871950
Loctite Threadlock 242

(6 ml.) (12 count)
AGL Full Synthetic Gearcase Lubricant

(1 Qt.) (12 Count)
2872189
DOT 4 Brake Fluid (12 count)
2878068
2871557
Crankcase Sealant, 3-Bond 1215 (5 oz.)
2878069

(1 Gal.) (4 Count)
2878070

(2.5 Gal.) (2 Count)
2879748
PTO Gearbox Oil (if equipped)

(6 oz.)
2879747
Angle Broom Oil (if equipped)

(14 oz.)
2870465
Oil Pump for 1 Gallon Jug
NOTE: The number count indicated by each part

number in the table above indicates the number of
units that are shipped with each order.
Grease / Specialized Lubricants

2871312
Grease Gun Kit
2871322
Premium All Season Grease

(3 oz. cartridge) (24 Count)
2871423
Premium All Season Grease

(14 oz. cartridge) (10 Count)
2871460
Starter Drive Grease (12 Count)
2871515
Premium U-Joint Lube (3 oz.) (24 Count)
2871551
Premium U-Joint Lube (14 oz.) (10 Count)
2871329
Dielectric Grease (Nyogel)
Hydraulic / Hydrostatic Fluid

2879746
Polaris Hydraulic Fluid
2.11
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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
Front A-arm
Pivot Bushings
Rear Suspension
Pivot Bushings
Front Propshaft Yoke
METHOD
Grease all fittings on

each side of the vehicle
RECOMMENDED LUBE
FREQUENCY
Polaris All Season

Grease
Grease fittings every 500

miles (800 km); Grease before
long periods of storage, and
after thoroughly washing or
submerging the vehicle
Grease the fitting

(3 pumps maximum)
2.12
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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
METHOD
PRO-TACH System
Attachment Arm
Fittings
(HD / HDPTO Models)
Grease all fittings at

attachment arm pivot
locations
PTO Shaft Yoke

(HDPTO Models Only)
Grease the fitting

(3 pumps maximum)
RECOMMENDED LUBE
FREQUENCY
Polaris All Season

Grease
Grease fittings every 500

miles (800 km); Grease before
long periods of storage, and
after thoroughly washing or
submerging the vehicle
2.13
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MAINTENANCE
Maintenance Quick Reference (All Models)
III.
#
ITEM
RECOMMENDED LUBE /
FLUID
METHOD
FREQUENCY*
Engine Oil
Polaris Diesel Engine Oil

Reference Engine Oil
Recommendations
Add oil to proper level on

dipstick
Perform an oil and filter change

after initial 50 hours; every 100
hours or 6 months thereafter
Engine Coolant
Polaris 60/40 Coolant
Maintain coolant level in

coolant reservoir bottle.
Check level daily; change

coolant every two years
* More often under severe use, such as operated in water or under severe loads.
2.14
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MAINTENANCE
Maintenance Quick Reference (All Models),
Continued.....
III.
#
ITEM
RECOMMENDED LUBE /
FLUID
METHOD
FREQUENCY*
Maintain fluid level

between MAX and MIN
lines on the master
cylinder reservoir
Check level daily; change fluid

every two years
Add lubricant until it is

visible at the fill hole
threads
Initial level check at 25 hours

or 1 month; Change lubricant
every 100 hours or 12 months
thereafter
Brake Fluid
Polaris DOT 4 Brake Fluid
Front Gearcase
Polaris Demand Drive Fluid
Transmission
Polaris AGL Full Synthetic

Gearcase Lubricant
2.15
Copyright 2014
MAINTENANCE
Maintenance Quick Reference (HD / HDPTO
Models)
III.
#
ITEM
RECOMMENDED LUBE /
FLUID
METHOD
FREQUENCY*
Hydraulic Fluid
Reservoir /
Filter
Maintain fluid level within

sight glass
Replace hydraulic filter after

initial 50 hours; replace
hydraulic fluid and filter every
400 hours thereafter
PTO Gearbox
(HDPTO Only)
Polaris PTO Gearbox Oil
Completely drain lubricant

and refill to recommended
capacity.
Perform oil change every 400

hours or 12 months; whichever
comes first
2.16
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MAINTENANCE
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.
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.
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.
2.17
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MAINTENANCE
3. Check the travel control pedal (Item 2) for excessive
freeplay.
4. The correct amount of total free travel on the travel

control pedal is 0.30 in. (7.6 mm).
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 a minimum of
3760 RPM. Repeat with travel control pedal fully in
reverse, the engine speed should be a minimum of
3500 RPM with Type 1 Command Lever and 3600
RPM or greater with Type 2 Command Lever. Refer
to ( Drive Performance Checks Command Lever
Type ) or (Drive Performance Checks Command
Lever Type 2). 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

Reference Chapter 10 - Hydrostatic Drive.
2.18
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MAINTENANCE
HYDROSTATIC / TREADLE PEDAL
ADJUSTMENTS
3. Disconnect the neutral safety switch connector (Item

2) and remove the controls cover (Item 3).
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.
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.
4. Verify that the speed control cable (Item 4) is

attached to the top hole of the engine speed control
lever.
2.19
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MAINTENANCE
Neutral Adjustment
1. Install a tie strap (Item 1) on the hydraulic hose
shown to serve as a pointer on the pump plate.
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 (3000 RPM). NOTE:
On non HD/HDPTO vehicles, the idle can be
increased by attaching a wire to the engine speed
control lever to manipulate the engine RPM.
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.
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).
3. Loosen the four pump plate mounting bolts (Item 2).
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.
2.20
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MAINTENANCE
8. Torque the four bolts (Item 5) to specification.
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.
2.21
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MAINTENANCE
Travel Cable Adjustment
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.
2. Locate PU-51261 - Drive Control Adjustment

Wrench (Item 2) and install it as shown.
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.
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.
2.22
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MAINTENANCE
6. Apply pressure on the tool in a counterclockwise
direction until the pintle lever is held against the
internal stop.
9. Remove the wood blocks (Item 9) from under the

foot pedal. Proceed to Forward Speed Control
Cable Adjustment.
7. Tighten the outer jam nut (Item 7) until it is tight

against the bracket. Use a paint pen to mark one flat
on the outer jam nut. Use the paint mark as a
reference to rotate the outer jam nut an additional
one-half turn.
8. While holding the outer jam nut, torque the inner jam
nut (Item 8) to specification.
Travel Control Cable Jam Nuts:

12 ft-lbs (16 Nm)
Forward Speed Control Cable Adjustment

1. Adjust the jam nuts (Item 1) to remove any slack in
the speed control cable (Item 2).
2. Hold the outside forward speed control cable

adjustment nut and tighten the inside adjustment nut
to specification.
Forward Speed Control Cable Adjustment Nut:
12 ft-lbs (16 Nm)
3. After adjustments are made, the protective boot
(Item 3) must be in place to prevent cable damage.
Proceed to Reverse Speed Control Cable
Adjustment.
NOTE: Over tightening the outer jam nut results

in over-stroking the command lever causing the
HP control spring to function improperly.
2.23
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MAINTENANCE
Reverse Speed Control Cable Adjustment
Engine Speed Control Cable Adjustment

the travel control cable (Item 2).

2. Hold the outside reverse speed control cable

to specification.
Reverse Speed Control Cable Adjustment Nut:
12 ft-lbs (16 Nm)
3. 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.
2.24
Copyright 2014
MAINTENANCE
ENGINE SPEED CONTROL LEVER
(HD / HDPTO MODELS)
FUEL SYSTEM
Fuel System Safety Precautions
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
cause erratic engine speed conditions.
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).
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.
NEVER use a shop rag to catch diesel fuel. Vapors
from the rag are flammable and explosive. Wipe up any
fuel spills immediately.
NEVER use diesel fuel as a cleaning agent.

lever in Park, move the engine speed control lever
(Item 1) to high idle position. The engine speed
should be a minimum of 3760 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.
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.
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.
2.25
Copyright 2014
MAINTENANCE
General Information
The fuel filter / water separator is located behind the
drivers seat and can be accessed by tilting the rear
cargo box. The filter should be:
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.
Inspected daily.
Drained every 50 hours (normal conditions with
quality fuel) OR drained daily (severe conditions /
poor fuel quality).
Replaced every 150 hours OR 12 months OR
2000 miles (3200KM). WHICHEVER COMES
FIRST.
Fuel Filter / Water Separator Draining

CAUTION
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).
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.
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.
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.
2.26
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MAINTENANCE
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.
NOTE: Be sure that the drain valve on the
bottom of the filter is snug and did not loosen up
during filter installation.
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.
6. Clean up any excess fuel properly.

fuel system.
Fuel Pick-up Screen

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.
3. Check the fuel tank vent line (Item 3) for signs of

wear, deterioration, damage or leakage. Replace
vent line every two years.
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.
If the fuel pick-up screen requires service, reference

Chapter 4 Fuel System for service procedure.
5. Be sure fuel lines and vent line are routed and

retained properly.
NOTE: Make sure lines are not kinked or
pinched.
2.27
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MAINTENANCE
AIR INTAKE SYSTEM
Air Filter Service
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:
1. The engine intake pre-filter (Item 1) is located just
behind the driver hip bolster on the left side of the
vehicle.
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).
2. Press in (towards the front of the unit) on intake prefilter tab (Item 2) to remove it.
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.
3. Inspect the pre-filter. If necessary, clean with soapy
water and dry with low pressure compressed air.
4. Inspect the air filter and replace if necessary.

4. If any damage is found, replace the pre-filter
assembly.
NOTE: 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.
2.28
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MAINTENANCE
7. Install the airbox cover and engage the 2 clips onto
the airbox.
NOTE: Be sure airbox cover TOP is positioned

at the top to allow the drain valve (Item 6) to
function properly.
2.29
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MAINTENANCE
Air Intake Exploded View
2.30
Copyright 2014
MAINTENANCE
ENGINE
Engine Oil Level
Engine Oil Recommendations
Always check the engine oil level daily. Change the

engine oil at the intervals outlined in the Periodic
Maintenance Chart.
NOTE: Use of a non-recommended engine oil may

cause serious engine damage.
Polaris recommends the use of Polaris Diesel Oil (SAE
CI-4) 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
Access the oil dipstick and oil fill cap by tilting the rear
cargo box.
1. Remove all cargo from the cargo box.
CAUTION
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.
3. Stop the engine and allow the oil level to settle for 3
minutes before removing the dipstick.
NOTE: 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.
Recommended Engine Oil:

All-Season (PN 2879832)
Ambient Temp Range: -40 F to 104 F
Summer (PN 2878473)
Ambient Temp Range: +5 F to 104 F
Winter (PN 2878474)
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.
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.
2.31
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MAINTENANCE
8. Add the recommended oil as necessary to bring the
oil level within the SAFE range on dipstick. Do not
overfill.
1. Run the engine for two to three minutes or until

warmed up.
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.
CAUTION
Use caution when performing this procedure.
Do not allow hot engine oil to come into contact with
skin, as serious burns may result.
NOTE: Use only the recommended engine oil

(see Engine Oil Recommendations).
4. Place a drain pan under the engine crankcase and

remove the drain plug (Item 3). Allow the engine oil
to drain completely.
9. Add engine oil through the oil fill cap (Item 2) located
on top of the valve cover.
5. Clean sealing area of drain plug and oil pan. Replace

the sealing washer on drain plug.
10. When finished, reinstall the oil fill cap and oil dipstick.
Engine Oil and Filter Change
NOTE: The sealing surface on the drain plug

should be clean and free of burrs, nicks or
scratches.
6. Remove all cargo from the cargo box.
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.
CAUTION
Access the oil dipstick and oil fill cap by tilting the rear
cargo box.
Always remove all cargo from the cargo box before

lifting the box to access the engine.
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.
7. Tilt the cargo box up.
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.
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8. Remove the oil fill cap (Item 4) to vent the engine
crankcase and allow the oil to drain more easily.
12. Install and tighten the oil filter to specification.
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.
9. Place shop towels beneath oil filter (Item 5). Using

Oil Filter Wrench (PU-50105), turn the filter counterclockwise to remove it.
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:

All-Season (PN 2879832)
Summer (PN 2878473)
Ambient Temp Range: +5 F to 104 F
Winter (PN 2878474)
Oil Filter Wrench:

PU-50105: 2.5 (64 mm)
10. Using a clean dry cloth, clean the filter sealing

surface on the engine crankcase.
Diesel Engine Oil Filter (3070131)
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.
Capacity: 2.75 Quarts (2.6 L)

15. Install the oil fill cap.
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.
NOTE: 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.
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.
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.
NOTE: Use only the recommended engine oil
(see Engine Oil Recommendations).
22. When finished, reinstall the oil fill cap and oil dipstick.
23. Dispose of used oil and filter properly.
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.
NOTE: 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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Engine Compression Test
NOTE: This engine does NOT have decompression
components. Compression readings will vary in
proportion to cranking speed during the test.
3. Remove the fuel injector (Item 2) from the cylinder to

be measured (see Removing the Fuel Injectors in
Chapter 4).
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).
4. Disconnect the fuel solenoid at the connector (Item
3).
NOTE: 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.
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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.
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.
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.
NOTE: NEVER get any oil on the belt. Oil on the belt
causes slipping and stretching. Replace the belt if
damaged.
Check and adjust the V-belt tension (deflection) as
follows:
1. Position the vehicle on a level surface, place the
transmission in PARK and stop the engine.
2. Tilt the rear cargo box.
3. Remove the three bolts (Item 1) and belt shield (Item
2) from the vehicle.
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
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).
4. Check the V-belt for cracks, oil or wear. If any of

these conditions exist, replace the V-belt.
NOTE: 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

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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5. At the mid span location shown, press down on the
V-belt with approximately 20 lbs. (89 N) of applied
force to check the belt deflection.
7. Torque the mounting bolt (Item 3) to specification.
Lower Alternator Mounting Bolt:

15 ft-lbs (20 Nm)
8. Torque the adjustment bolt (Item 4) to specification.
Upper Alternator Adjustment Bolt:

28 ft-lbs (38 Nm)
9. Install the belt shield and three retaining bolts.
Alternator/Fan/Water Pump Belt Tension
10. After adjusting, run the engine for 5 minutes or more.

Check the tension again referencing the previous
specification.
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
V-belt to the desired tension and then tighten the
adjustment bolt (Item 4).
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Valve Clearance Inspection / Adjustment
3. Insert a feeler gauge between rocker arm and valve

cap and record the measured valve clearance.
NOTE: Valve clearance inspection should be

performed on a cold engine, at room temperature.
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).
The No. 1 piston is on the flywheel end of the engine.

The firing order is 1-3-2.
Valve Clearance
0.006 - 0.010" (0.15 - 0.25 mm)
1. Remove the intake manifold / valve cover.

2. Bring No. 1 piston to TDC of the compression stroke.
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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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.
Use the following procedure to periodically purge

accumulated carbon from the exhaust pipe:
1. Remove the exhaust clean-out plug (Item 1) located
on the bottom of the silencer.
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.
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.
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.
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.
6. Repeat steps 3 and 4 until no more particles are
expelled when the engine is revved.
7. Stop the engine. Allow the exhaust silencer to cool.
8. Reinstall the clean-out plug (Item 1).
Never go under the vehicle while it's inclined.
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TRANSMISSION AND FRONT
GEARCASE
Specification Chart
GEARCASE
LUBRICANT
CAPACITY
FILL / DRAIN PLUG

TORQUE
Transmission
AGL Full Synthetic

Gearcase Lubricant
41 oz. (1200 ml)
10-14 ft-lbs. (14-19 Nm)
Front Gearcase
Demand Drive Fluid
6.75 oz. (200 ml)
8-10 ft-lbs. (11-14 Nm)
Shift Cable Inspection / Adjustment

Shift cable adjustment may be necessary if symptoms
include:
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).
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.
2. Inspect shift cable dust boot (Item 3) and the clevis
pin and pivot bushings (Item 4). Replace if worn or
damaged.
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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Transmission Lubrication
Transmission Lubricant Change
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.
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).
2. Place a drain pan under the transmission drain plug.
3. Remove drain plug and allow lubricant to drain
completely.
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.
4. Clean the drain plug magnetic surface. Reinstall drain

plug 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:

(PN 2878068) (Quart)
Capacity: 41 oz. (1200 ml)
3. If lubricant level is not even with bottom threads, add
recommended lubricant as needed. Do not overfill.
6. Reinstall fill plug and torque to specification.
4. Reinstall the fill plug and torque to specification.
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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Front Gearcase Lubrication
3. Remove the fill plug and check the fluid level.
NOTE: It is important to follow the front gearcase

Maintenance Chart.
The front gearcase fluid level should be checked and
Be sure vehicle is positioned on a level surface
when checking or changing the fluid.
Check vent hose to be sure it is routed properly
and unobstructed.
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.
2. Locate the gearcase fill plug (Item 1) through the
right front wheel well area.
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.
Fill / Drain Plug:

8-10 ft-lbs (11-14 Nm)
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Front Gearcase Fluid Change:
4. Clean the drain plug magnetic surface.
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.
5. Reinstall drain plug and torque to specification.
1. Remove the fill plug (refer to Front Gearcase Fluid

Level Check).
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.
2. Place a drain pan under the front gearcase drain

plug.
3. Remove the drain plug and allow fluid to drain
completely.
Recommended Front Gearcase Fluid:

Polaris Demand Drive Fluid
(PN 2877922) (Quart)
Capacity: 6.75 oz. (200 ml)
7. Reinstall fill plug and torque to specification.
Fill / Drain Plug:

8-10 ft-lbs (11-14 Nm)
8. Check for leaks. Dispose of used fluid properly.
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COOLING SYSTEM
Coolant Strength / Type
Liquid Cooling System Overview
Test the strength of the coolant using an antifreeze

hydrometer.
NOTE: Use ethylene glycol coolant / anti-freeze

only. Do not mix coolant types.
The engine coolant level is controlled or maintained by
the recovery system. The recovery system components
are the recovery bottle, radiator filler neck, radiator
pressure cap and connecting hose.
As coolant operating temperature increases, the
expanding (heated) excess coolant is forced out of the
radiator past the pressure cap and into the recovery
bottle. As engine coolant temperature decreases the
contracting (cooled) coolant is drawn back from the tank
past the pressure cap and into the radiator.
NOTE: Some coolant level drop on new machines is
normal as the system is purging itself of trapped air.
Observe coolant levels often during the break-in
period.
A 50/50 or 60/40 mixture of antifreeze and distilled

water will provide the optimum cooling, corrosion
protection, and antifreeze protection.
Do not use tap water, straight antifreeze, or
straight water in the system. Tap water contains
minerals and impurities which build up in the
system.
Straight water or antifreeze may cause the system
to freeze, corrode, or overheat.
Overheating of engine could occur if air is not fully

purged from system.
Polaris Premium 60/40 coolant is already premixed and
ready to use. Do not dilute with water.
Recommended Anti-Freeze/Coolant:
Polaris Premium Pre-Mixed Antifreeze
(PN 2871534) (Quart)
(PN 2871323) (Gallon)
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Coolant Level Inspection
The recovery bottle (Item 1) and radiator pressure cap
(Item 2) are located under the hood.
4. If the coolant level is below the MIN mark, inspect

the coolant level in the radiator.
NOTE: If overheating is evident, allow system to
cool completely and check coolant level in the
radiator and inspect for signs of trapped air in
system.
WARNING
Never remove the pressure cap when the engine is
warm or hot. Escaping steam can cause severe burns.
The engine must be cool before removing the pressure
cap.
5. Remove the pressure cap. Using a funnel, add
coolant to the top of the radiator filler neck.
6. Reinstall the pressure cap.
With the engine at operating temperature, the coolant
level should be between the MAX and MIN marks on
the recovery bottle. If not, perform the following:
1. Position the vehicle on a level surface
2. Remove the hood from the front cab.
3. Check the coolant level in the recovery bottle (Item
1). The coolant level must be maintained between
the MAX and MIN levels indicated on the recovery
bottle
NOTE: Use of a non-standard pressure cap will

not allow the recovery system to function
properly.
7. Remove the recovery bottle cap and add coolant
using a funnel.
8. Fill the recovery bottle to the MAX mark with the
recommended pre-mix coolant. You may use a 50/50
or 60/40 mixture of antifreeze and distilled water as
required for freeze protection in your area.
Recommended Anti-Freeze/Coolant:
Polaris Premium Pre-Mixed Antifreeze
(PN 2871534) (Quart)
(PN 2871323) (Gallon)
9. Reinstall the recovery bottle cap.
10. If coolant was required, start engine and check for
leaks. Make sure radiator fins are clean to prevent
overheating.
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Cooling System Hoses
HVAC SYSTEM
Reference Chapter 5 Engine Cooling System for further

details on servicing the cooling system hoses.
A/C Condenser Cleaning
1. Inspect all engine and vehicle hoses for cracks,

deterioration, abrasion or leaks. Replace if
necessary.
2. Check tightness and condition of all hose clamps.

2. Turn the two fasteners (Item 1) counterclockwise 1/4
turn and remove the grass screen (Item 2).
CAUTION
Do not over-tighten hose clamps at radiator, or radiator
fitting may distort.
Radiator hose clamp torque is 36 in-lbs (4 Nm).
Radiator Inspection / Cleaning

Reference Chapter 5 Engine Cooling System for further
details on servicing the radiator.
1. Check radiator air passages for restrictions or
damage.
2. Carefully straighten any bent radiator fins.
3. Remove any obstructions with compressed air or low
pressure water.
3. Carefully use low pressure air or water to clean the

condenser cooling fins (Item 3).
CAUTION
Washing the vehicle with a high-pressure washer is not
recommended and could damage the radiator fins and
impair the radiators effectiveness. Use of a highpressure washer is not recommended.
Coolant Drain / Fill

Reference Chapter 5 Engine Cooling System for
Coolant Drain and Cooling System Bleeding Procedure.
4. Reinstall the grass screen (Item 2) and turn the two

1/4 turn fasteners (Item 1) clockwise.
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HVAC Filter Inspection / Replacement
A/C Drive Belt
The HVAC filter is located below the dash.
The V-belt will slip if it does not have the proper tension.
This will prevent the A/C compressor from operating
efficiently.
1. Remove the two fasteners (Item 4) and remove the

filter cover (Item 5).
NOTE: NEVER get any oil on the belt. Oil on the belt
causes slipping and stretching. Replace the belt if
damaged.
Check and adjust the V-belt tension (deflection) as
follows:
3. Remove the three bolts (Item 1) and belt shield (Item
2) from the vehicle.
2. Clean the filter (Item 6) with low air pressure. Check

for damage, replace if damaged.

non-specified V-belt can shorten the belt life.
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5. At the mid span location shown, press down on the
V-belt with approximately 20 lbs. (89 N) of applied
force to check the belt deflection.
6. If adjustment is necessary, loosen the mounting bolt

(Item 3) and adjustment bolt (Item 4).
Air Conditioning Drive Belt Tension

NOTE: Remove the skid plate to better access

the compressor adjustment bolt (Item 4).
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7. Move the bottom of the compressor (Item 5) with a
pry bar to tighten the V-belt to the desired tension
and then tighten the adjustment bolt (Item 4).
8. Torque the mounting bolt (Item 3) and adjustment
bolt (Item 4) to specification.
2
Upper A/C Compressor Mounting Bolt:
28 ft-lbs (38 Nm)
Lower A/C Compressor Adjustment Bolt:
15 ft-lbs (20 Nm)
9. Install the belt shield and three retaining bolts.
10. After adjusting, run the engine and turn on the A/C
for 5 minutes or more. Check the tension again
referencing the previous specification.
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HYDRAULIC / HYDROSTATIC
SYSTEM
Hydraulic / Hydrostatic Hose
Reference Chapter 13 Hydraulics and Chapter 10 Hydrostatic Drive for further details on servicing the hydraulic /
hydrostatic system hoses.
Hydraulic / Hydrostatic Hose Inspection

Inspect all hydraulic and hydrostatic hoses for cracks, deterioration, abrasion or leaks. Replace if necessary. Check
tightness and condition of all threaded fittings and clamps.
BRUTUS Hose Layout
BRUTUS HD / HDPTO Hose Layout
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Hydraulic Fluid Level
NOTE: It is important to follow the hydraulic /
hydrostatic system maintenance intervals described
in the Periodic Maintenance Chart.
7. If fluid level is low, clean the area around the tank fill
cap (Item 3), remove the cap and add the
recommended hydraulic fluid as needed. Do not
overfill.
The hydraulic fluid level should be checked in

accordance with the maintenance schedule.
2. Lower the attachment arm and put the attachment
flat on the ground (HD / HDPTO models only).
3. Place the transmission in PARK and stop the engine.
4. Tilt the rear cargo box to access the hydraulic fluid
tank (Item 1).
Recommended Hydraulic Fluid:

(PN 2879746) (1 Gal.)
Tank Only Capacity: 2.75 qts. (2.6 L)
Full System Capacity: 7.2 qts. (6.8 L)
NOTE: Use only the recommended Polaris
hydraulic fluid when adding or changing the
fluid.
8. Lower the rear cargo box.
Hydraulic Fluid and Filter Replacement

NOTE: It is important to follow the hydraulic /
hydrostatic system maintenance intervals described
in the Periodic Maintenance Chart.
The hydraulic / hydrostatic fluid and filter should be
Always replace the hydraulic fluid whenever the filter is
replaced.
5. Check the fluid level in the sight gauge (Item 2).
6. The fluid level is correct when at the center of the

sight gauge (Item 2).
2. Lower the attachment arm and put the attachment

flat on the ground (HD / HDPTO models only).
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5. Remove the clamp (Item 1) and the hose (Item 2)
from the gear pump fitting and drain the hydraulic
fluid into a suitable container.
6. Thoroughly clean the area around the tank fill cap

(Item 3).
7. Slowly loosen the fill cap to relieve hydraulic system

pressure in the tank. Remove the fill cap.
8. Remove and clean the hydraulic fluid fill screen (Item

4). Use low air pressure to clean the screen.
9. Place a suitable container under the hydraulic filter

(Item 5) and remove the filter using a commercially
available filter wrench.
10. Clean the surface of the filter housing where the filter
seal contacts the housing.
11. Put clean oil on the seal of the new filter. Install and
hand tighten the new filter.
WARNING
12. Recycle or dispose of used

environmentally safe manner.
fluid
in
an
Hydraulic fluid under pressure can penetrate skin or

eyes, causing serious injury or death.
Fluid leaks under pressure may not be visible. Use a
piece of cardboard or wood to find leaks. Do not use
your bare hand.
Wear safety goggles.
If fluid enters skin or eyes, get immediate medical
attention from a physician familiar with this injury.
WARNING
Always clean up spilled fuel or oil. Keep heat, flames or
sparks away from fuel and oil. Failure to use care
around combustibles can cause explosion or fire.
13. Install the hydraulic fluid fill screen.
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14. Add the recommended hydraulic fluid to the tank.
Maintain the fluid level at the center of the sight
gauge (see Hydraulic Fluid Level). Do not overfill.

(PN 2879746) (1 Gal.)
Tank Only Capacity: 2.75 qts. (2.6 L)
Full System Capacity: 7.2 qts. (6.8 L)
POWER TAKE-OFF SYSTEM (PTO)

PTO Gearbox Oil Level
NOTE: It is important to follow the PTO gearbox
lubricant maintenance intervals described in the
Periodic Maintenance Chart. Periodic inspection of
the PTO gearbox lubricant is not needed. Visually
inspect the gearbox for leaks. If any leak is
suspected, check the lubricant level.
The PTO gearbox lubricant level should be checked in
Hydraulic / Hydrostatic Filter: PN 3120212

NOTE: Use only the recommended Polaris
hydraulic fluid when adding or changing the
fluid.

4. Thoroughly clean the area around the breather tube
fitting (Item 1) and remove the fitting.
15. Install and tighten the tank fill cap.

17. Start the engine and operate the hydraulic controls. If
any hydraulic function operation is not smooth, this
may indicate that air is trapped in the hydraulic
system. Continue to operate all the hydraulic
functions until operation is smooth.
18. Stop the engine and check for leaks.
19. Check fluid level again and add as needed.
NOTE: The PTO gearbox lubricant level must be

check through the breather tube fitting hole. The
other plug located on top of the gearbox is
positioned over a gear, so there is no access to
the bottom of the gear case.
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5. In order to accurately check the PTO gearbox
lubricant level, a dipstick must be constructed.
Use the T40 wrench (Item 2) that is included in the
vehicle tool kit and a piece of nylon tubing (Item 3)
that fits snug over the tool.
Mark the tool at two places: at 0.43 in. (11 mm)

and at 2.17 in. (55 mm).
7. If the lubricant level is low, install a piece of clear

tubing (Item 4) on the end of the gearbox oil bottle
(Item 5). Add the recommended PTO gearbox oil as
needed. Do not overfill.
NOTE: Take care to ensure no oil comes in

contact with the PTO drive belt.
Slide a piece of nylon tubing over the tool to use as

a stop and set it at the 2.17 in. (55 mm) mark.
6. Insert the tool into the PTO gearbox through the
breather tube fitting hole. The lubricant level should
be maintained between the tip of the tool and the
0.43 in. (11 mm) mark.
Recommended PTO Gearbox Oil:

PTO Gearbox Oil
(PN 2879748) (6 oz.)
NOTE: The PTO gearbox requires special
synthetic oil. Use only the recommended Polaris
PTO Gearbox Oil when adding or changing the
fluid.
8. If the fluid level is above the mark, it may indicate
that moisture has been ingested into the oil. If
moisture is present, replace the fluid (see PTO
Gearbox Oil Change). Also, if moisture is present,
check the breather tube to make sure it is in the
correct location.
NOTE: If the breather tube has been allowed to
hang down, water can enter the breather tube
and be sucked into the gear case.
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9. Reinstall the breather tube fitting (Item 1) and place
the end of the breather tube (Item 6) into the cross
member that is behind the operators seat.
5. Remove the drain plug (Item 7) and allow lubricant to

completely drain. Dispose of the used oil in an
environmentally safe manner.
WARNING
Always clean up spilled fuel or oil. Keep heat, flames or

sparks away from fuel and oil. Failure to use care
around combustibles can cause explosion or fire.
6. Reinstall the drain plug (Item 7) and torque to
specification.
PTO Gearbox Drain Plug:

11 ft-lbs (15 Nm)
7. Thoroughly clean the area around the breather tube

fitting (Item 8) and remove the fitting.
PTO Gearbox Oil Change

NOTE: It is important to follow the PTO gearbox
lubricant maintenance intervals described in the
Periodic Maintenance Chart.
The PTO gearbox lubricant should be changed in
4. Locate the PTO gearbox drain plug (Item 7) through
the skid plate. Place a suitable drain pan under the
drain plug.
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MAINTENANCE
8. Install a piece of clear tubing (Item 9) on the end of
the gearbox oil bottle (Item 10). Add 6 oz. (177 ml) of
the recommended PTO gearbox oil. Do not overfill.
NOTE: Take care to ensure no oil comes in

contact with the PTO drive belt.
9. Reinstall the breather tube fitting (Item 8) and place

the end of the breather tube (Item 11) into the cross
member that is behind the operators seat.
Recommended PTO Gearbox Oil:

PTO Gearbox Oil
(PN 2879748) (6 oz.)
NOTE: The PTO gearbox requires special
synthetic oil. Use only the recommended Polaris
PTO Gearbox Oil when adding or changing the
fluid.
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MAINTENANCE
PTO Drive Belt Inspection
PTO U-Joint Inspection
NOTE: It is important to follow the PTO drive belt

Maintenance Chart.
NOTE: It is important to follow the PTO shaft U-joint

Maintenance Chart.
The PTO drive belt has a constant tension idler to keep

the correct tension on the belt.
Remove the PTO Guard (Item 3) and vehicle skid plate

(Item 4) to properly inspect the PTO shaft U-joints (Item
5). If excessive wear is found, replace the PTO shaft as
an assembly.

4. The drive belt idler is under constant spring load to
keep the belt at the correct tension. No belt tension
adjustments can be made. If belt slippage is noticed,
the PTO drive belt (Item 1) and/or constant tension
pulley (Item 2) must be replaced.
5. Inspect drive belt condition. If belt wear, including the

side of the belt is visible, belt replacement is
required.
6. If the PTO drive belt requires replacement, the
hydrostatic pump and engine bell housing will need
to be removed (see Chapter 10 Hydrostatic Pump
Removal).
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MAINTENANCE
PTO Clutch Brake Inspection / Adjustment
NOTE: It is important to follow the PTO clutch brake
Maintenance Chart.
5. Insert the end of a feeler gauge (Item 3) into the

opening of the clutch pack to a depth of 0.31 in. (8
mm) and measure the clearance.
The PTO system is activated by engaging an electric

clutch. When the clutch is engaged, the PTO driveline
will rotate. When disengaged, a PTO brake is applied.
The PTO clutch brake must be inspected and adjusted in
3. Remove the passenger seat and storage container
to access the PTO clutch brake (Item 1).
NOTE: Do not insert the end of the feeler gauge

more than 0.31 in (8 mm) into the side of the
clutch to get an accurate measurement.
6. Measure the clearance at all three locations shown
to determine that the clearance is the same for all
three areas on the clutch pack.
NOTE: Removing the vehicle skid plate allows

better access to the PTO clutch brake for
measurement and adjustment purposes if
required.
4. Locate the clutch brake opening (Item 2) on the edge
of the clutch pack.
7. The correct clearance is 0.014 in. (0.35 mm).

PTO Clutch Brake Clearance:
0.014 in. (0.35 mm)
8. Tighten or loosen the three adjusting nuts (Item 4)
until the correct clearance is achieved evenly (at the
three areas checked) on the clutch.
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MAINTENANCE
FINAL DRIVE / WHEEL AND TIRE
Front Wheel Bearing Inspection
Drive Shaft Boot Inspection
1. Elevate front of vehicle and safely support machine

under the frame area.
Inspect the front and rear drive shaft boots (Item 1) for
damage, tears, wear or leaking grease. If the boots
exhibit any of these symptoms, they should be replaced.
Check to see the boot clamps (Item 2) are properly
positioned.
CAUTION
Serious injury may result if machine tips or falls. Be
sure machine is secure before beginning this service
procedure. Wear eye protection when removing
bearings and seals.
2. Check bearings for side play by grasping the top and
bottom of the tire firmly and checking for movement.
The tire should rotate smoothly without binding or
rough spots.
NOTE: Side to side play could also indicate tie

rod end wear and top to bottom play could also
indicate upper or lower ball joint wear. Be sure to
closely inspect these components if play is
found.
Refer to Chapter 7 for drive shaft boot replacement.
3. If an excessive amount of play or movement is

detected, proceed to Final Drive Chapter Bearing
Carrier Inspection / Removal.
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Wheel and Hub Torque Table
Wheel Installation
1. Verify the transmission is still in PARK.
ITEM
SPECIFICATION
Wheel Nuts
(Steel Wheels)
60 ft-lbs. (81 Nm)
Front Wheel Hub

Castle Nuts
75 ft-lbs. (102 Nm)
Rear Wheel Hub

Castle Nuts
110 ft-lbs. (149 Nm)
2. Install the wheel on the wheel hub with the valve

stem toward the outside. Be sure rotation arrow on
the tire (if applicable) point toward forward rotation.
3. Attach the wheel nuts (Item 1) and finger tighten
them.
4. Carefully lower the vehicle to the ground.
NOTE: Do not lubricate the stud or the lug nut.
5. Torque wheel nuts (Item 2) and/or hub nut (Item 4) to

the proper specification (see Wheel and Hub Torque
Table).
6. If wheel hub nut was removed, install a new cotter
pin (Item 3) after the hub castle nut has been
tightened. If the holes do not line up, turn the castle
nut counter-clockwise until the cotter pin can be
installed.
Wheel Removal
1. Position the vehicle on a level surface.
3. Loosen the wheel nuts (Item 1) slightly. If wheel hub
removal is required, remove the wheel cap (Item 2),
cotter pin (Item 3) and loosen the hub nut (Item 4)
slightly.
CAUTION
If wheels are improperly installed it could affect vehicle
handling and tire wear. On vehicles with tapered wheel
nuts, make sure tapered end of nut goes into taper on
wheel.
Tire Inspection
Improper tire inflation
maneuverability.
may
affect
vehicle
When replacing a tire always use original

equipment size and type.
The use of non-standard size or type tires may
affect vehicle handling.
WARNING
Operating with worn tires will increase the possibility of
the vehicle skidding easily with possible loss of control.
4. Elevate the appropriate side of the vehicle by placing
a suitable stand under the frame.
Worn tires can cause an accident.
5. Remove the wheel nuts (Item 1) and remove the

wheel (Item 5).
Always replace tires when the useable tread depth has

worn out.
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MAINTENANCE
Tire Pressure
ELECTRICAL SYSTEM
Remove the valve stem cap and check tire pressure

using the tire pressure gauge included in the vehicles
tool kit.
Battery Maintenance
CAUTION
Maintain proper tire pressure.
Refer to the warning tire pressure decal
applied to the vehicle.
Keep battery terminals and connections free of

corrosion. If cleaning is necessary, remove the corrosion
with a stiff wire brush. Wash with a solution of one
tablespoon baking soda and one cup water. Rinse well
with tap water and dry off with clean shop towels. Coat
the terminals with dielectric grease or petroleum jelly.
WARNING
BRUTUS
Tire Pressure Inspection (Cold)
Front
Rear
10 psi (69 kPa)
20 psi (138 kPa)
CALIFORNIA PROPOSITION 65 WARNING:

Batteries, battery posts, terminals and related
accessories contain lead and lead compounds, and
other chemicals known to the State of California to
cause cancer and birth defects or other reproductive
harm.
WASH HANDS AFTER HANDLING.
BRUTUS CAB / HD / HDPTO

Tire Pressure Inspection (Cold)
Front
Rear
20 psi (138 kPa)
20 psi (138 kPa)
WARNING
Battery electrolyte is poisonous. It contains sulfuric
acid. Serious burns can result from contact with skin,
eyes or clothing. Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow
with milk of magnesia, beaten egg, or vegetable oil. Call
physician immediately.
Eyes: Flush with water for 15 minutes and get prompt
medical attention.
Batteries produce explosive gases.
Keep sparks, flame, cigarettes, etc. away. Ventilate
when charging or using in an enclosed space. Always
shield eyes when
working near batteries.
KEEP OUT OF REACH OF CHILDREN.
NOTE: Batteries must be fully charged before use or
battery life will be reduced by 10-30% of full
potential. Charge battery according to Charging
Procedure provided in Chapter 10. Do not use the
vehicles stator/alternator to charge a new battery.
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Battery Removal
5. Install and tighten the black (negative) cable last.
1. Remove the passenger seat and storage container

to access the battery.
2. Disconnect the black (negative) battery cable (Item
1).
Battery Terminal Pinch Bolt:
12.5 ft-lbs (17 Nm)
6. Verify the cables are properly routed and reinstall the
storage container and passenger seat.
Battery Charging / Off Season Storage

Refer to Chapter 15 Electrical for charging and off
season storage procedures.
Chassis / Engine Electrical Ground

Inspect the ground cable connections. Be sure they are
clean and tight. Remove ground terminals and clean if
necessary.
3. Disconnect the red (positive) battery cable (Item 2).
1. Remove the passenger seat base and storage bin to

access the chassis ground terminal (Item 1), located
on the main frame, to the right of the battery.
CAUTION
To reduce the chance of sparks: Whenever removing
the battery, disconnect the black (negative) cable first.
When reinstalling the battery, install the black (negative)
cable last.
4. Remove the fastener retaining the battery hold-down
strap and lift the battery out of the vehicle.
Battery Installation
NOTE: Using a new battery that has not been fully
charged can damage the battery and result in a
shorter life. Follow the battery charging procedure in
Chapter 15 Electrical before installing the battery.
1. Ensure the battery is fully charged.
2. Place the battery in the vehicle. Install the hold-down
strap and retaining fastener.
3. Coat the battery terminals with Polaris corrosion
resistant Nyogel grease (PN 2871329).
4. Install and tighten the red (positive) cable first.
2. Inspect the chassis ground terminals. Be sure they

are clean and tight.
3. Inspect the engine ground terminal (Item 2), attached
to the front engine mounting bracket. The other end
of the engine ground cable is attached to the chassis
ground terminal (Item 1).
4. Inspect the engine ground terminals. Be sure they
are clean and tight.
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MAINTENANCE
STEERING
Tie Rod End / Wheel Hub Inspection
Steering Inspection
Steering system components should be checked
periodically for loose fasteners (Item 1), worn tie rod
ends (Item 2), loose steering shaft U-joints (Item 3), worn
A-arm ball joints and general damage. Also check to
make sure all cotter pins (Item 4) are in place. If cotter
pins are removed, they must be replaced.
To check for play in the tie rod end, grasp the

steering tie rod, pull in all directions feeling for
movement.
Replace any worn or damaged steering components.

While the engine is running, the steering system should
move freely through the entire range of travel without
binding. Check routing of all cables, hoses, and wiring.
Replace any worn steering components. Steering

should move freely through entire range of travel
without binding.
Elevate front end of machine so front wheels are
off the ground. Check for any looseness in front
wheel/hub assembly by grasping the tire firmly at
top and bottom first, and then at front and rear. Try
to move the wheel and hub by pushing inward and
pulling outward.
NOTE: Check front end alignment

steering components are replaced.
whenever
WARNING
Due to the critical nature of the procedures outlined in
this chapter, Polaris recommends steering component
repair and adjustment be performed by an authorized
Polaris MSD certified technician.
If abnormal movement is detected, inspect the hub
and wheel assembly to determine the cause (loose
wheel nuts or loose front hub nut).
Refer to Chapter 11 Final Drive for front hub or
bearing carrier service procedures.
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MAINTENANCE
Wheel Toe Alignment Inspection
NOTE: Make sure tire pressures are set the same on
the right and left tires.
1. Place machine on a smooth level surface and set
steering wheel in a straight ahead position. Secure
the steering wheel in this position.
5. Again measure the distance between the marks and

record. Call this measurement B. Subtract
measurement B from measurement A. The
difference between measurements A and B is the
vehicle toe alignment. The recommended vehicle toe
tolerance is 1/8 to 3/16 (3.2 to 4.8 mm) toe out. This
means the front of the tire (A) is 1/8 to 3/16 (3.2 to
4.8 mm) wider than the measurement at the rear (B).
2. Place a chalk mark on the center line of the front tires

approximately 10 (25.4 cm) from the floor or as
close to the hub/axle center line as possible.
Wheel Toe-Out:
(A) - (B) = 1/8" to 3/16" (3.2 to 4.8 mm)
Wheel Toe Adjustment

If toe alignment is incorrect, repeat steps 3-5 of Wheel
Toe Alignment Inspection, but instead measure the
distance between vehicle center and each wheel. This
will tell you which tie rod needs adjusting.
NOTE: It is important the height of both marks

be equally positioned to get an accurate
measurement.
3. Measure the distance between the marks and record
the measurement. Call this measurement A.
4. Rotate the tires 180 by moving the vehicle forward.
Position chalk marks facing rearward, even with the
hub/axle center line.
NOTE: Be sure steering wheel is straight ahead

before determining which tie rod needs adjustment.
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MAINTENANCE
CAUTION
During tie rod adjustment, it is very important that the
following precautions be taken when tightening tie rod
end jam nuts.
If the rod end is positioned incorrectly it will not pivot,
and may break.
SUSPENSION
Suspension Inspection
Compress and release the suspension. Damping should
be smooth throughout the range of travel.
Check all suspension components and mounting
fasteners for wear or damage.
Inspect each shock body for leakage.
To adjust toe alignment:

Hold tie rod end to keep it from rotating.
Loosen jam nuts at both end of the tie rod.
Shorten or lengthen the tie rod until alignment is as
required to achieve the proper toe setting as
specified in Wheel Toe Alignment Inspection.
IMPORTANT: When tightening the tie rod end jam
nuts, the rod ends must be held parallel to prevent
rod end damage and premature wear. Damage
may not be immediately apparent if done
incorrectly.
After alignment is complete, torque jam nuts to
specification.
Spring Pre-Load Adjustment

NOTE: DO NOT attempt to adjust the front shock
spring pre-load on BRUTUS HD / HDPTO models.
The factory has pre-set the spring rate for optimal
performance for use with the various attachments
that can be installed on the attachment arm.
The front and rear shock absorber springs are
adjustable. Rotate the adjuster cam either direction to
increase or decrease spring tension. Always adjust both
left and right sides equally.
NOTE: Adjusting all shock cams equally will only
affect ride height as the weight transfer will not be
changed.
Tie Rod Jam Nut:

14 ft-lbs. (19 Nm)
Vehicle loads effect suspension spring pre-load

requirements. Use the recommended Spanner Wrench
to adjust pre-load as necessary to avoid bottoming of the
shocks.
Shock Spanner Wrench:
PV-43507-A
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MAINTENANCE
BRAKE SYSTEM
Brake Pad / Disc Inspection
Brake Fluid Inspection
1. Check the brake pads for wear, damage, or

looseness.
Always check the brake pedal travel and inspect the

brake fluid reservoir level before each operation. If the
fluid level is low, add DOT 4 brake fluid only.
Brake fluid should be changed every two years. The fluid
should also be changed anytime the fluid becomes
contaminated, the fluid level is below the minimum level,
or if the type and brand of the fluid in the reservoir is
unknown.
2. Inspect the brake pad surface for excessive wear.

3. Pads should be changed when the friction material is
worn to .040 (1 mm).
The brake master cylinder reservoir (Item 1) can be

accessed through the front left wheel well.
4. Check surface condition of the brake discs.

5. Measure the thickness of the front and rear brake
discs.
1. Position the vehicle on a level surface.

2. Place the gear selector in Park.
3. View the brake fluid level in the reservoir. The level
should be between the MAX and MIN level lines.
4. If the fluid level is lower than the MIN level line, add
brake fluid until it reaches just below the MAX level
line (Item 2).
5. Install the reservoir cap and apply the brake pedal
forcefully for a few seconds and check for fluid
leakage around the master cylinder fittings and the
brake caliper fittings.
Brake Hose and Fitting Inspection

Check brake system hoses and fittings for cracks,
deterioration, abrasion, and leaks. Tighten any loose
fittings and replace any worn or damaged parts.
6. The disc (s) should be replaced if thickness is less

than the specified service limit (see Chapter 9 for
specifications).
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ENGINE
CHAPTER 3
ENGINE
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
ENGINE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
ENGINE SERVICE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
ENGINE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
EXHAUST REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
MUFFLER REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
INTAKE AIRBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
AIRBOX HOUSING REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
ENGINE REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.12
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.12
ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16
ENGINE MOUNT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20
OIL PAN REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20
OIL PUMP REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20
OIL PUMP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21
ENGINE OIL PRESSURE - TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.23
CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.24
INTAKE MANIFOLD / VALVE COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.24
GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.25
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.25
ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.26
INTAKE AND EXHAUST VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.27
CYLINDER HEAD - SERVICING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.29
VALVE SPRING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.31
ROCKER ARM / PUSH ROD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.33
VALVE TAPPET INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.34
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.35
VALVE CLEARANCE INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.37
CYLINDER HEAD INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.39
INTAKE MANIFOLD / VALVE COVER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.39
CAMSHAFT AND TIMING GEARS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.40
TIMING GEARCASE COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.40
TIMING GEARCASE COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.40
TIMING GEARS BACKLASH - CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.41
IDLER GEAR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.41
TIMING GEARS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.42
TIMING GEARS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.42
3.1
Copyright 2014
ENGINE
CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.43
CAMSHAFT INSPECTION / SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.43
CRANKSHAFT AND PISTONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.45

PISTON AND CONNECTING ROD REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.45
PISTON INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.47
CONNECTING ROD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.49
CYLINDER HONING AND BORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.50
PISTON AND CONNECTING ROD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.50
CYLINDER BORE - INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.53
CRANKSHAFT AND BEARINGS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.53
CRANKSHAFT AND BEARING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.55
CRANKSHAFT OIL SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.56
CRANKSHAFT AND BEARINGS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.56
ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.58
HAND LEVER REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.58
CABLE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.60
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.62
3.2
Copyright 2014
ENGINE
GENERAL INFORMATION
Special Tools
TOOL DESCRIPTION
Valve Guide Tool
(for removing valve guides)
Valve Guide Tool

(for installing valve guides)
Wrist Pin Bushing Tool
Stem Seal Tool

(for installing stem seals)
PART NUMBER / APPLICABLE MODEL AND TOOL SIZE

L1
L2
d1
d2
0.787 in.
(20 mm)
2.953 in.
(75 mm)
0.217 in.
(5.5 mm)
0.374 in.
(9.5 mm)
L1
L2
d1
d2
0.394 in.
(10 mm)
2.362 in.
(60 mm)
0.433 in.
(11 mm)
0.669 in.
(17 mm)
L1
L2
d1
d2
0.984 in.
(25 mm)
3.346 in.
(85 mm)
0.866 in.
(22 mm)
0.984 in.
(25 mm)
L1
L2
d1
d2
0.433 in.
(11 mm)
2.559 in.
(65 mm)
0.591 in.
(15 mm)
0.827 in.
(21 mm)
Valve Spring Compressor
Yanmar Part Number: 129100-92630
Piston Ring Compressor

(for installing pistons)

2.362-4.921 in. (60-125 mm)
Flex-Hone
(for preparing cylinder walls)

2.756-2.992 in. (70-76 mm)
Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com.
3.3
Copyright 2014
ENGINE
Engine Description
The Yanmar 3TNM72 is a vertical, water cooled, 4-cycle, three cylinder diesel engine.
A cylinder fires every 240 of crankshaft rotation.
3.4
Copyright 2014
ENGINE
ENGINE SERVICE SPECIFICATIONS
Engine Specifications
COMPONENT
Cylinder
Head
MEASUREMENT
STANDARD
SERVICE LIMIT
Cylinder Mating Surface Warpage
0.002" (0.05 mm)
Height
3.855" (97.92 mm)
Compression
470 15 PSI (3200 100 kPa)
370 15 PSI
(2600 100 kPa)
Intake Valve Recession
0.0157 - 0.0236" (0.4 - 0.6 mm)
0.0354" (0.9 mm)
Exhaust Valve Recession
0.0157 - 0.0236" (0.4 - 0.6 mm)
0.0315" (0.8 mm)
Intake Valve Seat Angle
120
Exhaust Valve Seat Angle
90
Valve Seat Correction Angle
40, 150
Intake Valve Seat Contacting Width
0.0028" (0.7 mm)
0.055" (1.4 mm)
Intake Valve (Margin Thickness)
0.039" (1.0 mm)
0.031" (0.8 mm)
Intake Valve Stem O.D.
0.2346 - 0.2356" (5.960 - 5.985 mm)
0.2323" (5.9 mm)
Intake Valve Stem Oil Clearance
0.0006 - 0.0020" (0.015 - 0.052 mm)
0.0063" (0.17 mm)
Intake Valve Length
3.976" (101.0 mm)
Exhaust Valve Seat Contacting Width
0.039" (1.0 mm)
0.071" (1.8 mm)
Exhaust Valve (Margin Thickness)
0.039" (1.0 mm)
0.031" (0.8 mm)
Exhaust Valve Stem O.D.
0.2342 - 0.2350" (5.945 - 5.970 mm)
0.2323" (5.9 mm)
Exhaust Valve Stem Oil Clearance
0.0012 - 0.0026" (0.030 - 0.067 mm)
0.0067" (0.15 mm)
Exhaust Valve Length
3.984" (101.2 mm)
Valve Guide I.D.
0.2362 - 0.2367" (6.0 - 6.012 mm)
Valve Guide Protrusion Above Head
0.3858 - 0.3937" (9.8 - 10.0 mm)
Valve Stem Bend
0.0004" (0.010 mm)
Valve Clearance
0.006 - 0.010" (0.15 - 0.25 mm)
Valve Spring Free Length
1.4882" (37.8 mm)
Valve Spring Squareness
0.512" (1.3 mm)
Rocker Arm I.D.
0.4724 - 0.4732" (12.00- 12.02 mm)
0.4752" (12.07 mm)
Rocker Shaft O.D.
0.4711 - 0.4718" (11.97 - 11.98 mm)
0.4701" (11.94 mm)
Rocker Shaft Oil Clearance
0.0006 - 0.0021" (0.016 - 0.055 mm)
0.0051" (0.13 mm)
Push Rod Bend
Less than 0.0012" (0.03 mm)
0.0012" (0.03 mm)
Valves
Valve Spring
Rocker Arms
Push Rod
3.5
Copyright 2014
ENGINE
COMPONENT
Tappet
Cylinder
Camshaft
Piston
MEASUREMENT
STANDARD
SERVICE LIMIT
Tappet Bore (Block) I.D.
0.8268 - 0.8276" (21 - 21.021 mm)
0.8284" (21.041 mm)
Tappet Stem O.D.
0.8239 - 0.8252" (20.93 - 20.96 mm)
0.8231" (20.907 mm)
Oil Clearance
0.0016 - 0.0037" (0.040 - 0.094 mm)
0.0053" (0.134 mm)
Cylinder - Surface Warp

(mating with cylinder head)
0.002" (0.05 mm)
Cylinder Bore
2.8346 - 2.8358" (72.0 - 72.03 mm)
Cylinder Out of Round Limit
0.0012" (0.03 mm)
Cylinder Taper Limit
0.0012" (0.03 mm)
Cylinder to Piston Clearance
0.0006 - 0.0020" (0.015 - 0.050 mm)
0.0024" (0.060 mm)
Cylinder Boring Limit
2.8425" (72.20 mm)
Cam Lobe Height

(Intake and Exhaust)
1.3596 - 1.3648" (34.54 - 34.67 mm)
1.3499" (32.287 mm)
Gear End Journal Bearing I.D.
1.5748 - 1.5758" (40 - 40.025 mm)
1.587" (40.100 mm)
Gear End Journal O.D
1.5724 - 1.5732" (39.94 - 39.96 mm)
1.5711" (39.906 mm)
Gear End Journal Oil Clearance
0.0016 - 0.0033" (0.04 - 0.085 mm)
0.0061" (0.154 mm)
Intermediate Bearing I.D.
1.5748 - 1.5758" (40 - 40.025 mm)
1.5699" (39.875 mm)
Intermediate Journal O.D.
1.5713 - 1.5722" (39.91 - 39.94 mm)
1.5699" (39.875 mm)
Intermediate Journal Oil Clearance
0.0026 - 0.0045" (0.065 - 0.115 mm)
0.0089" (0.225 mm)
Flywheel End Journal Bearing I.D.
1.5748 - 1.5758" (40.0 - 40.025 mm)
1.5787" (40.10 mm)
Flywheel End Journal O.D
1.5724 - 1.5732" (39.94 - 39.96 mm)
1.5711" (39.906 mm)
Flywheel End Journal Oil Clearance
0.0016 - 0.0033" (0.04 - 0.085 mm)
0.0061" (0.154 mm)
O.D.
2.8331 - 2.8343" (71.96 - 71.98 mm)
2.8313" (71.915 mm)
Piston to Cylinder Clearance
0.0004 - 0.0028" (0.01 - 0.07 mm)
Pin O.D.
0.8659 - 0.8661" (21.995 - 22.0 mm)
0.8648" (21.965 mm)
Pin Bore Diameter
0.8661 - 0.8665" (22.0 - 22.009 mm)
0.8677" (22.039 mm)
Pin Oil Clearance
0.0 - 0.0006" (0.0 - 0.014 mm)
0.0029" (0.074 mm)
Top Ring Groove Width
0.0610 - 0.0618" (1.55 - 1.57 mm)
0.0622" (1.58 mm)
Top Ring Width
0.0579 - 0.0587" (1.47 - 1.49 mm)
0.0571" (1.45 mm)
Top Ring Side Clearance
0.0024 - 0.0039" (0.06 - 0.10 mm)
Not Applicable
Top Ring End Clearance
0.0039 - 0.0098" (0.10 - 0.25 mm)
0.0013" (0.034 mm)
Second Ring Groove Width
0.0622 - 0.0628" (1.58 - 1.595 mm)
0.0667" (1.695 mm)
Second Ring Width
0.0579 - 0.0587" (1.47 - 1.49 mm)
0.0571" (1.45 mm)
Piston Rings
3.6
Copyright 2014
ENGINE
COMPONENT
Idle Gear
Shaft and
Bushing
Connecting
Rod
MEASUREMENT
STANDARD
SERVICE LIMIT
Second Ring Side Clearance
0.0035 - 0.0049" (0.09 - 0.125 mm)
0.0096" (0.245 mm)
Second Ring End Clearance
0.0098 - 0.0157" (0.25 - 0.40 mm)
0.0193" (0.49 mm)
Oil Ring Groove Width
0.1185 - 0.1191" (3.010 - 3.025 mm)
0.1232" (3.13 mm)
Oil Ring Width
0.1170 - 0.1177" (2.97 - 2.99 mm)
0.1161" (2.95 mm)
Oil Ring Side Clearance
0.0008 - 0.0022" (0.02 - 0.055 mm)
0.0071" (0.18 mm)
Oil Ring End Clearance
0.0079 - 0.0177" (0.20 - 0.45 mm)
0.0217" (0.55 mm)
Idle Gear Shaft O.D.
1.1795 - 1.1803" (29.96 - 29.98 mm)
1.1779" (29.919 mm)
Idle Gear Bushing I.D.
1.1811 - 1.1821" (30.0 - 30.025 mm)
1.1837" (30.066 mm)
Idle Gear Bushing Oil Clearance
0.0008 - 0.0026" (0.02 - 0.066 mm)
0.0059" (0.147 mm)
Small End I.D.
0.8671 - 0.8678" (22.03 - 22.04 mm)
0.7902" (20.072 mm)
Small End Radial Clearance
0.001 - 0.0019" (0.025 - 0.047 mm)
0.0041" (0.105 mm)
Big End Side Clearance
0.0079 - 0.0157" (0.20 - 0.40 mm)
Big End Radial Clearance
0.0008 - 0.0023" (0.020 - 0.058 mm)
0.0043" (0.110 mm)
Bend
0.0008" (0.02 mm)
End Play
0.0044 - 0.0098" (0.111 - 0.250 mm)
0.0110" (0.28 mm)
Thrust Bearing Thickness
0.076 - 0.078" (1.93 - 1.98 mm)
0.0728" (1.85 mm)
Roundness
0.0004" (0.01 mm) or less
0.0008" (0.02 mm)
Rod Journal O.D.
1.4942 - 1.4946" (37.95 - 37.96 mm)
1.4725" (37.402 mm)
Rod Bearing I.D.
1.4954 - 1.4965" (37.98 - 38.01 mm)
Rod Bearing Insert Thickness
0.0592 - 0.0594" (1.503 - 1.509 mm)
Rod Bearing Oil Clearance
0.0008 - 0.0023" (0.02 - 0.58 mm)
0.0043" (0.110 mm)
Engine Oil Pressure

(3600 RPM, Engine Hot)
42 - 64 PSI (289.6 - 441.3 kPa)
Outer Rotor Outside Clearance
0.0039 - 0.0063" (0.10 - 0.16 mm)
0.0098" (0.25 mm)
Outer Rotor Side Clearance
0.0019 - 0.0039" (0.05 - 0.10 mm)
0.0059" (0.15 mm)
Outer Rotor To Inner Rotor Tip

Clearance
0.0063" (0.16 mm)
Crankshaft
Oil Pump
3.7
Copyright 2014
ENGINE
Torque Values
TORQUE SPECIFICATIONS
Fastener
Size
ft-lbs (Nm)
Camshaft Pulley
12 mm
61 - 69 ft-lbs (83 - 93 Nm)
Connecting Rod Bolts
7 mm
83 - 90 ft-lbs (113 - 123 Nm)
10 mm
12 ft-lbs (16 Nm)
4 mm
15 in-lbs (2 Nm)
Main Cap Bolt
9 mm
33 ft-lbs (45 Nm)
Ladder Frame Bolt
9 mm
33 ft-lbs (45 Nm)
Fuel Nozzle Nut
20 mm
37 ft-lbs (50 Nm)
Fuel High Pressure Pipe Nut
12 mm
24 ft-lbs (32 Nm)
Fuel Pump Gear Bolt
8 mm
25 ft-lbs (34 Nm)
Cylinder Head Bolts
9 mm
42 ft-lbs (57 Nm)
Fuel Pump End Nut
12 mm
47 ft-lbs (64 Nm)
Flywheel
10 mm
60 ft-lbs (81 Nm)
Oil Pump
6 mm
7 ft-lbs (11 Nm)
Glow Plug
3.8
Copyright 2014
ENGINE
Engine Lubrication Specifications
NOTE: Use of a non-recommended engine oil may
cause serious engine damage.
Oil Capacity *
Polaris recommends the use of Polaris Diesel Oil (SAE
CI-4) for this vehicle. Always use the correct viscosity
grade based on the ambient temperature expected
during operation. See the chart below.
Approx. 2.75 Quarts (2.6 L)

Oil Filter Wrench
PU-50105 or 2.5 (64 mm)
Oil Viscosity / Ambient Air Temperature Chart
Oil Filter
PN 3070131
Oil Type
Ambient Temp Range:
-25 F to 104 F
Synthetic Diesel Engine Oil 5W-40 All-Season
(PN 2879832)
Oil Type
Ambient Temp Range:
+5 F to 104 F
Diesel Engine Oil
15W-40 Summer
(PN 2878473)
Oil Type
Ambient Temp Range:
-25 F to 80 F
Diesel Engine Oil
10W-30 Winter
(PN 2878474)
Oil Pressure
(Polaris engine oil at operating temperature)
8.8 PSI (60.7 kPa)
@ 1350 RPM
42 - 64 PSI (290 - 441 kPa) @ 3600 RPM
*Additional oil may be required after complete engine
disassembly. Check level after filling and add as needed.
3.9
Copyright 2014
ENGINE
ENGINE EXHAUST SYSTEM
Muffler Removal and Installation

1. Raise the cargo box.
Exhaust Removal / Installation

1. Tilt the rear cargo box to the raised position. Remove
upper cargo box shock clip and pin. Allow cargo box
to rest fully open.
2. Remove the springs (Item 1) that secure the muffler

(Item 2) to the exhaust pipe (Item 3).
2. Using spring puller PU-45485, remove the two

exhaust springs (Item 1) connecting silencer to
headpipe.
3. Remove the nuts (Item 4) washers (Item 5) and

bolts.
3. Pull the two rear isolator mounts (Item 2) toward the

right side of the vehicle to disengage from frame
mounting posts.
4. Pull silencer toward the rear of the vehicle to
disengage silencer mounting post from front isolator
mount (Item 3).
5. Remove silencer through right side of vehicle frame.
6. Remove the six mounting bolts (Item 4) retaining the
headpipe to the engine.
7. Remove the headpipe from the vehicle.
8. To reinstall the exhaust system, reverse the removal
steps.
4. Remove the muffler.
NOTE: Install new exhaust gaskets and torque

all hardware to specification.
Headpipe Mounting Bolts:

18 ft-lbs (24 Nm)
3.10
Copyright 2014
ENGINE
INTAKE AIRBOX
5. Remove the two bolts (Item 5) and remove the airbox

(Item 6) from the vehicle.
Airbox Housing Removal and Installation

2. Loosen the clamp (Item 1) and remove the hose
(Item 2) from the air cleaner housing.

(Item 4) from the air cleaner housing.
4. Plug the hoses to prevent dirt and debris from

entering the engine.
3.11
Copyright 2014
ENGINE
ENGINE REMOVAL / INSTALLATION
9. Disconnect the wires (Item 2) from the alternator.
Engine Removal
1. Clean the work area.
2. Thoroughly clean the engine and chassis.
WARNING
Always wear safety glasses and proper shop clothing
when performing the procedures in the manual. Failing
to do so may lead to possible injury or death.
3. Disconnect the negative (-) battery cable.
4. Drain the engine coolant from the cooling system
(see Chapter 5 Engine Cooling System).
5. Remove the transmission from the vehicle (see
Chapter 9 Transmission Removal).
10. Remove the four nuts (Item 3) for the exhaust shield
(Item 4).
6. Remove the hydrostatic pump (see Chapter 10

Hydrostatic Pump Removal).
NOTE: DO NOT remove the pressure hoses from
the A/C compressor when removing the engine.
Removing the pressure hoses requires A/C
system recovery and charging.
7. Remove the A/C compressor (if applicable) (see
Chapter 6 Compressor Removal / Installation).
8. Remove the three screws (Item 1) retaining the
guard to the frame and remove the shield.
11. Disconnect the fuel solenoid (Item 5) and glow plug

connector (Item 6).
3.12
Copyright 2014
ENGINE
12. Disconnect the oil pressure sensor (Item 7).
15. Remove the two tie straps (Item 11).
13. Disconnect the crankshaft position sensor connector

(Item 8).
14. Cut the tie strap (Item 9) and disconnect the coolant
temperature sensor (Item 10).
16. Disconnect the starter wires (Item 12).
17. Loosen the clamp and remove the water pump inlet
hose (Item 13).
18. Remove the coolant hose (Item 14) from the

thermostat housing.
3.13
Copyright 2014
ENGINE
19. Loosen the clamp and remove the heater hose. (If
equipped)
22. Remove the bolt (Item 18) securing the ground cable
to the engine block.
NOTE: Mark the coolant hoses for ease of

installation.
Drain and dispose of the fluids properly.
20. Loosen the clamps (Item 15) and remove the fuel
lines (Item 16). Plug the lines and cap the fittings.
23. Disconnect the wire harness (Item 19) from the PTO
clutch.
21. Secure chain to the engine lift brackets (Item 17) and
apply slight tension with a hoist.
24. Remove the wire harnesses from the harness clips

(Item 20) on the PTO mounting plate.
3.14
Copyright 2014
ENGINE
25. Remove the four bolts (item 21) and PTO shaft (Item
22).
26. Remove the motor mount bolts (Item 23) from both
sides of the engine.
27. With the help of an assistant, remove the engine

from the vehicle.
3.15
Copyright 2014
ENGINE
Engine Installation
1. With the help of an assistant, install the engine in the
chassis.
4. Install the PTO shaft (Item 3) and four PTO shaft

bolts (item 4). Torque fasteners to specification.
2. Leave the engine lift secured to the engine lift

brackets (Item 1) with a slight amount of tension
applied to aid installation.
3. Install the motor mount bolts (Item 2) on both sides.

Torque bolts to specification.
PTO Shaft to PTO Gearcase Bolts:

20 ft-lbs (27 Nm)
5. Install the wire harnesses into the harness clips (Item
5) on the PTO mounting plate.
Engine Mount to Engine Fastener:

33 ft-lbs (45 Nm)
Engine Mount to Frame Fasteners:
22 ft-lbs (30 Nm)
3.16
Copyright 2014
ENGINE
6. Connect the wire harness (Item 6) to the PTO clutch.
8. Remove the plugs from the lines and fittings. Install

the fuel lines (Item 8) and tighten the clamps (Item
9).
7. Install the bolt (Item 7) securing the ground cable to

the engine block. Torque bolt to specification.
9. Install the heater hose (if equipped) and tighten the
clamp.
10. Install the coolant hose (Item 10) on the thermostat
housing.
Engine Ground Bolt:

54 in-lbs (6 Nm)
11. Install the water pump inlet hose (Item 11) and
tighten the clamp.
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ENGINE
12. Connect the starter solenoid wire (Item 12) and the B
+ starter wire (Item 13). Tighten B + nut to
specification.
14. Connect the coolant temperature sensor (Item 15)

and install a new tie strap (Item 16).
15. Connect the crankshaft position sensor connector

(Item 17).
Starter B+ Cable:
54 in-lbs (6 Nm)
13. Install two new tie straps (Item 14).
16. Connect the oil pressure sensor (Item 18).
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ENGINE
17. Connect the fuel solenoid (Item 19) and glow plug
connector (Item 20).
19. Connect the wires (Item 23) to the alternator.
18. Install the four nuts (Item 21) retaining the exhaust
shield (Item 22). Torque nuts to specification.
20. Install the guard and the three screws (Item 24)
retaining the guard to the frame.
21. Install the A/C compressor (if applicable) (see

Chapter 6 Compressor Removal / Installation).
Exhaust Heat Shield Nuts:
20 ft-lbs (27 Nm)
NOTE: DO NOT remove the pressure hoses from

the A/C compressor when installing the engine.
Removing the pressure hoses requires A/C
system recovery and charging.
22. Install the hydrostatic pump (see Chapter 10
Hydrostatic Pump Removal and reverse the steps).
23. Install the transmission in to the vehicle and properly
torque the engine to transmission fasteners (see
Chapter 9 Transmission Installation).
24. Refill the engine coolant and bleed the system (see
Chapter 5 Engine Cooling System).
25. Connect the negative (-) battery cable.
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ENGINE
Engine Mount Replacement
ENGINE LUBRICATION SYSTEM
The engine mount consists of a one piece molded

design.
Oil Pan Removal and Installation

1. Remove the engine.
2. Remove the bolts (Item 1) and oil pan (Item 2).
1. Remove the existing mount from the engine (see

Engine Removal and Engine Installation for
mount locations).
2. Torque fasteners to specification.
Engine Mount to Engine Fastener:

33 ft-lbs (45 Nm)
Engine Mount to Frame Fasteners:
22 ft-lbs (30 Nm)
3. Remove the bolts (Item 3), pickup tube (Item 4) and
O-ring (Item 5).
4. Installation: Tighten the bolts (Item 3) to 8 ft-lbs (10
Nm).
Oil Pump Removal and Installation

The oil pump is located in the front gear case and is
driven by the same gear train that drives the camshaft
and fuel injection pump. You must remove the front gear
case cover to gain access to the oil pump.
1. Remove the water pump.
2. Remove the crank shaft pulley and gear case cover.
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ENGINE
3. Remove the bolts (Item 1) and oil pump assembly
(Item 2).
Oil Pump Inspection

1. Clean the lubricating oil pump, pressure regulator
valve (Item 1) and rotor inserting portion. Check the
parts for wear or flaw. Replace the parts with new
ones as needed.
4. Installation: Tighten the bolts to 7 ft-lbs (11 Nm).

5. Remove the cover (Item 3) and outer rotor (Item 4)
from the housing.
NOTE: If any oil pump component clearance

exceeds its limit, the oil pump must be replaced
as an assembly.
2. Check Outer Rotor Outside Clearance
Oil Pump Specifications

Outer Rotor Outside Clearance
Std: 0.0039 - 0.0063" (0.10 - 0.16 mm)
Limit: 0.0098" (0.25 mm)
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3. Inspect the outside diameter clearance of the outer
rotor. To inspect this, insert a feeler gauge between
the outer rotor (Item 2) and the lubricating oil pump
body (Item 3).
5. Inspect the tip clearance between the outer and

inner rotors. To inspect this, insert a feeler gauge
between the inner rotor tooth tip (Item 4) and the
outer rotor tooth tip (Item 5), and measure the
clearance.
4. Check Outer Rotor To Inner Rotor Tip Clearance
Outer Rotor To Inner Rotor Tip

Limit: 0.0063" (0.16 mm)
6. Check Outer Rotor Side Clearance
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7. Inspect the side clearance between the lubricating oil
pump body and the outer rotor. To measure the side
clearance, use a straight edge and feeler gauge or a
depth micrometer.
9. Inspect the rotor shaft clearance. Measure

outside diameter of the rotor shaft (Item 6) and
inside diameter of the cover. Determine
clearance by subtracting the outside diameter of
rotor from the inside diameter of the cover.
the
the
the
the
Engine Oil Pressure - Testing

Outer Rotor Side Clearance
Std: 0.0019 - 0.0039" (0.05 - 0.10 mm)
Limit: 0.0059" (0.15 mm)
1. Remove the oil pressure sender.

2. Install a pressure gauge.
8. Check Rotor Shaft Clearance
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ENGINE
3. Start the engine and run until it is at operating
temperature.
ENGINE OIL PRESSURE SPECIFICATION
Idle Speed (1350 RPM) Allowable Limit:
8.8 PSI (60.7 kPa)
CYLINDER HEAD
Intake Manifold / Valve Cover Removal
1. Remove the intake manifold bolts (Item 1) and valve
cover bolts (Item 2).
At 3600 RPM:
42 - 64 PSI (289.6 - 441.3 kPa)
If the oil pressure is less than the allowable limit,
check the following items.
Engine Oil Level Low
Oil Pump Defective
Oil Gallery Plugged
Oil Strainer Plugged
Excessive clearance at the Rod & Main Bearings
Oil Pump Relief Valve Stuck
2. Remove the valve cover / intake manifold (Item 3).

Discard gasket (Item 4).
3. Remove the exhaust manifold bolts (Item 5) and nuts
(Item 6). Remove the exhaust manifold (Item 7) and
the exhaust manifold gasket (Item 8).
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ENGINE
Glow Plugs
6. Remove the cylinder head bolts (Item 3).
NOTE: To prevent damage, the glow plugs must be

removed from the cylinder head before the cylinder
head is removed.
1. Disconnect the glow plug harness (Item 2) from the
glow plugs (Item 1).
2. Remove the glow plugs from the cylinder head.
Cylinder Head Removal

1. Drain coolant from engine into a suitable container.
2. Remove the water pump.
3. Loosen the cylinder head bolts following the
sequence shown in.
7. Lift the cylinder head away from the cylinder block.

Discard the cylinder head gasket (Item 4). Position
the cylinder head on the work bench to prevent
damage to the combustion surface.
4. For orientation, the cooling pump end (Item 1) and

camshaft side (Item 2) are identified.
5. Remove the high-pressure fuel lines and fuel
injectors from the cylinder head.
NOTE: Remove and install the high-pressure
fuel injection lines as an assembly whenever
possible. Disassembling the high-pressure fuel
injection lines from the retainers will result in
difficult installation.
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ENGINE
Rocker Arms
5. Remove the two snap rings (Item 3).
Removal
1. Remove the bolts (Item 1) that retain the rocker arm
shaft supports.
NOTE: The rocker arm shaft fits tightly in the

rocker arm supports. Clamp the support in a
padded vise. Twist and pull out on the rocker arm
shaft to remove. Reverse this process when
installing the rocker arm shaft into the supports.
6. Slide the rocker arm shaft (Item 4) out of the rocker
arm supports (Item 5), springs (Item 6) and rocker
arms (Item 7).
NOTE: Mark the rocker arms so they can be
reinstalled with the original matching valve and
push rod.
7. Remove the valve adjusting screw (Item 8) and lock
nut (Item 9) from the rocker arms. Mark parts so they
can be reinstalled on the same rocker arm.
Installation
1. Lubricate the rocker arm shaft. Slide the rocker arm
supports, springs and rocker arms onto the shaft.
NOTE: Ensure the lubrication holes in the rocker
arm shaft are oriented correctly with respect to
the rocker arms.
The rocker arm shaft fits tightly in the rocker arm
supports. Clamp the support in a padded vise.
Twist and push on the rocker arm shaft to
reinstall.
2. Remove the rocker arm shaft assembly from the

cylinder head.
NOTE: Identify the push rods so they can be
reinstalled in their original locations.
3. Remove the push rods and identify for reinstallation.
4. Remove the rocker arm shaft alignment set screw
(Item 2) from the support.
2. Align the hole in the rocker arm shaft and the hole in
the rocker arm support. Reinstall the alignment set
screw.
NOTE: The set screw is located in the center
support.
3. Place the rocker arm shaft assembly onto the cylinder
head.
4. If removed, reinstall the valve adjusting screws and
lock nuts.
5. Align the push rods with their respective rocker arms.
6. Reinstall and tighten the rocker arm shaft retaining
bolts to the specified torque.
7. Tighten the rocker arm shaft alignment screw.
8. Adjust the valve clearance.
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ENGINE
Intake and Exhaust Valves
Visually inspect the intake and exhaust valves. Replace
any valves that are damaged.
Valve Stem Diameter
Using a micrometer, measure the valve stem near the
combustion end and near the opposite end (Item 1).
Valve Stem O.D.

Intake (Std): 0.2346-0.2356" (5.960-5.985 mm)
Exhaust (Std): 0.2341-0.2350" (5.945-5.97 mm)
Limit: 0.2323" (5.900 mm)
Valve Stem Bend
Place the valve stem on a flat surface. Roll the valve until
a gap can be observed between a portion of the valve
stem and the surface. Use a feeler gauge to measure the
gap.
Valve Stem Bend

Limit: 0.0004" (0.010 mm)
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4. Remove the valve keepers (Item 2).
Valve Recession
NOTE: The valve guides must be installed to
perform this check.
Insert the valves into their original locations and press
them down until they are fully seated. Use a depth
micrometer to measure the difference between the
cylinder head gasket surface and the combustion surface
of each exhaust and intake valve.
Intake and Exhaust Valve Recession

Std: 0.0157 - 0.0236" (0.40 - 0.60 mm)
Limit (Intake): 0.0354" (0.90 mm)
Limit (Exhaust): 0.0315" (0.80 mm)
Valve Removal
1. Put the cylinder head on the work bench with the
combustion side down.
5. Slowly release the tension on the valve spring and

remove the spring retainer (Item 3) and valve spring
(Item 4).
6. Repeat procedure with all remaining valves.
NOTE: If the valves are to be reused, identify
them so they can be reinstalled in their original
location.
2. Remove the valve stem cap (Item 1) and keep it with

the valve it was installed on.
7. Turn the cylinder head so the exhaust port side faces

down. Remove the intake and exhaust valves (Item
6) from the cylinder head.
3. Using the valve spring compressor tool, compress

one of the valve springs.
8. Remove the valve stem seals (Item 5).
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ENGINE
Valve Guide Removal
Cylinder Head Distortion
NOTE: Removal of valve guides should be

postponed until inspection and measurement
procedures have been performed.
Put the cylinder head flat and inverted (combustion side

up) on the bench. Use a straightedge and feeler gauge to
measure cylinder head distortion. Measure diagonally
and along each side. Record the measurements.
If the valve guides are not within specifications, use a

drift pin and hammer to drive the valve guides (Item
1) out of the cylinder head.
If distortion exceeds the service limit, resurface or

replace the cylinder head. Remove only enough material
to make the cylinder head flat, but do not remove more
than 0,20 mm (0.008 in).
Cylinder Head - Servicing

Thoroughly clean all components using a non-metallic
brush and an appropriate solvent. Each part must be free
of carbon, metal filings and other debris.
Visually inspect the parts. Replace any parts that are
obviously discolored, heavily pitted or otherwise
damaged. Discard any parts that do not meet its
specified limits.
NOTE: Any part which is found defective as a result
of inspection or any part whose measured value
does not satisfy the standard or limit must be
replaced.
Any part determined to not meet the service
standard or limit before the next service, as
determined from the state of current rate of wear,
should be replaced even though the part currently
meets the service standard limit.
Mark all valve train components so they can be
installed in their original locations
Cylinder Head Distortion

Std: 0.0020" (0.05 mm) or less
Limit: 0.0059" (0.15 mm)
Valve Guide - Checking
Visually inspect the valve guides for distortions, scoring
or other damage.
NOTE: Measure valve guides while they are
installed in cylinder head.
Use a telescoping gauge and micrometer to measure the
inside diameter of the valve guide. Measure in three
places and 90 apart. Replace valve guides if not within
specification.
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ENGINE
Valve and Valve Seat Reconditioning
Valve Guide I.D.

Std: 0.2362 - 0.2367" (6.000 - 6.012 mm)
Always check the clearance between the valve and valve

guide before grinding or lapping the valve seats. If the
clearance exceeds the limit, replace the valve and / or
valve guide to bring the clearance within the limit.
Roughness or burrs will cause poor seating of a valve.
Visually inspect the seating surfaces of each valve and
valve seat to determine if lapping or grinding is needed.
1. Visually inspect all valve faces and valve seats for
pitting, distortion, cracking or evidence of
overheating. Usually the valves and valve seats can
be lapped or ground to return them to serviceable
condition. Severely worn or damaged components
will require replacement.
2. Coat the valve seat with a thin coat of bluing
compound. Install valve and rotate to distribute
bluing onto the valve face. The contact pattern
should be approximately centered on the valve face
(Item 1) and even in width.
3. Visually inspect the valve seat for even contact. Light

cutting can be performed by the use of a hand
operated cutter.
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4. Valve seat diameter can be adjusted by top-grinding
with a 150 stone to make the seat diameter smaller,
and bottom-grinding using a 40 stone to make the
seat diameter larger. Once the seat location has
been corrected, grind and lap the seat angle (Item 2)
to specification.
Seat Angle
Intake
120
Exhaust
90
5. Grind the valve face and / or valve seat only enough

to return them to serviceable condition. Grinding is
needed if the valve and the valve seat do not contact
correctly. Check the valve recession after grinding.
6. If the valve or seat require grinding, lap the valve
after grinding. Lap the valve face to the valve seat
using a mixture of valve lapping compound and
engine oil.
7. Be sure to thoroughly wash all parts to remove all
grinding powder or compound.
Valve Spring Inspection

Inspect the valve springs. If damage or corrosion is seen,
or if measurements exceed the specified limits, replace
the springs.
Fractures
Check for fractures on the inside and outside portions of
the springs. If the valve spring is fractured, replace the
valve spring.
Corrosion
Check for corrosion of spring material caused by
oxidation.
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Squareness
Use a flat surface and a square to check each spring for
squareness.
Valve Spring Squareness

Limit: 0.512" (1.30 mm)
Free Length
Use a caliper to measure the length of the spring.
Valve Spring Length

Std: 1.4882" (37.80 mm)
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ENGINE
Rocker Arm / Push Rod Inspection
Rocker Arm Shaft Hole Diameter
1. Use a telescoping gauge and micrometer to measure
the inside diameter of all the rocker arm support
brackets and the rocker arms.
2. Inspect contact areas (Item 1) for excessive wear or
damage.
Rocker Shaft O.D.

Std: 0.4711 - 0.4718" (11.966 - 11.984 mm)
Limit: 0.4701" (11.94 mm)
Push Rod Bend
Determine if the bend of the push rods is within the
specified limit.
1. Place the push rods on a flat inspection block or
layout bed.
Rocker Arm I.D.

Std: 0.4724 - 0.4732" (12.00 - 12.20 mm)
Limit: 0.4752" (12.07 mm)
Rocker Arm Shaft Outside Diameter
Use a micrometer to measure rocker arm shaft diameter.
Measure at each rocker arm location in two directions
90 apart.
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2. Roll the push rods until a gap can be observed
between a portion of the push rod and the surface of
the block or layout bed.
3. Use a feeler gauge to measure the gap.
Valve Tappet Inspection

1. Inspect the tappet contact surfaces for abnormal
wear (Item 1). Normal wear will be even as shown in
(Item 2). Slight surface defects can be corrected
using an oilstone.
Push Rod Bend

Less than 0.0012" (0.03 mm)
2. Measure the outside diameter of the tappet.
Tappet O.D.
Std: 0.8239 - 0.8252" (20.927 - 20.960 mm)
Limit: 0.8231" (20.907 mm)
3. Measure the tappet bores in the cylinder block.
Record the measurements.
Tappet Bore I.D.

Std: 0.8268 - 0.8276" (21.000 - 21.021 mm)
Limit: 0.8284" (21.041 mm)
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Cylinder Head Assembly
3. Finish installing the valve guides (Item 2) to the

proper height (Item 3) using the valve guide
installation tool (Item 4).
Valve Guide Installation

1. The valve guides are installed into the cylinder head
with an extremely tight press-fit. Before installing the
valve guides, place the valve guides in a freezer for
at least 20 minutes. This will cause the valve guides
to contract, making it easier to install the valve
guides in place.
2. Immediately after removing the valve guides from the
freezer, insert the valve guides (Item 1) in their
proper positions.
Valve Guide Protrusion Above Head

0.3858 - 0.3937" (9.80 - 10.00 mm)
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ENGINE
Valve Installation
NOTE: Always install new valve stem seals.
2. Measure the distance (Item 8) from the cylinder head

to valve stem seal to ensure proper clearance (Item
9) between the valve guide and seal.
1. Oil the lip of the valve stem seal (Item 6). Using the
valve stem seal installation tool (Item 5), install a new
valve stem seal on each of the valve guides (Item 7).
Valve Stem Seal Protrusion Above Head

0.543" (13.80 mm)
3. Put the cylinder head assembly on its exhaust port
side.
4. Install all the valves in their proper location in the
cylinder head.
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5. Put the cylinder head on the work bench with the
combustion side down to install the valve springs.
Reinstall the valve spring and spring retainer (Item
10).
Valve Clearance Inspection / Adjustment

NOTE: Valve clearance inspection should be
performed on a cold engine, at room temperature.
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).
The No. 1 piston is on the flywheel end of the engine.

The firing order is 1-3-2.
1. Remove the intake manifold / valve cover.
2. Bring No. 1 piston to TDC of the compression stroke.
6. Using a valve spring compressor tool, compress the

valve spring.
7. Insert the valve keeper (Item 11) and slowly release
the tension in the valve spring. Reinstall the valve cap
(Item 12).
8. Repeat steps on all remaining valves.
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3. Insert a feeler gauge between rocker arm and valve
cap and record the measured valve clearance.
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.
Valve Clearance
0.006 - 0.010" (0.15 - 0.25 mm)
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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ENGINE
Cylinder Head Installation
Intake Manifold / Valve Cover Assembly
NOTE: Use new gaskets, O-rings and seals for the

reassembly of the cylinder head.
1. Reinstall the glow plugs (Item 1) and tighten to

specification. Reinstall the electrical harness (Item
2).
Generously oil all components during reassembly

to prevent premature wear or damage.
1. Carefully clean both the combustion surface of the
cylinder head and the top surface of the cylinder
block. Install a new cylinder head gasket on the
cylinder block.
2. Position the cylinder head on the cylinder head

gasket.
3. Lightly oil the threads of the cylinder head bolts.
Tighten the bolts to the specified sequence shown
below. Tighten bolts to specification.
2. Lightly grease a new valve cover gasket. Place the

gasket in the groove of the intake manifold / valve
cover.
3. Place the valve cover on the cylinder head. Reinstall
and tighten bolts securely.
4. Reinstall the exhaust manifold using a new gasket.
Tighten the bolts and nuts securely.
5. Reinstall the fuel injectors.
Cylinder Head Bolts:
Step 1: Torque all bolts to 21 ft-lbs (28 Nm)
Step 2: Torque all bolts to 42 ft-lbs (56 Nm)
4. Insert the push rods in their respective positions.
6. Reinstall the high pressure and return fuel injection

lines.
7. Reinstall the coolant pump.
8. Reinstall the alternator.
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ENGINE
CAMSHAFT AND TIMING GEARS
Timing Gearcase Cover Installation
Timing Gearcase Cover Removal
NOTE: The gear housing must be installed prior to

reinstalling the camshaft.
1. Remove the crankshaft pulley bolt and washer.

NOTE: Do not damage the threads in the end of
the crankshaft when removing the crankshaft
pulley.
1. If removed, reinstall the camshaft end plate (Item 3),

key and camshaft gear (Item 4) onto the camshaft
using a press. Heat the gear to 350 - 390 F (180 200C) and press onto the end of the camshaft.
2. Remove the crankshaft pulley with a gear puller.

3. Remove the bolts that retain the gear case cover to
the cylinder block and oil pan.
4. Remove the gear case cover (Item 1).
2. Lubricate the camshaft with clean engine oil or

assembly lube. Slowly insert the camshaft through
the front of the engine.
3. Reinstall and tighten the cap screws (Item 5).
5. Remove the dowel pins (Item 2).
4. Lubricate the camshaft lobes and tappets with clean

oil or assembly lube. Reinstall the tappets in their
respective locations in the cylinder block. Push the
tappets fully into the tappet bores until they make
solid contact with the camshaft.
5. If removed, reinstall the fuel injection pump. Adjust
the fuel injection timing after installation.
6. Apply a continuous bead of ThreeBond Liquid
Gasket to the mounting area of the gear case cover.
7. Reinstall the dowels.
NOTE: Be sure to align the flats on the oil pump
with the flats on the crankshaft gear.
8. Reinstall the timing gear case cover. Reinstall and
tighten the gear case cover bolts.
9. Reinstall the crankshaft pulley.
10. Reinstall the washer and bolt. Tighten the bolt to
specification.
Crankshaft Pulley Bolt:

66 ft-lbs (90 Nm)
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ENGINE
Timing Gears Backlash - Checking
Idler Gear Inspection
Prior to removing the timing gears, measure the gear

backlash and determine the gear wear.
Measuring Idler Gear-To-Crankshaft Gear Backlash

1. Install a dial indicator as shown.
Check the backlash between each pair of mating

gears. If not within specification, replace both mating
gears. Do not allow the gear being checked to move
axially as excess end play could cause a false
reading.
2. Rotate the idler gear back and forth to check idler

gear-to-crankshaft gear backlash. Total indicator
reading is backlash. Record the measurement.
Measuring Idler Gear-To-Camshaft Gear Backlash
1. Drive a small wooden wedge between the crankshaft
gear and idler gear to prevent the idler gear from
rotating.
2. Install a dial indicator to read camshaft gear backlash.
Rotate camshaft drive gear against idler gear to
measure backlash. Record the measurement.
3. Check the idler gear-to-fuel injection pump drive gear
backlash in the same manner as the camshaft drive
gear. Record the measurement.
Timing Gear Backlash for Crank, Cam, Idle and Fuel
Injection Pump Gears
Std: 0.0024 - 0.0047" (0.06 - 0.12 mm)
Limit: 0.0055" (0.14 mm)
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ENGINE
Timing Gears Removal
Timing Gears Installation
1. Remove the bolts from the idler gear shaft (Item 1).
Remove the idler gear shaft, idler gear (Item 2) and
bushing (Item 3).
1. Set No. 3 piston to top dead center.
NOTE: Do not remove the crankshaft gear

unless it is damaged and requires replacement.
Do not remove the camshaft gear unless it or the
camshaft is damaged and requires replacement.
2. Lubricate the idler gear (Item 1), bushing (Item 2)

and idler gear shaft (Item 3) with clean engine oil or
assembly lube.
3. Rotate the camshaft until mark (B) is approximately

at the 8 oclock position and align the timing gears as
shown.
2. Do not remove the fuel injection pump drive gear

unless absolutely necessary. Do not loosen or
remove the four bolts (Item 4) retaining pump drive
gear to the hub. Only remove the nut (Item 5) and
washer (Item 6). Remove the pump drive gear and
hub as an assembly using a gear puller.
4. Install the idler gear and idler gear shaft. Be sure the
oil hole in the bushing is facing toward the top of the
engine.
5. Ensure all three timing marks (A, B, and C) are
aligned.
NOTE: Do not loosen or remove the four bolts
retaining the fuel injection pump drive gear to the
fuel injection pump hub. Correct fuel injection
timing will be very difficult to achieve
6. When all gears are properly aligned, tighten the idler

gear retaining bolts.
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Camshaft Removal
Camshaft Inspection / Servicing
1. Before removing the camshaft, check the camshaft

end play using a dial indicator or a feeler gauge
between the thrust plate and the front camshaft
bearing.
Camshaft - Servicing
1. Use V-blocks and a dial indicator to check camshaft
bend. Place the indicator on the center bearing
journal.
Camshaft End Play

Std: 0.0044 - 0.0098" (0.111 - 0.250 mm)
Limit: 0.011" (0.28 mm)
2. Remove two bolts (Item 1) retaining the camshaft
thrust plate (Item 2).
3. Extract the tappets (Item 3) through the top of the
cylinder block. Mark the tappets so they can be
reinstalled in the same location.
4. Slowly pull the camshaft assembly out of the engine
being careful not to damage the front camshaft
bushing.
5. Remove the camshaft gear (Item 4) only if the gear
or camshaft require replacement. Use a knife-edge
puller and a press to remove the gear. The gear is a
shrink-fit and will need to be heated to 180 - 200 C
(356 - 392F) to remove.
2. Rotate the camshaft and observe the runout.
Camshaft Runout
Std: 0.0000 - 0.0008" (0.00 - 0.02 mm)
Limit: 0.0020" (0.05 mm)
3. Measure the height of each lobe (Item 1).
Cam Lobe Height

Std: 1.3596 - 1.3648" (34.525 - 34.665 mm)
Limit: 1.3499" (32.287 mm)
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ENGINE
4. Measure the diameter of the gear end (Item 2),
intermediate (Item 3) and flywheel end (Item 4)
bearing journals.
Inspection Of Camshaft Insert Bores

1. There are no camshaft bushing in this engine.
Therefore, measure the camshaft bore ID in the
cylinder block. If the bore ID is out of the specification,
it is required to replace the cylinder block.
Camshaft Gear End I.D.

Std: 1.5748 - 1.5758" (40.000 - 40.025 mm)
Limit: 1.5787" (40.100 mm)
Camshaft Intermediate I.D.
Std: 1.5748 - 1.5758" (40.000 - 40.025 mm)
Limit: 1.699" (39.875 mm)
Camshaft Flywheel End I.D.
Std: 1.5724 - 1.5732" (39.940 - 39.960 mm)
Limit: 1.5787" (40.100 mm)
Camshaft Gear End O.D.
Std: 1.5724 - 1.5732" (39.940 - 39.960 mm)
Limit: 1.5711" (39.906 mm)
Camshaft Intermediate O.D.
Std: 1.5713 - 1.5722" (39.910 - 39.935 mm)
Limit: 1.5699" (39.875 mm)
Idler Gear and shaft Servicing

1. Measure the inside diameter (Item 3) of the idler gear
bushing (Item 4).
Camshaft Flywheel End O.D.

Std: 1.5724 - 1.5732" (39.940 - 39.960 mm)
Limit: 1.5711" (39.906 mm)
5. Measure the outside diameter (Item 1) of the idler
gear shaft (Item 2).
Idler Gear Shaft O.D.

Std: 1.1795 - 1.1803" (29.959 - 29.980 mm)
Limit: 1.1779" (29.919 mm)
Idler Gear Bushing I.D.
Std: 1.1811 - 1.1821" (30.000 - 30.025 mm)
Limit: 1.1837" (30.066 mm)
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ENGINE
CRANKSHAFT AND PISTONS
4. Wipe oil from the bearing insert and crankshaft

journal surfaces.
Piston and Connecting Rod Removal /

Inspection
NOTE: Keep the piston pin parts, piston assemblies
and connecting rod assemblies together to be
returned to the same position during the reassembly
process. Label the parts using an appropriate
method.
Engines with high operating hours may have a ridge
near the top of the cylinders that will catch the
piston rings and make it impossible to remove the
pistons. Use a suitable ridge reamer to remove
ridges and carbon prior to removing the pistons.
Pistons can fall from the cylinder block if engine is
inverted. Rotate the engine so the connecting rods
are horizontal before removing the connecting rod
caps.
1. Using a feeler gauge, measure the connecting rod
side clearance.
2. If the measurement is out of specification, replace
the crankshaft, connecting rod or both.
5. Place a piece of PLASTIGAGE (Item 1) along the

full width of the bearing insert.
NOTE: DO NOT rotate crankshaft when using
PLASTIGAGE. A false reading may result.
6. Reinstall the bearing cap. Tighten the bolts to 17 - 20
ft-lbs (23 - 28 Nm).
7. Remove the bearing cap. Compare the width of the
flattened PLASTIGAGE (Item 1) to the graduation
marks on the package. This will be the oil clearance.
NOTE: Mark the connecting rod caps and

connecting rods so the caps and connecting
rods stay together.
3. Remove the bearing cap. Do not remove the bearing
inserts at this time.
Connecting Rod Bearing Oil Clearance

Std: 0.0008 - 0.0023" (0.020 - 0.058 mm)
Limit: 0.0043" (0.110 mm)
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ENGINE
8. Repeat with the remaining connecting rods.
NOTE: Do not allow the connecting rod to
contact the crankshaft journal during piston
removal. Damage to the bearing journal may
result.
16. Repeat steps until all pistons are removed and

dissembled.
9. Use a wooden dowel against the connecting rod and

tap the piston / connecting rod assembly out of the
cylinder.
10. Mark the cylinder number on the piston and
connecting rod.
11. Remove the bearing inserts (Item 2).
12. Remove the compression rings (Item 3) from the

piston using a piston ring expander.
13. Remove the oil ring (Item 4) from the piston using a
piston ring expander.
14. Remove the snap rings (Item 5) from the wrist pin.
15. Remove the wrist pin (Item 6) and connecting rod
(Item 7) from the piston (Item 8).
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ENGINE
Piston Inspection
NOTE: On an engine with low hours, the pistons
and piston rings may be reused if they are found to
be within specifications. The pistons and piston
rings must be reinstalled in the same cylinders from
which they were originally removed.
On an engine with high hours, the piston rings
should be replaced and the cylinder honed or
replaced. The piston should be replaced as
necessary.
1. Clean piston ring grooves using a piston ring groove
cleaning tool. Follow manufacturers instructions for
correct operation.
5. Subtract the piston measurement from the greatest

measurement acquired during cylinder inspection to
obtain piston-to-cylinder clearance.
Piston to Cylinder Clearance

0.0004 - 0.0028" (0.010 - 0.070 mm)
6. Measure the diameter of the wrist pin bore on both
sides of the piston. Record the measurements.
2. Wash the pistons in an appropriate solvent using a

soft brush.
3. Visually inspect each piston for cracks. Pay
particular attention to the ring lands between the
piston ring grooves.
4. Measure the diameter of the piston skirt at 90 to the
wrist pin bore. Measurements must be taken at a
specified distance (Item 1) from the bottom of the
piston, based on engine model.
Piston Pin Bore Diameter

Std: 0.8661 - 0.8665" (22.000 - 22.009 mm)
Limit: 0.8677" (22.039 mm)
7. Measure the outside diameter of the wrist pin in three
places and at 90.
Piston Outer Diameter

Std: 2.8331 - 2.8343" (71.960 - 71.980 mm)
Limit: 2.8313" (71.915 mm)
Wrist Pin O.D.

Std: 0.8659 - 0.8661" (21.995 - 22.000 mm)
Limit: 0.8648" (21.965 mm)
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ENGINE
8. Using a micrometer, measure the thickness of each
piston ring.
10. To measure piston ring end gap, insert each

compression piston ring (Item 2), one at a time, into
the cylinder. Use a piston with the piston rings
removed to slide the ring into the cylinder bore until it
is approximately 1.18 in. (30 mm) (Item 3) from the
bottom of the bore. Remove the piston. Measure the
end gap (Item 4) of each piston ring.
Top and Second Ring Width

Std: 0.0579 - 0.0587" (1.470 - 1.490 mm)
Limit: 0.0571" (1.450 mm)
Oil Ring Width
Std: 0.1170 - 0.1177" (2.970 - 2.990 mm)
Limit: 0.1161" (2.950 mm)
9. Place each compression piston ring in the groove as
shown. Use a feeler gauge to measure the clearance
between the piston ring and the piston ring land.
Replace the piston if not within specification.
Top Ring Side Clearance

Std: 0.0024 - 0.0039" (0.060 - 0.100 mm)
Limit: Not Applicable
Second Ring Side Clearance
Std: 0.0035 - 0.0049" (0.090 - 0.100 mm)
Limit: 0.0096" (0.245 mm)
Oil Ring Side Clearance
Std: 0.0008 - 0.0022" (0.020 - 0.055 mm)
Limit: 0.0071" (0.180 mm)
Top Ring End Clearance

Std: 0.0039 - 0.0098" (0.100 - 0.250 mm)
Limit: 0.0013" (0.034 mm)
Second Ring End Clearance
Std: 0.0098 - 0.0157" (0.250 - 0.400 mm)
Limit: 0.0193" (0.490 mm)
Oil Ring End Clearance
Std: 0.0079 - 0.0177" (0.200 - 0.450 mm)
Limit: 0.0217" (0.550 mm)
NOTE: Always check the piston ring end gap
when installing new piston rings. Use a piston
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ENGINE
ring end gap filing tool to adjust the piston ring
end gap on new piston rings.
2. Measure the connecting rod twist (Item 1). If the twist

is outside the limit, you must replace the connecting
rod.
11. Repeat the above steps for each cylinder and piston
assembly.
Connecting Rod Inspection

1. Measure the inside diameter of the connecting rod
small end.
Connecting Rod Twist per 100 mm (4.0")

Std: Less than 0.001" (0.03 mm)
Limit: 0.003" (0.08 mm)
Connecting Rod Small End I.D.
Std: 0.8671 - 0.8678" (22.025 - 22.042 mm)
Limit: 0.7902" (20.072 mm)
3. Place the connecting rod bearing inserts into the

connecting rod and connecting rod cap. Install the
rod cap and tighten the bolts to 83 - 90 ft-lbs (113 123 Nm).
4. Measure the inside diameter.
Connecting Rod Journal Bearings I.D.

1.4954 - 1.4965" (37.982 - 38.010 mm)
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ENGINE
Cylinder Honing and Boring
Piston and Connecting Rod Installation
If the cylinder walls are scuffed, scored, out-of-round, or

tapered beyond specifications, rebore and hone to
restore cylinders to usable condition. Slight imperfections
can be corrected by honing alone.
NOTE: Proceed slowly. Do not force assemble

unless a pressing operation is required. All parts
must be clean and lubricated when assembled.
Boring
Use new gaskets, seals and O-rings during

assembly. Generously apply clean engine oil to all
internal parts during assembly.
Significant cylinder damage may be corrected by boring

the cylinder to an oversize dimension. See the parts
manual for available oversize pistons and piston rings.
A bored cylinder should always be finished with a
hone to properly prepare the cylinder surface so
the new piston rings will seat properly.
After the cylinder has been bored and honed,
install the appropriate oversize pistons and piston
rings.
Honing
Minor cylinder imperfections may be corrected by using a
rigid cylinder hone. Be sure not to exceed the maximum
cylinder bore specification.
1. If removed, install a new wrist pin bushing using a

press and the appropriate service tool. Be sure to
align the oil holes.
2. Reinstall one snap ring into the piston. Ensure the
snap ring is securely seated in the groove.
NOTE: When correctly assembled, the piston
identification mark (Item 1) stamped on top of the
piston will be on the opposite side of the
connecting rod as the match marks (Item 2)
stamped into the connecting rod and rod cap.
When installed in the cylinder, the embossed
mark (Item 3) cast into the rod will face the
flywheel end of the engine.
Deglazing
A used cylinder that did not require boring or honing,
should always be deglazed with a ball hone before
installing new piston rings. This will properly prepare the
cylinder surface to allow new piston rings to seat
properly.
NOTE: When honing a cylinder, with either a ridged
hone or a ball hone, move the rotating hone up and
down in the cylinder bore to accomplish a 30 - 40
crosshatch pattern. This will provide the ideal
surface for the proper seating of new piston rings.
Do not allow the honing tool to operate in one
position for any length of time. Damage to the
cylinder wall will occur.
Use a 50:50 mixture of diesel fuel and engine
oil as a honing fluid.
Use a 300-grit hone at 300 - 1200 rpm.
When honing is completed, wash the cylinder
block with hot water and soap.
Solvents will not adequately remove honing residue,
resulting in premature piston and ring wear. Always
wash cylinders using hot, soapy water. The cylinder
wall is adequately cleaned when a white rag wiped in
cylinder comes out clean. Rinse with hot water and
dry with compressed air. Apply clean engine oil to all
steel surfaces to prevent rusting.
The actual appearance of match marks will vary
but they will always be in the same locations.
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ENGINE
3. Place the connecting rod into the piston. The match
marks on the connecting rod and cap must be on the
opposite side as the piston identification mark on the
top of the piston.
4. Lubricate and install the wrist pin through the piston
and connecting rod.
6. Install the oil ring expander (Item 5). Install the oil
ring (Item 6).
NOTE: The oil ring expander end gap must be
located 180 from the oil ring end gap.
5. Install the second snap ring and ensure it is securely

seated in the groove.
NOTE: If installing new piston rings the end gap
must be checked and adjusted as necessary. Use
a piston ring end gap filing tool to adjust the
piston ring end gap on new piston rings.
Reinstall the top and second piston rings with

the stamped makers mark (Item 4) facing the
top of the piston. The makers mark may vary in
appearance but will always be located on the top
surface of the piston ring adjacent to the piston
ring gap. The oil ring and oil ring expander can
be installed either side up.
7. Install the second compression ring (Item 7). This

ring is identified by its dark color and tapered face
profile.
8. Install the top compression ring (Item 8). This ring is
identified by its silver color and barrel-shaped face
profile.
9. Stagger the piston ring end gaps at 120 apart. Do
not position the top piston ring end gap in line with
the wrist pin.
NOTE: Do not allow the connecting rod to
contact the crankshaft journal during piston
installation. Damage to the crankshaft bearing
journal may result.
Always use a piston ring expander when
installing piston rings. Never attempt to install
piston rings by hand.
10. Lubricate piston, piston rings and cylinder with clean

engine oil or assembly lubricant.
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ENGINE
11. Rotate the crankshaft so the crankpin for the piston
being installed is near bottom dead center.
14. Install bearing inserts in the connecting rod and cap.

15. Apply a liberal coat of clean engine oil to the bearing
inserts and crankshaft journal.
16. Apply a light coat of clean engine oil to the rod cap
bolts. Reinstall the connecting rod cap. Tighten the
connecting rod bolts to the specified torque in two
stages (1/2 then full torque). Tighten the bolts to
specification.
Connecting Rod Cap Bolts:

Step 1: 9 ft-lbs (12 Nm)
Step 2: 17-20 ft-lbs (23-28 Nm)
17. Reinstall the remaining pistons in their respective
cylinders.
12. Using a piston ring compressor, compress the piston

rings.
13. Carefully install the piston and rod assembly. Match
marks stamped on the connecting rod and cap are
facing the fuel injection pump side of the cylinder
block, and the piston identification mark is facing the
camshaft side. The mark cast into the connecting rod
will be facing the flywheel end of the engine.
NOTE: The piston and connecting rod must be
installed with the correct orientation. When
installed correctly, the identification mark
stamped into the top of the piston will be on the
same side of the engine as the fuel injection
pump and the embossed mark cast into the
connecting rod beam will face the flywheel end
of the engine.
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ENGINE
Cylinder Bore - Inspection
Crankshaft and Bearings Removal
1. Ensure that oil passages are clear and unobstructed.
1. Remove the flywheel (Item 1) from the crankshaft.
2. Check for discoloration or evidence of cracks. If a

fracture is suspected, use the color check method or
the MAGNAFLUX method to determine if the
cylinder block is fractured.
3. Measure cylinders for roundness, taper, and inspect
for evidence of scoring. Consider honing, re-boring
or replacing the cylinder block if the measurements
are not within specification.
4. Take measurements at three places (a, b, and c),

and in two directions (d and e) in each cylinder.
2. Remove the bolts from the back plate assembly

(Item 2). Remove the back plate from the engine.
3. Before removing the main bearing, measure the
crankshaft end play. Use either of the following two
methods:
Method A: Install a dial gauge on the cylinder
block. Move the crankshaft in and out to measure
the end play.
Cylinder Roundness
Roundness can be calculated by subtracting the
smaller measured value from the larger measured
value of d or e at each measuring location a, b, and
c.
Method B: Use a feeler gauge to measure the

clearance between the thrust bearing and
crankshaft.
Cylinder Taper
Taper can be calculated by subtracting the minimum
measured value from the maximum measured value
of locations a, b, and c. Calculate along both the d
axis and e axis and use the larger of the two
calculations as the value to compare to the
specifications.
Crankshaft End Play

Std: 0.0044 - 0.0098" (0.111 - 0.250 mm)
Limit: 0.0110" (0.280 mm)
4. Remove the ladder frame. Do not remove the
bearing inserts at this time.
Cylinder Out-Of-Round
Limit: 0.0012" (0.03 mm)
Cylinder Taper
Limit: 0.0012" (0.03mm)
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ENGINE
5. Wipe oil from the bearing insert and crankshaft
journal surfaces. Place a piece of PLASTIGAGE
(Item 3) along the full width of the bearing insert.
9. Repeat with the remaining main bearings.
NOTE: Be sure to note the markings on the main

bearing, or make marks so they can be
reinstalled in the same way they were removed.
NOTE: Do not rotate the crankshaft when using
PLASTIGAGE. A false reading may result.
6. Reinstall the ladder frame. Tighten the bolts to 33 ftlbs (45 Nm).
10. Remove the crankshaft from the engine.

NOTE: Do not remove the crankshaft gear
unless the gear or crankshaft are damaged and
require replacement.
7. Remove the ladder frame.

8. Compare the width of the flattened PLASTIGAGE
to the graduation marks on the package. This will
indicate the bearing oil clearance.
11. If necessary, remove the crankshaft gear (Item 6)
and key (Item 7). If using a gear puller, be careful not
to damage the threads in the end of the crankshaft.
Crankshaft Main Bearing Oil Clearance
Std: 0.0008 - 0.0023" (0.020 - 0.058 mm)
Limit: 0.0043" (0.110 mm)
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ENGINE
Crankshaft and Bearing Service
6. Measure the outside diameter of each crankpin (Item

2) and main bearing journal (Item 3).
NOTE: Any part which is found defective as a result

of inspection or any part whose measured value
does not satisfy the limit must be replaced.
1. Thoroughly clean all components using a brush and
appropriate solvent. Each part must be free of
carbon, gasket material, metal filings and other
debris.
2. Put the crankshaft end journals (Item 1) on V-blocks.
3. Place a dial indicator on a center main bearing

surface.
4. Rotate the crankshaft and observe runout. Record
the measurements.
Crankshaft Runout
Std: 0.0004" (0.01 mm) or less
Limit: 0.0008" (0.02 mm)
5. Use the color check method or MAGNAFLUX to
inspect the crankshaft for cracks. Replace the
crankshaft if evidence of fractures is found.
7. Take measurements at several places around each

bearing surface. If not within specification, grind the
journals and install undersize bearings, or replace
the crankshaft. Record the measurements.
Connecting Rod Journal O.D.

Std: 1.4942 - 1.4946" (37.952 - 37.962 mm)
Limit: 1.4725" (37.402 mm)
Measuring Crankshaft Bearing Oil Clearance
Oil clearance should be checked during disassembly
to determine the extent of wear, and during assembly
to ensure long engine life. The same procedure is
done for both connecting rods and main bearings.
Crankshaft Journal Oil Clearance

Std: 0.0008 - 0.0023" (0.020 - 0.058 mm)
Limit: 0.0043" (0.110 mm)
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ENGINE
Crankshaft Oil Seal Replacement
Crankshaft and Bearings Installation
1. Remove the seal (Item 2) from the gear case cover

(Item 1).
1. If removed, reinstall the key and timing gear on

crankshaft.
2. Install a new seal in the gear case cover with the lip
facing in away from the crankshaft pulley. Apply
lithium grease to the lip of the seal.
3. Remove the rear oil seal (Item 3) from the engine
block (Item 4).
2. Install new bearing inserts (Item 1) and thrust

bearing (Item 2) in the cylinder block and main
bearing caps. Be sure the oil holes in the upper
bearing shells align with the oil ports in the cylinder
block. Apply a liberal coat of clean engine oil to the
bearings and crankshaft journals.
3. Install the thrust bearing (side gap). Install the thrust
bearing on the flywheel side.
4. Install the thrust bearing (without a tab) to the
cylinder block after the crankshaft assembly.
4. Install a new seal in the block (Item 3) with the lip

facing in away from the flywheel. Apply lithium
grease to the lip of the seal.
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ENGINE
5. Mount the thrust bearing (with a tab) and turn it 90
degrees counterclockwise.
7. Reinstall the lower main bearing into the ladder

frame.
NOTE: Apply liquid gasket to these portions (in
the flywheel side) in particular until protruding to
the oil seal insertion hole, and wipe off the
protruded liquid gasket.
8. Apply a light coat of clean engine oil to the ladder

frame mounting bolts and tighten the bolts in two
stages (1/2 the required torque then full torque).
Tighten the bolts to specification.
6. Install the upper main bearing, thrust bearing and

crankshaft into the engine.
NOTE: The main bearings are numbered and
have arrows for proper positioning. The No.1
bearing is at the flywheel end.
Ladder Frame Bolts:

9. The surface difference between the surfaces on the
flywheel side and the gear case side and the ladder
frame surface should be 0.004" (0,1 mm) or less.
10. Rotate the crankshaft to ensure it turns freely.
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ENGINE
11. Apply ThreeBond Liquid Gasket to the mounting
flange of the flywheel housing (Item 5).
ENGINE SPEED CONTROL

Hand Lever Removal and Installation
1. Tilt the operator and passenger seat cushions
forward.
2. Remove the two plastic rivets (Item 1) from the rear
of the console.
12. Align the back plate with the two dowel pins (Item 6).
13. Reinstall the back plate and seal assembly.
14. Reinstall the flywheel (Item 7) and tighten the bolts to
specification.
3. Remove the two plastic rivets (Item 2) from the front
of the center console.
Flywheel Bolts:
62 ft-lbs (84 Nm)
4. Lift the center console over the joystick.
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ENGINE
5. Remove the cable end (Item 3) from the lever.
7. Remove the three bolts (Item 5) retaining the lever to

the seat base frame and remove the hand lever.
6. Loosen the jam nut (Item 4) and remove the cable.
3.59
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ENGINE
1. Loosen the bolts (Item 1) from the pump cover.
3. Remove the tie strap (Item 3) securing the cable to

the bracket.
4. Remove the cable end (Item 4) from the command

lever (Item 5).
2. Disconnect the neutral safety switch (Item 2) and

remove the pump cover.
5. Remove the jam nut (Item 6) and remove the cable
from the bracket.
6. Remove the cable end (Item 7) from the command
lever.
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ENGINE
7. Remove the jam nut (Item 8) and the cable from the
bracket.
8. Remove the end of the cable from the engine speed

control lever.
9. Remove any remaining tie straps holding the cable in
place and remove the cable.
10. Perform travel control adjustment procedures after
installation of the new cable (see Chapter 2).
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ENGINE
TROUBLESHOOTING
CAUSE
ENGINE SYSTEM
TROUBLE SYMPTOM
Improper
Intake /
Exhaust
Valve
Clearance
Compression
Leakage
From
Valve
Seat
Intake /
Exhaust
Valve
Seizure
Cylinder
Head
Gasket
Blowout
Seized
or
Broken
Piston
Ring
Starting Problem
Engine Does Not Start
Engine Starts but Stops
None
Exhaust Smoke
Little
Much
Insufficient Engine Output

Ordinary
Exhaust Color
White
Black
Poor Exhaust Color

During Work
White
Black
High Knocking Sound During

Combustion
Abnormal Engine Sound
Uneven Combustion Sound
During
Idling
Engine Surging
During
Work
Operation
Excessive Engine Vibration

Difficulty in Returning to Low
Speed
Excessive Fuel Consumption
Engine
Oil
Excessive Oil
Consumption
3.62
Copyright 2014
Worn
Piston
Ring,
Piston
or
Cylinder
Seized
Crankpin
Metal
or
Bearing
Improper
Arrangement of
Piston
Ring
Gaps
ENGINE
Dilution by Diesel
Fuel
Oil With Water
Low Oil Pressure
Excessive Blow-by Gas
Overheat
Engine
Coolant
Air
Intake
Low Coolant
Temperature
Pressure Drop
Pressure Rise
Exhaust Temperature Rise
Corrective Action
Adjust
the
Valve
Clearance
Lap the
Valve
Seat
Correct
or
Replace
Intake /
Exhaust
Valve
Replace
the
Gasket
Replace
the
Piston
Ring
Perform
Honing
and
Use
Oversize
Parts
Repair
or
Replace
Correct
the Ring
Joint
Positions
3.63
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ENGINE
CAUSE
ENGINE SYSTEM
TROUBLE SYMPTOM
Reverse
Assembly of
Piston
Rings
Worn
Crankpin and
Journal
Bearing
Loose
Connecting
Rod
Belt
Foreign
Matter
Trapped
in
Combustion
Chamber
Excessive
Gear
Backlash
Starting Problem
Exhaust Smoke
None
Little
Much

Exhaust Color
Ordinary
White
Black
Poor Exhaust Color

During Work
White
Black

Combustion
During Idling
Engine
Surging
During Work
Operation

Speed
Engine
Oil
Excessive Oil
Consumption
Dilution by Diesel
Fuel
3.64
Copyright 2014
Worn
Intake /
Exhaust
Valve
Guide
Governor
Adjusted
Incorrectly
Improper
Open /
Close
Timing
of
Intake /
Exhaust
Valves
ENGINE
Oil With Water
Low Oil Pressure
Overheat
Engine
Coolant
Air
Intake
Low Coolant
Temperature
Pressure Drop
Pressure Rise
Corrective Action
Reassemble
Correctly
Measure and
Replace
Tighten
to the
Specified
Torque
Disassemble
and
Repair
Adjust
Gear
Meshing
Measure and
Replace
Make
Adjustment
Adjust
the
Valve
Clearance
3.65
Copyright 2014
ENGINE
CAUSE
ENGINE COOLANT SYSTEM
TROUBLE SYMPTOM
Excessive
Radiator
Cooling
Insufficient
Radiator
Cooling
Insufficient
Engine
Coolant
Level
Cracked
Coolant
Jacket
Starting Problem
Exhaust Smoke
None
Little
Much

Exhaust Color
Ordinary
White
Black
Poor Exhaust Color

During Work
White
Black

Combustion
During Idling
Engine
Surging
During Work
Operation

Speed
Excessive Oil
Consumption
Engine
Oil
Dilution by Diesel
Fuel
Oil With Water
Low Oil Pressure
3.66
Copyright 2014
Stretched
Coolant
Pump VBelt
Defective
Thermostat
ENGINE
Overheat
Engine
Coolant
Air
Intake
Low Coolant
Temperature
Pressure Drop
Pressure Rise
Corrective Action
Replace
Thermostat
Replace
Thermostat
or Check
for Loose
Coolant
Pump Belt
Check
Coolant
Leakage
from
Engine
Coolant
System
3
Repair or
Replace
Adjust the
Belt
Tension
Check or
Replace
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ENGINE
CAUSE
ENGINE OIL SYSTEM
TROUBLE SYMPTOM
Incorrect
Engine
Oil
Engine
Oil
System
Leakage
Insufficient
Delivery
Capacity
of
Trochoid
Pump
Clogged
Engine
Oil Filter
Defective
Pressure
Regulating Valve
Starting Problem
Exhaust Smoke
None
Little
Much

Exhaust Color
Ordinary
White
Black
Poor Exhaust Color

During Work
White
Black

Combustion
During Idling
Engine
Surging
During Work
Operation

Speed
Excessive Oil
Consumption
Engine
Oil
Dilution by Diesel
Fuel
Oil With Water
Low Oil Pressure
3.68
Copyright 2014
Insufficient
Engine
Oil Level
Overfilled
Engine
Crankcase
ENGINE
Overheat
Engine
Coolant
Air
Intake
Low Coolant
Temperature
Pressure Drop
Pressure Rise
Corrective Action
Use
Correct
Engine
Oil
Repair
Check
and
Repair
Clean or
Replace
Clean,
Adjust or
Replace
Add
Correct
Engine
Oil
3
Check
Engine
Oil
3.69
Copyright 2014
ENGINE
CAUSE
FUEL SYSTEM
TROUBLE SYMPTOM
Too Early
Timing of Fuel
Injection
Pump
Too Late
Timing of Fuel
Injection
Pump
Incorrect
Diesel Fuel
Starting Problem
Exhaust Smoke
None
Little
Much

Ordinary
Exhaust Color
White
Black
Poor Exhaust Color

During Work
White
Black

Combustion
During Idling
Engine
Surging
During Work
Operation

Speed
Excessive Oil
Consumption
Engine
Oil
Dilution by Diesel
Fuel
Oil With Water
Low Oil Pressure
3.70
Copyright 2014
Water in Fuel
System
Clogged Fuel
Filter
ENGINE
Overheat
Engine
Coolant
Air
Intake
Low Coolant
Temperature
Pressure Drop
Pressure Rise

Corrective Action
Check and
Adjust
Check and
Adjust
Use the
Correct Diesel
Fuel
Drain the Fuel

Filter
Clean or
Replace
3.71
Copyright 2014
ENGINE
CAUSE
FUEL SYSTEM
TROUBLE SYMPTOM
Air in
Fuel
System
Clogged or
Cracked Fuel
Line
Insufficient
Fuel
Supply
to Fuel
Injection
Pump
Uneven
Injection
Volume
from
Fuel
Injection
Pump
Excessive
Fuel
Injection
Volume
Starting Problem
Exhaust Smoke
None
Little
Much

Exhaust Color
Ordinary
White
Black
Poor Exhaust Color

During Work
White
Black

Combustion
During Idling
Engine
Surging
During Work
Operation

Speed
Excessive Oil
Consumption
Engine
Oil
Dilution by Diesel
Fuel
Oil With Water
3.72
Copyright 2014
Poor
Spray
Pattern
from
Fuel
Injection
Nozzle
Priming
Failure
Clogged
Strainer
at Feed
Pump
Inlet
ENGINE
Low Oil Pressure
Overheat
Engine
Coolant
Air
Intake
Low Coolant
Temperature
Pressure Drop
Pressure Rise
Corrective Action
Bleed
the Air
Clean
or
Replace
Check
the Fuel
Tank,
Fuel
Filter,
Fuel
Line
and
Fuel
Feed
Pump
Check
and
Adjust
Check
and
Adjust
Check
and
Adjust
Foreign
Matter
Trapped
in the
Valve
Inside the
Priming
Pump
(Disassemble
and
Clean)
Clean
the
Strainer
3.73
Copyright 2014
ENGINE
CAUSE
AIR / EXHAUST GAS SYSTEM
TROUBLE SYMPTOM
Clogged
Air Filter
Engine
Used at
High
Temperatures or at
High
Altitude
Clogged
Exhaust
Pipe
ELECTRICAL SYSTEM
Starting
Motor
Defect
Alternator
Defect
Starting Problem
Exhaust Smoke
None
Little
Much

Exhaust Color
Ordinary
White
Black
Poor Exhaust Color

During Work
White
Black

Combustion
During Idling
Engine
Surging
During Work
Operation

Speed
Excessive Oil
Consumption
Engine
Oil
Dilution by Diesel
Fuel
Oil With Water
Low Oil Pressure
3.74
Copyright 2014
OpenCircuit in
Wiring
Battery
Voltage
Drop
ENGINE
Overheat
Engine
Coolant
Air
Intake
Low Coolant
Temperature
Pressure Drop
Pressure Rise
Corrective Action
Clean Air
Filter
Study
Output
Drop and
Load
Matching
Clean
Exhaust
Pipe
Repair or
Replace
Starter
Motor
Repair or
Replace
Alternator
Repair
Open
Circuit
Inspect
and
Change
the
Battery
3.75
Copyright 2014
ENGINE
NOTES
3.76
Copyright 2014
FUEL SYSTEM
CHAPTER 4
FUEL SYSTEM
SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
DIESEL FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
FUEL SYSTEM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
SPECIAL TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
TEST AND ADJUSTMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
DIESEL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
PRINCIPAL COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
PRIMING THE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
FUEL SYSTEM ASSEMBLY VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
FUEL TANK ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
FUEL PICK-UP / SENDING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
FUEL LINES / VENT LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
FUEL PICK-UP SCREEN SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
FUEL SENDER TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
FUEL PICK-UP / SENDING UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.10
FUEL TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.12
FUEL TANK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.14
FUEL TRANSFER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.16
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.16
FUEL PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.16
FUEL PUMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.18
FUEL FILTER / WATER SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.18
FUEL FILTER / WATER SEPARATOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.18
FUEL FILTER / WATER SEPARATOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.19
FUEL INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.20
ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.20
FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.21
FUEL SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.22
FUEL INJECTION LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.22
REMOVING THE HIGH-PRESSURE INJECTION LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.22
INSTALLING THE HIGH-PRESSURE INJECTION LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.23
REMOVING THE FUEL RETURN LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.23
INSTALLING THE FUEL RETURN LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.23
FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.24
REMOVING THE FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.24
INSTALLING THE FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.26
CHECKING AND ADJUSTING FUEL INJECTION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.29
CHECKING FUEL INJECTION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.29
ADJUSTING FUEL INJECTION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.32
4.1
Copyright 2014
FUEL SYSTEM
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.33
REMOVING THE FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.33
TESTING THE FUEL INJECTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.34
FUEL INJECTOR TEST RESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.35
DISASSEMBLING AND INSPECTING FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.36
ADJUSTING FUEL INJECTOR PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.37
ASSEMBLING THE FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.37
INSTALLING THE FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.37
4.2
Copyright 2014
FUEL SYSTEM
SAFETY PRECAUTIONS
FUEL SYSTEM SPECIFICATIONS
Diesel Fuel System
Special Torque Chart
WARNING
Component
Torque Value
Fuel Injector
Fuel injection components are under high pressure.

Verify system pressure has been relieved before
system disassembly.
36.1 - 39.1 ft-lbs

(49 - 53 Nm)
Fuel Pump Drive Gear Nut
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.
44 - 51 ft-lbs
(59 - 69 Nm)
Before you operate the engine, check for fuel leaks.
High-Pressure Fuel Injection Line Nuts
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.
22 - 25 ft-lbs
(29 - 34 Nm)
Fuel Return Line Nuts
18 - 24 ft-lbs
(24 - 33 Nm)
Fuel Injection Pump
Mounting Bolts
17 - 21 ft-lbs
(23 - 28 Nm)
Fuel Injector Nozzle Case Nut
21.4 - 36.1 ft-lbs
(29 - 49 Nm)
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.
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.
4.3
Copyright 2014
FUEL SYSTEM
Test and Adjustment Specifications
GENERAL INFORMATION
Special Tools
Fuel Injector Pressure

Fuel Injection Timing
Item
1784 - 1929 psi
Part Number
(12.3 - 13.3 MPa;
Tool Description
123 - 133 bar)
See Checking and Adjusting Fuel Injection Timing

NOTE: Fuel injector pressures given are for used
parts. New injectors (5 hours operation or less) will
read approximately 72.5 psi (0.5 MPa; 5 bar) higher.
PU-50326
PFA Nut Tool
B
PU-50530
Diesel Injection Timing Tool
C
PU-50532
Diesel Fuel Injector Tester
Bosch Automotive Service Solutions: 1-800-345-2233 or
http://polaris.service-solutions.com.
4.4
Copyright 2014
FUEL SYSTEM
NEVER start the engine when the cables are loose
or poorly connected to the battery terminals.
NEVER disconnect
running.
battery
while
engine
is
Do not charge battery with key switch "on."

Always disconnect negative (-) battery cable lead
before charging battery.
NOTE: The fuel system remains under
pressure, even when the engine is not running.
Before attempting to service any part of the
fuel system, pressure must be relieved (if
applicable).
4
Principal Components
The fuel system is a complete engine fuel management
design. This system includes the following principal
components:
Fuel Pump
Fuel Filter / Water Separator Assembly
Fuel Injection unit
The fuel system contains both high and low
pressure systems (supply and injection)
Operation Overview
Diesel Service Notes
NEVER attempt to service any fuel system
component while engine is running or ignition
switch is "on".
Cleanliness is essential and must be maintained at
all times when servicing or working on the fuel
system. Dirt, even in small quantities, can cause
significant problems.
Do not use compressed air if the system is open.
Cover any parts removed and wrap any open
joints with plastic if they will remain open for any
length of time. New parts should be removed from
their protective packaging just prior to installation.
Clean any connection before opening to prevent
dirt from entering the system.
The fuel injection system is designed to provide peak

engine performance with optimum fuel efficiency and
lowest possible emissions. The injection functions are
mechanically controlled and governed.
NOTE: The fuel injection unit is not serviceable. It
must be serviced by an authorized FIE repair facility.
An in-line electric fuel pump is used to move fuel from the
tank through the fuel line and in-line fuel filter/water
separator. The fuel pump maintains a system operating
pressure of 1-5 psi. Any excess fuel returns to the tank
via the return line attached to the injection system.
At the engine, fuel is fed to the fuel injection control unit,
which operates the injectors. A precise amount is
injected into the pre-combustion chambers.
Although every precaution has been taken to

prevent water intrusion failures, avoid high
pressure spray contact with system components.
Do not allow the battery cables to touch opposing
terminals. When connecting battery cables attach
the positive (+) cable to positive (+) battery
terminal first, followed by negative (-) cable to
negative (-) battery terminal.
4.5
Copyright 2014
FUEL SYSTEM
Priming the Fuel System
3. Turn the key switch to START until the engine

starts or 5 seconds has passed.
NOTE: The injection system must be purged of all

air prior to the initial start up, and / or any time the
system has been disassembled.
4. If the engine failed to start, repeat steps one and two.

If the engine fails to start, a fuel supply problem may
exist, and should be diagnosed.
If the fuel system is completely empty or has been

disassembled for repairs, perform the following:
1. Turn the key switch to the ON position for 10-15
seconds.
2. Locate the air bleed screw on top of the fuel filter /
water separator. Slowly open and close the bleed
screw to remove any air trapped in the system.
4.6
Copyright 2014
FUEL SYSTEM
Fuel System Assembly View
4.7
Copyright 2014
FUEL SYSTEM
FUEL TANK ASSEMBLY
Fuel Pick-Up / Sending Unit
4.8
Copyright 2014
FUEL SYSTEM
Fuel Lines / Vent Line
Fuel Pick-up Screen Service
1. Remove the drivers seat base and storage tray. Tilt

the rear cargo box.
The fuel pick-up screen (Item 1) is located in the fuel tank

at the bottom of the fuel pick-up. The screen can be
cleaned, but is not serviceable. If replacement is
required, the entire fuel pick-up / sender assembly (Item
2) must be replaced (see Fuel Pick-Up / Sending Unit
Removal).
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.
3. Check the fuel tank vent line (Item 3) for signs of

wear, deterioration, damage or leakage. Replace
vent line every two years.
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.
Fuel Sender Tests

If the fuel gauge reading on the instrument cluster is not
working, or if the display reading differs in large
comparison to the amount of fuel in the tank, perform a
resistance test on the fuel sender.
1. Remove the fuel sending unit assembly from the fuel
tank (see Fuel Pick-Up / Sending Unit Removal).
2. Using an Ohm meter, measure the resistance of the
fuel sender as shown below.
5. Be sure fuel lines and vent line are routed and

retained properly.
NOTE: Make sure lines are not kinked or
pinched.
4.9
Copyright 2014
FUEL SYSTEM
3. Allow the sender float to sit in the empty position
and compare to specification.
6. Disconnect the fuel supply line (Item 1) from the fuel

pick-up / sending unit (Item 2).
Fuel Sender - Empty: 6 2 W

4. Slowly move the sender float to the full position and
compare to specification.
Fuel Sender - Full: 102 2 W
5. If the readings are out of specification, or if the
reading is erratic or LCD display sticks, check the
following before replacing the fuel sending unit:
Loose float
Float contact with tank
Bent float rod
6. If none of the conditions exist, the fuel sending unit is
faulty and requires replacement (see Fuel Pick-Up /
Sending Unit Removal).
Fuel Pick-Up / Sending Unit Removal

1. Move the vehicle to a well ventilated area. Shift the
transmission into Park and turn the ignition key off.
2. Remove the passenger seat base and storage tray
to access the battery.
3. Disconnect the negative battery cable.
NOTE: A small amount of fuel may come out of

the fuel line. Properly drain fuel into a suitable
container.
7. Disconnect the fuel sending unit harness (Item 3).
8. Place the Special Tool (PU-50326) over the fuel pickup / sending unit PFA nut (Item 4). Using a 1/2 drive
ratchet or breaker bar, loosen and remove the PFA
nut. Discard the PFA nut.
4. Remove the drivers seat base and storage tray to

access the top of the fuel tank.
WARNING
Always wear safety goggles when working with
flammable fluids. Failure to do so could result in serious
injury or complications.
5. Thoroughly clean the top of the fuel tank before
disassembly.
WARNING
Failure to clean area around fuel pick-up / sending unit
may lead to debris entering the fuel tank during service.
Excessive debris in fuel tank may clog the fuel pick-up
screen.
Special Tool: PU-50326
4.10
Copyright 2014
FUEL SYSTEM
9. Carefully lift the fuel pick-up / sending unit out of the
fuel tank. During removal, be aware of the float arm
(Item 5) and pick-up screen (Item 6). Hold the float
arm in during removal to ensure that the float arm is
not bent when removed from the tank.
14. Install new PFA gasket onto fuel pick-up / sending

unit using care not to damage gasket or bend float
arm.
10. Discard the PFA gasket (Item 7).

11. Inspect the inside of the fuel tank for debris (may
require flashlight and mirror). If debris like mud or
sand is present, fuel tank should be flushed and
cleaned out prior to installation of new fuel pick-up /
sending unit.
NOTE: If there is debris in the fuel tank, it is
recommended to remove the fuel tank from the
vehicle and rinse it with a small amount of clean
fuel. Do not use water or any other chemicals to
remove debris.
12. Remove new fuel pick-up / sending unit, gasket and
PFA nut from packaging. Use care not to bend float
arm during un-packaging. Do not lift or carry fuel
pick-up / sending unit by wire harness or the float
arm
13. Use cleaning wipes provided to clean fuel tank
surface and threads. Remove all debris, grease and
oil. Allow surfaces to dry completely.
15. Install fuel pick-up / sending unit into fuel tank, hold
float arm in to ensure float arm does not get caught
or bent during installation.
4.11
Copyright 2014
FUEL SYSTEM
16. Roughly align the fuel supply outlet between the
orientation marks on fuel tank to ensure float arm
does not get bent or snagged.
22. Connect the fuel sending unit harness and connect

the negative battery cable.
23. Install the driver and passenger seat bases and
storage trays.
24. Test the fuel sending unit by turning on the ignition
key and observing the gauge to indicate present fuel
level.
Fuel Tank Removal

WARNING
Always wear safety goggles when working with high
pressure or flammable fluids. Failure to do so could
result in serious injury or complications.
1. Remove the passenger seat and storage tray.
Disconnect the negative (-) battery cable.
2. Remove the driver's seat, disconnect the seat switch
(if equipped) and remove the storage tray.
WARNING
Failure to align with the orientation marks may lead to
interferences with the fuel level float arm and cause
incorrect function.
3. Disconnect the fuel lines (Item 1), vent hose (Item 2)

and fuel sender harness (Item 3).
17. Thread the new PFA nut onto the fuel tank and hand
tighten. Use care when starting PFA nut, ensuring
threads are properly aligned. Verify the fuel supply
outlet is still aligned between the fuel tank marks.
18. Hold down on fuel pick-up / sending unit to prevent
from rotating. Use care when tightening PFA nut to
avoid damaging wire harness lead.
19. Torque PFA nut to specification using the Special
Tool (PU-50326) and a calibrated torque wrench.
PFA Nut:
70 5 ft-lbs (95 7 Nm)
NOTE: A small amount of fuel may come out of

the fuel line. Plug the fuel line during removal.
20. Verify fuel supply outlet is aligned with fuel tank

orientation marks.
21. Connect fuel supply line to fuel pick-up / sending
unit.
4.12
Copyright 2014
FUEL SYSTEM
4. Disconnect the harness (Item 4) from the 2-speed
solenoid.
9. Remove bolt (Item 7) retaining the hydraulic line

restrain to the frame.
4
5. Remove the center console.
6. Remove the fasteners (Item 5) retaining the joystick
to the seat base (HD / HDPTO models only).
10. Use a 13mm socket to remove the upper mounting

bolt (Item 8) and a 10mm socket to remove the two
lower mounting bolts (Item 9), retaining the A/C
condenser to the frame.
11. Remove the two fasteners (Item 10) retaining the 2speed manifold to the seat base.
12. Remove the two fasteners (Item 10) retaining the
lower part of the seat base to the frame.

throttle lever to the seat base (HD / HDPTO models
only).
8. Remove the floor (see Chapter 7 Main Floor).
13. Remove the two fasteners retaining the upper seat

base to the frame (there may be two T-40 Torx
screws retaining the block-off panel to the seat
support).
4.13
Copyright 2014
FUEL SYSTEM
14. Remove the two fuel tank strap fasteners (Item 12)
and remove both straps.
Fuel Tank Installation

1. Reinstall the fuel tank into the chassis taking care not
to damage brake lines, hoses or the wire harness.
2. Install (3) plastic tie straps to retain the wire harness
to the fuel tank (locations marked with white tape).
3. Install the fuel tank mounting straps and the two
fasteners retaining fuel tank to chassis. Torque
fasteners (Item 1) to specification.
15. Cut the three tie straps retaining the harness to the
side of the tank (locations marked with white tape).
NOTE: Syphon as much fuel from the tank as
possible before attempting to remove it. Drain
the remaining fuel into a suitable container upon
removal.
Tie the harness and hydraulic lines up and to the
passenger side so they are out of the way upon
tank removal and installation.
16. Remove the fuel tank by lifting the side towards the
middle of the vehicle (fuel sender side). Make sure
the fuel fill neck is clear of the A/C hoses running to
the condenser (HDPTO models only).
Fuel Tank Mounting Straps Fasteners:

8 ft-lbs (11 Nm)
4. Install the two fasteners retaining the upper seat
base to the frame. Torque fasteners to specification.
Upper/Lower Seat Base Fasteners:

14 ft-lbs (19 Nm)
5. Install the two fasteners retaining the lower part of
the seat base to the frame. Torque fasteners (Item 2)
to specification.
Upper/Lower Seat Base Fasteners:

14 ft-lbs (19 Nm)
4.14
Copyright 2014
FUEL SYSTEM
6. Install the two fasteners retaining the 2-speed
manifold to the seat base. Torque fasteners (Item 3)
to specification.
8. Install the hydraulic line restrain and the retaining

bolt. Torque the retaining bolt (Item 6) to
specification.
2-Speed Manifold Mounting Fasteners:

8 ft-lbs (11 Nm)
7. Position the A/C condenser on the frame. Use a
13mm socket to install the upper mounting bolt (Item
4) and a 10mm socket on the two lower mounting
bolts (Item 5). Torque fasteners to specification.
Hydraulic Line Restrain Mounting Bolt:

8 ft-lbs (11 Nm)
9. Install the floor (see Chapter 7 Main Floor).
10. Install the two fasteners retaining the throttle lever to
the seat base (HD / HDPTO models only). Torque
the fasteners (Item 7) to specification.
A/C Condenser Upper Mounting Fastener:

14 ft-lbs (19 Nm)
A/C Condenser Lower Mounting Fasteners:

8 ft-lbs (11 Nm)
Throttle Lever Mounting Fasteners:

15 ft-lbs (20 Nm)
4.15
Copyright 2014
FUEL SYSTEM
11. Install the fasteners retaining the joystick to the seat
base (HD / HDPTO models only). Torque the
fasteners (Item 8) to specification.
Hydraulic Joystick Mounting Bolts:

17 ft-lbs (23 Nm)
FUEL TRANSFER PUMP

Operation Overview
The electric fuel transfer pump (Item 1) is used to supply
fuel from the tank to the fuel injection system. The main
in-line components for fuel transfer include the fuel pump
and fuel/water separator. The pump is rated for a 1-5 psi
output.
12. Install the center console.

13. Connect the harness (Item 9) to the 2-speed
solenoid.
When the key switch is turned to "ON", 12Vdc power

activates the fuel pump, which pressurizes the system for
start-up.
14. Connect the fuel lines (Item 10), vent hose (Item 11)
and fuel sender harness (Item 12).
The fuel pump is activated any time the key switch is

turned to the "ON" position.
15. Connect the negative (-) battery cable.

16. Install the seat base storage trays.
17. Install the driver's seat and connect the seat switch
(if equipped).
18. Install the passenger seat.
4.16
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FUEL SYSTEM
Fuel Pump Test
NOTE: The fuel transfer pump is non-serviceable
and must be replaced if determined to be faulty. If a
fuel delivery problem is suspected, make certain the
fuel pump is being activated when the key switch is
ON, all electrical connections are properly secured,
the fuses are good, and a minimum of 12.0 Vdc is
being supplied.
WARNING
Fuel is extremely flammable and may cause severe
burns, injury, or death.
Do not use any device that produces a flame or
electrical devices that may spark around
fuel or fuel vapors.
1. Tilt the rear cargo box. Remove the fuel line from the
fitting on top of the fuel filter/water separator (Item 2).
3. Turn the key switch on and check the system

pressure on the gauge. If system pressure of 1-5 psi
is observed, the ignition switch and fuel pump are
working properly. Turn the key switch off to relieve
the system pressure.
Fuel Transfer Pump Pressure: 1-5 psi
NOTE: If the fuel pump did not operate, proceed
to the next step. If the pump operated, but fuel
pressure was too low, check the fuel pick-up
screen (see Fuel Pick-up Screen Service). If the
pick-up screen is ok and the pump still operates,
replace the fuel pump.
4. If the pump does not operate, disconnect the plug
from the fuel pump. Connect a DC voltmeter across
terminals in the plug on the vehicle harness side.
Turn on the key switch and observe voltage to
ensure a minimum of 12 Vdc is present.
NOTE: If the voltage was below 12 Vdc, test
battery, ignition switch, relay (s), wiring harness
and ECM.
5. If voltage at the plug is within the specified range,
and there is continuity across the pump terminals,
reconnect the plug to the fuel pump, making sure you
have clean connections. Turn on the key switch and
listen for the pump to activate.
NOTE: If the pump operates, verify you have the
correct amount of fuel pressure. If the pump still
does not operate, replace the fuel pump (see
Fuel Pump Replacement).
2. Install a commercially available low pressure test

gauge on the fuel line between the fuel pump and the
fuel filter / water separator.
4.17
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FUEL SYSTEM
FUEL FILTER / WATER SEPARATOR
Fuel Pump Replacement
Fuel Filter / Water Separator Draining

WARNING
Always wear safety goggles when working with high
pressure or flammable fluids. Failure to do so could
result in serious injury or complications.
CAUTION
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. Remove the driver's seat, disconnect the seat switch

(if equipped). Remove the storage tray to access the
fuel pump.
1. Be sure engine is cool and the battery is

disconnected.
2. Disconnect the electrical harness (Item 3) from the

fuel pump.
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).
3. Place a suitable container under the fuel pump and

remove the fuel line (Item 4) from each end of the
fuel pump. Dispose of the fuel properly.
4. Remove the bracket fasteners (Item 5) and remove
the pump from the frame.
5. Install the new pump onto the frame and reinstall the
bracket fasteners. Tighten fasteners securely.
6. Install the fuel lines and spring clamps securely.
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.
7. Reconnect the electrical harness.

8. Turn the ignition key ON for 10-15 seconds and
listen to be sure the pump operates.
9. Check for any fuel leaks.
10. Start engine and check for fuel leaks.
4.18
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FUEL SYSTEM
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).
Fuel Filter / Water Separator Replacement
6. Dispose of contaminants and excess fuel properly.
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.

fuel system. Doing so will force air out of the fuel
system.
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.
1. Follow Steps 1-6 from the Fuel Filter / Water

Separator Draining procedure.
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.
NOTE: 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.
fuel system.
4.19
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FUEL SYSTEM
FUEL INJECTION SYSTEM
Assembly View
4.20
Copyright 2014
FUEL SYSTEM
Fuel Injection Pump
NOTE: If the fuel injection pump itself requires

servicing, it must be taken to an authorized Yanmar
FIE (Fuel Injection Equipment) repair facility.
Contact Polaris Technical Service for assistance to
have the MC fuel injection pump serviced.
NEVER remove or attempt to remove the
tamper proof devices from the full-load fuel
adjusting screw or the high-speed throttle limit
screw on the fuel injection pump and governor
assembly. These adjustments have been made
at the factory to meet all applicable emissions
regulations and then sealed.
NEVER attempt to make any adjustments to
these
sealed
adjustment
screws.
If
adjustments are required, they can be made
only by a qualified fuel injection shop that will
ensure the injection pump continues to meet
all applicable emissions regulations, and then
replace the tamper-proof seals.
Tampering with or removing these devices may
void the Limited Warranty.
The following describes the features of the MC fuel
injection pump, manufactured by Yanmar.
good service practices and maintain cleanliness when

servicing the fuel injection pump.
The Yanmar Fuel Injection Pump is an in-line type pump
which consists of a fuel supply plunger (A) for each
cylinder, a camshaft (B) and a pump housing (C). A
delivery valve (D) connects to a high-pressure fuel line
for each cylinder. The fuel injection pump housing
contains a governor (E).
Fuel from the fuel tank to the fuel injection pump is
delivered by a low-pressure electric fuel feed pump. On a
few special models, a mechanical fuel feed pump is used
instead of an electric pump. The mechanical fuel feed
pump is mounted to the fuel injection pump housing in
place of the cover plate (F).
Fuel to be injected into the cylinders is pressurized by the
up and down motion of each camshaft-driven plunger,
and is then supplied by the high-pressure fuel lines to the
respective fuel injector.
The fuel injector is essentially a spring-loaded valve.
When fuel pressure from the fuel injection pump reaches
a pre-determined level, the pintle (valve) is forced off its
seat and fuel is atomized as it passes between the pintle
and seat. The timing and quantity of the fuel injected into
the cylinder is controlled by the fuel injection pump and
governor assembly.
The fuel injection pump is a very important component of

the engine. It is capable of making very precise fuel
delivery adjustments according to the varied loads
applied to the engine.
All of the fuel injection pump components are very
precisely machined. It is extremely important to follow
4.21
Copyright 2014
FUEL SYSTEM
Fuel Solenoid
FUEL INJECTION LINES
The fuel injection pump is equipped with a fuel solenoid

that controls the fuel flow inside the fuel injection pump.
Removing the High-Pressure Injection Lines
With the starter switch in the OFF position, no current

flows to the fuel solenoid and the solenoid plunger is
extended, holding the fuel injection pump fuel rack in the
closed position and not allowing fuel to flow through the
injection pump and to the engine.
NOTE: 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 install the fuel lines.
To prevent rounding the fuel line nuts, always use
a line or flare nut wrench.
When the starter switch is turned to the start position, the

pull coil (36.5-amp draw / white wire) inside the
solenoid is activated and pulls the solenoid plunger into
the solenoid. This releases the fuel injection pump fuel
rack, allowing fuel to flow through the injection pump and
allowing the engine to start and run.
When the starter switch is returned to the ON or RUN
position, the pull coil no longer receives current and the
hold coil (0.5-amp draw / red wire) inside the solenoid is
activated. The hold coil holds the solenoid plunger in
the RUN position, allowing fuel to continue flowing and
the engine to continue running.
To stop the engine, the key switch is turned to the OFF
position. Current no longer flows to the fuel solenoid
hold coil, and the solenoid plunger extends and moves
the injection pump fuel rack to the closed position,
shutting off the fuel flow and stopping the engine.
1. Close any fuel valves in the fuel supply line.

2. Clean the area to keep contaminants from entering
the fuel system.
3. Place a drain pan under the fuel injection pump to
catch any spillage.
4. Loosen the fuel line nuts at the fuel injection pump.
5. Next, loosen the fuel line nuts at the fuel injectors.
Use one wrench to hold the fuel return line nut and
fuel return line from rotating. Use a second wrench to
loosen the fuel line nut. Repeat with the remaining
fuel injectors.
Failure of the fuel solenoid could result in the engine not

starting, the engine stopping suddenly, the engine
continuing to run with the key switch returned to the ON
or RUN position or the engine failing to stop when the
key switch is turned to the OFF position. Use a VOA
multimeter or continuity light to check for a good ground
and 12V at the fuel solenoid in the correct sequence.
6. Finish loosening all the fuel line nuts and remove the
high-pressure fuel lines as an assembly, being
careful not to bend any of the fuel lines. Be sure to
protect the fuel system from contamination by
plugging or covering all open connections.
7. Plug or cap all openings to minimize leakage and
prevent contamination.
4.22
Copyright 2014
FUEL SYSTEM
Installing the High-Pressure Injection Lines
4. Remove the fuel return hose from the fuel return

fitting on the fuel injection pump.
NOTE: 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 install the fuel lines.
To prevent rounding the fuel line nuts, always use
a line or flare nut wrench.
5. Carefully remove the fuel return line assembly (C).
1. Start all the fuel line nuts by hand. Then use a

wrench to snug all the fuel line nuts.
2. Tighten the fuel line nuts on the fuel injection pump
to the specified torque (see Special Torque Chart).
3. When tightening the fuel line nuts on the fuel
injectors, use one wrench to hold the fuel return line
nut and fuel return line from rotating. Use a second
wrench to tighten the fuel line nuts (see Special
Torque Chart).
6. Remove and discard the copper gasket (A) from

each fuel injector.
Installing the Fuel Return Line

NOTE: The fuel return line is a one-piece assembly.
Use care not to bend or twist the fuel return line.
1. Install a new copper gasket on each fuel injector.
2. Carefully install the fuel return line assembly.
3. Install and hand-tighten the fuel return line nuts.
4. Tighten the fuel return line nuts to the specified
torque (see Special Torque Chart).
Removing the Fuel Return Line
5. Install the fuel return hose.
NOTE: The fuel return line is a one-piece assembly.

Use care not to bend or twist the fuel return line.
6. Install the high-pressure fuel injection line assembly

(see Installing the High-Pressure Injection Lines).

the fuel system.
2. Remove the high-pressure fuel injection lines as an
assembly (see Removing the High-Pressure
Injection Lines).
3. Remove all fuel return line nuts (B) from the injectors
(D).
4.23
Copyright 2014
FUEL SYSTEM
FUEL INJECTION PUMP
3. Place a drain pan under the fuel injection pump to

catch any spillage.
Removing the Fuel Injection Pump

the fuel system.
Injection Lines).
WARNING
When you remove any fuel system component to
perform maintenance (such as changing the fuel filter),
put an approved container under the opening to catch
the fuel.
6. Disconnect the fuel return lines from the fitting on the

fuel injection pump (D). Plug the open ends of the
lines
to
minimize
leakage
and
prevent
contamination.

Always wear eye protection. The fuel system is under
pressure and fuel could spray out when you remove
any fuel system component.
1. Loosen the cooling pump V-belt (A) by loosening the
alternator.
7. Remove the fuel supply line (E) from the fitting on the
fuel injection pump.
9. Remove the throttle cable from the fuel injection
pump.
10. Disconnect the fuel solenoid wiring connector (F).
2. Remove the engine belt guard, engine cooling pulley
bolts (B), V-pulley (C) and V-belt.
4.24
Copyright 2014
FUEL SYSTEM
11. Remove the fuel injection pump drive gear access
cover (G) from the gear case cover (H).
12. To aid in assembly, make alignment marks (J) on the

pump drive gear and idler gear.
NOTE: The cover is secured with an adhesive

sealant. Use a gasket scraper to separate the
cover from the gear case cover.
NOTE: Mark the gears with something that will

not rub off or be affected by oil and become
illegible. If the gears are not marked or are
illegible during installation, the gear case cover
must be removed to properly time the injection
pump gear.
After marking the position of the pump drive
gear, do not rotate the engine crankshaft.
Rotating the crankshaft will cause the fuel
injection pump to become misaligned.
13. Hold the gear train stationary using a wrench on the
crankshaft pulley bolt. Remove the fuel injection
pump drive gear retaining nut and washer (K).
NOTE: Do not loosen or remove the four bolts
retaining the fuel injection pump drive gear to the
fuel injection pump hub. Do not disassemble the
fuel injection pump drive gear from the hub.
14. Thread the drive gear nut onto the injection pump
shaft until it is even with the end of the shaft. This will
prevent the gear from falling off of the shaft when
using the puller.
4.25
Copyright 2014
FUEL SYSTEM
15. Remove the injection pump drive gear and hub from
the injection pump drive shaft as an assembly using
an appropriate gear puller.
18. If the fuel injection pump requires servicing, it must

be sent to an authorized Yanmar FIE repair facility
for repair and calibration, or replaced with a new fuel
injection pump.
NOTE: Contact Polaris Technical Service to
have the MC fuel injection pump serviced.
NEVER remove or attempt to remove the
tamper proof devices from the full-load fuel
adjusting screw or the high-speed throttle limit
screw on the fuel injection pump and governor
assembly. These adjustments have been made
at the factory to meet all applicable emissions
regulations and then sealed.
NEVER attempt to make any adjustments to
these
sealed
adjustment
screws.
If
adjustments are required, they can be made
only by a qualified fuel injection shop that will
ensure the injection pump continues to meet
all applicable emissions regulations, and then
replace the tamper-proof seals.
Tampering with or removing these devices may
void the Limited Warranty.
16. Once the fuel injection pump drive gear and hub
assembly have popped loose from the tapered fuel
injection pump drive shaft, carefully remove the drive
gear nut (L) and remove gear and hub assembly.
17. Remove the four bolts (M) and metal gasket (N)
fastening the fuel injection pump to the cylinder
block. Remove the fuel injection pump.
Installing the Fuel Injection Pump

1. Install a new gasket to the mounting surface of the
injection pump.
2. Install pump to the engine block using the four bolts
(P) and metal gasket (Q). Tighten to the specified
torque.
NOTE: Do not rotate the crankshaft with the

injection pump removed.
NOTE: Ensure the tapered surface of the fuel
injection pump shaft is clean and dry.
4.26
Copyright 2014
FUEL SYSTEM
3. Align the key on the fuel injection pump shaft with the
keyway in the fuel injection pump drive gear hub.
Ensure the fuel injection pump drive gear is aligned
with the idler gear using the reference marks made
earlier (R).
5. Install the fuel injection pump drive gear lock washer

(S) and nut (T). Do not lubricate threads of the nut or
shaft. Hold the crankshaft pulley bolt with a wrench
and tighten the pump drive gear nut to the specified
torque (see Special Torque Chart).
4. If installing the fuel injection pump on an engine with

the front gear case cover removed, the fuel injection
pump drive gear can be aligned with the idler gear by
aligning the stamped marks (A, B, C) on the fuel
injection pump drive gear, idler gear, camshaft gear
and crankshaft drive gear. Ensure all three timing
marks (A, B, C) are aligned.
6. Connect the fuel supply and return lines to the fuel

injection pump.
7. Connect the throttle linkage and fuel solenoid wire
connector.
8. If installing a new or recalibrated fuel injection pump,
check the fuel injection timing before completing the
installation of the fuel injection pump (see Checking
and Adjusting Fuel Injection Timing).
NOTE: While it is not required to check the
injection timing when installing the original fuel
injection pump, it is recommended that it be
done.
9. After adjusting the fuel injection timing, apply
ThreeBond Liquid Gasket No. 1212, or equivalent
sealant to the sealing surface of the fuel injection
pump drive gear access cover. Install the cover on
the front of the gear case and tighten the bolts.
4.27
Copyright 2014
FUEL SYSTEM
10. Install the fuel injection high-pressure lines (see
Installing the High-Pressure Injection Lines).
11. Install the coolant pump V-pulley (V), pulley bolts (W)
and V-belt (X).
NOTE: When installing a new or repaired fuel

injection pump, it is important to add engine oil
to the fuel injection pump to provide lubrication
for initial start-up. Add 5 to 7 oz (150 to 200 cc) of
clean engine oil to the fuel injection pump at the
fill plug (U) located in the upper outside section
of the governor housing.
12. After installing the V-belt (X), adjust as described in

Checking and Adjusting Cooling Pump V-Belt.
13. Install the engine belt guard.
14. Prime the fuel system (see Priming the Fuel
System).
15. Operate the engine and check for fuel and lube oil
leaks.
4.28
Copyright 2014
FUEL SYSTEM
CHECKING AND ADJUSTING FUEL
INJECTION TIMING
6. Remove the flywheel inspection port plug (D) to view

the flywheel markings.
Checking Fuel Injection Timing

NOTE: The following procedure is performed on the
No. 1 cylinder. While checking and adjusting the
timing on only No. 1 cylinder is usually sufficient,
the same procedure can be performed on any or all
cylinders.
Some fuel may drain from the fuel injection pump during
this process. Use an approved container to catch fuel.
WARNING
Use an approved container to catch fuel.
1. Ensure the fuel injection pump is primed with fuel
(see Priming the Fuel System).
7. Using a wrench on the crankshaft pulley bolt, rotate

the crankshaft in a clockwise direction while looking
through the flywheel inspection port. Rotate the
crankshaft until the injection timing marks on the
flywheel are visible for No. 1 cylinder.
2. Clean the area around the fuel injection pump.

NOTE: Clean the area around the fuel injection
pump to prevent any contamination when the
fuel injection pump plunger plug is removed.
The fuel solenoid must be removed to allow fuel
to flow through the fuel injection pump.
3. Remove the two screws (A).
NOTE: The flywheel has a timing grid for each

cylinder. Any grid and its corresponding cylinder
can be used to check the fuel injection timing.
4. Remove the fuel solenoid (B) and O-ring (C).
5. Set the throttle to the HIGH-IDLE position.
The TDC (Top Dead Center) mark can be

identified by the cylinder numbers stamped near
the TDC mark (5) on the flywheel.
4.29
Copyright 2014
FUEL SYSTEM
8. If you are uncertain as to the timing degree
designation of the timing marks on the flywheel
timing grid, you can determine the timing degree
designation by measuring the timing grid.
9. Highlight the timing reference mark on the flywheel

housing (E) or engine back plate (F). Highlight the
TDC mark (G) on the flywheel.
First measure the distance between two of the

longer marks on the timing grid. (They are 5
apart.) Then measure the distance from the TDC
mark to the first longer mark on the timing grid.
Divide that measurement by the distance between
the two longer marks. The resulting answer will
tell you how many degrees there are between the
TDC mark and the first longer mark.
EXAMPLE: If the distance between the two
longer marks is approximately 2.0 cm and the
distance from the TDC mark is approximately 4.0
cm, the answer is approximately 2. This indicates
there is 10 (2 x 5) between the TDC mark and
the first longer mark on the timing grid. That
means the first longer mark on the timing grid
indicates 10 BTDC, the second longer mark
indicates 15 BTDC and the third timing mark
indicates 20. If the answer is 3, that indicates
there is 15 (3 x 15) between the TDC mark and
the first longer mark and that the first longer
mark indicates 15 BTDC with the second and
third longer marks indicating 20 BTDC and 25
BTDC respectively.
4.30
Copyright 2014
FUEL SYSTEM
10. Highlight the target timing mark (H) on the flywheel
timing grid as the injection timing measured before
the fuel injection pump removal.
12. Install the spill-timing tool (K) onto the delivery

valve for the cylinder being checked (see Special
Tools).
Injection Timing (FID)
VH
RPM (min-1)
3600
3TNM72
20.0
11. Remove all high-pressure fuel injection lines (see
Removing the High-Pressure Injection Lines).
NOTE: As the injection pump injects fuel to a
cylinder only once every two engine revolutions,
it may be necessary to rotate the crankshaft
twice to see fuel being pumped from the timing
tool or delivery valve of the cylinder you are
using to check injection timing.
NOTE: If a timing tool is not available, timing can

be checked by watching the fuel in the delivery
valve itself.
The following references to the direction of
rotation are made facing the cooling pump end of
the engine and are adjusted by turning the
crankshaft.
13. Slowly rotate the crankshaft clockwise using a
wrench on the crankshaft pulley bolt until fuel is
pumped from the nozzle of the spill-timing tool or
delivery valve.
14. Slowly rotate the crankshaft clockwise approximately
two more revolutions until the timing grid on the
flywheel (for the cylinder being checked) is at
approximately 30 BTDC.
NOTE: The fuel injection pump injects fuel to a
cylinder only once every two engine revolutions.
15. Flick the nozzle of the timing tool with a finger to
remove bubbles and establish a fuel level of
approximately half the height of the nozzle.
16. Very slowly rotate the crankshaft clockwise until the
fuel level in the nozzle of the spill-timing tool, or in
the delivery valve, just begins to move. Immediately
stop rotating the crankshaft.
4.31
Copyright 2014
FUEL SYSTEM
17. Check the position of the flywheel target timing mark
(H) on the flywheel grid in relation to the timing
reference mark (J) on the flywheel housing or back
plate. If the two marks are aligned, the fuel injection
timing is correct. If the marks do not align, the fuel
injection timing must be adjusted (see Adjusting
Fuel Injection Timing).
3. The new injection pump will come with a timing grid

sticker. Each line on the timing grid sticker is 1.
Each line on the flywheel grid is also 1.
18. Repeat Steps 13-17 two or three times to verify

timing.
19. Remove the spill-timing tool.
20. Install the fuel solenoid.
21. Install the high-pressure fuel injection lines (see
22. Install the flywheel inspection port plug.
23. Prime the fuel system. Operate the engine and
check for leaks.
Adjusting Fuel Injection Timing

If the timing marks did not align when performing the
Checking Fuel Injection Timing, the following steps
must be performed to properly time the engine.
4. Observe the flywheel grid again and determine how

many degrees you need to advance or retard the
timing.
5. Clean the area of the gear by the pointer on the
timing cover and put the sticker on the drive gear,
aligning the timing mark on the timing cover (C) with
the center of the sticker.
The fuel injection pump of TNM engines is fixed with four

bolts. Adjust the injection timing by rotating the pump
drive gear on the pump flange.
1. Leave the spill-timing tool installed in the fuel
injection pump.
2. Determine if the timing is advanced or retarded by
comparing the position of the target timing mark on
the flywheel grid (A) with the timing mark on the
flywheel housing or back plate (B).
6. Loosen the four bolts (D) fastening the injection

pump drive gear to the flange.
7. If the injection timing was less than the target timing,
the injection timing is retarded and will need to be
advanced.
To advance the injection timing: Rotate the
crankshaft counterclockwise. If the injection timing
was greater than the target timing, the injection
timing is advanced and will need to be retarded.
To retard the injection timing: Rotate the
crankshaft clockwise.
4.32
Copyright 2014
FUEL SYSTEM
8. Slowly rotate the crankshaft while watching the
pointer on the timing cover and the timing grid sticker
on the injection pump gear. Turn it the required
number of degrees that was determined earlier when
observing the flywheel grid.
FUEL INJECTORS
Removing the Fuel Injectors
9. Tighten the pump drive gear mounting bolts.

10. Recheck the fuel injection timing. Repeat the fuel
injection timing and adjustment procedures until the
timing is correct.
WARNING
11. Remove the sticker from the pump drive gear.

12. Remove the spill-timing tool.
13. Install the fuel solenoid.
14. Install the high-pressure fuel injection lines (see
15. Apply ThreeBond Liquid Gasket No. 1212 or
equivalent sealant to the sealing surface of the fuel
injection pump drive gear access cover. Install the
cover on the front of the gear case and tighten the
bolts.
16. Install the flywheel inspection port plug.
17. Prime the fuel system. Operate the engine and
check for leaks.
When you remove any fuel system component to

perform maintenance (such as changing the fuel filter),
put an approved container under the opening to catch
the fuel.
Always wear eye protection. The fuel system is under
pressure and fuel could spray out when you remove
any fuel system component.
1. Close any fuel valves in the fuel supply line.
2. Clean the area around the fuel injection pump and
fuel injectors to keep contaminants from entering the
engine or fuel system.
3. Remove the intake manifold / valve cover assembly
(see Removing the Intake Manifold / Valve Cover in
the Engine Chapter).
Injection Lines).
4.33
Copyright 2014
FUEL SYSTEM
5. Remove the nut (A). Remove the fuel return line (B)
and copper washer (C) from the fuel injectors (see
Removing the Fuel Return Line).
3. Using the correct adapter, connect a fuel injector to a

nozzle tester. Aim the fuel injector into a suitable
container to catch the fuel spray.
WARNING
NEVER inject fuel toward you. Since the fuel is injected
at high pressure from the nozzle, it may penetrate the
skin, resulting in injury.
NEVER inject fuel toward a fire source. Atomized fuel is
highly flammable and may cause a fire or burn skin.
ALWAYS wear eye protection when servicing the
engine and when using compressed air or highpressure water. Dust, flying debris, compressed air,
pressurized water or steam may injure your eyes.
6. Remove the fuel injectors (D).

7. Remove the injector nozzle gaskets (E) and
protector (F) from the cylinder head.
Testing the Fuel Injectors

NOTE: Never use a steel wire brush to clean fuel
injectors. Damage to the nozzle and other
components is likely to result.
1. Thoroughly clean the fuel injector nozzle using clean
diesel fuel and a brass wire brush.
2. Visually inspect the fuel injectors and nozzle
protectors for deposits or damage. Clean, repair or
replace as necessary.
NOTE: Test the fuel injector using an injection
nozzle tester. Operate the tester following the
information provided by the tester manufacturer.
Use clean, filtered fuel or FIE calibration fluid for
the test.
4. Pump the operating lever of the tester slowly,

observing the pressure reading at the point where
the fuel injector begins spraying fuel (see Test and
Adjustment Specifications at the beginning of this
Chapter for correct pressure readings).
NOTE: Opening pressure of a new fuel injector
will be approximately 72.5 psi (0.5 MPa; 5 bar)
higher than one that has been operated for 5
hours or longer.
5. Pump the operating lever slowly to hold the pressure
steady at a point just below the opening pressure
and hold that pressure for 5 seconds. Observe the
injector to see that it is sealing properly and is not
dripping. If fuel leaks from the return line fitting,
check that the nozzle case nut is tight. Service or
replace the injector if fuel continues to leak from
either the return line fitting or nozzle.
6. Pump the operating lever more rapidly to repeatedly
pop the injector and observe the spray pattern. The
pattern should be a very fine uniform spray. If
dripping or an uneven pattern is seen, service or
replace the injector (see Fuel Injector Test Results).
4.34
Copyright 2014
FUEL SYSTEM
Fuel Injector Test Results
NOTE: If the fuel injector fails any tests, it should be serviced or replaced as necessary. If the pressure is
outside specified limits, adjust the pressure (see Adjusting Fuel Injector Pressure).
4.35
Copyright 2014
FUEL SYSTEM
Disassembling and Inspecting Fuel
Injectors
NOTE: Never use a steel wire brush to clean fuel
injectors. Damage to the nozzle and other
components is likely to result.
1. Clean carbon from used injectors using clean diesel
fuel. Hardened deposits or varnish can be cleaned
using a brass wire brush.
2. Place the fuel injector in a soft-jawed vise with the

nozzle pointing up.
3. Remove the nozzle case nut.
4. Carefully remove the injector from the vise.
5. Turn the injector over and remove the nozzle body,
nozzle valve, valve stop spacer, nozzle spring seat,
nozzle spring and shims.
6. Inspect the sealing surfaces (A) between the valve
stop spacer and nozzle body for nicks or scratches.
Check the contact area between the valve stop
spacer and the nozzle valve (B) for scoring or pitting.
Use a magnifying glass to inspect.
7. Perform a nozzle valve slide test:

Wash nozzle body and valve in clean diesel fuel.
While holding the nozzle body vertical, pull the
nozzle valve about 2/3 of the way out.
Release the valve. It should fall smoothly to its
seat by its own weight.
NOTE: Replace the fuel injector assembly if it

fails any inspection or if an injector tester is
not available.
4.36
Copyright 2014
FUEL SYSTEM
Adjusting Fuel Injector Pressure
Installing the Fuel Injectors
The fuel injectors open when pressure reaches a

predetermined pressure threshold. They close when the
pressure is reduced below that threshold. The pressure
threshold can be adjusted by adding or removing shims.
1. Insert the nozzle gaskets (E) and nozzle protector

(F) in the cylinder head.
Fuel Injector Shim Kit (PN 3070291)

The injection pressure will change by approximately 100
to 142 psi (0.69 to 0.98 MPa; 6.9 to 9.8 bar) for every
0.004 in. (0.1 mm) shim thickness.
See the Electronic Parts Catalog for available shims.
1. Disassemble the fuel injector assembly (see
Disassembling and Inspecting Fuel Injectors).
2. Remove or add adjusting shims as needed.

3. Assemble the fuel injector
Assembling the Fuel Injectors).
assembly
(see
4. Test the fuel injector (see Testing the Fuel

Injectors). If the injector cannot be adjusted to the
appropriate pressure, discard the fuel injector.
Assembling the Fuel Injectors

1. Secure the injector in a soft-jawed vise with the
nozzle end up.
2. Install the shims, nozzle spring, nozzle spring seat,
valve stop spacer, nozzle valve and nozzle body.
3. Install the nozzle case nut. Tighten it to specification.
2. Install the fuel injector (D) in the cylinder head and
tighten to specification.
3. Install new copper washers (C) and high-pressure
and return fuel lines (B) (see Installing the HighPressure Injection Lines and Installing the Fuel
Return Line). Tighten fuel line nuts (A) to
specification.
4. Install the intake manifold / valve cover (see
Assembling the Intake Manifold / Valve Cover in
Chapter 3).
5. Prime the fuel system (see Priming the Fuel
System).
6. Operate the engine and check for fuel leaks.
4.37
Copyright 2014
FUEL SYSTEM
NOTES
4.38
Copyright 2014
CHAPTER 5
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
RECOMMENDED COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
COOLING SYSTEM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
ENGINE COOLING SYSTEM FLOWCHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
ENGINE COOLING SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
ENGINE COOLING SYSTEM PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
RADIATOR CAP PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
ENGINE COOLING SYSTEM COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
COOLING SYSTEM BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
RADIATOR CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
COOLANT DRAIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
RADIATOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
WATER PUMP WEEP HOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
WATER PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
WATER PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.10
THERMOSTAT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.10
THERMOSTAT INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.10
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
5.1
Copyright 2014

GENERAL INFORMATION
Torque Specifications
CONDITION
APPROX.
TEMPERATURE
Coolant Hot Lamp

(On Solid)
1.45 k 2%
230 F (110
C)
Cooling Fan On
2.80 k 2%
194 F (90
C)
Cooling Fan Off
3.40 k 2%
182 F (83
C)
77 F (25 C)
ITEM
SIZE
TORQUE VALUE
Thermostat Cover
8 mm
11 ft-lbs (17 Nm)
Alternator Bracket
(upper)
8 mm
24 ft-lbs (33 Nm)
Alternator Bracket
(middle)
10
mm
33 ft-lbs (45 Nm)
Room Temperature
29.9 k 2%
Water Pump Mount

Bolts
8 mm
17 ft-lbs (23 Nm)
System Capacity
Brutus / Brutus HD - 6.6 qts (6.2

L)
Brutus HDPTO - 6.9 qts (6.5 L)
Engine Temperature
Sensor (ECT)
3/8
NPT
17 ft-lbs (23 Nm)
Radiator Cap Relief

Pressure
13 PSI
Upper Radiator Bracket

Mounting Bolt
6 mm
8 ft-lbs (11 Nm)
Coolant Hose Clamps
35 in-lbs (4 Nm)
Engine Cooling System Flowchart
Recommended Coolant
Use only high quality antifreeze/coolant mixed with
distilled water in a 50/50 or 60/40 ratio, depending on
freeze protection required in your area.
Polaris Premium Antifreeze
2871534 - Quart
2871323 - Gallon
NOTE: Using tap water in the cooling system will
lead to a buildup of deposits which may restrict
coolant flow and reduce heat dissipation, resulting
in possible engine damage. Polaris Premium 60/40
Antifreeze/Coolant is recommended for use in all
cooling systems, and comes pre-mixed and ready to
use.
Cooling System Specifications

The engine coolant temperature sensor is located in the
water pump housing behind the thermostat cover.
CONDITION
APPROX.
TEMPERATURE
Engine Shutdown
(temp. is sustained
for 25 seconds)
1.22 k 2%
248 F (120
C)
Coolant Hot Lamp

(Blinking)
1.30 k 2%
240 F (116
C)
5.2
Copyright 2014

ENGINE COOLING SYSTEM TESTING
Radiator Cap Pressure Test
Engine Cooling System Pressure Test
1. Remove radiator pressure cap and test using a

cooling system pressure tester (commercially
available).
1. Remove the hood.
WARNING
Never remove radiator cap when engine is warm or hot.
The cooling system is under pressure and serious
burns may result.
Allow the engine and cooling system to
cool before servicing.
2. Remove the pressure cap from the radiator and
pressure test the cooling system using a
commercially available tester.
2. The radiator cap relief pressure is 13 lbs. Replace

cap if it does not meet this specification.
WARNING
Never remove radiator cap when engine is warm or hot.
The cooling system is under pressure and serious
burns may result.
Allow the engine and cooling system to
cool before servicing.
3. The system must retain 11-14 psi (75-95 kPa) for five
minutes or longer. If pressure loss is evident within
five minutes, check the radiator, all cooling system
hoses, hose clamps and water pump for leakage.
5.3
Copyright 2014

Engine Cooling System Component Locations
5.4
Copyright 2014

Cooling System Bleeding Procedure
1. Place the vehicle in PARK.
CAUTION
Be sure the engine has cooled and there is no pressure
built up in the cooling system before removing the
radiator cap. The coolant may be hot and could cause
severe injury or burns.
2. Remove the hood to access the radiator pressure
cap and recovery bottle.
3. Remove the pressure cap and top off coolant. Leave
the pressure cap off at this point.
4. Remove recovery bottle fill cap and fill the bottle to
the MAX line. Reinstall the recovery bottle cap.
NOTE: If coolant level is very LOW in the
radiator, or if there are leaks in the system, the
coolant system will not draw coolant from the
recovery bottle.
5. Start the engine and allow it to idle for 5-10 minutes
until the thermostat opens and allows coolant to
travel through the entire system.
7. With engine still idling, top off the radiator with

Polaris Premium Antifreeze. If no air bubbles are
seen at the radiator filler neck and you only get
coolant out of the bleed screw, the system should be
purged of air.
8. Reinstall the radiator pressure cap.
WARNING
Be sure to install the radiator pressure
cap before shutting off the engine.
Coolant may spit out of the radiator.
9. Stop the engine and allow it to cool. Top off the
radiator with coolant. If the coolant level drops
indicating that coolant has been pulled into the
system, fill the radiator first then fill the recovery
bottle.
10. Any air remaining in the system should continue to
bleed out through the recovery bottle.
11. Repeat this procedure if you are still having difficulty
bleeding the system.
NOTE: When the thermostat opens the radiator

coolant level will drop significantly.
6. Crack the bleed screw (Item 1) on the thermostat
housing to release any air from the system. Squeeze
coolant lines to help purge the system of air.
5.5
Copyright 2014

RADIATOR
4. Drain coolant by loosening the drain plug (Item 1)

until coolant starts to flow out of the valve.
Radiator Cleaning
1. Check radiator air passages for restrictions or
damage on both the radiator and hydraulic cooler.
5. Completely drain coolant and properly dispose of it.

2. Carefully straighten any bent radiator fins.
Radiator Removal
3. Remove any obstructions with compressed air or low

pressure water.
1. Drain coolant
procedure).
from
radiator
(see
previous
2. Remove the front fascia (see Chapter 7 - Front

Fascia).
CAUTION
Washing the vehicle with a high-pressure washer is not
recommended and could damage the radiator fins and
impair the radiators effectiveness. Use of a highpressure washer is not recommended.
3. Remove the four 10 mm screws (Item 2) retaining

the upper radiator mount brackets.
Coolant Drain
1. Remove the hood to access the pressure cap.
WARNING
Never drain the coolant when the engine and radiator
are warm or hot. Hot coolant can cause severe burns.
Allow engine and radiator to cool.
2. Slowly remove the pressure cap to relieve any
cooling system pressure.
3. Place a suitable drain pan underneath the radiator
drain on the left-hand side of the vehicle.
4. Remove recovery bottle return line (Item 3) from the

radiator.
5. Remove the lower radiator hose.
5.6
Copyright 2014

6. Remove the three plastic rivets (Item 4) from the air
deflectors on both sides of the radiator and remove
the deflectors.
Radiator Installation
1. Lift the hood liner and install the radiator into the
vehicle.
2. Connect the radiator fan harness (Item 1) and upper
radiator hose (Item 2).
5
NOTE: Be sure the lower grommets or the
radiator are positioned properly in the frame
upon installation.
7. Remove the two 10 mm screws (Item 5) retaining the
hydraulic oil cooler to the radiator. Lift the hydraulic
oil cooler up and towards you to release the lower
slotted oil cooler mounts.
3. Install the two bolts (Item 3) retaining the hydraulic oil

cooler to the radiator.
4. Install the air deflectors on both sides of the radiator.
5. Install the lower radiator hose.
6. Connect the recovery bottle hose to the radiator.
7. Install the upper radiator mount brackets and torque
the fasteners to specification.
Upper Radiator Mount Screws

(M6 and T-40 Torx)
8 ft-lbs (11 Nm)
8. After installation and reassembly, remove the
pressure cap and fill the radiator and recovery bottle
with coolant.
8. Carefully lift up on the hood liner and disconnect the
radiator fan motor harness (Item 6) and the upper
radiator hose (Item 7).
9. Refer to the Cooling System Bleeding Procedure in

this chapter.
9. Keep the hood liner up and carefully lift the radiator

and fan assembly upward to remove it from the
vehicle.
10. Once out of the vehicle, remove the 4 screws that
retain the fan and shroud assembly to the radiator.
5.7
Copyright 2014

WATER PUMP
4. Loosen the alternator mount adjuster one turn, pull

the alternator towards the engine to get slack in the
belt and remove the belt from the water pump pulley.
Water Pump Weep Hole

The water pump weep hole is located on the housing
underneath the water pump belt pulley. If there is coolant
leaking out of this hole, the mechanical seal is damaged
and the water pump assembly would need to be
replaced.
5. Remove the four bolts (Item 2) retaining the engine

fan / water pump pulley assembly and remove the
assembly from the engine.
6. Remove the coolant hoses (Item 3) going to the

water pump.
NOTE: On units with a heater system, there will
be three hoses off the water pump instead of two.
Water Pump Removal

NOTE: The water pump impeller, mechanical seal,
pump shaft, and pump shaft bearing are not
serviceable components. If one of these
components fails, the water pump assembly must be
replaced.
1. Disconnect the battery.
2. Drain coolant from the radiator (see Coolant Drain
earlier in this chapter) and put a catch pan under the
vehicle below the water pump assembly.
3. Remove the three screws (Item 1) retaining the
engine fan guard.
7. Disconnect the engine temperature sensor (Item 4).

8. Remove the two bolts (Item 5) retaining the
alternator bracket to the engine.
9. Pivot the alternator bracket towards the front of the
vehicle to gain access to the hidden water pump
mounting bolt. (you may need to slightly loosen the
A/C compressor mount to get the bracket to pivot)
5.8
Copyright 2014

10. Remove three bolts (Item 6) retaining the water
pump to the engine.
6. Install the fan, spacer and pulley onto the water

pump assembly. Torque the four bolts to
specification.
7. Install the belt onto the waterpump, engine, and
alternator pulleys. Properly set the tension on the
alternator belt (see Chapter 2 - Alternator / Fan
/Water Pump Drive Belt). Torque adjuster bolt to
specification.
8. Install the engine fan guard. Torque the three screws
to specification.
9. Connect the battery.
10. Top off the coolant in the radiator and recovery bottle
and perform the Cooling System Bleeding
procedure.
11. Remove water pump assembly.

Thermostat Cover Bolts:
11 ft-lbs (17 Nm)
12. Remove the two thermostat cover bolts and remove

the cover and the thermostat.
Water Pump Mounting Bolts:

17 ft-lbs (23 Nm)
Water Pump Installation

1. Install thermostat and thermostat cover. Torque bolts
to specification
2. Clean the water pump to engine block mating
surface.
Alternator Bracket Bolts:

M8 (upper): 17 ft-lbs (23 Nm)
M10 (middle): 35 ft-lbs (47 Nm)
3. Install water pump assembly and torque the three

mounting bolts to specification.
Engine Fan / Water Pump Pulley Bolts:

11 ft-lbs (17 Nm)
4. Pivot the alternator bracket back towards the engine.

Install the top bolt first by hand. Install middle bracket
bolt and torque to specification then torque middle
bolt to specification.
Engine Fan Guard Screws:

8 ft-lbs (11 Nm)
5. Connect the engine coolant temperature sensor and

the coolant hoses going to the water pump.
NOTE: On units with a heater system, there will
be three hoses off the water pump instead of two.
5.9
Copyright 2014

THERMOSTAT
Thermostat Installation
Thermostat Removal
1. Clean the mating surfaces on the thermostat cover

and the water pump assembly to assure a good seal.
1. Drain coolant so the coolant level is below the

thermostat housing (see Coolant Drain / Radiator
Removal).
2. Install the thermostat, thermostat cover, and two

bolts. Torque bolts to specification.
2. Tilt the cargo box so it is in the fully open position.

3. Remove the two bolts (Item 1) retaining the
thermostat cover.
4. Lightly pry on the thermostat to remove the

thermostat from the engine.
Thermostat Cover Bolts:

11 ft-lbs (17 Nm)
3. Top off the coolant in the radiator and recovery bottle
and perform the Cooling System Bleeding
procedure.
NOTE: Do NOT pry between the thermostat and

the water pump housing or damage to the
sealing surface will occur.
5.10
Copyright 2014

TROUBLESHOOTING
Cooling System
Overheating
Low coolant level
Air in cooling system
Wrong type/mix of coolant
Faulty pressure cap or system leaks
Restricted system (mud or debris in radiator fins
causing restriction to air flow, passages blocked in
radiator, lines, pump, or water jacket, accident
damage)
Engine running lean (fuel system restriction)
Fuel pump output weak
Water pump failure/ Loose impeller
Engine Coolant Temperature Sensor failure

Electrical malfunction
Cooling fan inoperative or turning too slowly
Low oil level
Faulty hot lamp circuit
Thermostat
completely
stuck
closed
or
not
opening
Temperature Too Low

Thermostat stuck open
Leak at Water Pump Weep Hole
Faulty water pump mechanical seal
Worn pump shaft or pump shaft bearing
5.11
Copyright 2014
NOTES
5.12
Copyright 2014
HVAC
CHAPTER 6
HVAC
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
HVAC SYSTEM FASTENER TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
SPECIAL TOOLS AND SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
AIR CONDITIONING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
A/C SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
SAFETY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
HVAC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.10
COMPRESSOR DRIVE BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.10
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.10
A/C EVAPORATOR COIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
SYSTEM RECOVERY AND CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
RECLAMATION AND CHARGING WITH RECOVERY / CHARGING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.13
BELT ADJUSTMENT / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.13
COMPRESSOR REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.13
A/C OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.14
A/C OIL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.15
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.16
RECEIVER / DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.18
PRESSURE RELIEF VALVE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.18
HPCO (HIGH PRESSURE CUT-OUT) SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.19
HPCO SWITCH REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.19
EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.20
REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.20
EVAPORATOR COIL, HEATER COIL AND A/C THERMOSTAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.21
A/C THERMOSTAT DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.21
EVAPORATOR COIL, HEATER COIL AND THERMOSTAT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.21
BLOWER FAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.22
REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.22
HEATER VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.24
HEATER VALVE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.24
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.26
BLOWER MOTOR DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.27
BLOWER MOTOR OPERATES NORMALLY BUT AIR FLOW IS INSUFFICIENT . . . . . . . . . . . . . . . . . . . .6.27
INSUFFICIENT COOLING (AIR FLOW AND COMPRESSOR OPERATION ARE NORMAL). . . . . . . . .6.27
COMPRESSOR DOES NOT OPERATE AT ALL OR OPERATES IMPROPERLY . . . . . . . . . . . . . . . . . . . .6.27
6.1
Copyright 2014
HVAC
GAUGE PRESSURE RELATED TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.28
TEMPERATURE / PRESSURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.29
POOR A/C PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.31
ENGINE COOLANT BYPASSING THE HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.31
A/C ELECTRICAL SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.31
6.2
Copyright 2014
HVAC
HVAC System Fastener Torques
ITEM
TORQUE VALUE
Compressor High Pressure Hose
24 ft-lbs (33 Nm)
Compressor Low Pressure Hose
18 ft-lbs (24 Nm)
Compressor Mount / Adjuster

Bolt
33 ft-lbs (45 Nm)
Compressor Drain Plug
10 ft-lbs (14 Nm)
Compressor Armature Nut
10 ft-lbs (14 Nm)
Condenser Lower Mounting

Bolts
8 ft-lbs (11 Nm)
Condenser Upper Mounting Bolt
14 ft-lbs (19 Nm)
Upper Condenser Hose
18 ft-lbs (24 Nm)
Lower Condenser / ReceiverDrier Hose
12 ft-lbs (16 Nm)
Expansion Valve Tubes
22 ft-lbs (30 Nm)
Expansion Valve High / Low

Pressure Hoses
12 ft-lbs (16 Nm)
SPECIAL TOOLS AND SUPPLIES

TOOL DESCRIPTION
PART NUMBER
Refrigerant Recovery / Recycle

/Recharging Machine
PU-51021
Recharge Service Kit (for PU51021)
PU-51021-1

6.3
Copyright 2014
HVAC
AIR CONDITIONING SYSTEM
Description
In an air conditioning system heat is removed from the
cab by circulating R-134a refrigerant though a closed
system containing five major components. At these five
points in the system the refrigerant goes through
pressure and temperature changes.
The compressor takes in heated, low pressure
refrigerant gas through the suction valve (low pressure
side) and pressurizes the heated refrigerant and forces it
through the discharge valve (high pressure side) on the
condenser. Should the pressure on the high pressure
side become to high, the HPCO (High Pressure Cut-Out)
switch will cycle the compressor clutch off.
Ambient air passing through the condenser removes the
heat from refrigerant resulting in physical state change in
the refrigerant from a gas to a liquid.
The liquid refrigerant moves on to the receiver / drier
where impurities such as moisture and dirt are filtered
out. The receiver / drier also serves as the storage tank
for the liquid refrigerant. The liquid refrigerant (still under
high pressure) flows to the expansion valve.
The expansion valve meters the amount of refrigerant
into the evaporator coil. As the refrigerant passes
through the expansion valve, an extreme pressure and
temperature drop occurs. It becomes a low temperature,
low-pressure liquid and saturated vapor. The low
pressure liquid immediately starts to boil and vaporize as
it enters the evaporator. The warmer air of the machine's
cab is drawn through or blown into the evaporator by the
evaporator blower.
Since the refrigerant is colder than the air, it absorbs the
heat from the air and produces cooled air, which is
pushed into the cab by the blower. The moisture in the air
condenses on the evaporator coil and drips into the drain
pan, which directs the water out of the cab.
The refrigerant cycle is completed when the heated low
pressure gas is again drawn into the compressor. The
compressor cycles on and off to maintain the desired cab
temperature. The Electronic De-icing Thermostat is a
micro controller based module that measures evaporator
coil temperature and cycles the compressor clutch to
maintain a constant evaporator pressure.
6.4
Copyright 2014
HVAC
A/C System Diagram
6.5
Copyright 2014
HVAC
or the manifold gage set connectors. Safety glasses or a
transparent face shield are practical safety items and one
or the other is absolutely required.
Safety Equipment
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In contact
with a flame, R-134a refrigerant gives off a toxic gas.
In servicing A/C and heater systems you will be exposed

to high pressures, temperatures and several chemical
hazards. Moving belts and pulleys are normal shop
hazards.
In addition to exercising caution in your work, WEAR
SAFETY GLASSES OR A FACE SHIELD when you are
using R-134a or a leak detector, adjusting service valves
6.6
Copyright 2014
HVAC
R-134a inside a canister or in an A/C system is a liquid
under pressure. When it escapes or releases into the air,
ITS TEMPERATURE DROPS TO -5.8 C (21.6 F)
INSTANTLY. If it spills on your skin or in your eyes you
should flood the area with cool water and SEEK
MEDICAL ATTENTION FAST! It is a good idea to wear
gloves to prevent frost bite if you should get refrigerant
on your hands.
WARNING
HFC R-134a refrigerant can be dangerous if not
properly handled. Liquid R-134a may cause blindness if
it contacts the eyes and may cause serious frostbite if it
contacts the skin.
Gaseous R-134a becomes lethal (phosgene gas) when
it contacts open flame or very hot substances.
NEVER smoke when there is the possibility of even
small amounts of R-134a in the air.
Any servicing work that involves release or addition of
R-134a to the system must be done by a competent
refrigeration dealer who has the proper equipment,
knowledge, and experience to service refrigeration
equipment.
6.7
Copyright 2014
HVAC
Components
Pressure Relief Valve: The pressure relief valve (Item

4) is located on the receiver drier assembly. This small
brass valve is a safety feature that is designed to open
and release the A/C charge if the pressure reaches 535
psi (3.7 MPa).
Expansion Valve: The expansion valve (Item 5) controls
the amount of refrigerant entering the evaporator coil.
Compressor: The compressor (Item 1) is the pump that

circulates the refrigerant throughout the system. It raises
the pressure of the refrigerant for heat transfer through
the condenser and evaporator.
NOTE:
The A/C system (Compressor) is
recommended to be turned on for at least 5 minutes
weekly throughout the year to lubricate the internal
components.
Condenser: The condenser (Item 2) is the unit that
receives the high pressure, high temperature refrigerant
vapor from the compressor and condenses it into a high
temperature liquid.
Heater / Evaporator Unit: The heater / evaporator unit

(Item 6) is located below the dash on the passenger side.
The unit delivers the cold air for the A/C and warm air for
heat into the cab. The unit contains the heat and A/C
coils, thermostat, and expansion valve.
Heater Coil: The heater coil (Item 7) supplies the warm

air into the cab by passing air through the coil.
Receiver / Drier: The receiver / drier (Item 3) is the unit
that receives the liquid refrigerant from the condenser
and removes moisture and foreign matter from the
system. It also serves as a storage tank for the extra
liquid refrigerant until it is needed by the evaporator.
Evaporator Coil: The evaporator coil (Item 8) cools and

dehumidifies the air before it enters the cab.
6.8
Copyright 2014
HVAC
Thermostat: The thermostat (Item 9) and probe (Item
10) controls the temperature of the evaporator coil.
Fan Switch: This is a four position rotary switch (Item

12). When the fan switch is in the off position the A/C will
not engage, but the heater valve will operate, as it is
controlled by the ignition power.
A/C Switch: The rocker switch (Item 13) will be
illuminated when the A/C is engaged.
Potentiometer: The potentiometer (Item 14) controls the
Heater Valve from fully Off to fully On. This can be used
in conjunction with the A/C for defrost of the windows and
temperature control.
Heater Valve: The heater valve (Item 15) is used to
control the amount of engine coolant that flows to the
heater coil.
Heater / Evaporator Blower: The blower (Item 11) is

used to pull air through the heater and evaporator coils
and into the cab.
Pressure Switch: The high pressure switch (Item 16)

will disengage the compressor clutch at high pressure
readings over 400 psi. (2.8 MPa) and will engage the
clutch when pressures lower to 325 psi (2.2 MPa).
Control Panel:
components.
The
panel
has
three
separate
6.9
Copyright 2014
HVAC
HVAC MAINTENANCE
Condenser
Compressor Drive Belt Inspection

1. Remove the three bolts (Item 1) and shield (Item 2).
1. Turn the two fasteners (Item 1) counterclockwise 1/4

turn and open or remove the cover.
non-specified V-belt can shorten the belt life.
3. At the mid span location shown (Item 3), press down
on the V-belt with approximately 20 lbs. (89 N) of
applied force to check the belt deflection.
2. Clean the condenser with water or air.
Air Conditioning Drive Belt Tension

4. If belt deflection adjustment is necessary, reference
Air Conditioning Drive Belt in Chapter 2.
6.10
Copyright 2014
HVAC
A/C Evaporator Coil Filter
1. Remove the two fasteners (Item 1) and cover (Item
2).
SYSTEM RECOVERY AND

CHARGING
Refrigerant
This system uses R-134a refrigerant. Running or mixing
any other refrigerant will contaminate and damage your
A/C Recovery / Recycling / Recharging Machine (Item 1)
as well as the A/C system on the vehicle.
NOTE: System Capacity: R134a 1.8 lbs (.816 kg)
2. Clean the filter (Item 3) with low air pressure.
6.11
Copyright 2014
HVAC
Reclamation and Charging with Recovery /
Charging Unit
WARNING
NOTE: Only A/C trained technicians should perform

the reclaiming and recharging.
This test is run with the engine OFF, and the A/C
switch in the OFF position.
HFC R-134a refrigerant can be dangerous if not

properly handled. Liquid R-134a may cause blindness if
it contacts the eyes and may cause serious frostbite if it
contacts the skin.
1. Remove the caps on the low pressure port (Item 1)

and high pressure port (Item 2).
Gaseous R-134a becomes lethal (phosgene gas) when

it contacts open flame or very hot substances.
NEVER smoke when there is the possibility of even
small amounts of R-134a in the air.
Any servicing work that involves release or addition of
R-134a to the system must be done by a competent
refrigeration dealer who has the proper equipment,
knowledge, and experience to service refrigeration
equipment.
2. Use an approved recovery / charging unit to
evacuate the system.
3. Connect the reclaimer to the A/C charge ports on the
utility vehicle.
4. Connect the Blue hose (Item 3) to the low pressure
port and open the valve.
NOTE: Do not use the high pressure port (Item

2) for testing or charging.
WARNING
with a flame, R-134a refrigerant gives a toxic gas.
5. Connect the Red hose (Item 4) to the high pressure

port and open the valve.
6.12
Copyright 2014
HVAC
6. Turn the reclaimer unit to the ON position and follow
the on screen instructions.
COMPRESSOR
Belt Adjustment / Replacement
Reference Air Conditioning Drive Belt in Chapter 2 for
belt adjustment procedure.
Compressor Removal / Installation
WARNING
with a flame, R-134a refrigerant gives off a toxic gas.
1. Evacuate the refrigerant using an A/C recovery
system.
NOTE: The reclaimer unit, has a complete step
by step set of instructions to follow for
reclimation and recharging of the A/C system. A
trained
technician
should
follow
these
instructions as they may very slightly depending
on the model and brand of reclaimer used.
2. Remove the three bolts (Item 1) and remove the

shield (Item 2).
3. Disconnect the compressor clutch wire (Item 3).
6.13
Copyright 2014
HVAC
4. Remove the low pressure hose (Item 4) from the
compressor.
9. Remove the A/C compressor belt.

10. Remove the compressor from the utility vehicle.
11. To install, reverse the procedure.
Compressor Low Pressure Hose:

24 ft-lbs (33 Nm)
Compressor High Pressure Hose:
18 ft-lbs (24 Nm)
Compressor Adjustment Bolt:
33 ft-lbs (45 Nm)
12. Recharge the A/C system.
5. Remove the high pressure hose (Item 5) from the
compressor.
A/C Oil
6. Cap and plug the compressor hoses and the fittings

with the proper A/C caps and plugs.
The compressor is factory filled with 150 - 170 cc's of

PAG 100 oil (Poly Alkelene Glycol).
7. Remove A/C compressor adjustment bolt (Item 6).
It is only necessary to check, replenish or replace the

compressor oil in the following cases:
When the evaporator, condenser or receiver-drier
is replaced.
When refrigerant has leaked from the system.
When refrigerant is suddenly released from the
cooling cycle.
When any oil related problems occur in the cooling
cycle.
NOTE: When one of the components (the
evaporator, condenser or receiver-drier) is
replaced, 1.0 ounce (30 cc) of PAG 100 oil
should be added for each component replaced.
8. Remove the compressor mount bolt (Item 7).
If the A/C compressor is changed, no oil

should be added to the system, because the
compressor comes factory filled with oil.
Only PAG 100 oil should be used. Never mix R12 and R-134a Oils.
6.14
Copyright 2014
HVAC
A/C Oil Check
6. Tighten the oil drain plug to specification.
The compressor oil should be checked as follows when

oil is being added to an in service utility work machine.
There is a close affinity between oil and refrigerant.
During normal operation, part of the oil circulates with the
refrigerant in the system. Therefore, when checking the
amount of oil in the system or replacing any system
component, the compressor must be run in advance to
insure return of oil to the compressor.
If the amount of refrigerant in the system has decreased,
charge the system.
Compressor Oil Drain Plug:

10 ft-lbs (14 Nm)
NOTE: Extract the remaining oil through the
discharge-side connector by rotating the drive
pulley (Item 3) several times by hand.
1. Open the cab door and windows.

2. Run the blower at maximum speed.
3. Run the compressor for at least 20 minutes at idle.
4. Remove the compressor from the vehicle.
5. Remove the oil drain plug (Item 1) and drain the oil
through the connectors (Item 2) and the oil drain
hole.
7. Measure the drained oil in a measuring cylinder.

8. Check the oil for contamination, dirt, metal shavings,
or varnish color, discard the oil if contaminated.
NOTE: If metal shavings are found in the
compressor oil, replace the compressor
assembly.
6.15
Copyright 2014
HVAC
9. Add new compressor oil through the suction side
connector (Item 4). Add 150 - 170 cc's of PAG 100
oil.
CONDENSER
Removal
1. Remove the refrigerant from the A/C system.
WARNING
2. Remove the left rear fender.
3. Disconnect the outlet hose (Item 1) from the
condenser.
NOTE: The suction port on the compressor is

marked with an S and is the larger.
4. Disconnect the inlet tube (Item 2) from the

condenser
5. Cap and plug the tube and the condenser fittings
with the proper A/C caps and plugs.
6. Remove the two bolts (Item 3) and move the drier
out of the way.
6.16
Copyright 2014
HVAC
7. Remove the two bolts (Item 4) from the bottom of the
condenser.
10. Installation: Reverse procedure. Tighten fasteners

to specification.
Upper Condenser Hose:

18 ft-lbs (24 Nm)
Lower Condenser / Receiver-Drier Hose
12 ft-lbs (16 Nm)
Condenser Upper Mounting Bolt:
14 ft-lbs (19 Nm)
Condenser Lower Mounting Bolts:
8 ft-lbs (11 Nm)
8. Remove the bolt (Item 5) from the top of the
condenser.
11. Recharge A/C system.
9. Remove the condenser from the vehicle.
6.17
Copyright 2014
HVAC
RECEIVER / DRIER
4. Remove the hose (Item 3) from the receiver / drier.
Removal
WARNING
1. Remove the left rear fender.
NOTE: Whenever the A/C system is opened to
the atmosphere or there has been a leak in the
system, the receiver / drier (Item 1) must be
changed.
5. Cap and plug the hoses and the receiver / drier

fittings with the proper A/C caps and plugs.
6. Remove the bolts (Item 4).
7. Remove the receiver / drier.
NOTE: When replacing a receiver / drier in an A/
C system 1 ounce (30cc) of PAG 100 oil must be
added to the system when recharging.
8. To install, reverse procedure. Torque fasteners to
specification.
Lower Condenser / Receiver-Drier Hose

12 ft-lbs (16 Nm)
3. Remove the tube line (Item 2) from receiver / drier.
NOTE: Never leave hose fittings, compressor
fittings or components uncapped while working
on the A/C system.
6.18
Copyright 2014
HVAC
Pressure Relief Valve Removal and
Installation
The pressure relief valve (Item 1) is located on the
receiver drier assembly (Item 2).
HPCO (HIGH PRESSURE CUT-OUT)

SWITCH
The HPCO switch will cycle the compressor off if
pressure is too high on the high pressure side.
Location
The HPCO switch is located on the AC hose coming off
the receiver / drier.
HPCO Switch Removal and Installation

NOTE: Replacement of the high pressure cut out switch
does NOT require discharging/recharging the R-134a
refrigerant.
1. Disconnect the pressure switch connector (Item 1)
from the wire harness.
WARNING
The pressure relief valve is designed to open and
release the A/C charge if the pressure reaches 535 psi
(3.7 MPa).This will cause the A/C system to shut down,
saving the compressor.

2. Remove the pressure switch (Item 2).
The Pressure Relief Valve is a secondary protection

device in the A/C system, with the Pressure Switch
shutting down the system at 384 psi (2.6 MPa).
NOTE: If a Pressure Relief Valve is found open,
check the A/C system for problems. Replace the
complete receiver / drier unit.
6.19
Copyright 2014
HVAC
3. Reverse removal for installation and torque the
HPCO switch to specification.
Torque Specification
6 ft-lbs (8 Nm)
EXPANSION VALVE
Removal and Installation
WARNING
2. Remove the hoses (Item 1) from the expansion
valve.
3. Remove the tube lines (Item 2) from the expansion

valve.
4. Cap and plug the hoses and the expansion valve
fittings with the proper A/C caps and plugs.
5. Remove the two bolts (Item 3) and the expansion
valve (Item 4).
6. To Install, reverse procedure. Tighten fasteners to
specification.
Expansion Valve Pressure Hoses (Item 1):

12 ft-lbs (16 Nm)
Expansion Valve Tubes (Item 2):
22 ft-lbs (30 Nm)
7. Recharge the A/C system.
6.20
Copyright 2014
HVAC
EVAPORATOR COIL, HEATER COIL
AND A/C THERMOSTAT
Evaporator Coil, Heater Coil and Thermostat

Removal
1. Remove the evaporator / heater unit.
A/C Thermostat Description
2. Remove the two bolts (Item 1).
The Electronic De-icing Thermostat (EDT) is a micro

controller based module that measures evaporator coil
temperature and cycles the compressor clutch to
maintain a constant evaporator pressure.
NOTE: The EDT has a six second delay before start
up to protect the compressor clutch.
The EDT will turn the clutch on when the evaporator coil
temperature is above 35.6F (2C). If the EDT does not
detect any malfunction, it will continue to operate and the
status LED will be lit continuously. When the evaporator
temperature is below 28.4F (-2C), the EDT will turn off
the clutch and status LED.
3. Remove the three bolts (Item 2) retaining the

evaporator / heater coils.
When the EDT detects an error from the temperature

sensor, the status LED will blink. Refer to the chart
below.
MALFUNCTION
DETECTION
INTERVAL
STATUS LED
Temperature
sensor open
and short
detection
Continuous
1x per second
Clutch circuit
open, short or
over current
At A/C start up
2x per second
Compressor
clutch short to
ground
Continuous
3x per second
4. Remove the evaporator / heater coils (Item 3).
NOTE: The EDT will attempt to restart every 20

seconds until the fault is repaired.
6.21
Copyright 2014
HVAC
5. Remove the clips (Item 4) retaining the two coils
together on both sides.
BLOWER FAN
NOTE: The blower fan assembly can be removed
from the evaporator / heater unit without
disconnecting the heater or A/C plumbing.
1. Remove the upper dash.
2. Remove the lower dash.
3. Remove the storage panel.
4. Remove the screws (Item 1) and front cover.
6. Separate the coils and remove the thermostat probe

(Item 5) from the evaporator coil.
5. Disconnect the fan harness (Item 2) from the main

harness.
7. Loosen the two fittings (Item 6) and remove the

expansion valve.
8. Remove the thermostat assembly from the bracket.
9. Remove the evaporator coil.
6.22
Copyright 2014
HVAC
6. Remove the rivets (Item 3) from both sides of the
duct.
7. Loosen the clamp and remove the drain hose (Item

4).
10. Remove the screws (Item 6) and fan housing.
11. Remove the four screws (Item 7) on the fan cover.
8. Remove the four evaporator / heater unit nuts (Item

5).
12. Remove the two screws (Item 8) and fan cover from
both sides.
9. Pull the evaporator / heater unit away from the front

floor.
6.23
Copyright 2014
HVAC
13. Remove the screws (Item 9) on both sides of the
motor.
HEATER VALVE
Removal
14. Remove the screw (Item 10) on the bottom of the

blower housing.
1. Remove the wiring harness (Item 1) and hose (item

2) from the heater valve.
NOTE: Plug the hoses to prevent contamination
and coolant loss from the system.
(Item 4) from the heater valve.
15. Remove the clamp (Item 11) and fan blade on both
sides and remove the motor.
3. Remove the two bolts (Item 5) retaining the heater

valve and remove the heater valve from the vehicle.
NOTE: Plug the hoses to prevent contamination
and coolant loss from the system.
6.24
Copyright 2014
HVAC
Heater Valve Disassembly
1. Remove the screw (Item 1), washer, spacer (Item 2)
and nut (Item 3).
4. Remove the two screws (Item 8) and heater valve

(Item 9) from the bracket.
5. Loosen the clamp and remove the hose.

2. Remove the screws (Item 4), washers, spacers (Item
5) and nuts (Item 6).
6. Reverse procedure to assemble the heater valve.

3. Remove the heater valve motor (Item 7) from the
bracket.
6.25
Copyright 2014
HVAC
6.26
Copyright 2014
HVAC
TROUBLESHOOTING
Blower Motor Does Not Operate
SYMPTOM
POSSIBLE CAUSE
SOLUTION
1. Blown fuse
Inspect the fuse / wiring.
Replace fuse / repair wiring
2. Broken wiring / connection
Check the fan motor ground and connectors.
Repair the wiring or connector
3. Fan motor malfunction
Check the lead wires form the motor with a circuit

tester.
Replace Motor
4. Resistor malfunction
Check resistor using a circuit tester.
Replace Resistor
5. Fan switch malfunction
Check power into and out of the fan switch.
Replace Fan Switch
Blower Motor Operates Normally But Air Flow Is Insufficient

SYMPTOM
POSSIBLE CAUSE
SOLUTION
1. Evaporator inlet obstruction
Check evaporator for plugging.
Remove obstruction and clean

evaporator fins
2. Air leak
Check to make sure air hoses are properly

hooked to Louvers, and air ducts.
Repair or adjust
3. Defective thermostat.
switch (frozen evaporator)
Check thermostat using a circuit tester.
Replace thermostat
4. Plugged cab filters
Check cab filter condition.
Clean or replace filters
Insufficient Cooling (Air Flow and Compressor Operation Are Normal)

SYMPTOM
POSSIBLE CAUSE
SOLUTION
1. System low on refrigerant.
The high side pressure will be low and bubbles

may be present in sight glass on receive drier.
Repair any leaks and

recharge the A/C system
2. Excessive refrigerant.
The high pressure side pressure will be high.
Recover and recharge system

to the correct refrigerant level.
Compressor Does Not Operate At All Or Operates Improperly

SYMPTOM
POSSIBLE CAUSE
SOLUTION
1. Loose drive belt.
The belt is vibrating or oscillating.
Adjust tension.
2. Internal compressor
malfunction.
The compressor is locked up and the belt slips.
Replace compressor.
3. Low battery voltage.
Clutch slips.
Recharge the battery.
4. Faulty coil.
Clutch slips.
Replace the magnetic clutch.
5. Oil on the clutch surface.
Clutch slips.
Replace or clean the clutch

surface.
6. Open coil.
Clutch does not engage and there is no reading

when a circuit tester is connected between the coil
and terminals.
Replace clutch.
6.27
Copyright 2014
HVAC
SYMPTOM
POSSIBLE CAUSE
SOLUTION
7. Broken wiring / poor

ground.
Clutch will not engage. Inspect the ground and

connections.
Repair.
8. Wiring harness
components.
Test the conductance of the pressure switch,

thermostat, Relay, etc.
Check operation.
Gauge Pressure Related Troubleshooting

Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 86 - 96F (30 38C) and compressor speed of approximately 2000 rpm are:
High pressure side pressure: 210 - 265 psi (1448 1827 kPa)
Low pressure side pressure: 15 - 33 psi (103 - 228

kPa)
As a rule of thumb the high side pressure will be around eight times greater then the low side pressure.
SYMPTOM
POSSIBLE CAUSE
SOLUTION
1. Expansion valve opens

too far.
Frost is present on the suction hose.
Replace expansion valve.
2. Dective compressor.
The high and low pressure side gauge pressures

equalize when the magnetic clutch is engaged.
Replace compressor.
1. Low refrigerant charge.

Repair leaks and recharge the

refrigerant to the correct level.
2. Clogged or closed
expansion valve.
The expansion valves inlet side is frosted.

Moisture or other Contaminants can be the cause.
Clean or replace the expansion

Valve.
3. Restriction between
drier and expansion valve.
Frost on the line between drier and expansion

valve. A Negative low pressure reading may be
shown.
Flush system or replace hose.
4. Thermostat malfunction.
The evaporator is frozen.
Adjust themostats temperature

setting or probe placement or
replace thermostat.
5. Receiver drier restriction
Excessive frost on receiver drier.
Replace receiver drier.
1. Poor condenser
performance.
Dirty or clogged condenser fins. Condenser fans

not Operating.
Clean fins, and / or repair the fan.
2. Excessive refrigerant.
The high pressure side pressure will be high.
Evacuate and recharge to correct

refrigerant level.
3. Excessive oil charge.
The high pressure side will be high.
Evacuate system. Remove oil

from condenser and compressor.
Add correct oil charge back into
compressor. Flush system with
nitrogen. Replace drier.
4. Air in system.
Pressure is high on both high and low sides.
Evacuate and recharge with

Refrigerant.
Low pressure side too high
Low pressure side too low
High pressure side too high
6.28
Copyright 2014
HVAC
SYMPTOM
POSSIBLE CAUSE
SOLUTION
5. Restriction in drier,
condenser or high
pressure line.
High pressure side will be high, and low pressure

side will be low.
Evacuate and flush system

replacing defective parts.

Repair any leaks and recharge

the refrigerant to the correct level.
High pressure side too low

1. Low refrigerant charge.
System pressures equal
1. Clutch not operating.
See compressor clutch related topics above.
2. Compressor not
pumping.
Equal high and low pressures.
Replace compressor.
6.29
Copyright 2014
HVAC
Temperature / Pressure Chart
TEMP F
PSIG
TEMP F
PSIG
16
15.69
93
110.20
18
17.04
94
112.10
20
18.43
95
114.10
22
19.87
100
124.30
24
21.35
102
128.50
26
22.88
104
132.90
28
24.47
106
137.30
30
26.10
108
141.90
32
27.79
110
146.50
34
29.52
112
151.30
36
31.32
114
156.10
38
33.17
116
161.10
40
35.07
118
166.10
42
37.03
120
171.30
44
39.05
122
176.60
45
40.09
124
182.00
50
45.48
126
187.50
55
51.27
128
193.10
60
57.47
130
198.90
65
64.10
135
213.70
70
71.19
140
229.40
75
78.75
145
245.80
80
86.80
150
263.00
85
95.40
155
281.10
90
104.40
160
300.10
91
106.30
165
320.10
92
108.20
170
340.80
Evaporator
Pressures represent gas temperatures inside the coil, not the coil surface. For an estimate of the temperature of the air
coming off the coil add 8 - 10F (-13 to -12C) to the temperature on the chart.
Condenser
Temperatures are not ambient temperatures but condensing temperatures. Add 4.4 C (40 F) to the ambient
temperature to get the condensing temperature and then refer to the pressure chart to see appropriate pressure for
ambient temperature.
Example: Ambient Temperature = 90F
90F + 40F = 130F condenser temperature / 200 PSIG
Conditions and pressures will vary from system to system.
6.30
Copyright 2014
HVAC
Poor A/C Performance
1. Start the utility vehicle. Engage the A/C system with
the blower fan on high. Run the vehicle at full rpm for
approximately 15 minutes, with the cab door closed.
3. Check the heater hose (Item 4) for temperature. If

the hose is hot, the heater valve is leaking by, and
needs to be replaced.
2. Check the temperature at the louvers (Item 1) with a

thermometer
4. Push the A/C switch to the OFF position. Turn the

fan switch to position 1. Turn the temperature control
to the High A/C position.
3. The louver temperature should be between 36 - 53F
(2 - 12C) depending on the humidity in the air.
4. If temperature is too high, check the blower fan for
proper operation or noise, and replace if necessary.
Engine Coolant Bypassing the Heater Valve

1. Push the A/C switch (Item 1) to the OFF position.
Turn the fan switch (Item 2) to the High Speed
position. Turn the temperature control (Item 3) to the
High A/C position.
2. Start the utility vehicle and run at high idle, for ten
minutes.
5. Listen for the heater valve (Item 1) as the key is

turned to the ON position without starting the utility
vehicle. The heater valve should rotate.
6. Turn the key to the OFF position. Turn the
temperature control to the High Heater position.
7. Listen for the heater valve (Item 5) as the key is
turned to the ON position without starting the utility
vehicle. The heater valve should rotate. If it does not
rotate, check the potentiometer for proper function.
8. Replace the heater valve.
A/C Electrical System Troubleshooting

Refer to Chapter 15 - Electrical for component testing.
6.31
Copyright 2014
HVAC
NOTES
6.32
Copyright 2014
BODY / CAB / FRAME
CHAPTER 7
BODY / CAB / FRAME
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
MULTI-FUNCTION PLIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
CAB FRAME ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
CAB FRAME / HEADRESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
DOORS / CAB SEALS (BRUTUS HDPTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
ROOF / WINDSHIELD / WIPER (BRUTUS HDPTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
MAIN FRAME / BUMPER (BRUTUS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
MAIN FRAME / FRONT ATTACHMENT (BRUTUS HD / HDPTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
BODY COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
HOOD / FRONT FENDERS / FRONT FASCIA (BRUTUS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
HOOD / FRONT FENDERS / FRONT FASCIA (BRUTUS HD / HDPTO). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
FLOOR / REAR FENDERS / SKID PLATE / STORAGE (BRUTUS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.10
FLOOR / REAR FENDERS / SKID PLATE / STORAGE (BRUTUS HD / HDPTO) . . . . . . . . . . . . . . . . . . . . 7.11
SEAT MOUNTING / SEAT BELTS (BRUTUS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.12
SEAT MOUNTING / SEAT BELTS (BRUTUS HD / HDPTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.13
DASH PANELS / GLOVE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.14
REAR CARGO BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.14
CARGO BOX PANELS / TAILGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.15
CARGO BOX SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.16
CARGO BOX REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.16
CARGO BOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.17
BODY COMPONENT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.18
LOWER SEAT BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.18
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.18
FRONT BUMPER (BRUTUS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.18
ATTACHMENT MOUNT (BRUTUS HD / HDPTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.19
FRONT FASCIA (BRUTUS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.19
FRONT FASCIA (BRUTUS HD / HDPTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.20
FRONT FENDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.21
DASH PANELS / GLOVE BOX REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.21
ROCKER PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.22
MAIN FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.23
FRONT FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.25
DECAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.26
7.1
Copyright 2014
BODY / CAB / FRAME

SPECIAL TOOLS
ITEM
TORQUE VALUE
TOOL DESCRIPTION
PART NUMBER
Cab Frame Bolts
30 ft-lbs (41 Nm)
Multi-Function Pliers
2876389
Cab / Seat Base Bolts
14 ft-lbs (19 Nm)
Cargo Box Latch Bolts
17 ft-lbs (23 Nm)
Cargo Box Support Bolts
14 ft-lbs (19 Nm)
Floor Support Bolts
30 ft-lbs. (41 Nm)
Included in the tool kit, this multi-function pliers is

designed to remove plastic push rivets and install body
components.
Frame Mast (HD / HDPTO)

Attachment Cross Brace
Bolts
35 ft-lbs. (47 Nm)
Frame Mast (HD / HDPTO)

Lower Vertical Bolts
95 ft-lbs. (129 Nm)
Front Bumper Bolts
30 ft-lbs. (41 Nm)
Passenger Grab Handle

Bolts
14 ft-lbs (19 Nm)
Hip Bolster Bolts (Upper)
8 ft-lbs (11 Nm)
Hip Bolster Bolts (Lower)
14 ft-lbs (19 Nm)
Headrest Bolts
8 ft-lbs (11 Nm)
Rear Cab Support Bolts
30 ft-lbs (41 Nm)
Rocker Support Bolts
8 ft-lbs (11 Nm)
Seat Back Mounting Screws
24 in-lbs (3 Nm)
Seat Belt Mounting Bolts
40 ft-lbs (54 Nm)
Shock Mounting Bolts
40 ft-lbs (54 Nm)
Skid Plate Bolts
8 ft-lbs (11 Nm)

NOTE: Refer to exploded views throughout this

chapter for more torque specifications, component
identification, and location of components.
7.2
Copyright 2014
BODY / CAB / FRAME

CAB FRAME ASSEMBLY
Cab Frame / Headrests
7.3
Copyright 2014
BODY / CAB / FRAME

Doors / Cab Seals (BRUTUS HDPTO)
7.4
Copyright 2014
BODY / CAB / FRAME

Roof / Windshield / Wiper (BRUTUS HDPTO)
7.5
Copyright 2014
BODY / CAB / FRAME

FRAME
Main Frame / Bumper (BRUTUS)
7.6
Copyright 2014
BODY / CAB / FRAME

Main Frame / Front Attachment (BRUTUS HD / HDPTO)
7.7
Copyright 2014
BODY / CAB / FRAME

BODY COMPONENTS
Hood / Front Fenders / Front Fascia (BRUTUS)
7.8
Copyright 2014
BODY / CAB / FRAME

Hood / Front Fenders / Front Fascia (BRUTUS HD / HDPTO)
7.9
Copyright 2014
BODY / CAB / FRAME

Floor / Rear Fenders / Skid Plate / Storage (BRUTUS)
7.10
Copyright 2014
BODY / CAB / FRAME

Floor / Rear Fenders / Skid Plate / Storage (BRUTUS HD / HDPTO)
7.11
Copyright 2014
BODY / CAB / FRAME

Seat Mounting / Seat Belts (BRUTUS)
7.12
Copyright 2014
BODY / CAB / FRAME

Seat Mounting / Seat Belts (BRUTUS HD / HDPTO)
7.13
Copyright 2014
BODY / CAB / FRAME

Dash Panels / Glove Box
7.14
Copyright 2014
BODY / CAB / FRAME

REAR CARGO BOX
Cargo Box Panels / Tailgate
7.15
Copyright 2014
BODY / CAB / FRAME

Cargo Box Support
7.16
Copyright 2014
BODY / CAB / FRAME

Cargo Box Removal
Cargo Box Installation
1. Fully tilt the rear cargo box.
1. Place the cargo box onto the frame. Align the hinges
of the box with the bracket on the frame.
2. Pull the clip (Item 1) and remove the pin at the upper
cargo box shock mount.
2. Install the cargo box hinge fasteners on both sides

and torque to specification.
Cargo Box Hinge Fasteners:

14 ft-lbs (19 Nm)
3. With the hinge bolts installed, attach the shock to the
cargo box by inserting the pin and clip.
4. Connect the tail light harness connector to the main
harness.
5. Lower the box and secure the latch.
3. Disconnect the tail light harness connector (Item 2)

from the main harness.
4. Remove the clip and pin at the bottom shock mount
for replacement or removal of cargo box shock.
CAUTION
Safely support the box during the remainder of the

removal process. The box is not as stable with the
shock removed.
5. Using a 15mm socket, remove the two hinge
fasteners that retain the cargo box to the frame.
CAUTION
Use caution when removing the box. It is recommended
to have two people carefully remove the box from the
frame.
6. Lift the cargo box from the frame. Two people or an
appropriate overhead hoist may be needed to
remove the box from the frame.
7.17
Copyright 2014
BODY / CAB / FRAME

BODY COMPONENT REMOVAL
Front Bumper (BRUTUS)
Lower Seat Base

bottom of the bumper to the frame.
1. Lift up on the back of the seat to disengage the seat

pin from the rubber grommet.
2. Remove the two fasteners (Item 2) retaining the top

of the bumper to the frame.
2. With the s eat sitting vertically, lift the seat up to

remove the seat tabs from the slots on the frame.
3. Carefully pull the bumper straight out to remove it

from the vehicle.
Hood
1. Turn each 1/4 turn latch 90 degrees to unlock the
hood.
2. Lift up the hood between the locks and slide hood
forward to disengage the front of the hood from the
front fascia.
7.18
Copyright 2014
BODY / CAB / FRAME

Attachment Mount (BRUTUS HD / HDPTO)
Front Fascia (BRUTUS)
1. Remove the hardware (Item 1) retaining the bottom

of the attachment frame to the chassis.
1. Remove the hood.

2. Disconnect both front headlights.
3. Remove the two T-40 Torx-head screws (Item 1)
retaining the front fascia to the upper radiator
brackets.
2. Remove the auxiliary couplers (Item 2) from the

attachment mount frame.
retaining the front fascia to the frame.
5. Remove the push rivets (Item 3) retaining the front
fascia to the front fenders on each side.
NOTE: This image shows the tilt and lift

cylinders removed for clarity purposes.
3. Remove the hardware (Item 3) retaining the front
attachment mount assembly to the frame.
4. Remove the front attachment mount assembly from
the vehicle.
6. Carefully pull the front fascia straight out to remove it

from the vehicle.
7.19
Copyright 2014
BODY / CAB / FRAME

Front Fascia (BRUTUS HD / HDPTO)
1. Remove the hood.

retaining the front fascia to the upper radiator
brackets.
2. Disconnect both front headlights.

3. Remove the hardware (Item 1) retaining the bottom
of the attachment frame to the chassis.

retaining the front fascia to the frame.
4. Remove the hardware (Item 2) retaining the front
attachment mount to the frame.
NOTE: This image shows the tilt and lift

cylinders removed for clarity purposes only. The
hydraulic lines do not need to be disconnected
for front fascia removal.

fascia to the front fenders on each side.
9. Carefully pull the front fascia straight out to remove it

from the vehicle.
5. Remove the two T-40 Torx-head screws (Item 3) and

the for T-27 Torx-head screws (Item 4) retaining the
lower grill and remove the lower grill.
7.20
Copyright 2014
BODY / CAB / FRAME

Front Fenders
Dash Panels / Glove Box Removal
1. Remove the hood (see Hood removal).
Upper Dash Panel

fascia to the front fender (Item 2).
1. Remove the four push rivets (Item 1) from the upper

dash panel (Item 2) and pull the panel towards the
seats to release the front tabs.

two push rivets (Item 4) retaining the top and rear
portion of the fender. Remove the three T-40 Torxhead screws (ITem 5) retaining the front portion of
the fender to the frame.
Lower Dash Panel

2. Disconnect the ignition, headlight and AWD
switches, instrument cluster, and both 12V power
points on the control dash panel.
retaining the bottom of the control dash panel and
remove the panel.
4. Open the glove box and remove the four T-25 Torxhead screws (Item 4).
two push rivets (Item 6) retaining the front fenders to
the lower dash.
6. Remove the shifter cap and the T-25 Torx-head
screw and pull up on the shifter grip to remove it.
7.21
Copyright 2014
BODY / CAB / FRAME

7. Remove the nine T-40 Torx-head screws (Item 7)
retaining the bottom of the lower dash.
NOTE: One T-40 Torx-head screw is hidden

inside the glove compartment.
8. Remove the two push rivets (Item 8) that were
hidden behind the control dash panel and one to the
right of the instrument cluster.
9. Tilt the steering wheel to its lowest position and put
the gear selector in Low or High gear to ease
removal.
10. Carefully pull the lower dash panel towards the seat
and up to remove it.
Dash Storage Panel
11. Remove the four T-25 Torx-head screws along the
bottom of the dash storage panel and the one T-40
Torx-head screw inside the glove box in the back.
12. Carefully remove the dash storage panel.
7.22
Copyright 2014
BODY / CAB / FRAME

Rocker Panels
4. Pull rocker panel out to remove it.
1. Remove the seat bottom and under seat storage

box.
2. Remove the six T-40 Torx-head screws (Item 1).
BRUTUS HD PTO MODELS

5. Remove the grass screen (Item 3) by turning the two
1/4 turn studs (Item 4) counter-clockwise.
3. Remove the two push rivets (Item 2).

NOTE: If removing the LH panel, loosen the
hose clamp retaining the fuel fill hose to the LH
panel.
7.23
Copyright 2014
BODY / CAB / FRAME

Main Floor
1. Remove both rocker panels (see "Rocker Panels").
4. Remove one push rivet (Item 2) retaining the treadle

pedal rubber grommet and remove the rubber
grommet.
2. Remove the push rivets retaining the upper and

lower floor cover and remove the cover from the
vehicle.
5. Remove the ten T-40 Torx-head screws (Item 3) and

two push rivets (Item 4) retaining the main floor.
3. Remove the four T-40 Torx-head screws (Item 1)

retaining the forward and reverse pedals to the
treadle pedal.
6. Lift the seat side of the floor and maneuver the front
left side around the brake pedal to remove it from the
vehicle.
7.24
Copyright 2014
BODY / CAB / FRAME

Front Floor
1. Remove the lower dash panel and dash storage
panel (see Dash Panels / Glove Box Removal).
2. Remove the main floor (see Main Floor).
3. Remove the clip and pin (Item 1) securing the brake
pedal to the master cylinder push rod.
5. Using a 13 mm socket, remove the fasteners (Item 3)

retaining the Power Steering unit to the lower
steering shaft.
6. Remove the four fasteners (Item 4) for the power
steering mount and remove the power steering unit
and mount as an assembly.
NOTE: The power steering hydraulic lines do
NOT need to be removed for this procedure.
7. Remove the lower steering shaft (see Chapter 8 Lower Steering Shaft Removal).
8. For BRUTUS HDPTO units, remove the Evaporator
and Heater Coil Assembly and ducting (see Chapter
6 - Evaporator Coil, Heater Coil removal).
9. Remove two T-40 Torx-head screws (Item 3)
retaining the front floor to the frame.
4. Using a 13 mm socket, remove the four bolts (Item 2)

retaining the brake pedal mount.
10. Remove four push rivets retaining the front floor to

the front fenders and front cab frame mounts.
11. Remove the front floor from the vehicle.
7.25
Copyright 2014
BODY / CAB / FRAME

DECAL REPLACEMENT
WARNING
The following procedure involves the use of an open
flame. Perform this procedure in a well ventilated area,
away from gasoline or other flammable materials. Be
sure the area to be flame treated is clean and free of
gasoline or flammable residue.
WARNING
Do not flame treat components that are installed on the
vehicle. Remove the component from the vehicle
before flame treating.
The vehicle body panels are plastic polyethylene
material. Therefore, they must be flame treated prior to
installing a decal to ensure good adhesion. A bonus of
the flame treating procedure is it can be used to reduce
or eliminate the whitish stress marks that are sometimes
left after a fender or cab is bent, flexed, or damaged.
CAUTION
Do not flame treat painted plastic components. Painted
plastic surfaces should only be wiped clean prior to
decal adhesion.
To flame treat the decal area:
1. Pass the flame of a propane torch back and forth
quickly over the area where the decal is to be applied
until the surface appears slightly glossy. This should
occur after just a few seconds of flame treating. Do
not hold the torch too close to the surface (2-3 inches
from the flame tip is recommended). Keep the torch
moving to prevent damage.
2. Apply the decal on one edge first. Slowly lay down
remainder of the decal while rubbing lightly over the
decal surface to eliminate any air bubbles during the
application.
7.26
Copyright 2014
CHAPTER 8
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
MULTI-FUNCTION PLIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
STEERING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
STEERING WHEEL / UPPER STEERING SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
STEERING SHAFT BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
POWER STEERING UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
POWER STEERING / STEERING SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
FRONT A-ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
FRONT LOWER A-ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
FRONT LOWER A-ARM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
FRONT UPPER A-ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.10
FRONT UPPER A-ARM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.10
BALL JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
SERVICE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
BALL JOINT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
BALL JOINT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.12
REAR SUSPENSION LINK AND AXLE BRACE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.13
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.13
REAR UPPER SUSPENSION LINK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.14
REAR UPPER SUSPENSION LINK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.14
REAR LOWER SUSPENSION LINK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.15
REAR LOWER SUSPENSION LINK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.15
REAR AXLE BRACE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.16
REAR AXLE BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.16
REAR AXLE BRACE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.17
SHOCKS / SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.18
EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.18
SHOCK REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.19
SHOCK / SPRING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.19
8.1
Copyright 2014
SPECIAL TOOLS
ITEM
TORQUE VALUE
TOOL DESCRIPTION
PART NUMBER
A-arm to Frame Bolts
40 ft-lbs (54 Nm)
Ball Joint Tool
PU-50506
A-arm to Bearing Carrier Bolts
40 ft-lbs. (54 Nm)
Shock Spanner Wrench
PV-43507-A
Ball Joint Pinch Bolts
42 ft-lbs (57 Nm)
Shock Spring Compressor Tool
N/A
Lower Steering Shaft

Upper Pinch Bolt
15 ft-lbs (20 Nm)
2876389
Lower Steering Shaft

Lower Pinch Bolt
36 ft-lbs (49 Nm)
Pivot Tube Mounting Bolts
18 ft-lbs (24 Nm)
Power Steering Unit

Mounting Bolts
30 ft-lbs (41 Nm)
Power Steering Unit

Mount Bracket Bolts
14 ft-lbs (19 Nm)
Rear Brake Junction Block
35 in-lbs (4 Nm)
Shock Mounting Bolts
40 ft-lbs (54 Nm)
Steering Gearbox Bolts
16 ft-lbs (22 Nm)
Steering Wheel Nut
65 ft-lbs (88 Nm)
Tie Rod to Steering Knuckle

Mounting Bolts
40 ft-lbs (54 Nm)
Tie Rod End Jam Nut
13 ft-lbs (18 Nm)
Tilt Shock Mounting Bolts
7 ft-lbs (10 Nm)
Upper Steering Shaft

Pinch Bolt
15 ft-lbs (20 Nm)
Wheel Hub Castle Nut (Front)
75 ft-lbs (102 Nm)
Wheel Hub Castle Nut (Rear)
110 ft-lbs (149

Nm)
Wheel Nuts
60 ft-lbs (81 Nm)

Included in the tool kit, this multi-function pliers is
designed to remove plastic push rivets and install body
components.
NOTE: Refer to exploded views throughout this

chapter for more torque specifications, component
identification, and location of components.
8.2
Copyright 2014
STEERING ASSEMBLY
Exploded View
8.3
Copyright 2014
Steering Wheel / Upper Steering Shaft
Removal
1. Remove upper and lower dash panels (see Dash
Panel / Glove Box Removal).
5. Mark the upper steering shaft (Item 2) and power

steering unit splines to assist with steering wheel
alignment upon installation.
CAUTION
Striking the steering wheel or steering shaft
while installed in the vehicle can permanently damage
the power steering unit and cause a
Power Steering Fault.
2. Using a 6mm Allen wrench and a 17mm open-end
wrench, remove the steering pivot fasteners.
6. Remove the steering wheel, upper steering shaft and

pivot out as an assembly.
7. Remove the steering wheel cap.
3. Using a 4mm Allen wrench and 10mm open-end

wrench, remove the upper tilt steering locking shock
fastener (Item 1).
8. Loosen the nut and back it half way off the steering
shaft.
9. Place the assembly in a vise.
10. Using a large bronze drift and hammer, strike
steering shaft nut to pop the steering wheel off the
tapered shaft.
11. Once the steering wheel pops loose, completely
remove the nut and lift the steering wheel off the
shaft.
4. Using a 13mm socket, remove the fastener retaining
the upper steering shaft to the power steering unit.
8.4
Copyright 2014
Steering Shaft Bearing Replacement
NOTE: The replacement pivot tube assembly comes
with new upper and lower bearings installed. Use
this procedure if replacing the bearings only.
1. Perform the Steering Shaft Removal procedure.
2. Remove the steering wheel cap and retaining nut.
3. Press steering shaft out of the steering wheel and
pivot tube.
4. Note the location of the bushings on each end of the
pivot tube.
5. Drive the bearings out of the pivot tube using a drift
punch.
6. Inspect the pivot tube bearing surfaces for signs of
excessive wear or damage.
7. Apply Loctite 271 (Red) to the outer circumference
of the new lower bearing race. Slide the new lower
bearing onto the steering shaft and install the
steering shaft through the pivot tube.
NOTE: Use care not to allow any of the Loctite
to get in the bearing.
8. Apply Loctite 271 (Red) to the outer circumference

of the new upper bearing race. Slide the new upper
bearing onto the steering shaft and press it into the
pivot tube by hand.
NOTE: Use care not to allow any of the Loctite
to get in the bearing.
Bearings will be seated in the pivot housing
upon tightening the steering wheel nut.
9. Install the steering wheel and hand tighten the nut.
10. Reinstall the steering shaft assembly in the vehicle.
Install the lower portion of the steering shaft onto the
steering gear box assembly. Torque the lower pinch
bolt to 36 ft-lbs (49 Nm).
11. Install the two fasteners that retain the pivot tube.
Torque fasteners to 18 ft-lbs (24 Nm).
12. Install the fastener retaining the upper portion of the
steering wheel tilt shock to the pivot tube. Torque
fastener to 7 ft-lbs (10 Nm).
13. Be sure the front wheels are facing straight forward.
Remove the steering wheel and align if needed.
Torque the steering wheel nut to 65 ft-lbs (88 Nm).
14. Wipe the pivot tube clean of any excess Loctite.
15. Install steering wheel cap and field test steering
operation.
Be sure the lower bushing is still on the steering

shaft.
8.5
Copyright 2014
Power Steering Unit Removal
Power Steering / Steering Shaft Installation
NOTE: DO NOT attempt to service the internal

components of the power steering unit. The power
steering unit can only be replaced as an assembly.

1. Remove upper steering shaft and steering wheel

(see Steering Wheel / Upper Steering Shaft
Removal).
1. Install the power steering unit onto the mount bracket

and torque the four power steering mounting bolts to
specification.
2. Loosen the three hydraulic lines (Item 1) going to the

power steering unit.
Power Steering Unit to Power Steering Mount:

30 ft-lbs (41 Nm)
2. Install the three hydraulic hoses to the power
steering assembly. Torque to specification.
Power Steering Hydraulic Hose:

22 ft-lbs (30 Nm)
3. Using a 13 mm socket, remove the fastener retaining
the lower steering shaft to the power steering unit.
3. Install the pinch bolt retaining the lower power

steering shaft to the power steering unit. Torque to
specification.
4. Remove the four 6mm allen bolts (Item 2) retaining

the power steering unit to the power steering mount.
Lower Power Steering Shaft Upper Pinch Bolt:

15 ft-lbs (20 Nm)
4. Position the steering wheel, pivot tube and upper
steering shaft assembly to the proper mounting
location.
5. Align the marks previously made on the upper
steering shaft and power steering unit. Slide the
upper shaft onto the power steering splined shaft.
5. Put a suitable drain pan under the power steering

unit and remove the three hydraulic lines from the
power steering assembly.
8.6
Copyright 2014
6. Loosely install the pivot tube shoulder bolts and nuts.
8. Verify that the pivot tube bushings are properly

seated into the pivot tube. Torque the pivot tube
shoulder bolts and nuts to specification.
CAUTION
Striking the steering wheel or steering shaft
can permanently damage the power steering unit and
cause a Power Steering Fault.
Pivot Tube Shoulder Bolts:

18 ft-lbs (24 Nm)
9. Install locking tilt shock and torque the fastener to
specification.
Tilt Shock Fastener:

7 ft-lbs (10 Nm)
10. Reinstall the upper and lower dash panels making
sure to reconnect the instrument cluster, both 12V
outlets and all the switches.
7. Install the upper steering shaft pinch bolt and torque
to specification.
11. Start unit and turn the steering wheel lock to lock
several times to bleed out the power steering
system. Test power steering operation.
Upper Power Steering Shaft Pinch Bolt:

15 ft-lbs (20 Nm)
8.7
Copyright 2014
FRONT A-ARMS
Exploded View
8.8
Copyright 2014
Front Lower A-Arm Removal
Front Lower A-Arm Installation
1. Properly lift and support the vehicle by the frame.

2. Remove the four wheel nuts and remove the wheel.
3. Using a 15mm socket and open-end wrench, remove
the lower ball joint pinch bolt (Item 1) at the bearing
carrier.
WARNING
The locking agent on the existing bolts was destroyed
during removal. DO NOT reuse old hardware. Serious
injury or death could result if fasteners come loose
during operation.
1. Install the lower A-arm onto the frame. Torque the
new lower A-arm fasteners to specification.
Lower A-Arm to Frame:

40 ft-lbs (54 Nm)
2. Install the lower A-arm ball joint into the bearing
carrier. Torque the new fastener to specification.
the two fasteners retaining the lower A-arm to the
frame.
Ball Joint Pinch Bolts:
42 ft-lbs (57 Nm)
5. Remove the lower A-arm from the vehicle.
3. Install wheel and torque wheel nuts to specification.
8
Wheel Nuts:
60 ft-lbs (81 Nm)
WARNING
Upon A-arm installation completion, test vehicle at low
speeds before putting into service.
8.9
Copyright 2014
Front Upper A-Arm Removal
2. Install the upper A-arm ball joint into the bearing

carrier. Torque the new fastener to specification.
2. Remove the four wheel nuts and remove the wheel.

the fastener (Item 1) retaining the lower portion of the
shock to the upper A-arm.
the upper ball joint pinch bolt (Item 2) at the bearing
carrier.

42 ft-lbs (57 Nm)
3. Attach the lower portion of the shock to the upper Aarm. Torque the new fastener to specification.
Shock Mounting Bolts:

40 ft-lbs (54 Nm)
Wheel Nuts:
60 ft-lbs (81 Nm)
the fastener retaining the upper A-arm to the frame.
6. Remove the upper A-arm from the vehicle.
Front Upper A-Arm Installation
WARNING
Upon A-arm installation completion, test vehicle at low
speeds before putting into service.
WARNING
during operation.
1. Install the upper A-arm onto the frame. Torque the
new upper A-arm fastener to specification.
Upper A-Arm to Frame:

40 ft-lbs (54 Nm)
8.10
Copyright 2014
BALL JOINT SERVICE
Ball Joint Removal

1. Remove the retaining ring from the ball joint.
Service Preparation
NOTE: Do not reuse a ball joint if it has been
removed. If removed, it must be replaced. Use this
removal procedure only when replacing the ball
joint.
Ball joint tool PU-50506 will allow the upper and
lower ball joints to be replaced with the A-arm
installed on the vehicle.
2. Install Spacer (Item 1) over the top of the ball joint

face.
3. Place Removal Adaptor (Item 2) over the ball joint

shaft.
4. Install the Press Asm. (Item 3) onto the A-arm to
engage the ball joint Removal Adapter.
NOTE: Be sure the Press Asm. opening is only
contacting the Spacer and not the ball joint face.
The A-arm does not need to be removed to perform this
procedure if ball joint tool PU-50506 is used.
5. Tighten the Press Asm. screw and fully remove the

ball joint from the A-arm.
2. Remove the appropriate front wheel.

3. To service the upper ball joint:
4. - Remove and discard the two front brake caliper
mounting bolts and remove the caliper from the
brake disc (see Brakes chapter).
5. - Remove and discard the upper ball joint pinch bolt.
6. - If necessary, remove the lower front shock fastener
from the A-arm to gain enough clearance to install
ball joint tool (PU-50506) on the upper ball joint.
7. To service the lower ball joint:
8. - Remove and discard the lower ball joint pinch bolt.
9. - If necessary, remove the lower front shock fastener
from the A-arm to gain enough clearance to install
ball joint tool (PU-50506) on the lower ball joint.
8.11
Copyright 2014
Ball Joint Installation
1. By hand, install the NEW ball joint into the A-arm.
7. Repeat the ball joint service procedure for any

additional A-arm ball joint replacements.
2. Position the Installation Adapter (Item 1) over the

face of the ball joint.
42 ft-lbs (57 Nm)
8. Insert upper / lower A-arm ball joint end into the
bearing carrier. Install new pinch bolts and nuts.
Torque to specification.
Front Shock Mounting Bolts:

40 ft-lbs (54 Nm)
9. If removed, install new brake caliper mounting bolts
3. Position the Spacer (Item 2) over the shaft of the ball
joint so it is against the A-arm.
4. Install the Press Asm. (Item 3) onto the A-arm to
engage the Installation Adapter and Spacer.
5. Tighten the Press Asm. screw and fully install the
ball joint into the arm.
Front Caliper Mounting Bolts:

30 ft-lbs (41 Nm)
CAUTION
Brake caliper mounting bolts have a pre-applied locking
agent which is destroyed upon removal. Always use
new bolts upon assembly.
10. Install wheel and four wheel nuts. Torque wheel nuts
to specification.
Wheel Nuts:
60 ft-lbs (81 Nm)
6. After the new ball joint is fully installed into the Aarm, install a new retaining ring.
8.12
Copyright 2014
REAR SUSPENSION LINK AND AXLE
BRACE
Exploded View
8.13
Copyright 2014
Rear Upper Suspension Link Removal
Rear Upper Suspension Link Installation
WARNING
CAUTION
Do not lift vehicle on the rear axle brace as this will
keep the upper and lower suspension links loaded.
2. Remove the rear fastener (Item 1) retaining the
upper suspension link to the rear axle brace.

during operation.
1. Install the upper suspension link onto the frame.
Torque new fasteners to specification.
Upper Suspension Link to Frame:

40 ft-lbs (54 Nm)
2. Attach the upper suspension link to the rear pivot
point on the rear axle brace. Torque new fastener to
specification.
3. Remove the fastener (Item 2) retaining the upper

suspension link to the frame on each side.
4. Remove the upper suspension link out the back of
the machine.
Upper Suspension Link to Rear Axle Brace:

40 ft-lbs (54 Nm)
WARNING
Upon repair completion, test vehicle at low speeds
before putting into service.
8.14
Copyright 2014
Rear Lower Suspension Link Removal
Rear Lower Suspension Link Installation
WARNING
CAUTION
Do not lift vehicle on the rear axle brace as this will
keep the upper and lower suspension links loaded.
2. Remove the four wheel nuts and remove the rear
wheel.
3. Remove the lower shock mounting hardware (Item
1).

during operation.
1. Install the lower suspension link on the frame.
Lower Suspension Link to Frame:

40 ft-lbs (54 Nm)
2. Attach the lower A-arm to the axle brace. Torque new
fastener to specification.
4. Remove the lower suspension link to the axle brace

hardware and the lower suspension link to frame
hardware (Item 2). Remove the lower suspension
link.
Lower Suspension Link to Axle Brace:

40 ft-lbs (54 Nm)
3. Attach the lower portion of the rear shock to the
lower suspension link. Torque new fastener to
specification.

40 ft-lbs (54 Nm)
Wheel Nuts:
60 ft-lbs (54 Nm)
WARNING
Upon repair completion, test vehicle at low speeds
before putting into service.
8.15
Copyright 2014
Rear Axle Brace Removal
8. Remove the upper suspension link to the rear axle

brace hardware (Item 4).
2. Remove the four wheel nuts and remove rear wheel.

3. Remove the two 15 mm bolts (Item 1) retaining the
caliper. Remove the caliper and restrain it with wire.
Do not let the caliper hang by the brake lines.
9. Remove hardware retaining the lower suspension

links to the axle brace (Item 5).
10. Guide half shafts out while removing the axle brace.
4. Remove the dust cap, cotter pin, axle nut and
washers. Pull the hub/disc assembly out to remove
it.
5. Repeat steps 2-4 for the other side.
Rear Axle Bearing Replacement

1. Remove the rear axle brace from the vehicle.
2. Remove the snap ring retaining the axle bearing
(Item 1).
6. Remove the two T-25 Torx head screws (Item 2)

retaining the brake junction block to the rear axle
brace.
7. Remove the brake line from the four retainer clips

(Item 3).
8.16
Copyright 2014
3. From the back side, tap on the outer bearing race
with a drift punch in the casting reliefs (Item 2).
Rear Axle Brace Installation

WARNING
during operation.
1. Install both rear half shafts into the axle brace.
2. Attach the lower suspension links to the axle brace.
4. Thoroughly clean the rear bearing carrier housing

and the outer race on the new bearing. Be sure that
all oil residue has been removed from each surface.
5. Support the bottom of the axle brace bearing
housing in preparation for new bearing installation.
CAUTION

40 ft-lbs (54 Nm)
3. Install the two T-25 Torx head screws (Item 1)
securing the brake junction block to the rear axle
brace. Torque screws to specification.
Use an arbor and press only on the outer race,

otherwise bearing damage may occur.
6. Apply Loctite 603 retaining compound to the
outer circumference of the new bearing race and
carefully press the new bearing into the axle brace
bearing housing.
NOTE: Do not allow the Loctite compound to

get in the bearing.
7. Wipe the housing clean of any excess compound
and install the snap ring.
Rear Brake Junction Block Screws:

35 in-lbs (4 Nm)
4. Install the brake lines back in the four retainer clips
(Item 2).
8.17
Copyright 2014
5. Attach the rear axle brace to the upper suspension
link. Torque new fasteners to specification.
SHOCKS / SPRINGS
Exploded View

40 ft-lbs (54 Nm)
6. Install the hub/disc assembly, two washers, and new
axle nut. Torque nut to specification.
Rear Axle Nut:

110 ft-lbs (149 Nm)
7. Install a new cotter pin and dust cap.
8. Install brake caliper. Torque new mounting fasteners
to specification.
Rear Caliper Mounting Bolts:

48 ft-lbs (65 Nm)
Wheel Nuts:
60 ft-lbs (54 Nm)
WARNING
Upon rear axle brace installation completion, test
vehicle at low speeds before putting into service.
8.18
Copyright 2014
Shock Removal / Installation
1. Elevate the vehicle far enough off the ground to
relieve the suspension load.
2. Remove the upper and lower fasteners retaining the
shock and remove the shock from the vehicle.
Discard nuts and replace with new upon installation.
3. Reverse the procedure to reinstall the shock. Torque
new shock mounting fasteners to specification.
Shock / Spring Replacement

NOTE: DO NOT attempt to adjust the front shock
spring pre-load on BRUTUS HD / HDPTO models.
The factory has pre-set the spring rate for optimal
performance for use with the various attachments
that can be installed on the attachment arm.
1. Remove the shock and note the spring preload cam
setting.
2. Using a commercially available spring compressor
(automotive-type), compress the shock spring far
enough to remove spring retainer.

40 ft-lbs (54 Nm)
3. Remove the spring and adjusting cam from the

existing shock and install components onto the new
shock.
4. Install the spring retainer using a commercially
available (automotive-type) spring compressor to
compress the spring far enough to install the
retainer.
NOTE: The spring retainer gap should be 180
from the end of the spring upon installation.
5. Turn adjustment cam to set preload distance noted in
Step 1. Reference Chapter 2 Maintenance for
recommended spring preload settings.
6. Reinstall shock onto vehicle and torque new
fasteners to specification (see Exploded View).
8.19
Copyright 2014
NOTES
8.20
Copyright 2014
TRANSMISSION
CHAPTER 9
TRANSMISSION
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
TRANSMISSION MOUNTING AND TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
SHIFT LEVER / SHIFT CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
ASSEMBLY VIEW / MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
SHIFT LEVER REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
SHIFT CABLE INSPECTION / ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
SHIFT CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.13
TRANSMISSION SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.19
DIFFERENTIAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.19
TRANSMISSION DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.20
SNORKEL SHAFT REMOVAL / DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.23
TRANSMISSION SHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.25
PLANETARY DIFFERENTIAL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.27
PLANETARY DIFFERENTIAL BUSHING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.28
PLANETARY DIFFERENTIAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.31
SNORKEL GEAR BACKLASH PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.31
TRANSMISSION EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.38
EXPLODED VIEW, CONTINUED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.38
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.40
TROUBLESHOOTING CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.41
9.1
Copyright 2014
TRANSMISSION
SPECIFICATIONS
Special Tools
PART NUMBER
TOOL DESCRIPTION
PA-50231
Snorkel Tool
ITEM
TORQUE VALUE
Bearing Retaining
Plate Screws
8-10 ft-lbs (11-14 Nm)
2871698
(Part of 2871702 Kit)
Rear Output Seal Driver
Bellcrank Nut
12-18 ft-lbs (16-24 Nm)
2871699
(Part of 2871702 Kit)
Rear Driveshaft Seal Guide
Fill / Drain Plugs
10-14 ft-lbs (14-19 Nm)
2871282
Bearing Seal Driver (50 mm)
Gear Sector Cover
9-12 ft-lbs (12-16 Nm)
Park Flange Screws
8-10 ft-lbs (11-14 Nm)

Rear Transmission Isolator

Mount Nut
22 ft-lbs (30 Nm)
Lubrication
Engine to Transmission
Mount Bolts
47 ft-lbs (64 Nm)
Shift Fork
Retaining Screws
7-10 ft-lbs (10-14 Nm)
Snorkel Tube
Refer to Snorkel Gear

Backlash Procedure
Recommended Transmission Lubricant:

(PN 2878068) (Quart)
Snorkel Tube
Locking Screw
8-10 ft-lbs (11-14 Nm)
Differential Solenoid
25 ft-lbs (34 Nm)
Transmission Case
Screws
15-20 ft-lbs (20-27 Nm)
Speed Sensor Screw
9-12 ft-lbs (12-16 Nm)
9.2
Copyright 2014
TRANSMISSION
Transmission Mounting and Torque Values
9.3
Copyright 2014
TRANSMISSION
SHIFT LEVER / SHIFT CABLE
Assembly View / Mounting
9.4
Copyright 2014
TRANSMISSION
Shift Lever Removal / Installation
3. Remove the rubber grommet (Item 7) from the dash.
1. Remove the four push rivets (Item 1) retaining the

upper dash panel (Item 2). Remove the panel to
access the shift lever mounting.
4. Remove clip (Item 8) and washer (Item 9) retaining

the shift cable (Item 10) to the shift lever (Item 11).
Disconnect cable end from the lever.
2. Remove the shift knob cover (Item 3), retaining
screw (Item 4) and shift knob (Item 5) from the shift
lever (Item 6).
9
5. Remove the retaining ring (Item 12) and slide the
shift lever off the mounting bracket and out from the
frame.
6. Remove both bushings (Item 13) from the shift lever
and service as needed.
7. Perform the previous steps in reverse order to
reinstall the shift lever (lever, cable, grommet, shift
knob, dash panel).
9.5
Copyright 2014
TRANSMISSION
Shift Cable Inspection / Adjustment
Shift cable adjustment may be necessary if symptoms
include:
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).
No gear position or AWD display on gauge 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.
2. Inspect shift cable dust boot (Item 3) and the clevis
pin and pivot bushings (Item 4). Replace if worn or
damaged.
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.
9.6
Copyright 2014
TRANSMISSION
Shift Cable Replacement
1. Remove the four push rivets (Item 1) retaining the
upper dash panel (Item 2). Remove the panel to
access the shift cable mounting.
5. Remove the clevis pin (Item 8) and remove the shift

cable from the transmission bellcrank (Item 9).
6. Loosen the lower jam nut (Item 10) and pull the shift
cable out of the mount bracket (Item 11).
2. Remove clip and washer (Item 3) retaining the shift
cable (Item 4) to the shift lever (Item 5). Disconnect
cable end from the lever.
7. Remove the fasteners retaining the skid plate and

remove the skid plate to access the shift cable.
3. Loosen the lower jam nut (Item 6) and pull the shift
cable out of the mount bracket (Item 7).
4. Locate the shift cable in the right rear wheel well.
9.7
Copyright 2014
TRANSMISSION
8. Remove the push rivets retaining the drive shaft
cover and remove the cover to access the shift cable
(Item 12).
TRANSMISSION REMOVAL
CAUTION
sure machine is secure before beginning this
procedure. Always wear eye protection.
1. Elevate the vehicle and safely support the vehicle
2. Remove the rear
Maintenance).
wheels
(see
Chapter
3. Remove the hydrostatic drive motor from the

transmission (see Chapter 10 Hydrostatic Drive).
4. Loosen the airbox hose clamps (Item 1) and remove
the hose (Item 2).
9. Remove the shift cable from the vehicle.
10. Route the new shift cable same as previously
removed. Be sure to route the shift cable together
with the brake line (Item 13) in the area under the
driveshaft cover as previously shown.
11. When installation is complete, adjust the shift cable
so there is the same amount of cable travel when
shifting slightly past HIGH gear and PARK (see Shift
Cable Inspection / Adjustment).
5. Remove the two airbox bolts (Item 3) and remove the

airbox (Item 4).
9.8
Copyright 2014
TRANSMISSION
6. Loosen the intake hose clamp (Item 5).
9. Disconnect the gear indicator connector (Item 10).
7. Remove the two bolts (Item 6) and intake plenum

(Item 7).
10. Remove the clip (Item 11), washer and shift cable
(Item 12) from the transmission.
8. Disconnect the speed sensor (Item 8) and the box

harness connectors (Item 9).
11. Remove two bolts (Item 13) retaining the cable

mount.
9.9
Copyright 2014
TRANSMISSION
12. Remove the two bolts (Item 14) retaining the brake
caliper. Repeat for the other side.
16. Remove the wheel bearing dust cover (Item 17) from
each wheel hub.
13. Remove the brake line from the clips (Item 15).
17. Remove the cotter pin (Item 18), nut (Item 19) and
washer (Item 20) from each wheel hub.
14. Remove the two screws (Item 16) retaining the brake
line junction block.
18. Remove the bolt and nut (Item 21) retaining the
lower suspension arm to the axle brace. (Both Sides)
15. Reposition the calipers and brake lines to prevent

damage.
9.10
Copyright 2014
TRANSMISSION
19. Remove the nut and bolt (Item 22) from the
suspension pivot and remove the rear axle brace.
20. Remove each rear drive shaft using short, sharp

pulls to free the circlip from the vehicle.
21. Remove the roll pin (Item 23) from the front prop
shaft.
22. Remove the bolts (Item 24) from the front gear box.
Slide the gear box towards the front of the vehicle
allowing the drive shaft to slide off the splined shaft.
23. Slide the drive shaft (Item 25) off the transmission
output shaft.
24. Remove the bolts (Item 26) from the engine speed
control cable bracket.
9.11
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TRANSMISSION
25. Remove the end of the engine speed control cable
(Item 27) from the pump linkage. Reposition the
cable to prevent damage.
29. Remove the two left side mount bolts (Item 29).
26. Support the rear of the transmission.

27. Support the rear of the engine to prevent the engine
from tipping backwards when the rear transmission
mount bolt is removed.
30. Remove the four right side mount bolts (Item 30) and
spacer block (Item 31).
28. Remove the nuts

transmission mount.
(Item
28)
from
the
rear
NOTE: Remove the engine oil filter (Item 32) to

aid with fastener removal. Reinstall the oil filter
once the upper fastener has been removed.
31. With the help of an assistant, manually lift and turn
the transmission to get it out of the vehicle.
32. Remove the transmission.
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TRANSMISSION
TRANSMISSION INSTALLATION
4. Install the two mounting bolts (Item 4) and washers

(Item 5) on the left side of the transmission. Torque
the two left side fasteners to specification.
CAUTION
sure machine is secure before beginning this
procedure. Always wear eye protection.
1. Lift and tilt the transmission to reinstall it.
2. Support the rear of the engine to ease transmission
mount bolt installation.
Engine to Transmission Mounting Bolts:

47 ft-lbs (64 Nm)
3. Loosely install the two fasteners (Item 1) retaining

the spacer block (Item 2) to the transmission on the
right side of the transmission.
5. Install the remaining two fasteners (Item 6) and

washers (Item 7) on the right side of the
transmission. Torque the bottom fastener to 5 ft-lbs.
(6.8 Nm) in order to prevent any pre-stress on
mounting components during the final torque
procedure.
NOTE: Remove the engine oil filter to aid with

fastener installation. Reinstall the oil filter once
the upper fastener has been installed.
Install the washers (Item 3) on the nut side (drive

side).
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TRANSMISSION
6. Torque the four fasteners on the right side of the
transmission to specification in the sequence shown.
8. Install the end of the engine speed control cable

(Item 9) into the pump linkage.
9. Install the bolts (Item 10) that retain the engine

speed control cable bracket.
NOTE: Be sure to torque fastener #1 and #2 from
the nut side.
10. Lubricate the splines with an anti-seize compound

and slide the drive shaft (Item 11) onto the
transmission output shaft.
Engine to Transmission Mounting Bolts:

47 ft-lbs (64 Nm)
7. Install the nuts (Item 8) onto the rear transmission
mount. Torque nuts to specification.
Rear Transmission Mount Nut:

22 ft-lbs (30 Nm)
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TRANSMISSION
11. Line up the splines on the front gearcase to the prop
shaft. Line up the front gearcase with the mounting
holes and install the mounting bolts (Item 12). Torque
bolts to specification.
Front Gearcase Mounting Bolts:

30 ft-lbs (41 Nm)
12. Install a NEW roll pin (Item 13) in the front prop shaft.
14. Install the rear axle brace and install the nut and bolt
(Item 14) for the rear suspension pivot. Torque bolt to
specification.
Upper Suspension Link to Rear Axle Brace Bolt:

40 ft-lbs (54 Nm)
15. Install the bolt and nut (Item 15) retaining the lower
suspension arm to the axle brace on both sides.
Torque the bolts to specification.
13. Lubricate the splines with an anti-seize compound

and install both rear drive shafts into the
transmission.
Rear Axle Brace to Lower Suspension Link Bolt:

40 ft-lbs (54 Nm)
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TRANSMISSION
16. Install rear hubs, washer, nut and NEW cotter pin.
Torque nuts to specification.
20. Install the brake caliper and mounting bolts (Item 18)
on each wheel hub. Torque the mounting bolts to
specification.
Rear Axle Nut:

110 ft-lbs (149 Nm)
17. Install the wheel bearing dust cover on both sides.
18. Install the two screws (Item 16) retaining the brake
line junction block. Torque screws to specification.
Brake Caliper Mounting Bolts:

30 ft-lbs (41 Nm)
21. Install the two shift cable mount bolts (Item 19).
Torque bolts to specification.
Brake Line Junction Block Screws:

35 in-lbs (4 Nm)
19. Secure all rear brake lines into the clips (Item 17).
Transmission Shift Cable Mount Bolts:

37 ft-lbs (50 Nm)
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TRANSMISSION
22. Install the shift cable, washer and clip (Item 20), on
the transmission.
25. Install the intake plenum and torque the mounting

bolts (Item 24) to specification.
23. Connect the gear switch harness (Item 21).
Intake Plenum Mounting Bolts:

4 ft-lbs (5.4 Nm)
26. Tighten the intake hose clamp (Item 25).
24. Connect the speed sensor (Item 22) and the box
harness connectors (Item 23).
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TRANSMISSION
27. Install the airbox and tighten the mounting bolts (Item
26) to specification.
28. Install the intake hose and tighten the airbox hose
clamps (Item 27).
29. Install the hydrostatic drive motor to the transmission

(see Chapter 10 Hydrostatic Drive). Torque
Airbox Mounting Bolts:
8 ft-lbs (10.8 Nm)
Hydrostatic Motor Mounting Bolts:
100 ft-lbs (136 Nm)
30. Install the wheels and torque the wheel nuts to
specification (see Chapter 2 Maintenance).
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TRANSMISSION
TRANSMISSION SERVICE
The rear drive shafts are now dependent on the

differential allowing for tighter turns.
Differential Operation
The transmission has two traction operational modes:
Differential Lock and Differential Unlock. Locking the rear
differential is beneficial in low traction and rough terrain
conditions. Unlocking the rear differential makes
maneuvering easier and minimizes damage to terrain.
When Differential-Lock is selected, power is removed

from the electrical solenoid allowing the solenoid plunger
to retract. Spring tension moves the shift fork back into
place and mates the engagement dog to the side gear
that is part of the planetary differential assembly. This
locks the rear differential as a solid rear axle, increasing
traction.
When Differential-Unlock is selected, the rear

differential becomes unlocked for tighter turns. An
electrical solenoid mounted in the rear portion of the
gearcase actuates the shift fork. The solenoid plunger
extends out to move the fork and slides the engagement
dog away from the side gear that is part of the planetary
differential assembly. This unlocks the rear differential.
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TRANSMISSION
Transmission Disassembly
NOTE: Refer to the exploded view at the end of this
chapter as a reference.
1. Drain and properly dispose of the transmission
lubricant (see Chapter 2).
2. Remove the bellcrank nut (Item 1) and bellcrank
(Item 2).
6. Remove the detent star (Item 9). Note how the

detent star fits onto the splined shaft with the skip
tooth aligned and tall center hub facing inward for
reassembly.
7. Remove the shift shaft (Item 10), detent pawl (Item
11) and the shift sector gears (Item 12).
NOTE: Note the timing marks on the shift gears
for reassembly purposes.
8. Remove the O-rings (Item 13) from each shaft and
discard. Use new O-rings upon assembly.
9. Remove all the transmission case bolts. Using
suitable pry bars, remove the cover using the
designated pry points (indicated by the black arrows
in the illustration below).
3. Remove E-clip (Item 3) that retains spring and flat

washers (Item 4), and gear switch (Item 5). Remove
the switch.
4. Remove the sector cover bolts (Item 6) and remove
the sector cover (Item 7).
NOTE: Removal can be aided by using your
thumbs to press in on the shafts while pulling
out the cover with your fingers.
5. Remove the compression spring (Item 8).
CAUTION
Do not pry on case sealing surfaces.
Use only the designated pry points
on the transmission.
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TRANSMISSION
10. Lift up on the shift drum (Item 14) to disengage the
shift fork pins and remove the shift drum from the
housing.
11. Lift up to remove the shift shaft rail (Item 15) and shift
forks from the transmission housing as an assembly.
12. Remove the rear output shaft assembly (Item 16) by

lifting underneath the gear or by tapping the shaft
from the opposite side. If use of a pry bar is
necessary, take care not to pry on sealing surfaces
of case.
13. Remove the input shaft assembly (Item 17) from the
transmission housing by pulling straight up.
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TRANSMISSION
14. Remove the gear cluster assembly (Item 18) and
idler gear shaft assembly (Item 19) from the
transmission housing by pulling both assemblies
straight up.
15. Inspect the gear cluster assembly and idler gear

shaft assembly. Inspect each gear for damage, chips
or abnormally worn teeth. Replace bearings if
needed. If disassembly is required, refer to
Transmission Shaft Service.
17. Slide engagement dog (Item 21) off of shift fork

guides.
18. Remove two screws and retaining plates, then lift the
shift fork (Item 22) and torsion spring out of
transmission housing.
19. Using a 5 mm Allen wrench, remove the screws that
secure the pinion shaft assembly (Item 23). Lift the
pinion shaft assembly straight up to remove it from
the housing. Note the longer screw (Item 24) that
locks the snorkel tube.
CAUTION
Use caution when disassembling the shift rail. The
compressed springs on the shift rail may pop off
causing eye or face injury.
16. To disassemble the shift shaft rail remove the snap
ring (Item 20) from the end of the shift rail on either
side. Refer to Transmission Shaft Service if
needed.
20. If snorkel shaft removal is not required, remove all

seals from the gearcase halves and clean the cases
in preparation for assembly.
21. If snorkel shaft removal is required, proceed to
Snorkel Shaft Removal / Disassembly procedure.
9.22
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TRANSMISSION
Snorkel Shaft Removal / Disassembly
3. Remove the snorkel tube and shaft assembly from

the transmission case.
CAUTION
The pinion shaft must be removed prior to removing the
snorkel shaft assembly. Failure to remove pinion shaft,
will result in damage to the snorkel shaft.
1. Extract the seal from the snorkel shaft to access the
snorkel tube for removal.
4. Remove the snap ring (Item 1) and shim (Item 2)

from the snorkel shaft.
2. Using the Snorkel Tool (PA-50231), fully loosen the

snorkel tube.
5. Use an arbor press to remove the snorkel tube from

the snorkel shaft.
9.23
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TRANSMISSION
6. Remove the snap ring (Item 3) and shim (Item 4)
retaining the bearing in the snorkel tube.
8. Remove the retaining ring to remove the remaining

washer, bearing and gear from the snorkel shaft.
7. Lightly tap on the bearing from the opposite side to

remove it from the snorkel tube.
9. Remove all seals from the gearcase halves and

clean the cases in preparation for assembly.
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TRANSMISSION
Transmission Shaft Service
Idler Shaft Assembly
Use the exploded views within this section when

servicing the transmission shafts.
Inspect all gear sets and shafts for excessive wear or
damage.
NOTE: If gear replacement is required, be sure to
also replace the corresponding gear or gear shaft.
Inspect all bearings for signs of wear or damage. If
replacement is required, use a standard bearing puller or
an arbor press.
Gear Cluster / Reverse Shaft Assembly
16) Bearing
17) Idler Shaft
18) Gear, 38T
19) Washer
20) Retaining Ring
21) Bearing
Input Shaft Assembly
1) Bearing
2) Shift Dog, Park
3) Retaining Ring
4) Washer
5) Needle Bearing
6) Low Gear, 67T
7) Reverse Shaft, 35T
8) Engagement Dog, 6-Face
9) Retaining Ring
10) Washer
11) Gear, 52T
12) Needle Bearing
13) Washer
22) Bearing
14) Retaining Ring
23) Input Shaft
15) Bearing
24) Bearing
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TRANSMISSION
Shift Shaft Assembly
Pinion Shaft Assembly
35) Retaining Ring

25) Bearing
36) Cup Washer
26) Retaining Ring
37) Shift Shaft Rail
27) Washer
38) Compression Spring, Long
28) Gear, 46T
39) Shift Fork
29) Screw, M6 x 1.0 x 18
40) Compression Spring, Short
30) Screw, M6 x 1.0 x 40
41) Shift Collar
31) Bearing Cover

32) Retaining Ring
33) Bearing
34) Pinion Shaft
A Longer
screw is used to lock the snorkel tube.
Bearing cover must be installed on the shaft before

installing the 46T gear.
C
Bevel side should face away from the bearing.
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TRANSMISSION
Snorkel Shaft / Snorkel Tube Assembly
Planetary Differential Disassembly

NOTE: If the gearcase is completely assembled,
perform the Gearcase Disassembly and Inspection
procedure.
1. Use a scribe to mark the differential cover and ring
gear prior to disassembly.
42) Retaining Ring

2. Remove the six screws retaining the differential
cover and remove the cover.
43) Washer
44) Bearing
45) Snorkel Gear, 13T
46) Front Output Shaft
47) Snorkel Tube
48) Bearing
49) Shim
50) Retaining Ring
51) Shim
52) Retaining Ring

*After the 13T gear and bearing are pressed onto the
snorkel shaft (flush to the shoulder), install the washer
and new retaining ring. Press the gear back towards the
retaining ring. Avoid excessive force so the retaining ring
is not damaged or pre-stressed significantly.
NOTE: Failure to press the gear back against the
washer and retaining ring will lead to a gear
backlash change after vehicle is placed into service.
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TRANSMISSION
3. Remove the six planet gears and each side gear
assembly from the ring gear.
4. Inspect the female side gear (Item 1), male side gear
(Item 2), planet gears (Item 3) and ring gear (Item 4).
Replace components or bushings as needed.
Bushing replacement can be performed on all
necessary differential components. If bushing
replacement is required, proceed to Planetary
Differential Bushing Replacement.
9.28
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TRANSMISSION
Planetary Differential Bushing Replacement
4. Install the bushing to the specified depth as shown.
NOTE: If the differential is completely assembled,

perform the Planetary Differential Disassembly
procedure.
Ring Gear Bushing Replacement
1. Press the old bushing out of the ring gear.
2. Thoroughly clean the bore of the ring gear and check
for any unwanted burs.
3. Press the new bushing into the ring gear housing.
Planet Gear Bushing Replacement

5. Press the old bushing out of the planet gear.
6. Thoroughly clean the bore of the planet gear and
check for any unwanted burs.
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TRANSMISSION
7. Press the new bushing into the planet gear until it is
flush on each end. Repeat this procedure for the
remaining planet gears.
11. Install the bushing to the specified depth as shown.
Differential Cover Bushing Replacement

8. Press the old bushing out of the differential cover.
9. Thoroughly clean the bore of the differential cover
and check for any unwanted burs.
10. Press the new bushing into the differential cover.
Female Side Gear Bushing Replacement

12. Locate the bushing split. Using a small chisel or flat
blade screwdriver, peel back and remove the old
bushing from the side gear, being careful not to
damage the side gear.
13. Thoroughly clean the bore of the side gear and

check for any unwanted burs.
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TRANSMISSION
14. Press the new bushing into the side gear until it
bottoms out.
5. Install screws hand tight. Place assembly in soft jaw

vise and torque to specification.
Planetary Differential Assembly

1. Thoroughly clean the differential components.
2. Assemble the side gears and place them onto the
ring gear along with the six planet gears.
Differential Cover Screws:

18-22 ft-lbs (24-30 Nm)
Snorkel Gear Backlash Procedure

1. Reassemble the snorkel tube and snorkel shaft
assembly by reversing the disassembly procedure
(see Snorkel Shaft Removal / Disassembly).
2. After the 13T gear and bearing are pressed onto the
snorkel shaft (flush to the shoulder), install the
washer and new retaining ring.
3. Press the gear back towards the retaining ring. Avoid
excessive force so the retaining ring is not damaged
or pre-stressed significantly.
3. Align and install the differential cover using the

previously made scribe marks.
NOTE: Failure to press the gear back against the

washer and retaining ring will lead to a gear
backlash change after vehicle is placed into
service.
4. Apply Loctite 2760 to cover screws.
9.31
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TRANSMISSION
4. Apply a small amount of white lithium grease or AntiSeize on the threads of the snorkel tube.
9. Using a 5 mm Allen wrench, install only the (3)

screws that secure the pinion shaft assembly as
shown below. Leave the longer locking screw (A) out
at this point.
5. Install the snorkel shaft into the gearcase. Using the

Snorkel Tool (PA-50231), tighten the snorkel tube
until it is lightly seated in the transmission housing.
NOTE: DO NOT install the longer screw (A).
Installing the longer screw will lock the snorkel
tube and not allow for backlash setting
adjustment.
10. Torque the bearing cover retaining screws to
specification.
Bearing Cover Retaining Screws:

8-10 ft-lbs (11-14 Nm)
11. Rotate the snorkel tube counterclockwise using the
snorkel tool (PA-50231) until the snorkel gear and
pinion gear have zero backlash.
6. Inspect the pinion shaft assembly. Replace bearings
if needed. Inspect each gear for damage, chips or
abnormally worn teeth. If disassembly is required,
refer to Transmission Shaft Service.
NOTE: If pinion shaft was disassembled, the
bearing cover must be installed on the shaft
before installing the 46T gear.
7. Install the pinion shaft assembly. Be sure to properly
mesh the snorkel shaft bevel gear with the pinion
shaft bevel gear.
8. Apply Loctite 242 to the threads of the bearing
cover retaining screws.
NOTE: DO NOT overtighten the snorkel tube

when backing it out. At the 'zero' backlash
position, you should still be able to turn the
snorkel shaft using your fingers, but it will feel
rough and may have some tight spots.
12. Look down into the transmission housing to see the
snorkel locking screw hole opening to reference your
starting point.
NOTE: If you have a hard time seeing into the
hole, insert a small Allen wrench, punch or
screwdriver into the hole to feel when the notch
is aligned with the hole.
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TRANSMISSION
13. Slowly rotate the snorkel tube clockwise while
counting the number of notches passing through the
hole opening as you rotate the tube. Rotate the
snorkel tube to the 3rd notch from the zero
backlash position obtained in step 11.
16. Torque the locking screw to specification.
14. Check the pinion shaft gear backlash again by feel. If

the pinion shaft gear lash appears to be too tight,
rotate the snorkel shaft clockwise to the next notch
(4th notch).
15. Once the backlash is set, apply Loctite 242 to the
threads and install the locking screw to secure the
snorkel tube.
Snorkel Locking Screw:

8-10 ft-lbs (11-14 Nm)
Transmission Assembly
NOTE: The snorkel shaft and pinion shaft must
be installed prior to transmission assembly. The
snorkel shaft cannot be installed after
assembling the transmission.
17. Clean both transmission case halves thoroughly.
Inspect case half mating surfaces for damage.
18. Install the input shaft seal (Item 1) into the
transmission LH case half. The seal, should be
pressed in until it is flush with the internal bearing
surface as shown.
9.33
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TRANSMISSION
19. Install shift fork (Item 2) and torsion spring into
transmission housing as an assembly. Load spring
as shown in image below
20. Apply Loctite 242 to two screws (Item 3) and install

with retaining plates over shift fork. Torque to
specification.
24. Install the input shaft assembly (Item 7) into the

transmission housing.
25. Install the rear output shaft assembly (Item 8).

Rotate output shaft assembly to align slots with
engagement dog. Ensure bearing is fully seated
upon assembly.
Shift Fork Screws:

7-10 ft-lbs (10-14 Nm)
21. Slide the engagement dog (Item 4) onto retaining
pins of shift fork.
22. Assemble the gear cluster assembly and idler gear
shaft assembly if previously disassembled (see
Transmission Shaft Service).
23. Install the gear cluster assembly (Item 5) and idler
gear shaft assembly (Item 6) into the transmission
housing at the same time.
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TRANSMISSION
26. Assemble shift shaft rail if previously disassembled.
NOTE: Both shift forks need to be orientated the

same way, so that the shift fork pins (Item 9) are
both offset to the same side of the rail.
27. Install the shift shaft rail (Item 10) and shift forks into
the transmission housing as an assembly. Be sure
the shift forks are engaged into the engagement
dogs.
28. Inspect the shift drum for any damage or wear.

Inspect the splines of the shift drum.
29. Install the shift drum (Item 11) into the transmission
housing. Lift up on the shift shaft rail and move the
rail assembly towards the shift drum to allow the shift
fork and collar pins to be installed into the shift drum.
9
30. Apply a continuous bead of Crankcase 3 Bond
Sealant (PN 2871557) to the left hand transmission
mating surface.
NOTE: Shift fork pins should be offset towards
the input shaft as shown above.
9.35
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TRANSMISSION
31. Install the transmission case cover and retaining
bolts. Torque bolts to specification.
32. Install new seals into the transmission case halves.

NOTE: The input shaft seal (Item 13), should
have been installed during Step 2. The seal must
be pressed in until it is flush with the internal
bearing surface, which can not be seen with the
transmission assembled.
The snorkel shaft seal (Item 14), should be
pressed in until it seats against the housing
counter-bore.
The rear output shaft seals (Item 15), can be
installed using a standard bushing installation
tool. Seals should be installed just past the
case lead-in chamfer (.070" or 1.8 mm from
outer face of bore).
NOTE: Six of the case bolts (Item 12) are longer

than the rest. These bolts are used to retain the
motor flange at the input shaft location and to
retain the rear mount brackets to the
transmission.
Transmission Case Bolts:

15-20 ft-lbs (20-27 Nm)
33. Thoroughly clean the shift shaft housing. Shift the

transmission into High gear to ease assembly.
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TRANSMISSION
34. Install the sector gear (16T) onto the shift drum shaft.
Install the shift shaft assembly and sector gear (11T)
into the bushing pocket on the left side. Align the
timing marks (Item 16) on the gears as shown (high
gear).
37. Install a new O-ring (Item 20) on each shift shaft.

Apply a small amount of white lithium grease on the
O-rings, shift shafts and component contact surfaces
prior to installing the sector cover.
38. Clean the transmission and gear sector cover mating

surfaces thoroughly.
35. Install the detent star (Item 17) onto the shift drum
shaft. Be sure to install the detent star with the tall
center hub facing inward and skip-tooth aligned.
39. Apply Crankcase Sealant (3-Bond) (PN 2871557)

onto the cover and transmission case mating
surface.
40. Install the sector cover and align the transmission
case dowel (Item 21) with the alignment hole. Install
and torque the bolts to specification.
Sector Cover Bolts:

9-12 ft-lbs (12-16 Nm)
41. Install the drain plug and torque to specification.
Fill / Drain Plug:

10-14 ft-lbs (14-19 Nm)
36. Install the detent pawl (Item 18) onto the shift shaft
and carefully install the compression spring (Item
19).
42. Install the bellcrank onto the shift shaft. Note the key
splined on the bellcrank and shift shaft. Install the nut
Bellcrank Nut:
12-18 ft-lbs (16-24 Nm)
43. Reference Transmission Installation to complete
repair.
9.37
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TRANSMISSION
TRANSMISSION EXPLODED VIEW
9.38
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TRANSMISSION
Exploded View, Continued
REF.
QTY.
DESCRIPTION
REF.
QTY.
DESCRIPTION
1.
Fill Plug
50.
Gear, Sector 16T
2.
Drain Plug, Magnetic
51.
Gear, Sector 31T
3.
Screw, M8 x 1.25 x 16
52.
Pawl, Detent
4.
11
Screw, M8 x 1.25 x 30
53.
Star, Detent
5.
Screw, M6 x 1 x 20
54.
Flange, Motor
6.
Screw, M8 x 50
55.
Shaft, Idler 29T
7.
Screw, M6 x 1 x 40
56.
Shaft, Reverse 35T
8.
Screw, M6 x 1 x 18
57.
Shaft, Front Output
9.
Screw, M6 x 1 x 16
58.
Shaft, Input Helical
10.
Nut, NyLoc, M8 x 1.25
59.
Shaft, Pinion
11.
Washer, Cup
60.
Plate, Park, 12-Face
12.
Washer
61.
Bellcrank
13.
Washer
62.
Collar, Shift
14.
Washer
63.
Rail, Shift Shaft
15.
Pin, Dowel
64.
Tube, Vent, 1/4 in.
16.
Pin, Spring
65.
Fork, Pivot Shaft
17.
Retaining Ring, External
66.
Dog, Engagement
18.
Snap Ring
67.
Shift Dog, Park
19.
68.
Gear, 38T
20.
69.
Fork, Shift
21.
Retaining Ring, Internal
70.
Bracket, Wire Harness
22.
71.
Gear, Low 67T
23.
72.
Engagement Dog, 6-Face
24.
73.
Gear, 52T
25.
74.
Gear, 46T
26.
Washer, Thrust
75.
Gear, Snorkel 13T
27.
Washer, Thrust
76.
Shaft, Shift
28.
Shim
77.
Weldment, Rear Mount Bracket
29.
Shim
79.
Retainer, Fork
30.
Bearing, Needle Cage
80.
Bracket, Rear Mount
31.
Bearing, Ball
81.
Cover, Bearing, Center Drive
9.39
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TRANSMISSION
REF.
QTY.
DESCRIPTION
REF.
QTY.
DESCRIPTION
32.
Bearing, Ball
83.
Bearing, Plain
33.
Bearing, Ball
84.
Solenoid
34.
Bearing, Ball
85.
Switch, Rotary, 2-Pin
35.
Bearing, Needle Cage
86.
O-Ring
36.
Bearing, Ball
87.
O-Ring
37.
Bearing, Ball
88.
O-Ring
38.
Bearing, Ball
89.
Seal, Triple Lip
39.
Spring, Compression
90.
Seal, Dual Lip
40.
Spring, Compression
91.
Seal, Triple Lip
41.
Spring, Torsion Return
93.
Sensor, Speed
42.
Spring, Compression
97.
Plug, Expansion
43.
Spring, Compression, Detent
98.
Side Gear, Male, 39T
44.
Spring, Washer
99.
Bearing, Plain
45.
Snorkel Tube
100.
Side Gear, Female, 39T
46.
Cover, Sector Gears
101.
Diff Cover
47.
Case, LH
102.
Planet Gear
48.
Case, RH
103.
Screw, M8 x 1.25 x 25
49.
Drum, Shift
104.
Ring Gear, 53T
9.40
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TRANSMISSION
TROUBLESHOOTING
Troubleshooting Checklist
Check the following items when shifting difficulty is
encountered.
Shift cable adjustment/condition
Vehicle creep (travel control adjustment)
Transmission lubricant type/quality
Loose fasteners on sector gear cover
Worn rod ends, clevis pins, or pivot arm bushings
Shift selector rail travel
Worn, broken or damaged internal transmission
components
NOTE: To determine if shifting difficulty or
problem is caused by an internal transmission
problem,
isolate
the
transmission
by
disconnecting the shift cable end from the
transmission bellcrank. Manually select each
gear range at the transmission bellcrank, and
test ride vehicle. If it functions properly, the
problem is outside the transmission.
If transmission problem remains, disassemble
transmission and inspect all gear dogs for
wear (rounding) or damage. Inspect all
bearings, circlips, thrust washers and shafts
for wear.
9.41
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TRANSMISSION
NOTES
9.42
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HYDROSTATIC DRIVE
CHAPTER 10
HYDROSTATIC DRIVE
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3
LUBRICATION SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3
HYDROSTATIC SYSTEM INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3
HYDROSTATIC DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.4
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.4
REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.4
HYDROSTATIC DRIVE MOTOR EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.6
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.7
DRIVE MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
HYDROSTATIC PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
DRIVE RELIEF PRESSURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
HYDROSTATIC PUMP REMOVAL AND INSTALLATION TYPE 1 COMMAND LEVER. . . . . . . . . . . . . 10.16
HYDROSTATIC PUMP REMOVAL AND INSTALLATION TYPE 2 COMMAND LEVER. . . . . . . . . . . . . 10.27
COUPLER REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37
HYDROSTATIC PUMP EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39
HYDROSTATIC PUMP DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.40
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.45
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.46
HYDROSTATIC / TREADLE PEDAL ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.52
HYDROSTATIC TRAVEL CONTROL ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.52
NEUTRAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.53
TRAVEL CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.55
FORWARD SPEED CONTROL CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.56
REVERSE SPEED CONTROL CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.57
ENGINE SPEED CONTROL CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.57
TRAVEL CONTROL (TREADLE) PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.58
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.58
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.58
PEDAL REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.59
CABLE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.59
DRIVE PERFORMANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.61
DRIVE PERFORMANCE CHECKS TYPE 1 COMMAND LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.61
DRIVE PERFORMANCE CHECKS TYPE 2 COMMAND LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.63
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.67
HYDROSTATIC DRIVE TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.67
10.1
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10
HYDROSTATIC DRIVE
PERFORMANCE CHECKS FLOW CHART COMMAND LEVER TYPE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.68
PERFORMANCE CHECKS FLOW CHART COMMAND LEVER TYPE 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.69
10.2
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HYDROSTATIC DRIVE
GENERAL INFORMATION
ITEM
TORQUE VALUE
Hydrostatic Drive Motor

Mounting Bolts
100 ft-lbs (136 Nm)
Drive Motor Poppet Valve

Plug
20 ft-lbs (27 Nm)
Drive Motor Centering

Spring Plug
27 ft-lbs (37 Nm)
Hydrostatic Pump
Coupler Bolt
40 ft-lbs (54 Nm)
Hydrostatic Pump
End Cap Plug
20 ft-lbs (27 Nm)
Hydrostatic Pump
Relief Valve Plug
20 ft-lbs (27 Nm)
Special Tools
PART NUMBER
TOOL DESCRIPTION
PU-51022-1
Coupler Kit
PU-51261
Drive Control Adjustment Wrench
PU-51219
Hydraulic Adapter Kit
PU-51199
Quick Coupler Kit
PU-51022
Quadrigage
HYDROSTATIC SYSTEM
INFORMATION
Description
WARNING
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and decals on the machine.
Follow warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or service.
Failure to follow instructions can cause injury or death.
The hydrostatic system consists of a hydrostatic pump
and hydrostatic drive motor that allows forward and
reverse motion in the vehicle.
The hydrostatic pump is connected to the engine by a
coupler and provides fluid to the hydrostatic drive motor.
The charge pressure system assists in replenishing the
fluid that is lost due to internal leakage in the
components of the hydrostatic system.

Lubrication Specification
10
Polaris Hydraulic Fluid (PN 2879746) (Gallon)
Reservoir Capacity:
All Models: 2.75 qts (2.6 L)
Full System Capacity:
BRUTUS: 7.2 qts. (6.8 L)
BRUTUS HD / HDPTO: 8.4 qts (7.9 L)
10.3
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HYDROSTATIC DRIVE
HYDROSTATIC DRIVE MOTOR
2. Loosen the intake hose clamps (Item 1).
Description
Mounted to the transmission input shaft, the hydrostatic
drive motor is powered by the hydrostatic pump. A
shuttle valve located inside the end cap of the hydrostatic
drive motor helps to keep the motor cool by mixing case
drain oil with cooled low pressure oil from the charge
circuit. The shuttle valve is shifted by the high pressure
oil coming from the hydrostatic pumps.
Removal / Installation
WARNING
To avoid serious injury or death, clean up spilled fuel or
oil. Keep heat, flames, sparks or lighted tobacco away
from fuel and oil. Failure to use care around
combustibles can cause explosion or fire
NOTE: When repairing hydrostatic and hydraulic
systems, clean the work area before disassembly
and keep all parts clean. Always use caps and plugs
on hoses, tubelines and ports to keep dirt out. Dirt
can quickly damage the system
1. For installation, reverse this procedure.
3. Remove the bolts (Item 2) and remove the air intake.
10.4
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HYDROSTATIC DRIVE
4. Mark and remove the hoses (Item 3) from the top of
the drive motor.
6. Remove the top bolt (Item 5) and drive motor (Item

6).
5. Remove the drive motor bottom bolt (Item 4).
10
10.5
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HYDROSTATIC DRIVE
Hydrostatic Drive Motor Exploded View
10.6
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HYDROSTATIC DRIVE
3. Remove the snap ring (Item 4) and remove the
output shaft (Item 5).
Disassembly
1. Remove the snap ring (Item 1).
4. If the bearing or shaft needs replacement, remove

the bearing (Item 6) from the shaft.
2. Remove the seal (Item 3).
5. Remove bolts (Item 7) end cap (Item 8).
10
10.7
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HYDROSTATIC DRIVE
6. Remove the valve plate (Item 9) and the angle stop
(Item 10).
9. Remove the plug (Item 14) and centering spring

(Item 15).
7. Remove the plugs (Item 11) and remove the o-rings

from the plugs.

(Item 17). Remove the o-ring from the plug.

(Item 13). Remove the o-ring from the plug.
11. Remove the poppet (Item 18).
10.8
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HYDROSTATIC DRIVE
12. Remove the shift spool (Item 19).
13. Remove the spring (Item 20) and the cylinder block
(Item 21).
14. Remove the piston assembly (Item 22) and retainer

ball from the cylinder block.
NOTE: The following procedure shown is to

disassemble the rotating group for inspection
only. The rotating group parts can not be ordered
separately and must be ordered as an assembly.
15. Inspect the pistons for scoring and scratches. Verify
the holes (Item 23) in the slippers are not plugged.
10
10.9
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HYDROSTATIC DRIVE
16. Inspect the mating surface of the retaining ring (Item
24) for scoring and scratches.
18. Remove the bearings (Item 26).
19. Remove the servo piston (Item 27).

17. Remove the swash plate (Item 25).
20. Remove the seal (Item 28) from the servo piston.
10.10
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HYDROSTATIC DRIVE
Drive Motor Assembly
4. Install the swash plate (Item 4).
1. Clean all parts in solvent and dry with compressed

air. Replace all o-rings and seals. Inspect all parts for
wear or damage. Replace any worn or damaged
parts.
2. Install the seal (Item 1).
5. Install the retainer ball (Item 5) on the cylinder block.
3. Install the bearings (Item 2) and servo piston (Item

3).
6. Install the piston assembly (Item 6).
10
10.11
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HYDROSTATIC DRIVE
7. Install the cylinder block (Item 7) into the motor
housing.
8. Install the spring (Item 8) into the motor housing.
10. Install the poppet (Item 10) into the end cap.
11. Install a new o-ring on the plug (Item 12) and install
the centering spring (Item 11) and plug into the end
cap. Torque the plug to specification.
9. Install the shift spool (Item 9) into the end cap.
Poppet Valve Plug:

20 ft-lbs (27 Nm)
10.12
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HYDROSTATIC DRIVE
12. Install a new o-ring on the plug (Item 13) and install
the centering spring (Item 14) and plug into the end
cap. (Both sides) Torque the plug to specification.
14. Install the plugs (Item 16) into the back of the end
cap.
15. Install the angle stop (Item 17) into the end cap.
Centering Spring Plug:

27 ft-lbs (37 Nm)
13. Install the o-ring (Item 15) on the plugs.
16. Install the end cap (Item 18) and bolts (Item 19).
10
17. If Removed, press a new bearing onto the shaft.
10.13
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HYDROSTATIC DRIVE
18. Install the output shaft (Item 20) into the motor
housing.
21. Install the washer (Item 23) and snap ring Item 24).
19. Install the snap ring (Item 21).
10.14
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HYDROSTATIC DRIVE
CHARGE PRESSURE
4. Install the quadrigage (PU-51022) (Item 4).
Description
Charge pressure is a supply of oil feeding the hydrostatic
pump. Charge pressure is regulated by a charge relief
valve located inside the hydrostatic pump. Charge
pressure is used to replenish hydrostatic fluid removed
from the drive circuit, pump and motor Internal leakage,
and from the hydrostatic drive motors shuttle flushing
valve.
Charge pressure is also used to operate other hydraulic
functions, such as shifting the auxiliary spool in the
priority valve.
The charge pressure is tested at the outlet side of the
hydraulic filter.
Testing
5. Start the engine.
1. Lift and block the machine.
The gauges should read as follows:
2. Remove the hose (Item 1) from the hydraulic filter

outlet (Item 2).
87 PSI (0,6 MPa) with approximately 140F (53

C) fluid @ High Idle.
The charge pressure relief valve is not adjustable
and must be replaced if desired pressures cannot be
obtained.
3. Install a hydraulic adapter fitting (PU-51219) with test

adapter (PU-51199) (Item 3).
10
10.15
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HYDROSTATIC DRIVE
HYDROSTATIC PUMP
5. Start the engine and place the shift lever in high.
Description
6. Use the travel control pedal to obtain high idle. The

gauge should read 5004 PSI (34501 kPa).
Bolted on the engine just off the crankshaft, the

hydrostatic pump is composed of a single (piston) pump.
The pump provides flow to the drive motor.
Hydrostatic Pump Removal and Installation

Type 1 Command Lever
The pump contains replenishing valves that provide fluid

to the low pressure side of the hydrostatic circuit. The
replenishing valve also keeps high pressure fluid out of
the low pressure side of the hydrostatic circuit.
Drive Relief Pressure Testing

2. Remove the hose (Item 1) from port B on the drive
motor.

oil. Keep heat, flames, sparks away from fuel and oil.
and keep all parts clean. Always cap / plug the
hoses, lines and ports to keep dirt out.
IMPORTANT: Two types of Command Levers have been
produced, Type 1 and Type 2.
It is important to identify which command lever is being
serviced and utilize the corresponding adjustment
procedure.
The Type 1 Command Lever has a shoulder (Item A) and
no nut is used on the bolt (Item B). Type 2 Command
Lever does not have a shoulder (Item A) and uses a nut
(Item B) on the bolt (see Drive Performance Checks
Type 1 Command Lever or Type 2).
TYPE 1 Command Lever
NOTE: Port B on the drive motor is the forward

port and port A is the reverse port.
3. Install an adapter (PU-51199) (Item
quadrigage (PU-51022) on the hose.
2)
and
4. Install a cap (PU-51219) (Item 3) on the drive motor.
10.16
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HYDROSTATIC DRIVE
3. Remove the bolts (Item 2) and air duct (Item 3).
1. Park vehicle on level ground and turn off engine.

4) from the main harness.
2. Remove the engine air inlet duct hose clamps (Item

1).
5. Loosen the bolt (Item 5) from the front of the controls

cover.
10
10.17
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HYDROSTATIC DRIVE
6. Loosen the bolts (Item 6) and remove the controls
cover (Item 7) from the top of the pump.
7. Cut and remove the tie strap (Item 8) from the engine
speed control cables.
8. Loosen the jam nuts on the forward speed control

cable (Item 9).
9. Remove the cable end (Item 10) from the pump plate.
10. Loosen the jam nuts (Item 11) on the reverse speed
control cable.
10.18
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HYDROSTATIC DRIVE
12. Remove the C clip (Item 13) and washer (Item 14)
from the travel control cable end.
13. Loosen the travel control cable jam nuts (Item 15)
and remove the cable from the pump plate.
14. Remove the centering springs (Item 16).
10
10.19
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HYDROSTATIC DRIVE
15. Loosen the horsepower (HP) spring bolt (Item 17)
until spring pressure has been released.
16. Remove the bolt (Item 18) and washer (Item 19).
21. Remove the steel washer (Item 25).

22. Remove the plastic washer (Item 26).
17. Remove the bushing (Item 20).
23. Remove the top centering plate (Item 27).

18. Remove the command lever (Item 21) and HP spring
(Item 22).
24. Remove bottom centering plate (Item 28).
10.20
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HYDROSTATIC DRIVE
29. Mark and remove the hoses (Item 33).
26. Loosen the bolt (Item 30) and remove the pintle lever
(Item 31).
30. Remove the bolts (Item 34) and the hydrostatic pump
(Item 35).
27. Mark the position of the pump plate with reference to

the bell housing for ease of installation.
28. Remove the four bolts (Item 32) and pump plate.
10
10.21
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HYDROSTATIC DRIVE
Hydrostatic Pump Installation
1. Install the mounting bolts (Item 34) securing the
hydrostatic pump (Item 35) and torque to
specification.
3. Install the pump plate four bolts (Item 32) to hand

tightness.
Hydrostatic Pump Mount Bolts:

60 ft-lbs (81 Nm)
4. Align the marks made during removal on the pump

plate with reference mark on the bell housing and
torque the pump plate bolts (Item 32) to specification.
Hydrostatic Pump Plate Bolts:

22 ft-lbs (30 Nm)
2. Reconnect the hoses (Item 33).
10.22
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HYDROSTATIC DRIVE
5. Install the pintle lever (Item 31) and tighten bolt (Item
9. Install the plastic washer (Item 26).
Pintle Lever Bolt:

18 ft-lbs (24 Nm)
10. Install the washer (Item 25) and snap ring (Item 24).

7. Install the bottom centering plate (Item 28) and plastic
washer.
11. Install the steel washer (Item 23).
10
8. Install the top centering plate (Item 27).
10.23
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HYDROSTATIC DRIVE
12. Install the command lever (Item 21) and horsepower
spring (Item 22).
14. Reconnect the balance springs (Item 16).
15. Install the command torsion spring bolt and washer

(s).
13. Install the bushing (Item 20), washer (Item 19),
control bolt (Item 18) and torque control bolt to
specification.
16. Perform the neutral adjustment procedure (See

Neutral Adjustment).
17. Reconnect the travel control cable and perform
adjustment
procedure
(See
Travel
Cable
Adjustment). Hold the command travel control cable
outside adjustment nut (Item 13) and tighten the
inside adjustment nut (Item 12) to specification.
Control Bolt:
18 ft-lbs (24 Nm)
Travel Control Cable Adjustment Nut:

12 ft-lbs (16 Nm)
10.24
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HYDROSTATIC DRIVE
18. Reconnect the reverse speed control cable and
perform adjustment procedure (See Reverse Speed
Control Cable Adjustment). Hold the outside reverse
speed control cable adjustment nut (Item 11) and
tighten the inside adjustment nut (Item 10) to
specification. See Reverse Speed Control Cable
Adjustment procedure.
19. Reconnect the forward speed control cable and perform adjustment procedure (See Forward Speed
Control Cable Adjustment). Hold the outside forward
speed control cable adjustment nut and tighten the inside adjustment nut (Item 9) to specification.

12 ft-lbs (16 Nm)
12 ft-lbs (16 Nm)
20. Perform the Drive Performance Checks Command

Lever Type 1. See (Drive Performance Checks
Command Lever Type 1).
21. Install a new tie strap (Item 8) on the engine speed
control cables.
10
10.25
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HYDROSTATIC DRIVE
22. Install the controls cover (Item 7) and bolts (Item 6)
on top of the pump.
23. Install the bolt (Item 5) in the front of the controls

cover.
25. Install the air duct (Item 3) and bolts (Item 2).
26. Install the engine air inlet duct hose clamps (Item 1).
24. Reconnect the neutral safety switch connector (Item

4) to the main harness.
10.26
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HYDROSTATIC DRIVE
Hydrostatic Pump Removal and Installation
Type 2 Command Lever
1. Park vehicle on level ground and turn off engine.

oil. Keep heat, flames, sparks away from fuel and oil.
2. Remove the engine air inlet duct hose clamps (Item

1).

and keep all parts clean. Always cap / plug the
hoses, lines and ports to keep dirt out.
produced, Type 1 and Type 2.
It is important to identify which command lever is being
serviced and utilize the corresponding adjustment
procedure.
The Type 1 Command Lever has a shoulder (Item A) and
no nut is used on the bolt (Item B). Type 2 Command
Lever does not have a shoulder (Item A) and uses a nut
(Item B) on the bolt (see Drive Performance Checks
Type 1 Command Lever or Type 2).
3. Remove the bolts (Item 2) and air duct (Item 3).

10
10.27
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HYDROSTATIC DRIVE
4) from the main harness.
7. Cut and remove the tie strap (Item 8) from the engine
speed control cables.
5. Loosen the bolt (Item 5) from the front of the controls

cover.
8. Loosen the jam nuts on the forward speed control

cable (Item 9).
6. Loosen the bolts (Item 6) and remove the controls

cover (Item 7) from the top of the pump.
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10. Loosen the jam nuts (Item 11) on the reverse speed
control cable.
13. Loosen the travel control cable jam nuts (Item 15)
and remove the cable from the pump plate.
14. Remove the centering springs (Item 16).
12. Remove the C clip (Item 13) and washer (Item 14)
from the travel control cable end.
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15. Loosen the horsepower (HP) spring bolt nut, then
loosen bolt (Item 17) until spring pressure has been
released.
17. Remove the bushing (Item 20).

18. Remove the command lever (Item 21) and HP spring
(Item 22).
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23. Remove the top centering plate (Item 27).
28. Remove the four bolts (Item 32) and pump plate.
24. Remove bottom centering plate (Item 28).
26. Loosen the bolt (Item 30) and remove the pintle lever
(Item 31).
30. Remove the bolts (Item 34) and the hydrostatic pump
(Item 35).
27. Mark the position of the pump plate with reference to

the bell housing for ease of installation.
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Hydrostatic Pump Installation
1. Install the mounting bolts (Item 34) securing the
hydrostatic pump (Item 35) and torque to
specification.
3. Install the pump plate four bolts (Item 32) to hand

tightness.
Hydrostatic Pump Mount Bolts:

60 ft-lbs (81 Nm)
4. Align the marks made during removal on the pump

plate with reference mark on the bell housing and
torque the pump plate bolts (Item 32) to specification.
Hydrostatic Pump Plate Bolts:

22 ft-lbs (30 Nm)
2. Reconnect the hoses (Item 33).
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5. Install the pintle lever (Item 31) and tighten bolt (Item
Pintle Lever Bolt:

18 ft-lbs (24 Nm)
10. Install the washer (Item 25) and snap ring (Item 24).

7. Install the bottom centering plate (Item 28) and plastic
washer.
11. Install the steel washer (Item 23).
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8. Install the top centering plate (Item 27).
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12. Install the command lever (Item 21) and horsepower
spring (Item 22).
14. Reconnect the balance springs (Item 16).
15. Install the command torsion spring bolt and washer.

13. Install the bushing (Item 20), washer (Item 19),
control bolt (Item 18) and torque control bolt to
specification.
16. Rotate the command lever (Item 21) forward until it

contacts the pintle lever (Item 31) at point (A). DO
NOT move the pintle lever. Hold the torsion spring
(Item 22) loop towards the command lever until
contact occurs at point (B) without pre-loading the
torsion spring.
Control Bolt:
18 ft-lbs (24 Nm)
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17. While holding the command lever and torsion spring
as described in step 16, use a digital caliper to
measure the distance (A) from the outside edge of
the torsion spring and the inside edge of the
command lever. Record this measurement as
MEASUREMENT A. Then, if the vehicle is equipped
with air conditioning, subtract 6.0 mm (.24 in.) OR if
the vehicle is not equipped with air conditioning,
subtract 6.5 mm (.26 in.) from MEASURMENT A to
determine MEASUREMENT B. MEASURMENT B will
be the spring preload setting established in step 17.
Measurement A:
______________inches/
millimeters
Subtract with A/C:
.24 in / 6.0 mm
Subtract
A/C:
.26 in / 6.5 mm
without
Equals
Measurement B:
______________inches/
millimeters
19. Prevent the command torsion spring bolt (Item 17)

from turning, install the nut (Item 14) and torque nut to
specification.
Control Bolt:
18 ft-lbs (24 Nm)
20. Perform the neutral adjustment procedure (See

Neutral Adjustment).
21. Reconnect the travel control cable and perform
adjustment
procedure
(See
Travel
Cable
Adjustment). Hold the command travel control cable
outside adjustment nut (Item 13) and tighten the
inside adjustment nut (Item 12) to specification. .
18. Install the horsepower command torsion spring bolt

(Item 17) and washer (Item 15). Tighten the
horsepower command torsion spring bolt (Item 17)
until MEASUREMENT B is achieved.
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Control Cable Adjustment Nut:

12 ft-lbs (16 Nm)
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22. Reconnect the reverse speed control cable and
perform adjustment procedure (See Reverse Speed
Control Cable Adjustment). Hold the outside reverse
speed control cable adjustment nut (Item 11) and
tighten the inside adjustment nut (Item 10) to
specification.
24. Perform the Drive Performance Checks Command

Lever Type 2. See (Drive Performance Command
Lever Type 2).
25. Install a new tie strap (Item 8) on the engine speed
control cables.
26. Install the controls cover (Item 7) and bolts (Item 6)

on top of the pump.

12 ft-lbs (16 Nm)
23. Reconnect the forward speed control cable and perform adjustment procedure (See Forward Speed
Control Cable Adjustment). Hold the outside forward
speed control cable adjustment nut and tighten the inside adjustment nut (Item 9) to specification.
27. Install the bolt (Item 5) in the front of the controls

cover.

12 ft-lbs (16 Nm)
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28. Reconnect the neutral safety switch connector (Item
4) to the main harness.
30. Install the engine air inlet duct hose clamps (Item 1).
29. Install the air duct (Item 3) and bolts (Item 2).
Coupler Removal and Installation

Removal
1. Remove the bolt (Item 1) from the coupler.
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2. Slide the coupler of the pump shaft.
Installation
1. Install the coupler on the pump shaft.
2. When installing the coupler, maintain 2.24 - 2.26 in.
(56.9 - 57.3 mm) over all length from the pump
housing to the coupler edge. Tighten the coupler bolt
to specification.
Hydrostatic Pump Coupler Bolt:

40 ft-lbs (54 Nm)
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Hydrostatic Pump Exploded View
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3. Remove the O-rings (Item 3) from the plate.
Hydrostatic Pump Disassembly

1. Remove the 0-ring (Item 1) from the bottom of the
hydrostatic pump.
4. Remove the plugs (Item 4) (Both sides).
2. Remove the four bolts (Item 2) retaining the back

plate and remove the back plate from the hydrostatic
pump.
5. Remove the O-ring (Item 5) from the plugs.
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6. Remove the valve body (Item 6) from the hydrostatic
pump.
9. Remove the springs (Item 9) and relief valves (Item

10) from the valve block.
7. Remove the gasket from the hydrostatic pump and

remove the valve plate (Item 7).
10. Remove the plugs (Item 11).
11. Remove the O-rings from all the plugs.

8. Remove the relief valve plugs (Item 8) from the valve
block.
12. Remove the spring (Item 12) and the charge

pressure relief valve (Item 13).
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13. Remove the rotating block and piston assembly
(Item 14) from the housing.
16. Remove the snap ring (Item 17) and seal (Item 18).

14. Remove the pistons (Item 15) from the rotating
block.
18. Remove the shaft (Item 20) from the pump housing.
15. Remove the spherical washer (Item 16).
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19. Remove the spacer (Item 21) from the pump
housing.
21. Remove the snap rings (Item 24) and the caps (Item
25) from the pump housing.
20. If replacing the shaft or bearing, remove the snap

ring (Item 22) from the shaft and press the bearing
(Item 23) off the shaft.
22. Remove the O-rings (Item 26) from the caps.
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23. Remove the swash plate (Item 27) from the pump
housing.
25. Remove the O-rings (Item 29) from the plugs.
24. Remove the plugs (Item 28) from the pump housing.
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Inspection
1. Inspect the valve plate (Item 1) for scratches or
scoring. Replace a valve plate if the scratches are
deep enough to catch with a fingernail.
3. Inspect the mating surface of the spherical washer

for scoring or scratches (Item 3).
4. Inspect the pins (Item 4). They should all be the

same length. Do not remove.
2. Inspect the pistons, look for scoring and scratches.
Ensure the holes (Item 2) in the slippers are not
plugged.
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5. Inspect the spherical washer (Item 5) for scoring and
wear.
Assembly
6. Inspect the back surface of the rotating block (Item 6)

where the valve plate seals. Check for scratches and
scoring.
2. Install the plugs (Item 2) into the pump housing.
1. Install the O-ring (Item 1) onto the plugs.
7. Inspect the spring (Item 7) and C-clip (Item 8) for

excessive wear or damage.
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3. Install the swash plate (Item 3) into the pump
housing.
5. Install the caps (Item 5).
4. Install the O-rings (Item 4) on the caps.
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6. Install the snap rings (Item 6) over the caps.
8. Press the new bearing (Item 8) onto the drive shaft.
9. Install the snap ring (Item 9) on the drive shaft.
7. Install the spacer (Item 7) onto the swash plate.

10. Install the drive shaft (Item 10) into the pump
housing.
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14. Install the spherical washer (Item 14) onto the

rotating block (Item 15).
12. Install the pump seal (Item 12).

15. Install the pistons (Item 16) into the rotating block
(Item 17).
16. Install the rotating block and piston assembly (Item

18) into the housing.
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17. Install the charge pressure relief valve (Item 19) and
spring (Item 20).
20. Install the relief valves (Item 23), springs (Item 23)
and plugs. Torque plugs to specification.
18. Install the o-ring on the plug. Install the plug (Item
21).
19. Install the o-ring (Item 22) onto the relief valve plugs.
Hydrostatic Pump Relief Valve Plug:
20 ft-lbs (27 Nm)
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21. Install the alignment pin (Item 24) and valve plate
(Item 25).
24. Install o-rings on the plugs and install the plugs (Item
27) into the end cap. (Both sides). Torque plugs to
specification.
22. Install the gasket onto the pump housing.
Hydrostatic Pump End Cap Plugs:

20 ft-lbs (27 Nm)
25. Install the o-rings (Item 28) into the end cap.
23. Position the valve body on the housing.
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26. Position the end cap (Item 29) onto the valve body.
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.
WARNING
27. Install the four bolts (Item 30).
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.
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2) and remove the controls cover (Item 3).
4. Verify that the speed control cable (Item 4) is

attached to the top hole of the engine speed control
lever.
Neutral Adjustment
1. Install a tie strap (Item 1) on the hydraulic hose
shown to serve as a pointer on the pump plate.
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 (3000 RPM). NOTE:
On non HD/HDPTO vehicles, the idle can be
increased by attaching a wire to the engine speed
control lever to manipulate the engine RPM.
3. Loosen the four pump plate mounting bolts (Item 2).
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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.
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.
8. Torque the four bolts (Item 5) to specification.
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).
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.
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Travel Cable Adjustment
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.
2. Locate PU-51261 - Drive Control Adjustment

Wrench (Item 2) and install it as shown.
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.
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.
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6. Apply pressure on the tool in a counterclockwise
direction until the pintle lever is held against the
internal stop.
7. Tighten the outer jam nut (Item 7) until it is tight

against the bracket. Use a paint pen to mark one flat
on the outer jam nut. Use the paint mark as a
reference to rotate the outer jam nut an additional
one-half turn.
8. While holding the outer jam nut, torque the inner jam
nut (Item 8) to specification.
Travel Control Cable Jam Nuts:

12 ft-lbs (16 Nm)
9. Remove the wood blocks (Item 9) from under the

foot pedal. Proceed to Forward Speed Control
Cable Adjustment.
Forward Speed Control Cable Adjustment

2. Hold the outside forward speed control cable

to specification.
12 ft-lbs (16 Nm)
3. After adjustments are made, the protective boot
(Item 3) must be in place to prevent cable damage.
Proceed to Reverse Speed Control Cable
Adjustment.
NOTE: Over tightening the outer jam nut results

in over-stroking the command lever causing the
HP control spring to function improperly.
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Reverse Speed Control Cable Adjustment
Engine Speed Control Cable Adjustment

the travel control cable (Item 2).

2. Hold the outside reverse speed control cable

to specification.
12 ft-lbs (16 Nm)
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3. 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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TRAVEL CONTROL (TREADLE)
PEDAL
3. Check the travel control pedal (Item 2) for excessive

freeplay.
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
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.
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.
4. The correct amount of total free travel on the travel

control pedal is 0.30 in. (7.6mm).
lever in Park, press the travel control pedal to full
forward, the engine speed should be a minimum of
3760 RPM. Repeat with travel control pedal fully in
reverse, the engine speed should be a minimum of
3500 RPM with Type 1 Command Lever and 3600
RPM or greater with Type 2 Command Lever. Refer
to ( Drive Performance Checks Command Lever
Type ) or (Drive Performance Checks Command
Lever Type 2). 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.
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Pedal Removal and Installation
1. Remove the bolts (Item 1) and skid plate.
1. Loosen the cable cover bolts (Item 1).
2. Remove the nut (Item 2) and slide the pedal off the
shaft.

2) and remove the pump cover (Item 3).
3. Reverse removal procedure for installation.
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3. Remove the clip (Item 4), washer and cable end
(Item 5) from the command lever.
6. Remove the nut (Item 1).
4. Loosen the jam nuts (Item 6) and remove the cable

from the bracket.
7. Loosen the jam nuts (Item 2) and remove the cable

(Item 3) from the travel control pedal.
8. For installation, reverse the procedure. Torque
fasteners to specification
Travel Cable Cover Bolts:

7 ft-lbs (10 Nm)
9. Perform Hydrostatic Travel Control Adjustments.
5. Remove the ten skid plate screws (Item 7) and skid

plate.
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DRIVE PERFORMANCE CHECKS
Type 2 Command Lever does not have a shoulder (A)

and uses a nut (B) on the bolt.
Drive Performance Checks Type 1

Command Lever
utilized. It is important to correctly identify the command
lever type being serviced and utilize the corresponding
adjustment procedure. See Drive Performance Checks
Command Lever Type 1 or Type 2.
Identifying features of the Type 1 Command Lever are a
shoulder (A) and no nut on the bolt (B).
FULL FORWARD ENGINE RPM CHECK

1. Place the transmission in PARK.
2. Fully depress the travel control pedal to the full
forward position and verify engine RPM is greater
than 3760 RPM. If the full forward engine rpm is
below specification proceed to step 3. If full forward
engine RPM is meeting the specification, proceed to
the FULL REVERSE ENGINE RPM CHECK.
3. Tighten the forward speed control cable outer
adjustment nut (Item 1) to increase the full forward
engine RPM. (Note: Excessive engine RPM does not
provide significant performance gains).
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MAXIMUM TRAVEL SPEED IN LOW RANGE

This check ensures the command (travel control) cable is
set correctly to pull the pump to full stroke.
FULL REVERSE ENGINE RPM CHECK

1. Place transmission in PARK.
reverse position and verify engine RPM is greater
than 3500 RPM. If the full reverse engine rpm is
below specification proceed to step 3. If the full
reverse engine RPM is meeting the specification,
proceed to IDLE ENGINE RPM CHECK.
3. Tighten the reverse speed control cable outer
adjustment nut (Item 2) to increase the full reverse
engine RPM.
1. Drive the vehicle in LOW range to a maximum

sustained speed and observe the reading on the
vehicle display. This speed should be at least 13.5
mph (21.7 km/h). The average maximum vehicle
speed in low range will be approximately 14 mph
(22.5 km/h) on most vehicles. If the maximum
sustained speed is below specification proceed with
steps 2 - 5. If the maximum travel speed is within
specification, proceed to the HORSEPOWER
MANAGEMENT FUNCTIONALITY CHECK.
2. Hold the command (travel control) cable outside
adjustment nut (Item 3) and loosen the inside
adjustment nut (4).
ENGINE IDLE RPM CHECK

2. Verify the engine idles at 1500 or lower RPM. Note: If
engine idle is above specification inspect throttle
cables for binding. On BRUTUS HD and BRUTUS
HDPTO models, the hand throttle may be limiting the
ability to achieve low idle. Verify the hand throttle is in
the full rearward/idle position and is adjusted correctly
if there are issues achieving low idle.
3. Tighten the outside adjustment nut (Item 3) 1/2 turn.

4. Hold the outside adjustment nut (Item 3) and tighten
the inside adjustment nut (Item 4) to 12 ft-lbs (16
Nm).
5. Retest. Repeat steps 2 - 4 until there is no change in
maximum travel speed.
NOTE - Verify engine RPM settings after any command
(travel control) cable adjustment as RPM re-adjustment
may be required.
HORSEPOWER MANAGEMENT FUNCTIONALITY
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This check verifies the horsepower management system
is functional and adjusted correctly.
1. With transmission in HIGH range on level asphalt
depress the travel control pedal to the full forward
position with a quick fluid motion.
2. The engine RPM at 20 mph (32.2 km/h) should be in
the range of 3500 - 3700 RPM. The vehicle should
accelerate from 0 - 20 mph (32.2 km/h) in less than
8.5 seconds. If engine RPM or acceleration time is
not within specifications proceed to steps 3-6. If the
horsepower management functionality is within
specification, proceed to the REVERSE SPEED
SECONDARY CHECK.
3. To decrease the engine RPM (increased engine pull
down), or if the acceleration time was over 8.5
seconds, hold the travel control cable outside
adjustment nut (Item 4).
6. Retest. Repeat steps 2 - 4 until the reverse speed is

within specification.
NOTE: There is a trade off between reverse travel speed
and forward engine RPM pull down. As the reverse travel
speed is increased, forward travel engine RPM pulldown
will be reduced.
Drive Performance Checks Type 2

Command Lever
utilized. It is important to correctly identify the command
lever type being serviced and utilize the corresponding
adjustment procedure. See Drive Performance Checks
Command Lever Type 1 or Type 2.
Identifying features of the Type 1 Command Lever are a
shoulder (A) and no nut on the bolt (B).
4. Tighten the travel control cable outside adjustment

nut (Item 3) turn.
5. Hold the outside adjustment (Item 3) nut and torque
Nm).
6. Retest. Repeat steps 3 - 5 until the RPM and
acceleration time is within specification.
NOTE - Verify engine RPM targets after adjustment as
re-adjustment may be required.
REVERSE SPEED SECONDARY CHECK
This check verifies the reverse travel speed meets
specification.
Type 2 Command Lever does not have a shoulder (A)

and uses a nut (B) on the bolt.
1. With the transmission in HIGH range from a stop on

level asphalt depress the travel control pedal to the
full reverse position until a maximum sustained speed
is attained. This speed should be over 8.0 mph (12.9
km/h).
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2. If the vehicle speed is not to specification proceed

with steps 2 - 5.
3. To increase the reverse travel speed and reduce the
amount of forward engine RPM pull down, hold the
travel control cable outside adjustment nut (Item 3)
and loosen the inside adjustment nut (Item 4).
4. Loosen the outside adjustment nut (Item 3) turn.
Nm).
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engine RPM is meeting the specification, proceed to
the FULL REVERSE ENGINE RPM CHECK.
FULL FORWARD ENGINE RPM CHECK

1. Place the transmission in PARK.
forward position and verify engine RPM is greater
than 3760 RPM. If the full forward engine rpm is
below specification proceed to step 3. If full forward
3. Tighten the forward speed control cable outer

adjustment nut (Item 1) to increase the full forward
engine RPM. (Note: Excessive engine RPM does not
provide significant performance gains).
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FULL REVERSE ENGINE RPM CHECK
reverse position and verify engine RPM is greater
than 3600 RPM. If the full reverse engine rpm is
below specification proceed to step 3. If the full
reverse engine RPM is meeting the specification,
proceed to IDLE ENGINE RPM CHECK.
3. Tighten the reverse speed control cable outer
adjustment nut (Item 2) to increase the full reverse
engine RPM.
MAXIMUM TRAVEL SPEED IN LOW RANGE

This check ensures the command (travel control) cable is
set correctly to pull the pump to full stroke.
1. Drive the vehicle in LOW range to a maximum
sustained speed and observe the reading on the
vehicle display. This speed should be at least 13.5
mph (21.7 km/h). The average maximum vehicle
speed in low range will be approximately 14 mph
(22.5 km/h) on most vehicles. If the maximum
sustained speed is below specification proceed with
steps 2 - 5. If the maximum travel speed is within
specification, proceed to the HORSEPOWER
MANAGEMENT FUNCTIONALITY CHECK.
2. Hold the command (travel control) cable outside
adjustment nut (4).
ENGINE IDLE RPM CHECK

2. Verify the engine idles at 1500 or lower RPM. Note: If
engine idle is above specification inspect throttle
cables for binding. On BRUTUS HD and BRUTUS
HDPTO models, the hand throttle may be limiting the
ability to achieve low idle. Verify the hand throttle is in
the full rearward/idle position and is adjusted correctly
if there are issues achieving low idle.
3. Tighten the outside adjustment nut (Item 3) 1/2 turn.

Nm).
5. Retest. Repeat steps 2 - 4 until there is no change in
maximum travel speed.
NOTE - Verify engine RPM settings after any command
(travel control) cable adjustment as RPM re-adjustment
may be required.
HORSEPOWER MANAGEMENT FUNCTIONALITY
This check verifies the horsepower management system
is functional and adjusted correctly.
1. With transmission in HIGH range on level asphalt
depress the travel control pedal to the full forward
position with a quick fluid motion.
2. The engine RPM at 20 mph (32.2 km/h) should be in
the range of 3500 - 3600 RPM. If the horsepower
management functionality is within specification,
proceed to the REVERSE SPEED SECONDARY
CHECK.
3. To decrease the engine RPM (increased engine pull
down), tighten the command torsion spring bolt (Item
5) in turn increments and retest.
4. To increase the engine RPM (decreased engine pull
down), loosen the command torsion spring bolt (Item
5) in turn increments and retest.
NOTE: This setting can be adjusted to match user
preference, if desired. Tightening the spring will result
in increased engine pull down/lug and may require
more modulation of the travel control pedal when
under load. Loosening the spring will result
decreased engine pull down/lug under load.
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5. Retest. Repeat steps 3 - 5 until the RPM and
acceleration time is within specification.
6. If the engine RPM is within specification, proceed to
Reverse Speed Secondary Check.
REVERSE SPEED SECONDARY CHECK
This check verifies the reverse travel speed meets
specification.
1. With the transmission in HIGH range from a stop on
level asphalt depress the travel control pedal to the
full reverse position until a maximum sustained speed
is attained. This speed should be over 8.0 mph (12.9
km/h).
2. If the vehicle speed is not to specification proceed
with steps 2 - 5.
3. To increase the reverse travel speed and reduce the
amount of forward engine RPM pull down, hold the
travel control cable outside adjustment nut (Item 3)
and loosen the inside adjustment nut (Item 4).
4. Loosen the outside adjustment nut (Item 3) turn.
Nm).
6. Retest. Repeat steps 2 - 4 until the reverse speed is
within specification.
NOTE: There is a trade off between reverse travel speed
and forward engine RPM pull down. As the reverse travel
speed is increased, forward travel engine RPM pulldown
will be reduced.
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TROUBLESHOOTING
Hydrostatic Drive Troubleshooting
The following troubleshooting chart is provided for assistance in locating and correcting problems. Many of the
recommended procedures must be done by authorized Polaris Service Personnel only.
PROBLEM
CAUSE
No drive on both axles
1, 2, 3, 4, 5, 6, 7, 13, 15
No drive on one axle
1, 3, 4, 5, 8,
The hydraulic system is overheating.
1, 3, 4, 9, 10, 11, 12,
Drive axles turning at different speeds
1, 3, 4, 5, 8, 14
KEY TO CORRECT THE CAUSE

1. Check for drive codes.
2. The directional control is not working correctly.
3. A hydrostatic drive motor has damage.
4. The brake is not releasing.
5. A hydrostatic pump has damage.
6. The accelerator is not working correctly.
7. The charge pressure is low.
8. A replenishing valve not seating.
9.The hydraulic fluid is not at correct level.
10.The hydraulic cooler has a restriction.
11.The hydraulic temperature sender is not working correctly.
12.The cooling fan is not turning
13.Servo enable not working correctly.
14.Two-speed not working correctly.
15.The drive controller is not working correctly.
10
10.67
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HYDROSTATIC DRIVE
Performance Checks Flow Chart Command
Lever Type 1
10.68
Copyright 2014
HYDROSTATIC DRIVE
Performance Checks Flow Chart Command
Lever Type 2
10
10.69
Copyright 2014
HYDROSTATIC DRIVE
NOTES
10.70
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FINAL DRIVE
CHAPTER 11
FINAL DRIVE
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2
FRONT BEARING CARRIER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
BEARING CARRIER INSPECTION / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4
BEARING CARRIER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7
FRONT PROPSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8
REMOVAL (BRUTUS MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8
REMOVAL (BRUTUS HD / HDPTO MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9
PROPSHAFT U-JOINT SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.10
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.10
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.11
FRONT GEARCASE - CENTRALIZED HILLIARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CENTRALIZED HILLIARD EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALL WHEEL DRIVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AWD DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT GEARCASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT GEARCASE DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT GEARCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE SHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE SHAFT / CV JOINT HANDLING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTER CV JOINT / BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INNER PLUNGING JOINT / BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE SHAFT CUTAWAY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.12
11.12
11.13
11.14
11.15
11.16
11.20
11.22
11.24
11.24
11.25
11.26
11.26
11.26
11.29
11.31
11
11.1
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FINAL DRIVE
SPECIAL TOOLS
PART NUMBER
TOOL DESCRIPTION
ITEM
SPECIFICATION
2872608
Roll Pin Removal Tool
Wheel Nuts
60 ft-lbs (81 Nm)
PU-48951
Axle Boot Clamp Tool
Front Wheel Hub Castle Nut
75 ft-lbs (102 Nm)
8700226
CV Boot Clamp Pliers:
Rear Wheel Hub Castle Nut
110 ft-lbs (149 Nm)
Ball Joint Pinch Bolts
42 ft-lbs (57 Nm)
Tie Rod End Fastener
40 ft-lbs (54 Nm)
Front Caliper Mounting Bolts
30 ft-lbs (41 Nm)
Rear Caliper Mounting Bolts
48 ft-lbs (65 Nm)
Front Gearcase Mounting Bolts
30 ft-lbs (41 Nm)
Front Gearcase Cover Bolts
10 ft-lbs (14 Nm)
Lower Suspension Link

to Axle Brace
40 ft-lbs (54 Nm)
Upper Suspension Link

to Axle Brace
40 ft-lbs (54 Nm)

11.2
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FINAL DRIVE
FRONT BEARING CARRIER
Bearing Carrier Inspection / Removal
1. Elevate front of vehicle and safely support machine
5. Remove the two brake caliper mounting bolts (Item

4). CAUTION: Do not hang caliper by the brake line.
Use wire to hang caliper to prevent damage to brake
line.
CAUTION
bearings and seals.
2. Check bearings for side play by grasping the top and
bottom of the tire firmly and checking for movement.
The tire should rotate smoothly without binding or
rough spots.
NOTE: Side to side play could also indicate tie
rod end wear and top to bottom play could also
indicate upper or lower ball joint wear. Be sure to
closely inspect these components if play is
found.
3. Remove the center cap and/or rubber dust cap.
Remove the cotter pin (Item 1) and loosen the front
wheel hub castle nut (Item 2).
6. Remove the castle nut and two cone washers from

the front wheel hub assembly.
7. Remove the wheel hub and brake disc assembly.
8. Remove cotter pin (Item 5). Using a 15mm socket,
remove the fastener (Item 6) retaining the tie rod end
to the bearing carrier.
9. Remove the upper and lower ball joint pinch bolts

(Item 7).
NOTE: Lower the vehicle so the front wheels are
on the ground to prevent the wheel from
spinning while attempting to loosen the castle
nut.
4. Lift the vehicle up again safely and remove the four
wheel nuts (Item 3). Remove the front wheel from the
vehicle.
10. Using a soft faced hammer, lightly tap the bearing

carrier while removing the upper and lower ball joints
ends from the bearing carrier.
11. Pull the bearing carrier out to remove it from the
driveshaft.
12. Rotate bearing by hand and check for rough spots.
The bearing should rotate quietly and smoothly with
no detectable up and down movement and minimal
movement sideways between the inner and outer
races. Visually inspect for moisture, dirt or corrosion.
11.3
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11
FINAL DRIVE
Bearing Replacement
Bearing Installation
Bearing Removal
1. Thoroughly clean the front bearing carrier housing

and the outer race on the new bearing. Be sure that
all oil residue has been removed from each surface.
1. Remove outer snap ring.
2. Support the bottom of the bearing carrier housing.
CAUTION
Use an arbor and press only on the outer race,
otherwise bearing damage may occur.
3. Apply Loctite 603 retaining compound to the outer
circumference of the new bearing race and carefully
press the new bearing into the bearing carrier
housing.
2. From back side of the bearing carrier, tap on the

outer bearing race with a drift punch in the reliefs as
shown.
NOTE: Use care to not allow any of the Loctite

compound to get in the bearing.
4. Wipe the housing clean of any excess compound and
install the snap ring.
3. Drive bearing out evenly by tapping on outer race

only. Once bearing is at bottom of casting, support
casting on outer edges so bearing can be removed.
4. Inspect bearing carrier housing for scratches, wear
or damage. Replace front bearing carrier if damaged.
11.4
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FINAL DRIVE
Bearing Carrier Installation
1. Install the end of the drive shaft through the backside
of the bearing carrier.
6. Install front wheel hub assembly, cone washers, and

hand tighten the castle nut. Install washers with
domed side out.
2. Install the upper and lower ball joint ends into the
front bearing carrier.
7. Install the front brake caliper. Install the mounting

bolts (Item 4) and torque to specification.
3. Install pinch
specification.
bolts
(Item
1)
and
torque
to

30 ft-lbs (41 Nm)
42 ft-lbs (57 Nm)
4. Install the steering tie rod end onto the front bearing
carrier and torque the fastener (Item 2) to
specification. Install a NEW cotter pin (Item 3)
CAUTION
New bolts have a pre-applied locking agent which is
destroyed upon removal. Always use new brake caliper
mounting bolts
upon assembly.
Tie Rod End Fastener:

40 ft-lbs (54 Nm)
5. Apply grease to the drive shaft splines.
11
11.5
Copyright 2014
FINAL DRIVE
8. Torque wheel hub castle nut (Item 5) to specification
and install a NEW cotter pin (Item 6). Tighten nut
slightly if necessary to align holes for the cotter pin.
Front Hub Castle Nut:

75 ft-lbs (102 Nm)
9. Install wheel and four wheel nuts (Item 7). Torque
wheel nuts to specification.
Wheel Nuts:
60 ft-lbs (81 Nm)
10. Rotate wheel and check for smooth operation. Bend
both ends of cotter pin around the end of the shaft.
Install the center cap and/or rubber dust cap.
11.6
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FINAL DRIVE
FRONT DRIVE SHAFT
Installation
Removal
1. Install new spring ring on the end of the drive shaft.

Apply an anti-seize compound to splines.
1. Perform the Bearing Carrier Inspection / Removal

procedure listed under the FRONT BEARING
CARRIER section within this chapter.
NOTE: Perform all removal steps with the
exception of removing the steering tie rod end. It
will not be necessary to remove the tie rod end
from the front bearing carrier when removing the
front drive shaft.
CAUTION
sure machine is secure before beginning
this service procedure.
2. Remove the drive shaft from the front bearing carrier.
3. With a short, sharp jerk, remove drive shaft from the
front gearcase.
2. Align splines of drive shaft with front gearcase and
reinstall the drive shaft. Use a rubber mallet to tap on
the outboard end of the drive shaft if necessary.
Lightly tug on the shaft to make sure the retaining
ring is locked into the front gearcase.
4. Refer to the DRIVE SHAFT SERVICE procedure if

repairing the drive shaft.
3. Install drive shaft into the front bearing carrier.

4. Perform the Bearing Carrier Installation procedure
listed under the FRONT BEARING CARRIER
section within this chapter.
11.7
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11
FINAL DRIVE
FRONT PROPSHAFT
Removal (BRUTUS Models)
5. Pull the front propshaft towards the front of the

vehicle until the splines on the rear yoke disengage
from the transmission snorkel shaft.

bottom of the bumper to the frame.
6. Remove the propshaft (Item 3) out the front of the

vehicle as shown.
2. Remove the two fasteners (Item 2) retaining the top

of the bumper to the frame and pull the bumper
straight out to remove it.
7. Reverse this procedure to reinstall the front

propshaft. Use a NEW roll pin upon installation.
3. Elevate and safely support vehicle under the frame.

The use of a vehicle hoist is recommended for this
procedure.
CAUTION
bearings and seals.
4. Remove the front gearcase from the vehicle (see
Front Gearcase Removal provided in this chapter).
11.8
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FINAL DRIVE
Removal (BRUTUS HD / HDPTO Models)
1. Remove the two cotter pins and clevis pins (Item 1)
that retain the hydraulic arms to the PRO-TACH
attachment interface.
5. Elevate and safely support vehicle under the frame.

The use of a vehicle hoist is recommended for this
procedure.
CAUTION
bearings and seals.
6. Remove the front gearcase from the vehicle (see
Front Gearcase Removal provided in this chapter).
7. Pull the front propshaft towards the front of the
vehicle until the splines on the rear yoke disengage
from the transmission snorkel shaft.
8. Remove the propshaft (Item 3) out the front of the
vehicle as shown.
2. Support the PRO-TACH attachment interface to keep

it from falling upon removal.
3. Remove the two cotter pins and clevis pins (Item 2)
that retain the PRO-TACH attachment interface to
the frame mast.
NOTE: Take care not to damage hydraulic hoses

upon propshaft removal.
9. Reverse this procedure to reinstall the front
propshaft. Use a NEW roll pin upon installation.
11
4. With the help of an assistant, remove the PRO-TACH

attachment interface from the vehicle as an
assembly.
11.9
Copyright 2014
FINAL DRIVE
PROPSHAFT U-JOINT SERVICE
3. Support U-joint in vise as shown and drive inner yoke

down to remove remaining bearing caps.
Disassembly
1. Remove internal or external snap ring from all
bearing caps.
CAUTION
Always wear eye protection.
4. Force U-joint cross to one side and lift out of inner

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

bearing must be replaced. Note orientation of
grease fitting and mark inner and outer yoke for
correct re-positioning during installation.
2. Support inner yoke as shown and drive outer yoke
down (bearing cap out) with a soft face hammer.
11.10
Copyright 2014
FINAL DRIVE
Assembly
1. Install new bearing caps in yoke by hand. Carefully
install U-joint cross with grease fitting properly
positioned inward toward center of shaft. Take care
not to dislodge needle bearings upon installation of
cross joint. Tighten vise to force bearing caps in.
5. Install outer yoke, aligning marks made before

disassembly.
6. Repeat Steps 1-4 to install bearing caps on outer

yoke.
2. Using a suitable arbor, fully seat bearing cap in one

side.
7. Seat all bearing caps against snap rings by

supporting cross shaft and tapping on each corner
as shown.
3. Continually check for free movement of bearing

cross as bearing caps are assembled.
4. Install snap ring to contain bearing cap just installed.

Repeat procedure for other side.
8. When installation is complete, yokes must pivot

freely in all directions without binding. If the joint is
stiff or binding, tap the yoke lightly to center the joint
until it pivots freely in all directions.
11
11.11
Copyright 2014
FINAL DRIVE
FRONT GEARCASE - CENTRALIZED HILLIARD
Centralized Hilliard Exploded View
REF#
DESCRIPTION
QTY
REF#
DESCRIPTION
QTY
Pinion Gear
17
Hub Assembly
O-Ring
18
Rollers
20
Dowel Pin
19
Torsion Spring
Vent Hose Fitting
20
Spring, Wireform
Ball Bearing
21
H-Clip Spring
20
Ball Bearing (Double Row)
22
Connector Assembly
Bushing
23
Nylon Spacer
Bushing
24
Torsion Spring Retainer
Oil Seal
25
Backlash Spacer
10
Oil Seal
26
Armature Plate
11
Retaining Ring, Internal
27
AWD Coil
12
Cover Screws, M6 (T30 Torx)
28
Grommet
13
Cover Plate Assembly
29
Fill Plug
14
Gearcase Housing
30
Drain Plug, Magnetic
15
Clutch Housing (Ring Gear)
31
16
Roll Cage
11.12
Copyright 2014
FINAL DRIVE
All Wheel Drive Operation
The AWD switch may be turned on or off while the
vehicle is moving, however, AWD will not enable until the
wheel speed drops below 0.2 mph (0.3 km/h). Once the
AWD is enabled, it remains enabled until the switch is
turned off and the wheel speed drops below 15 mph (24
km/h). To prevent wedging, the AWD system will
disengage when the treadle pedal is in the neutral
position (treadle switch circuit open).
Engage the AWD switch before getting into conditions
where the front wheel drive may be needed. If the rear
wheels are spinning, release the treadle pedal before
switching to AWD.
CAUTION
Switching to AWD while the rear wheels are spinning
may cause severe drive shaft and gearcase damage.
Always switch to AWD while the rear wheels have
traction or are at rest.
With the AWD switch off, the vehicle drives through the
rear wheels only (2 wheel drive). When the AWD is
enabled, the front drive acts as an on-demand AWD
system. This means, the front drive will engage once the
rear wheels have lost traction, and will remain engaged
until the torque requirement goes away (i.e. rear wheels
regain traction).
AWD Disengagement: Once the rear wheels regain

traction, the front wheels will return to the over-running
condition. The vehicle is now back to rear wheel drive
until the next loss of rear wheel traction occurs.
Torsion Spring Operation: The torsion spring acts as a
return mechanism to help disengage the coupling of the
output hubs and ring gear by creating an over-running
condition for the rollers upon disengagement.
CAUTION
If the rear wheels are spinning, release the throttle
before turning the AWD switch on.
If AWD is engaged while the wheels are spinning,
severe drive shaft and front
gearcase damage could result.
AWD Engagement: When the AWD switch is activated,
the AWD coil is powered by a 12 Vdc input which creates
a magnetic field. This magnetic field attracts an armature
plate that is keyed to the roll cage. When the ring gear
and roll cage are spinning (vehicle is moving), the
energized coil and armature plate will apply drag to the
roll cage that indexes the rollers inside the ring gear to an
engagement position. While in the engagement position,
the front drive will be in an over-running condition (not
engaged), until the rear wheels lose traction. Once the
rear wheels begin to lose traction, the front drive will
engage by coupling the output hubs to the ring gear via
the rollers. The front drive will remain engaged until the
torque requirement goes away (i. e. rear wheels regain
traction).
11
11.13
Copyright 2014
FINAL DRIVE
AWD Diagnosis
Symptom: AWD Will Not Engage
1. Check the gearcase coil resistance. To test the coil
resistance, measure between Grey and Brown/White
wires. Measurement should be within specification.
Front Gearcase Coil Resistance:

21.6 - 26.4 Ohms
2. Turn the ignition and AWD switches on and place
gear selector in High or Low gear. Check for
minimum battery voltage at the Gray and Brown/
White chassis wires that power the coil. A minimum
of 11 Vdc should be present.
3. If electrical tests are within specification, remove
gearcase (see Gearcase Removal) and inspect
components.
4. Inspect armature plate for a consistent wear pattern.

There should be two distinct wear bands (one band
inside the other). If only one band of wear is present
(or if there is wear between the two bands), inspect
the coil area as indicated in Step 5. A wear band with
an interrupted wear mark may indicate a warped
plate, which may cause intermittent operation.
5. Check to make sure the coil is seated in the Ushaped insert that is pressed into the gearcase
cover. The top of the coil should be seated below the
U-shaped insert. The U-shaped insert controls the
pole gap. If the top of the coil is above the surface of
the U-shaped insert it raises the armature plate,
thereby increasing pole gap. If the pole gap
increases the coil will not be strong enough to
engage the AWD system. If this is found, replace the
cover plate assembly.
6. Inspect the rollers for nicks and scratches. The

rollers must slide up, down, in and out freely within
the roll cage sliding surfaces and H-springs.
11.14
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FINAL DRIVE
7. Inspect the roll cage assembly for cracks or
excessive wear. If damaged, replace the roll cage
assembly.
8. Remove the front gearcase mounting bolts:

BRUTUS Models
Using a 15mm socket, remove the (4) bolts
retaining the gearcase to the skid plate frame.
Front Gearcase Removal

1. Place the transmission in Park. Elevate front of
vehicle and safely support machine under the frame.
CAUTION
BRUTUS HD / HDPTO Models

Using a 15mm socket and open-end wrench,
remove the four fasteners retaining the PTO shaft
and plate assembly to the frame.
Serious injury may result if machine tips or falls.

Be sure machine is secure before beginning
this service procedure.
2. Remove both front drive shafts from the front
gearcase (see FRONT DRIVE SHAFT - Removal).
3. Use the Roll Pin Removal Tool 2872608 to drive the
roll pin out of the front propshaft yoke at the front
gearcase.
Roll Pin Removal Tool (PN 2872608)
4. Slide the propshaft off the front gearcase input shaft
splines.
5. Disconnect the AWD wire harness and remove the
plastic zip tie holding the AWD coil pigtail.
6. Remove the vent hose from the front gearcase.
11
7. Remove the grease zerk fitting from the left front

lower control arm.
11.15
Copyright 2014
FINAL DRIVE
Using a 15mm socket, remove the four bolts
retaining the gearcase to the skid plate frame.
Front Gearcase Disassembly / Inspection

1. Drain and properly dispose of gearcase fluid.
Remove any metal particles from the drain plug
magnet.
2. Remove the seven cover screws and remove the
cover plate assembly.
9. Remove the front gearcase from the left-hand side

between the upper and lower control arms.
11.16
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FINAL DRIVE
3. Remove the LH output hub assembly from the clutch
housing or outer cover plate assembly.
4. Remove and inspect the armature plate. Refer to

AWD Diagnosis for detailed inspection process.
5. Remove the torsion spring retainer and torsion

spring from the top of the ring gear.
NOTE: Nylon spacer is non-serviceable and

should not be removed.
11
11.17
Copyright 2014
FINAL DRIVE
6. Remove the clutch housing / ring gear and roll cage
assembly from the gearcase housing.
8. Remove pinion seal, internal retaining ring and

pinion gear assembly from the gearcase housing.
Inspect and clean the gearcase housing and replace
all oil seals and O-rings.
7. Remove the RH output hub assembly from the

gearcase housing.
9. Inspect the pinion gear for chipped, broken or
missing teeth. Inspect the pinion bearing for signs of
wear and the pinion shaft seal surface for pitting.
11.18
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FINAL DRIVE
10. Inspect the AWD coil located in the outer cover plate
assembly. Refer to AWD Diagnosis for detailed
inspection process. Replace the cover plate seal and
O-ring.
13. Inspect clutch housing ring gear (Item 3) for a

consistent wear pattern. Inspect the ring gear for
chipped, broken, or missing teeth.
14. Inspect the roll cage assembly sliding surfaces and
H-springs. The sliding surfaces must be clean and
free of nicks, burrs or scratches. If damaged, replace
the roll cage assembly.
11. Remove the roll cage assembly and rollers from the
clutch housing. Use a shop towel to cover the
housing in order to retain all the rollers.
NOTE: Rollers are spring loaded. Take care not
to allow them to fall out or lose them upon
removal of the roll cage.
15. Inspect both output hub assemblies. Inspect the

bearings and replace if needed.
12. Thoroughly clean all parts and inspect the rollers

(Item 1) for nicks and scratches. The rollers must
slide up and down and in and out freely within the roll
cage (Item 2) sliding surfaces and H-springs.
16. Clean and inspect all remaining front gearcase

components. Check each for excessive wear or
damage.
11
NOTE: Refer to the Electronic Parts Catalog
for individual part availability. Most parts are to
be replaced as an assembly or as a complete kit.
11.19
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FINAL DRIVE
Front Gearcase Assembly
1. As mentioned during gearcase disassembly section,
replace all O-rings, seals and worn components.
2. Install pinion shaft assembly and install internal snap
ring.
5. Carefully install the rollers into the roll cage

assembly while installing the assembly into the
clutch housing.
NOTE: Install the roll cage so that the ring gear
grooves line up with the roll cage slots (see
below).
NOTE: If bearing replacement was required,

press new bearing onto the pinion shaft and
install a new external snap ring.
3. Install a new pinion shaft seal into the pinion gear
housing. Using a universal seal installer, press the
new seal into the housing until the seal is just below
the housing chamfer.
6. Install the torsion spring by wrapping each leg of the

spring around the dowel pin on the ring gear.
4. Install the RH output hub into the gearcase housing.
11.20
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FINAL DRIVE
7. Align the spring retainer dowel pin with the ring gear
dowel pin and install the retainer on top of the torsion
spring.
8. Check the action of the torsion spring by rotating in

both directions to ensure the spring and retainer are
installed properly.
9. Be sure the armature plate tabs are fully engaged

into the roll cage assembly and are resting on the
cut-grooves of the ring gear.
NOTE: Verify armature plate tabs are in the slots

on the roll cage and are resting in the ring gear
grooves.
10. Carefully install the ring gear and roll cage assembly
into the gearcase housing.
11. Install a new O-ring on the cover plate assembly.

NOTE: Be sure the square O-ring is placed flat
on the cover surface. If the O-ring is twisted fluid
leakage may occur.
11.21
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11
FINAL DRIVE
12. Carefully install the LH output hub assembly into the
cover plate. Take care not to damage the new cover
plate seal while installing the output hub.
Front Gearcase Installation
13. Install the output cover assembly onto the gearcase

housing. Install the seven cover plate screws and
torque to specification.
2. Install the vent line on the gearcase and ensure its

routed properly.
1. Install the gearcase between the left-hand upper and

lower control arms into the frame.
3. Install the left front lower control arm grease zerk

fitting.
4. Install the propshaft onto the front gearcase.
Cover Plate Screws:

7-11 ft-lbs (10-15 Nm)
11.22
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FINAL DRIVE
5. Install new gearcase mounting bolts and torque to
specification:
Install the PTO shaft and plate assembly to the

frame. Install four fasteners using a 15 mm socket
and open-end wrench. Torque plate fasteners to
specification.
Front Gearcase Mounting Bolts:

30 ft-lbs (41 Nm)
BRUTUS Models
Install four fasteners and torque to specification
using a 15 mm socket.
PTO Plate Mounting Bolts:

35 ft-lbs (47 Nm)
6. Drive a new roll pin into the front propshaft yoke.
BRUTUS HD / HDPTO Models
7. Install the drive shafts into the front gearcase (see

FRONT DRIVE SHAFT - Installation).
Install four fasteners and torque to specification

using a 15 mm socket.
8. Connect the AWD harness and tie the harness to the

brake lines with a plastic tie strap.
11
9. Add the proper lubricant to the front gearcase. Check

drain plug for proper torque. Refer to Chapter 2 for
fluid fill and change information.
11.23
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FINAL DRIVE
REAR DRIVE SHAFT
8. Remove the hardware retaining the upper

suspension link to the rear axle brace (Item 4).
Removal
2. Remove the four wheel nuts and remove the rear
wheel.
3. Remove the two 15 mm bolts (Item 1) retaining the
caliper. Remove the caliper and restrain it with wire.
Do not let the caliper hang by the brake lines.
9. Remove hardware from both lower suspension links

to the axle brace (Item 5).
10. Guide half shafts out of the bearings while removing
the axle brace.
4. Remove the dust cap. Remove the cotter pin, axle

nut and washers. Pull the hub/disc assembly out to
remove it.
5. Repeat steps 2-4 for the other side.
NOTE: If rear axle bearing replacement is

required, reference Chapter 8 Steering /
Suspension.
11. With a short, sharp jerk, remove the drive shaft from
the transmission.
6. Remove the two T-25 Torx head screws (Item 2)

retaining the brake junction block to the rear axle
brace.
7. Remove the brake line from the four retainer clips

(Item 3).
11.24
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FINAL DRIVE
Installation
5. Attach the rear axle brace to the upper suspension

link. Torque new fasteners to specification.
WARNING
during operation.
1. Install a new spring ring on the end of the drive shaft
if not replacing the drive shaft assembly. Apply an
anti-seize compound to the splines.

40 ft-lbs (54 Nm)
6. Install the hub/disc assembly, two washers, and new
axle nut. Torque fastener to specification.
Rear Axle Nut:

110 ft-lbs (149 Nm)
7. Install a new cotter pin and dust cap.
8. Install brake caliper. Torque new fasteners to
specification.
Rear Caliper Mount Bolts:

48 ft-lbs (65 Nm)
2. Align splines of the drive shaft with the transmission
and reinstall the drive shaft. Use a rubber mallet to
tap on the outboard end of the drive shaft if
necessary.
3. Install both rear half shafts into the axle brace.

Wheel Nuts:
60 ft-lbs (54 Nm)
4. Attach the lower A-arm to the axle brace. Torque new

fastener to specification.
WARNING
40 ft-lbs (54 Nm)
Upon rear axle brace installation completion, test

vehicle at low speeds before putting into service.
11
11.25
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FINAL DRIVE
DRIVE SHAFT SERVICE
Outer CV Joint / Boot Replacement
Drive Shaft / CV Joint Handling Tips
1. Use a side cutters to cut and discard the boot

clamps.
Care should be exercised during drive shaft removal or

when servicing CV joints. Drive shaft components are
precision parts.
Cleanliness and following these instructions is very
important to ensure proper shaft function and a normal
service life.
The complete drive shaft and joint should be
handled by getting hold of the interconnecting
shaft to avoid disassembly or potential damage to
the drive shaft joints.
Over-angling of joints beyond their capacity could
result in boot or joint damage.
Make sure surface-ground areas and splines of
shaft are protected during handling to avoid
damage.
Do not allow boots to come into contact with sharp
edges or hot engine and exhaust components.
The drive shaft is not to be used as a lever arm to
position other suspension components.
2. Remove the large end of the boot from the CV joint

and slide the boot down the shaft.
Never use a hammer or sharp tools to remove or

to install boot clamps.
Be sure joints are thoroughly clean and that the
proper amount and type of grease is used to refill
when joint boots are replaced and when joints are
cleaned. Refer to text for grease capacity of CV
joints and CV joint boots.
3. Clean the grease from the face of the joint.

4. Place the drive shaft in a soft-jawed vise.
11.26
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FINAL DRIVE
5. Using a soft-faced hammer, or brass drift, strike inner
race of the joint to drive the joint off the drive shaft.
Be sure to tap evenly around the joint to avoid
binding.
7. Remove the CV boot from the shaft.
CAUTION
Complete disassembly of the CV joint is NOT
recommended. The internal components are precision
fit and develop their own characteristic wear patterns.
Intermixing the internal components could result in
looseness, binding, and/or premature failure of the joint.
NOTE: If the grease in the joint is obviously
contaminated with water and/or dirt, the joint
should be replaced.
NOTE: Tap on inner race only!

6. Make sure circlip is on the shaft and not left in the
joint.
8. Thoroughly clean the joint with an appropriate

solvent and dry the joint to prevent any residual
solvent from being left in the joint upon reassembly.
9. Visually inspect the joint by tilting the inner race to
one side to expose each ball. Severe pitting, galling,
play between the ball and its cage window, any
cracking or damage to the cage, pitting or galling or
chips in raceways call for joint replacement.
NOTE: Shiny areas in ball tracks and on the
cage spheres are normal. Do not replace CV
joints because parts have polished surfaces.
Replace CV joint only if components are cracked,
broken, worn or otherwise unserviceable.
10. Clean the splines on the end of the shaft and apply a
light coat of grease prior to reassembly.
11. Slide the small boot clamp and boot (small end first)
onto the drive shaft and position the boot in its
groove machined in the shaft.
12. Install a NEW circlip on the end of the shaft.
11.27
Copyright 2014
11
FINAL DRIVE
13. Grease the joint with the special CV joint grease
provided in the boot replacement kit. Fill the cavity
behind the balls and the splined hole in the joints
inner race. Pack the ball tracks and outer face flush
with grease. Place any remaining grease into the
boot.
19. Install and tighten the large clamp using the

appropriate clamp tool.
CAUTION
The grease provided in the replacement kit is specially
formulated for wear resistance and durability. DO NOT
use substitutes
or mix with other lubricants.
NOTE: It is very important to use the correct
type and quantity of grease by using all the
grease included with the boot kit. DO NOT use a
substitute grease and DO NOT overfill or under
fill the CV joint.
14. Slide the joint onto the drive shaft splines and align
the circlip with the lead-in chamfer on the inner race
of the joint.
Axle Boot Clamp Tool: PU-48951

or
CV Boot Clamp Pliers: 8700226
20. While pulling out on the CV shaft, fully extend the CV
joint and slide a straight O-ring pick or a small slotted
screw driver between the small end of the boot and
the shaft. This will allow the air pressure to equalize
in the CV boot in the position that the joint will spend
most of its life. Before you remove your instrument,
be sure the small end of the boot is in its correct
location on the shaft.
21. Install and tighten the small clamp on the boot using
the appropriate clamp tool.
15. Use a soft-faced hammer to tap the joint onto the

drive shaft until it locks into place.
16. Pull on joint to make sure it is securely locked in
place.
17. Remove excess grease from the CV joint's external
surfaces and place the excess grease in the boot.
18. Pull the boot over the joint and position the boot lips
into the grooves on the joint housing and shaft. Make
sure the boot is not dimpled or collapsed.
or
11.28
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FINAL DRIVE
Inner Plunging Joint / Boot Replacement
1. Use a side cutters to cut and discard the boot
clamps.
2. Remove the large end of the boot from the plunging

joint and slide the boot down the shaft.
5. Using a soft-faced hammer, or brass drift, strike inner

race of the joint to drive the joint off the drive shaft.
Be sure to tap evenly around the joint to avoid
binding.
NOTE: Tap on inner race only!

6. Make sure circlip is on the shaft and not left in the
joint.
3. Clean the grease from the face of the joint.

4. Place the drive shaft in a soft-jawed vise.
11
11.29
Copyright 2014
FINAL DRIVE
7. Remove the boot from the shaft.
CAUTION
Complete disassembly of the plunging joint is NOT
recommended. The internal components are precision
fit and develop their own characteristic wear patterns.
Intermixing the internal components could result in
looseness, binding, and/or premature failure of the joint.
NOTE: If the grease in the joint is obviously
contaminated with water and/or dirt, the joint
should be replaced.
13. Grease the joint with the special CV joint grease

provided in the boot replacement kit. Fill the cavity
behind the balls and the splined hole in the joints
inner race. Pack the ball tracks and outer face flush
with grease. Place any remaining grease into the
boot.
CAUTION
The grease provided in the replacement kit is specially
formulated for wear resistance and durability. DO NOT
use substitutes
or mix with other lubricants.
NOTE: It is very important to use the correct
type and quantity of grease by using all the
grease included with the boot kit. DO NOT use a
substitute grease and DO NOT overfill or under
fill the CV joint.
14. Fully compress the joint and push the drive shaft
firmly into the inner race.
15. Align the circlip with the lead-in chamfer.
8. Thoroughly clean the joint with an appropriate

solvent and dry the joint to prevent any residual
solvent from being left in the joint upon reassembly.
9. Visually inspect joint for damage. Replace if needed.
10. Clean the splines on the end of the shaft and apply a
light coat of grease prior to reassembly.
11. Slide the small boot clamp and boot (small end first)
onto the drive shaft and position the boot in its
groove machined in the shaft.
12. Install a NEW circlip on the end of the shaft.
16. Use a soft-faced hammer to tap the joint onto the

drive shaft until you reach the end of the splines and
the joint locks in place.
17. Pull on the joint to test that the circlip is seated and
that the joint is securely fastened to the shaft.
18. Remove excess grease from plunging joints external
surfaces and place the excess grease in the boot.
19. Pull the boot over the joint and position the boot lips
into the grooves on the joint housing and shaft. Make
sure the boot is not dimpled or collapsed.
11.30
Copyright 2014
FINAL DRIVE
20. Install and tighten the small clamp using the
appropriate clamp tool.
Drive Shaft Cutaway View

or
21. Pull out on drive shaft to center joint in the housing.
Slide a straight O-ring pick or a small slotted screw
driver between the large end of the boot and the joint
housing and lift up to equalize air pressure in the
boot.
22. Position the boot lip in its groove. Install and tighten
the large clamp using the appropriate clamp tool.
11
or
11.31
Copyright 2014
FINAL DRIVE
NOTES
11.32
Copyright 2014
PTO
CHAPTER 12
PTO
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.2
PTO DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.2
DRIVE BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.2
DRIVE BELT PULLEY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.3
DRIVE BELT PULLEY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.4
PTO GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.5
PTO GEARBOX EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.5
GEARBOX REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.5
GEARBOX DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.6
PTO CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.8
CLUTCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.8
CLUTCH BRAKE ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.9
12
12.1
Copyright 2014
PTO
GENERAL INFORMATION
PTO DRIVE BELT
Drive Belt Removal
ITEM
TORQUE VALUE
PTO Belt Tensioner

Fasteners
35 ft-lbs (47 Nm)
PTO Gearbox Pulley Set

Screws
20 ft-lbs (27 Nm)
PTO Gearbox Mount Bolts
20 ft-lbs (27 Nm)
PTO Gearbox Case Bolts
20 ft-lbs (27 Nm)
PTO Clutch Mounting Bolts
28 ft-lbs (38 Nm)
PTO Shaft to Gearbox

Mounting Bolt
20 ft-lbs (27 Nm)
1. Using a 3/8 drive ratchet, rotate the automatic

tensioner (Item 1) counter clockwise to relieve belt
tension and remove the belt (Item 2).
Lubrication
2. Remove the belt (Item 3) from the pulley and pull
through the bell housing opening.
Recommended PTO Gearbox Lubricant:
PTO Gearbox Oil (PN 2879748) (6 oz.)
12.2
Copyright 2014
PTO
Drive Belt Pulley Removal
3. Remove the bolt (Item 5) and tensioner (Item 6).
1. Remove the PTO drive belt.
4. Remove the bolt (Item 7) and pulley (Item 8).

2. Loosen the set screws (Item 3) and remove the
pulley (Item 4).
12
12.3
Copyright 2014
PTO
Drive Belt Pulley Installation
1. Insert the peg (Item 9) on the tensioner into the hole
(Item 10) located on the casting.
2. Install the pulley

specification.
fasteners
and
torque
3. Install the PTO gearbox pulley. The key way stock

(Item 11) should be flush with the surface of the
pulley when properly installed. Use a straight edge to
align the pulley face with the rear pulley face on the
engine. Torque set screws to specification.
to
PTO Gearbox Pulley Set Screws:

20 ft-lbs (27 Nm)
PTO Belt Tensioner Fasteners:
35 ft-lbs (47 Nm)
NOTE:
Installation without proper pulley
alignment could result in premature belt wear
and possible belt squeal.
4. Reinstall the belt.
12.4
Copyright 2014
PTO
PTO GEARBOX
PTO Gearbox Exploded View
12
12.5
Copyright 2014
PTO
Gearbox Removal and Installation
Gearbox Disassembly and Assembly
1. Using a 3/8 drive ratchet, rotate the automatic

tensioner (Item 1) counter clockwise to relieve belt
tension and remove the belt (Item 2).
1. Remove the bolts (Item 1) retaining the cover and

remove the cover.
2. Remove the shaft assembly (Item 2) and seal (Item

3).
2. Remove the drive pulley.

3. Remove the PTO shaft bolts (Item 3).
3. Remove the clip (Item 4).

4. Remove the mounting bolts (Item 4) and the PTO
gearbox.
5. To install, reverse procedure. Tighten the bolts to
specification.
PTO Gearbox Mounting Bolts:

20 ft-lbs (27 Nm)
12.6
Copyright 2014
PTO
8. Remove the shaft assembly (Item 10), bearing race
(Item 11) and seal (Item 12).
4. Remove the gear (Item 5).
5. Place the shaft in a press and remove the bearing

(Item 6) and race (Item 7).
NOTE: The bearing races will slide off the

bearings as soon as the shaft assembly is
removed from the housing.
12
7. Place the shaft in a press and remove the bearing
(Item 9).
12.7
Copyright 2014
PTO
11. Place the shaft assembly in a press and remove the
bearing.
12. Rotate the shaft and remove the bearing (Item 17)
from the opposite end.
PTO CLUTCH
Clutch Removal
1. Note the orientation of the clutch harness for proper
installation.
2. Disconnect the clutch harness (Item 1) from the
vehicle harness.
13. For assembly, reverse the procedure. Tighten the

gearbox bolts to specification.
3. Remove the bolts (Item 2) from the PTO shaft and
position the shaft off to the side.
PTO Gearbox Case Bolts
20 ft-lbs (27 Nm)
NOTE: The following two figures are shown with

the engine removed for photo clarity.
12.8
Copyright 2014
PTO
Clutch Brake Adjusting

1. Remove the passenger seat and storage container.
2. Remove the three bolts (Item 1).
5. Install a puller (Item 5) and remove the clutch from

the gearbox.
6. To install, reverse procedure. Torque fasteners to

specification.
NOTE: The PTO clutch is removed for photo
clarity.
PTO Shaft to Gearbox Mounting Bolts:

20 ft-lbs (27 Nm)
PTO Clutch Mounting Bolt:
28 ft-lbs (38 Nm)
4. Insert a feeler gauge (Item 3) 0.3" (8 mm) into the

edge of the clutch pack and measure the clearance.
Measure in three places (between the three
adjusting nuts) to determine if the clearance is the
same for all three areas on the clutch pack.
5. The correct clearance is 0.014" (0.35 mm).
NOTE: An inaccurate measurement will be taken
if the feeler gauge is inserted more than 0.4" (10
mm).
6. Tighten or loosen the three adjusting nuts (Item 4)
until the correct clearance is a achieved evenly (at
the three areas checked) on the clutch.
12.9
Copyright 2014
12
PTO
NOTES
12.10
Copyright 2014
HYDRAULICS
CHAPTER 13
HYDRAULICS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.3
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.3
HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.4
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.4
LIFT CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.5
LIFT CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.5
TILT CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.5
TILT CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.6
HYDRAULIC CYLINDER EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.7
HYDRAULIC CYLINDER REBUILDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.8
CYLINDER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.8
CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.10
HYDRAULIC CONTROL VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.13
MAIN RELIEF VALVE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.13
PORT RELIEF VALVE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.14
HYDRAULIC CONTROL VALVE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.14
HYDRAULIC CONTROL VALVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.17
JOYSTICK EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.18
JOYSTICK DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.19
JOYSTICK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.25
AUXILIARY CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.34
PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.35
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.35
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.40
HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.45
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.45
REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.45
FRONT AUXILIARY HYDRAULIC COUPLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.47
POWER STEERING UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.47
MANIFOLD VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.48
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.48
TWO SPEED PRESSURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.48
TWO SPEED MANIFOLD EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.50
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.50
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.53
HYDRAULIC FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.55
13.1
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HYDRAULICS
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.55
HOUSING REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.55
OIL COOLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.56

REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.56
GEAR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.56
REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.56
GEAR PUMP EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.58
DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.58
HYDRAULIC SYSTEM INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.61
GLOSSARY OF HYDRAULIC / HYDROSTATIC SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.61
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.65
13.2
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SPECIFICATIONS
Lubrication
ITEM
TORQUE VALUE
Hydraulic Cylinder Hose

Coupler
22 ft-lbs (30 Nm)
Gear Pump Mounting Bolts
26 ft-lbs (35 Nm)
Hydraulic Cylinder Piston

Nut
140 ft-lb (190 Nm)
Housing Plug
17 ft-lbs (23 Nm)
Hydraulic Filter Housing

Mounting Bolts
26 ft-lbs (34 Nm)
Hydraulic Control Mounting

Bolts
22 ft-lbs (30 Nm)
37 Hydraulic Control
Valve Hose Fitting
40 ft-lbs (54 Nm)
Straight Hydraulic Control

Valve Hose Fitting
22 ft-lbs (30 Nm)
13
Polaris Hydraulic Fluid (PN 2879746) (Gallon)
Reservoir Capacity:
All Models: 2.75 qts (2.6 L)
Full System Capacity:
BRUTUS: 7.2 qts. (6.8 L)
BRUTUS HD / HDPTO: 8.4 qts (7.9 L)
Special Tools
PART NUMBER
TOOL DESCRIPTION
PU-51022
Quadrigage
PU-51107
O-ring Seal Hook
PU-51108
Adjustable Gland Nut Wrench

(PU-51108-1) and
Standard Pins (PU-51108-2)
PU-51199
Quick Coupler Kit
PU-51219
Hydraulic Adapter Kit
PU-51225
Port Relief Pressure Tool
PU-51292
Rod Seal Install Tool
PU-51293
Seal Expander / Compression

Tool

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HYDRAULICS
HYDRAULIC CYLINDER
6. Start the engine and actuate the lift cylinder. If there

is any leakage from the base end fitting remove the
cylinder for repair or replacement.
Testing
7. Remove and cap the hose (Item 4) from the base

end of the tilt cylinder.
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a persons body by penetrating
the skin. This may cause serious injury or death if
proper medical treatment by a physician familiar with
this injury is not received immediately.
1. Lower the work equipment to the ground.
2. Remove the retaining pin (Item 1) and pin (Item 2)
from the rod end of the lift cylinder.
8. Start the engine and retract the tilt cylinder. If there is

any leakage from the base end fitting, remove the
cylinder for repair or replacement.
9. Reinstall hydraulic lines to the cylinders. Torque
fasteners to specification.
Hydraulic Cylinder Hose Coupler:

22 ft-lbs (30 Nm)
3. Unlock the attachment arm tilt and lift switches to
enable the joystick.
4. Start the engine and fully retract the cylinder rod.

Turn the key switch OFF.
5. Remove and cap the hose (Item 3) from the base
end of the lift cylinder.
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HYDRAULICS
Lift Cylinder Removal
Lift Cylinder Installation
1. Mount the case end of the lift cylinder to the

attachment mount and install the retaining pin and
clip.
2. Remove the hoses (Item 1) from the lift cylinder.
2. Mount the rod end of the lift cylinder to the

attachment adapter assembly. Install the retaining
pin and clip.
3. Install the hydraulic hose with the green strap to the
base end of the lift cylinder. Install the hydraulic hose
with the blue strap to the rod end of the lift cylinder.
Torque hydraulic couplers to specification.

22 ft-lbs (30 Nm)
3. Remove the retaining clip (Item 2) and pin (Item 3)
from the rod end of the cylinder.
Tilt Cylinder Removal

2. Remove the hoses (Item 1) from the tilt cylinder.

from the base end of the lift cylinder.
5. Remove the cylinder.
13.5
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13
HYDRAULICS
from the rod end of the cylinder.
Tilt Cylinder Installation

1. Mount the case end of the tilt cylinder to the
attachment mount and install the retaining pin and
clip.
2. Mount the rod end of the tilt cylinder to the
attachment adapter assembly. Install the retaining
pin and clip.
3. Install the hydraulic hose with the pink strap to the
base end of the tilt cylinder and the hose without
markings to the rod end of the tilt cylinder. Torque
hydraulic couplers to specification.

from the base end of the tilt cylinder and remove the
cylinder.

22 ft-lbs (30 Nm)
13.6
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HYDRAULICS
Hydraulic Cylinder Exploded Views
13
13.7
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HYDRAULICS
HYDRAULIC CYLINDER REBUILDING
6. Remove the cylinder case from the vise.
Cylinder Disassembly
7. Install the rod end in the vise.
Use the following tools to disassemble the cylinder.
8. Remove the nut (Item 2) from the piston end of the

rod.
PU-51107 - O-ring Seal Hook

PU-51108-1 - Adjustable Gland Nut Wrench
PU-51108-2 - Standard Pins
PU-51293 - Seal Expander and Compression Kit
PU-51292 - Rod Seal Installation Tool
1. Clean the outside of the cylinder before disassembly.
2. Hold the hydraulic cylinder over a drain pan and
move the rod in and out slowly to remove fluid from
cylinder.
3. Put the base end of the cylinder in a vise.
4. Insert the adjustable gland nut wrench into the holes
and loosen the head.
9. Remove the piston (Item 3), cushion sleeve (Item 4)
(if equipped) and head (Item 5).
5. Remove the rod assembly (Item 1) from the cylinder

case.
13.8
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HYDRAULICS
13
11. Remove the O-ring (Item 7) and back-up ring (Item

8).
14. Remove the seal (Item 11) from the piston.
15. Remove the O-ring (Item 12).

12. Remove the wiper seal (Item 9).
13.9
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HYDRAULICS
Cylinder Assembly
4. Install the seal (Item 3) on the piston.
Always use new O-rings and seals during assembly.

1. Clean parts in
compressed air.
clean
solvent
and
dry
with
2. Install the O-ring (Item 1) on the piston.
5. Use a ring compressor (PU-51293-2) to compress

the piston seal.
3. Install the seal (Item 2) on the seal expander tool

(PU-51293-1). Allow the seal to stretch for 30
seconds before removing.
6. Leave the piston in the ring compressor for at least

three minutes.
13.10
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HYDRAULICS
7. Install the seal (Item 4) in the head using the rod seal
tool (PU-51292).
13
8. Install the wiper seal (Item 5) with the lip towards the
outside of the head.
NOTE: Do not roll the seal. Seal damage may

result.
11. Use a ring compressor to compress the seal on the
head and leave it on for at least five minutes.
9. Install the back-up washer (Item 6) and the o-ring

(Item 7) on the head.
12. Install the head on the rod.
13.11
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HYDRAULICS
13. Install the piston (Item 9) on the rod with the tapered
end towards the head. Install the nut and torque to
specification.
16. Apply oil to the piston teflon seal.
17. Install the rod assembly (Item 10) into the cylinder
case.
Hydraulic Cylinder Piston Nut

140 ft-lb (190 Nm)
14. Remove the rod from the vise.
15. Install the cylinder case in the vise and apply oil to
the seal surface of the cylinder case.
18. Apply oil to the head seals and threads.
13.12
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HYDRAULICS
19. Using an adjustable gland wrench, tighten the head
until it is flush with the case.
HYDRAULIC CONTROL VALVE

Main Relief Valve Testing
1. Remove the cover (Item 1) from the factory installed
quick coupler (Item 2) on the gear pump.
13
2. Install the Quadrigage (PU-51022) gauge onto the

coupler (Item 3).
3. Start the engine and run at high idle. The gauge

should read 1378 - 1522 psi (9501 - 10494 kPa).
13.13
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HYDRAULICS
Port Relief Valve Testing
4. Loosen the lock nut (Item 4).
A portable hydraulic port relief pressure tool will be used

to test the work port relief valves. The port relief pressure
tool must have clean hydraulic fluid that is compatible
with the Polaris fluid.
1. Install the port relief pressure tool (PU-51225), hose
(Item 1) and the quadrigage (PU-51022) onto a front
auxiliary quick coupler (Item 2).
5. Turn the adjustment screw (Item 5).

NOTE: 1/4 turn is approximately 100 psi (689
kPa). When the correct pressure setting is
obtained, tighten the lock nut while holding the
adjustment screw from turning.
6. Adjust the main relief valve until the correct setting is
obtained
2. With the engine off, pressurize the section with the

port relief pressure tool and watch the gauge. When
the pressure stops increasing, relief pressure 1740 1957 psi (11997 - 13493 kPa) has been reached. Do
not exceed the listed relief pressure.
13.14
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HYDRAULICS
Hydraulic Control Valve Removal
5. Disconnect the negative battery cable (Item 3).
1. Lower the lift arm and stop the engine.

2. Relieve the pressure from the hydraulic system by
turning engine off and moving the joystick around.
13
WARNING
AVOID INJURY OR DEATH Always clean up spilled
fuel or oil. Keep heat, flames, sparks or lighted tobacco
away from fuel and oil. Failure to use care around
and keep all parts clean. Always use caps and
plugs on hoses, tubelines and ports to keep dirt
out. Dirt can quickly damage the system
6. Tip the drivers seat forward and cut the cable ties
(Item 4). Disconnect the seat sensor harness (Item
5).
3. Remove the passenger side seat base (Item 1) by

tipping it forward and lifting straight up.
7. Remove the seat base (Item 6).

8. Remove the storage tray (Item 7).
4. Remove the storage tray (Item 2).
13.15
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HYDRAULICS
9. Remove the four plastic rivets (Item 8) from the
center console.
12. Remove the two screws (Item 10) from the center
tray.
10. Position the center console out of the way.

11. Remove the three bolts (Item 9) and reposition the
Speed Control Lever off to the side.
13.16
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HYDRAULICS
15. Disconnect the wire harness (Item 13).
Hydraulic Control Valve Installation

To install the hydraulic control valve, reverse the removal
procedure. Torque fasteners to specification.
13
Hydraulic Control Valve Mounting Bolts:
22 ft-lbs (30 Nm)
37 Hydraulic Control Valve Hose Fitting:
40 ft-lbs (54 Nm)
Straight Hydraulic Control Valve Hose Fitting:
22 ft-lbs (30 Nm)
16. Remove the bolt (Item 14).
17. Remove the bolt (Item 15) and the hydraulic control
valve (Item 16).
13.17
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Joystick Exploded View
13.18
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HYDRAULICS
Joystick Disassembly
4. Remove the rod end (Item 5).
WARNING
13
AVOID INJURY OR DEATH

Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil. Failure
to use care around combustibles can cause explosion
or fire
1. Clean the outside of the control valve before
disassembling.
5. Remove the nut (Item 6) and pin (Item 7).
2. Loosen the jam nut (Item 1) and remove the hand

grip (Item 2).
6. Remove the nut (Item 8) and rod end assembly (Item

9).
3. Remove the bolts (Item 3) and boot (Item 4).
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HYDRAULICS
7. Remove the two screws (Item 10) and rod end
assembly bracket.
8. Remove the other two screws (Item 11) from the

bracket.
9. Remove the gasket (Item 12).
10. Remove the relief valve (Item 13).
11. Remove the o-rings (Item 14) and backup ring (Item
15).
12. Remove the nuts (Item 16) from the coils.
13.20
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HYDRAULICS
13. Remove the o-rings (Item 17) and coils (Item 18).
16. Remove the two screws (Item 22) and end cap (Item
23).
13
14. Remove the o-rings (Item 19) and spools (Item 20).
17. Remove the spool (Item 24).\
15. Remove the o-ring (Item 21) from the spool.
13.21
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HYDRAULICS
18. To remove the plugs from the spool, a holding fixture
will have to be made from a block of wood 0.75 in.
(19 mm) thick x 1.5 in. (38 mm) wide x 2 in. (51 mm)
long.
20. Remove the pin (Item 28).
21. Remove the screws (Item 29) and end cap (Item 30).
NOTE: Do not use anything other than

hardwood blocks to grip the spool or the spool
will be damage.
19. Using the wood blocks (Item 25) clamp the spool
assembly (Item 26) in a vise and remove the spool
positioner (Item 27).\
22. Remove the spool (Item 31).
13.22
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HYDRAULICS
23. Using the wood blocks clamp the other spool in a
vise.
27. Remove the screws (Item 35) and spacers (Item 36).
13
24. Loosen the screw and remove the spool positioner

(Item 32).
28. Remove the o-rings (Item 37) and from both sides of
the spacers.
25. Remove the pin (Item 33).
29. Remove the brass seals (Item 38).

26. Remove the o-rings (Item 34).
13.23
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HYDRAULICS
30. Remove the o-rings (Item 39) and cross port relief
valves (Item 40). Remove the o-rings from the cross
port relief valves.
33. Remove the plugs (Item 45).
34. Remove the o-rings (Item 46) and backup rings (Item
47).
31. Remove the caps (Item 42).
32. Remove the spring (Item 43) and pin (Item 44).
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HYDRAULICS
35. Remove the plugs (Item 48) and the plug o-rings.
Joystick Assembly
air. Replace all o-rings and seals. Inspect all parts for
wear or damage. Replace worn or damaged parts.
2. Install o-rings on the plugs and install the plugs (Item
1). Torque to specification.
Joystick Body Plug:

17 ft-lbs (23 Nm)
13.25
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13
HYDRAULICS
3. Install the o-rings (Item 2) and backup ring (Item 3).
5. Install the relief valve (Item 5) and spring (Item 6).
4. Install the plugs (Item 4). Torque to specification.
6. Install the caps (Item 7). Torque to specification.
Joystick Body Plug:

17 ft-lbs (23 Nm)
Relief Valve Cap:

17 ft-lbs (23 Nm)
13.26
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HYDRAULICS
7. Install the o-ring (Item 8) on the cross port relief
valve.
10. Install the brass seals (Item 11).
13
11. Install the o-rings (Item 12) and in both sides of the
spacers.
8. Install the o-rings (Item 9).
9. Install the cross port relief valves (Item 10) and

torque valves to specification.
Cross Port Valve:

17 ft-lbs (23 Nm)
13.27
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HYDRAULICS
12. Install the spacers (Item 13) and screws (Item 14).
Torque screws to specification.
14. Using the wood blocks, clamp the spool (Item 16) in
a vise.
15. Install the pin (Item 17).
Spool Cylinder Screws:

58 in-lbs (6 Nm)

hardwood blocks to grip the spool, or the spool
will be damage.
16. Install the spool positioner (Item 18).
13. Install the o-rings (Item 15).
13.28
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HYDRAULICS
17. Install the spool (Item 19).
20. Install the pin (Item 22).
13
18. Install the end cap (Item 20) and screws (Item 21).

hardwood blocks to grip the spool, or the spool
will be damage.
21. Install the spool positioner (Item 23).
End Cap Screws:

58 in-lbs (6 Nm)
22. Install the spool (Item 24).
19. Using the wood blocks, clamp the other spool into a
vise
13.29
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HYDRAULICS
23. Install the end cap (Item 25) and screws (Item 26).
25. Install the spools (Item 28) and o-rings (Item 29).
26. Install the coils (Item 30) and o-rings (Item 31).
End Cap Screws:

58 in-lbs (6 Nm)
24. Install the o-ring (Item 27).
13.30
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HYDRAULICS
27. Install the nuts (Item 32) and torque to specification.
29. Install the relief valve (Item 35) and gasket (Item 36).
13
30. Install the plate and the two bolts (Item 37). Torque
bolts to specification.
Coil Nuts:
58 in-lbs (6 Nm)
28. Install the o-rings (Item 33) and backup ring (Item
34).
Plate Mounting Bolts:

11 ft-lbs (15 Nm)
13.31
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HYDRAULICS
31. Install the rod end assembly (Item 38) and mounting
bolts (Item 39). Torque bolts to specification.
33. Install the pin (Item 42) and nut (Item 43).
34. Install the rod end (Item 44).
Rod End Assembly Mounting Bolts:

11 ft-lbs (15 Nm)
32. Install the rod end assembly (Item 40) and nut (Item
41).
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35. Install the plate (Item 45), bolts (Item 46) and boot
(Item 47). Torque bolts to specification.
37. Install the hand grip (Item 49) and tighten the jam nut
(Item 50).
13
Rod End Bolts:

11 ft-lbs (15 Nm)
36. Install the cable tie (Item 48).
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HYDRAULICS
AUXILIARY CONTROL VALVE
6. Disconnect the solenoid harness (Item 2).
NOTE: Port reliefs must be installed in the auxiliary

control valve when using the snow blade or angle
broom accessories. Failure to install these port
reliefs may lead to accessory or vehicle damage.
Removal
WARNING
7. Disconnect the solenoid harness (Item 3).
1. Lower the lift arm and stop the engine.
2. Relieve the pressure from the hydraulic system.
3. Remove the passenger side seat base and storage
bin.
4. Remove the battery.
5. Mark and remove the hoses (Item 1) from the valve.
8. Under the passengers seat, remove the two bolts

(Item 4) and valve/bracket assembly.
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Parts Identification
13
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HYDRAULICS
Disassembly
4. Remove the plug (Item 5).
1. Remove the bolts (Item 1) and bracket (Item 2) from

the valve.

2. Mark the orientation of the fitting (Item 3) and
remove.
6. Remove the nuts (Item 7).

3. Remove the o-ring (Item 4).
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7. Remove the O-ring (Item 8) (Both sides).
13
8. Remove the coil (Item 9) (Both sides).
9. Remove the O-ring (Item 10) (Both sides).
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13. Remove the o-rings (Item 14) and backup ring (Item
15).
16. Remove the spring (Item 19), spring stop (Item 20)
and the spool (Item 21).
14. Remove the screws (Item 16) and spool (Item 17)
from the auxiliary valve.
17. Remove the plugs (Item 22) and the plug o-rings.
18. Remove the bolts (Item 23) and spool (Item 24).
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19. Remove the spring (Item 25) and spring stop (Item
26).
13
20. Remove the o-ring (Item 27) from the auxiliary valve.
24. Remove the O-rings (Item 31) and backup ring (Item
32).
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25. Remove the spool (Item 33) and o-ring (Item 34).
Assembly
air. Replace all O-rings and seals. Inspect all parts
for wear or damage. Replace any worn or damaged
parts.
2. Install the o-rings on the fittings and install the fittings
(Item 1) into the housing.
26. Note the orientation and remove the fittings (Item

35).
3. Install the O-rings (Item 2) and backup ring (Item 3)

onto the plug.
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HYDRAULICS
4. Install the plug (Item 4) into the housing.
7. Install the O-ring (Item 7) then install the spool (Item

8) into the housing (Item 9).
13
5. Install the o-ring (Item 5) onto the plug.

8. Install the spring stop (Item 10), and spring (Item 11).
6. Install the plug (Item 6).

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HYDRAULICS
10. Position the spool (Item 13) and install the bolts (Item
14).two
13. Install the spring spool (Item 17), spring stop (Item
18) and spring (Item 19).
11. Install the o-ring (Item 15) on the plugs.
12. Install the plugs (Item 16).
15. Position the spool (Item 21) and install the bolts (Item
22).
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16. Install the backup ring (Item 23) and o-rings (Item 24)
on the plug.
13
20. Install the o-ring (Item 28) (Both spools).

21. Install the coils (Item 29).

18. Install the o-ring (Item 26) on the plug.
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22. Install the O-ring (Item 30) (Both sides).
25. Install the O-ring (Item 34) onto the fitting.
23. Install the nuts (Item 31).
26. Install the fitting (Item 35).
24. Install the O-ring on the plug and install the plug
(Item 33).
27. Position the bracket (Item 36) and install the bolts
(Item 37).
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HYDRAULICS
HYDRAULIC RESERVOIR
4. Remove the cable ties bases (Item 2) from the

crossmember.
Description
The hydraulic fluid reservoir is a container that stores
and helps cool the hydraulic oil. It contains a strainer and
is a closed system that builds a small amount of
pressure. The reservoir provides the fluid for the
hydraulic/hydrostatic system and provides the necessary
flow to keep the pump inlet full to avoid cavitation.
13
The hydraulic reservoir is located behind the operator

and is accessed by raising the cargo box.

2. Drain the hydraulic fluid.
WARNING

3. Remove the transmission vent hose (Item 1) from
the crossmember.
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6. Loosen the hose clamps (Item 4).
9. Remove the bolts (Item 7) and the bracket (Item 8).
7. Remove the two bolts (Item 5) and air box.
10. Remove the reservoir (Item 9).
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FRONT AUXILIARY HYDRAULIC
COUPLER
POWER STEERING UNIT
Reference Chapter 8 - Steering / Suspension for Power

Steering Unit Removal and Power Steering / Steering
Shaft Installation procedures.
WARNING


1. Mark the auxiliary hoses (Item 1) and remove from
the couplers.
2. Remove the jam nuts (Item 2) and the couplers.
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13
HYDRAULICS
MANIFOLD VALVE
2. Install adapter (PU-51219) (Item 2), hose (Item 3)

and quadrigauge (PU-51022).
Description
The manifold valve controls the flow of fluid to the
steering valve and work cylinders.
The manifold valve is located under the operators seat.
3. Start the engine and gradually accelerate while

watching the pressure gauge. The two speed should
shift at a minimum pressure of 203 psi (1400 kPa)
and a noticeable jump in pressure should occur. At
high idle, pressure can not exceed 1000 psi (6895
kPa).
Two Speed Pressure Testing

1. Remove the hose (Item 1) from the X1 port on top of
the drive motor.
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HYDRAULICS
1. Disconnect the connector (Item 1) from the solenoid.
3. Pull out on the floor back and remove the two bolts
(Item 3).
13
2. Mark and remove the hydraulic hoses (Item 2).
4. Remove the manifold valve.
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Two Speed Manifold Exploded View
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Disassembly
1. Remove the fittings (Item 1) from the valve and
remove the o-rings from the fittings.
4. While counting the number of revolutions, bottom out

the relief adjustment. This will be your initial
adjustment for assembly.
13
2. Remove the fitting (Item 2) and remove the o-ring

from the fitting.
NOTE: The relief valve is factory set and there

are no provisions for field adjustments. If the
relief valve is removed the valve must be
replaced.
5. Remove the adjustment plug (Item 5), spring (Item 6)
and poppet (Item 7).
3. Remove the housing plugs (Item 3) and the relief

valve plug (Item 4). Remove the o-rings from the
plugs.
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6. Remove the priority flow regulator (Item 8).
7. Remove the backup rings (Item 9) and o-rings (Item

2) from the priority flow regulator.
9. Remove the backup rings (Item 13) and o-rings (Item

14) from the 2-speed valve.
10. Remove the orifices (Item 15).
8. Remove the two bolts (Item 1) and the 2 speed valve

(Item 2).
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Assembly
4. Install the 2-speed valve (Item 5) and bolts (Item 6)

and torque bolts to specification.
1. Install the orifice (Item 1).
13
2. Install the orifice (Item 2).
2-Speed Valve Bolts:

15 in-lbs (2 Nm)
5. Install the o-rings (Item 7) and backup rings (Item 8)
onto the priority flow regulator.
3. Install the o-rings (Item 3) and backup rings (Item 4)

on the 2-speed valve.
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6. Install priority flow regulator (Item 9) and torque to
specification.
9. Install the o-rings (Item 13) on the plugs.
10. Install the relief valve plug (Item 14) and two other
plugs (Item 15). Torque to specification.
Priority Flow Regulator:

25 ft-lbs (34 Nm)
7. Install the poppet (Item 10), spring (Item 11) and
adjustment plug (Item 12).
Relief Valve Plug (Item 14):

25 ft-lbs (34 Nm)
8. Bottom the adjustment plug out and back it off the
number of revolutions recorded in for initial
adjustment.
Housing Plug (Item 15):

20 ft-lbs (27 Nm)
11. Install the o-ring on the fitting.
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HYDRAULIC FILTER
12. Install the fitting (Item 16).
Description
Located behind the operator near the hydraulic fluid
reservoir, the hydraulic filter removes contaminants from
the fluid when the hydraulic system is operating.
Housing Removal and Installation
WARNING
13. Install the o-rings (Item 17) on the fittings.
and keep all parts clean. Always use caps on hoses,
tubelines and ports to keep dirt out.
1. Disconnect the hydraulic pressure sensor wire (Item
1) and oil temperature sensor connector (Item 2).
14. Install the fittings (Item 18).
2. Remove the filter outlet hose (Item 3) and the inlet

hose (Item 4) from the filter housing.
3. Remove the filter housing mounting bolts (Item 5)
and remove the filter housing.
4. To install, reverse the procedure. Tighten the
housing mounting bolts to specification.
Hydraulic Filter Housing Mounting Bolts:

25 ft-lbs (34 Nm)
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13
HYDRAULICS
OIL COOLER
GEAR PUMP
1. Remove the front access cover.
1. Drain the hydraulic reservoir.
2. Remove the fender flares.
NOTE: The hydrostatic pump is shown removed

from the vehicle for photo clarification. Use the
same procedure for removing and installing the
gear pump while installed on the vehicle.
3. Remove the front fenders.

4. Remove the bumper cover.
5. Remove the hydraulic hoses (Item 1) from the oil
cooler.

(Item 2).
6. Install caps on the cooler and plugs in the lines.

7. Remove the bolt (Item 2).
3. Remove the fitting (Item 3) from the pump.
8. Remove the oil cooler.
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7. Remove the two bolts (Item 7) and pump (Item 8).
13
5. Remove the fitting (Item 5).
8. Remove the coupler (Item 9) and O-ring (Item 10).
9. To Install, reverse the procedure. Torque fasteners to

specification
Gear Pump Mounting Bolts:

26 ft-lbs (35 Nm)
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Gear Pump Exploded View
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Disassembly and Assembly
1. Clean the outside of the gear pump before
disassembly.
5. Remove the back-up ring (Item 5, shown as white

color) and the seal (Item 6, shown as black color).
2. Mark the outside of the gear pump before

disassembly.
13

3. Remove the four endcap bolts (Item 1) and the end
cap (Item 2).
6. Separate the bearings and remove the dowel pin

(Item 7).
4. Remove the seal (Item 3). Record bearing

orientation and remove the bearings/seal assembly
(Item 4).
7. Remove the mounting flange (Item 8) from the

housing (Item 9).
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HYDRAULICS
8. Remove the seal (Item 10). Record bearing
orientation and remove the bearings/seal assembly
(Item 11).
11. Remove the gears (Item 15).
12. Remove the snap ring (Item 16) and seal (Item 17).
9. Remove the back-up ring (Item 12, shown as white
color) and the seal (Item 13, shown as black color).
13. To assemble, reverse the procedure.

10. Separate the bearings and remove the dowel pin
(Item 14).
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HYDRAULICS
HYDRAULIC SYSTEM INFORMATION
Glossary of Hydraulic / Hydrostatic Symbols
SYMBOL
DESCRIPTION
SYMBOL
CYLINDER: Equipment to convert hydraulic energy

into linear energy and in which the fluid pressure
operates alternately in both directions (forward and
backward strokes).
CONTROL VALVE
ACTIVATED BY A PUSHPULL BUTTON (manual).
DOUBLE ACTING
HYDRAULIC CYLINDER,
UNEQUAL
DISPLACEMENT With
single piston rod.
CONTROL VALVE
ACTIVATED BY A LEVER
(manual).
DOUBLE ACTING
HYDRAULIC CYLINDER,
UNEQUAL
DISPLACEMENT and
CUSHION ON ONE END
With single piston rod.
CONTROL VALVE
ACTIVATED BY A PEDAL
(manual).
CONTROL VALVE WITH

SPRING RETURN
(mechanical).
PUMP: To convert mechanical energy into hydraulic

energy.
FIXED CAPACITY
DISPLACEMENT
HYDRAULIC PUMP
With one direction to flow.
CONTROL VALVE
ACTIVATED BY AN
ELECTRIC SOLENOID
(electrical).
VARIABLE CAPACITY
DISPLACEMENT
BIDIRECTIONAL
HYDRAULIC PUMP
With two directions to flow
(bidirectional).
CONTROL VALVE
ACTIVATED BY A
PROPORTIONAL
ELECTRICAL
SOLENOID (electrical).
MOTOR: To convert hydraulic energy into rotary

mechanical energy.
CONTROL VALVE
ACTIVATED BY DUAL
ELECTRICAL
SOLENOID (electrical).
FIXED CAPACITY
DISPLACEMENT
BIDIRECTIONAL
HYDRAULIC MOTOR
With two directions of flow
(bidirectional).
CONTROL VALVE
ACTIVATED BY PILOT
PRESSURE (indirect
control, pilot actuated by
application of pressure).
CONTROL MECHANISMS
CONTROL VALVE WITH
DETENT (Holds valve in
position) Device for
maintaining a given
position (mechanical).
DESCRIPTION
FLOW LINES and CONNECTIONS
CONTROL VALVE
ACTIVATED BY A PULL
BUTTON (manual).
WORKING CIRCUITS
Continuous, solid line
working (main) line, return
line (line conduction fluid
from working devices to
the reservoir) and feed
line (main line conductor).
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HYDRAULICS
SYMBOL
DESCRIPTION
SYMBOL
PILOT PRESSURE
Dashed line pilot line
(line which conducts
control fluid).
DRAIN CIRCUITS
Dotted line drain line
(drain or bleed line-line
conducting fluid from a
component housing to the
reservoir).
COMPONENTS Long
chain line enclosure
outline for several
components assembled in
one unit.
MECHANICAL
CONNECTIONS
Double line (shaft, lever,
piston rod).
DESCRIPTION
TEMPERATURE
INDICATOR
(temperature
measurement
thermometer).
FILTER (strainer or
screen) For Fluid
conditioning.
VENTED AND FILTERED
RESERVOIR (reservoir
uses a pressured cap).
PRESSURIZED,
VENTED AND FILTERED
RESERVOIR (reservoir
open to atmosphere).
CONNECTED
JUNCTION OF OIL
LINES (flow line
connection).
OIL LINES CROSSING
(not connected).
COUPLER Quick
acting coupling
(uncoupled, closed by
non-return valve).
BASIC and MISCELLANEOUS SYMBOLS
RESTRICTION Line
with fixed restriction
affected by viscosity
(property of resistance to
flowing fluid).
VARIABLE
ADJUSTMENT
RESTRICTION
Regulated or variable
restriction.
TEMPERATURE
CONTROL (indication
of temperature).
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OIL COOLER (heat

exchanger) the arrows
in the diamond indicate
the extraction of heat
(heat dissipation).
PRESSURE SENSOR
Varies electric signal with
pressure.
DIFFERENTIAL
PRESSURE SWITCH
Switch activates when
pressure difference
reaches specified level.
PRESSURE SWITCH
switch activates when
pressure reaches
specified level.
MUFFLER (silencer)
reduces noise.
HYDRAULICS
SYMBOL
DESCRIPTION
SYMBOL
MANUALLY ACTIVATED
DIRECTION CONTROL
VALVE (variable position)
joystick controlled,
variable pressure to shift
the pilot activated
directional control valve
spool.
NON-RETURN VALVE SHUTTLE VALVE: Valve

which allows free flow in one direction only.
NON-RETURN VALVE
(check valve) Used as
replenishing valve, lock
check valve opens if
the inlet pressure is
higher than the outlet
pressure. Often contains
integral spring which has
NO significant pressure
valve.
MANUALLY ACTIVATED
DIRECTION FLOW
CONTROL VALVE (two
position) allows for
changing pilot flow to
control switching joystick
functions for STD/ISO
control (excavators only).
SPRING LOADED VALVE

(bypass valve) opens if
the inlet pressure is
greater than the outlet
pressure plus the spring
pressure.
PILOT CONTROLLED
NON-RETURN VALVE
it is possible to open the
valve by pilot pressure.
SHUTTLE VALVE the

inlet port connected to the
higher pressure id
automatically connected
to the outlet port while the
other inlet port is closed.
DESCRIPTION
STEERING CONTROL
VALVE (variable position)
used for controlling the
hydraulic flow for the
steering cylinders in
relationship to the amount
the steering wheel is
rotated.
PRESSURE CONTROL VALVE: Valve ensuring the
control of pressure.
DIRECTIONAL CONTROL VALVE: Valve providing

the opening (fully or restricted) or the closing of one
more flow paths (represented by several squares).
TWO PORTS and
CLOSED FLOW PATHS
SOLENOID ACTIVATED
DIRECTIONAL
CONTROL VALVE (two
position) controlled by
an electric solenoid (with
return spring).
PILOT ACTIVATED
DIRECTIONAL
CONTROL VALVE (two
position) controlled by
pressure (with return
spring).
RELIEF VALVE when

the inlet pressure
overcomes the opposing
force of the spring, the
valve opens permitting
flow from the outlet port.
RELIEF /
REPLENISHING VALVE
or RELIEF /
ANTICAVITATION VALVE
When the inlet
pressure becomes the
opposing force of the
spring, the valve opens
permitting flow from the
outlet port allows free
flow in the opposite
direction.
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13
HYDRAULICS
SYMBOL
DESCRIPTION
DUAL PRESSURE
RELIEF VALVE when
the inlet pressure
overcomes the opposing
force of the spring, the
valve opens permitting
flow from the outlet port.
Pilot pressure provides a
second pressure valve.
LOCK VALVE hydraulic
pressure is applied to
open the valve to allow
the hydraulic cylinder to
move.
FLOW CONTROL VALVE: Valve controlling the flow in

one or both directions.
ONE WAY RESTRICTOR
VALVE (non-return
valve with restriction)
unit allowing free flow in
one direction but
restricted flow in the other
direction.
TOW VALVE normally
in closed position.
LOAD SENSE BLEED

VALVE regulates small
amount of fluid flow
(leakage).
MISCELLANEOUS
ACCUMULATOR
Supplies temporary
reserve pressure to the
hydraulic system when
the engine has been
stopped.
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HYDRAULICS
Troubleshooting
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Polaris Service Personnel only.
13
WARNING
Check for correct function after adjustments, repairs or service. Failure to make correct repairs or adjustments can
cause injury or death.
PROBLEM
CAUSE
The hydraulic system will not operate.
1, 2, 3, 5, 8,
Slow hydraulic system action.
1, 2, 3, 6, 8, 11
Hydraulic action is not smooth.
1, 4, 5, 6, 7
Hydraulic functions move when controls are in neutral position.
9, 10, 11
Auxiliary hydraulics will not function.
1, 2, 3, 5
KEY TO CORRECT THE CAUSE

1. The fluid level is not correct.
2. Low charge pressure.
3. The hydraulic pump has damage.
4. The relief valve is not at the correct pressure.
5. Relief valve is not at the correct pressure.
6. Suction leak on the inlet side of the hydraulic pump.
7. Fluid is cold. Wrong viscosity fluid.
8. Rated capacity is exceeded.
9. Internal leak in the cylinder(s).
10. External leak from the cylinder(s).
11. Damage to the control spool.
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NOTES
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BRAKES
CHAPTER 14
BRAKES
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.4
BRAKE SYSTEM SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.5
BRAKE NOISE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.5
HYDRAULIC BRAKE SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.6
BRAKE SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.7
BRAKE SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.7
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.8
FOOT BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.9
BRAKE BLEEDING / FLUID CHANGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14.9
FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.11
PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.11
PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.12
PAD ASSEMBLY / INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.12
BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.13
FRONT CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.14
CALIPER EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.14
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.14
CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.15
CALIPER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.16
CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.16
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.17
FRONT BRAKE DISC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.18
DISC RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.18
DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.18
FRONT DISC REMOVAL / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.19
REAR BRAKE PADS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.20
PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.20
PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.20
PAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.21
BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.21
REAR CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.22
CALIPER EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.22
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.22
CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.23
CALIPER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.24
14.1
Copyright 2014
14
BRAKES
CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.24
CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.25
REAR BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.26

DISC RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.26
DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.26
REAR DISC REMOVAL / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.27
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.28
BRAKES SQUEAL / POOR BRAKE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.28
PEDAL VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.28
CALIPER OVERHEATS (BRAKES DRAG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.28
BRAKES LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.28
14.2
Copyright 2014
BRAKES
GENERAL SPECIFICATIONS
FRONT BRAKE SYSTEM
Item
Standard
Service Limit
Front Brake Pad Thickness
.298 .007" / 7.56 .178 mm
.180" (4.6 mm)
Front Brake Disc Thickness
.188" ( 4.78 mm)
.170" (4.32 mm)
Front Brake Disc Runout
.010" (.254 mm)
Front Caliper Piston Bore I.D.
1.373 (34.87 mm)
1.375 (34.93 mm)
Front Caliper Piston O.D.
1.370 (34.80 mm)
1.368 (34.75 mm)
Item
Standard
Service Limit
Rear Brake Pad Thickness
.298 .007"/ 7.56 .178 mm
.180" (4.6 mm)
Rear Brake Disc Thickness
.188" (4.78 mm)
.170" (4.32 mm)
Rear Brake Disc Runout
.010" (.254 mm)
Rear Caliper Piston Bore I.D.
1.505 (38.23 mm)
1.507 (38.28 mm)
Rear Caliper Piston O.D.
1.500 (38.10 mm)
1.498 (38.05 mm)
14
REAR BRAKE SYSTEM
14.3
Copyright 2014
BRAKES
SPECIAL TOOLS
Item
ft-lbs
Nm
Part Number
Tool Description
Brake Disc to Hub Bolts (Front)
18
24
2870975
Mity Vac Pressure Test Tool
Brake Disc to Hub Bolts (Rear)
28
38
Brake Line Banjo Bolts (All)
15
20
Brake Line Flare Fittings
12-15
16-20
Brake Switch
15
20
Caliper Bleed Screws
Caliper Mounting Bolts (Front)
30
41
Caliper Mounting Bolts (Rear)
48
65
Front Brake Scraper Screws
10
Master Cylinder Mounting Bolts
23
31
Pedal Mount Bracket Nuts
18
24
Rear Brake Junction Block

14.4
Copyright 2014
BRAKES
BRAKE SYSTEM SERVICE NOTES
BRAKE NOISE TROUBLESHOOTING
Disc brake systems are light weight, low maintenance,

and perform well in the conditions this vehicle will
routinely encounter. There are a few things to remember
when replacing disc brake pads or performing brake
system service to ensure proper system function and
maximum pad service life.
Dirt or dust buildup on the brake pads and disc is the

most common cause of brake noise (squeal caused by
vibration). If cleaning does not reduce the occurrence of
brake noise, Permatex Disc Brake Quiet can be
applied to the back of the pads. Follow directions on the
package. This will keep pads in contact with caliper
piston(s) to reduce the chance of squeaks caused by dirt
or dust.
DO NOT over-fill the master cylinder fluid reservoir.

Make sure the brake pedal returns freely and
completely.
Brake Noise Troubleshooting
Adjust the caliper stop pin after pad service.
Possible Cause
Remedy
Dirt, dust, or imbedded

material on pads or disc
Spray disc and pads with

CRC Brakeleen or an
equivalent non-flammable
aerosol brake cleaner.
Remove pads and/or disc
hub to clean imbedded
material from disc or
pads.
Check and adjust master cylinder reservoir fluid

level after pad service.
Make sure atmospheric vent on reservoir is
unobstructed.
Test for brake drag after any brake system service
and investigate cause if brake drag is evident.
Make sure caliper moves freely on guide pins
(where applicable).
Inspect caliper piston seals for foreign material
that could prevent caliper pistons from returning
freely.
Perform a brake burnishing procedure after
installing new pads to maximize service life.
DO NOT lubricate or clean the brake components
with aerosol or petroleum products. Use only
approved brake cleaning products.
14
Pad(s) dragging on disc

(noise or premature pad
wear) because of
improper adjustment
Master cylinder reservoir
overfilled
Master cylinder
compensating port
restricted
Master cylinder piston not
returning completely
Caliper piston(s) not
returning
Operator error (riding the
brake)
Adjust pad stop
Loose wheel hub or

bearings
Check wheel and hub for

abnormal movement.
Brake disc warped or

excessively worn
Replace disc
Brake disc misaligned or

loose
Inspect and repair as

necessary
Noise is from other source

(axle, hub, disc or wheel)
If noise does not change

when brake is applied
check other sources.
Inspect and repair as
necessary
Set to proper level

Clean compensating port
Inspect. Repair as
necessary
Clean piston(s) seal
Educate operator
14.5
Copyright 2014
BRAKES
HYDRAULIC BRAKE SYSTEM OPERATION
The Polaris brake system consists of the following components or assemblies: brake pedal, master cylinder, hydraulic
brake lines, brake calipers, brake pads, and brake discs, which are secured to the drive line.
When the foot activated brake lever is applied it applies pressure on the piston within the master cylinder. As the
master cylinder piston moves inward it closes a small opening (compensating port) within the cylinder and starts to
build pressure within the brake system. As the pressure within the system is increased, the pistons located in the brake
calipers move outward and apply pressure to the moveable brake pads. These pads contact the brake discs and move
the calipers in their floating bracket, pulling the stationary side pads into the brake discs. The resulting friction reduces
brake disc and vehicle speed.
The friction applied to the brake pads will cause the pads to wear. As these pads wear, the piston within the caliper
moves further outward and becomes self adjusting. Fluid from the reservoir fills the additional area created when the
caliper piston moves outward.
Brake fluid level is critical to proper system operation. Too little fluid will allow air to enter the system and cause the
brakes to feel spongy. Too much fluid could cause brakes to drag due to fluid expansion.
Located within the master cylinder is the compensating port which is opened and closed by the master cylinder piston
assembly. As the temperature within the hydraulic system changes, this port compensates for fluid expansion or
contraction. Due to the high temperatures created within the system during heavy braking, it is very important that the
master cylinder reservoir have adequate space to allow for fluid expansion. Never overfill the reservoir! Do not fill
the reservoir beyond the MAX LEVEL line!
When servicing Polaris brake systems use only Polaris DOT 4 Brake Fluid (PN 2872189).
WARNING: Once a bottle of brake fluid is opened,
use what is necessary and discard the rest in
accordance with local laws. Do not store or use a
partial bottle of brake fluid. Brake fluid is
hygroscopic, meaning it rapidly absorbs moisture.
This causes the boiling temperature of the brake
fluid to drop, which can lead to early brake fade and
the possibility of serious injury.
14.6
Copyright 2014
BRAKES
BRAKE SYSTEM EXPLODED VIEW
Brake System Exploded View
14
14.7
Copyright 2014
BRAKES
MASTER CYLINDER
5. Discard seals (Item 6) and replace upon assembly.
Removal
1. Remove retaining clip (Item 1) from the clevis pin
(Item 2) attaching the master cylinder to brake pedal
lever.
NOTE: Make note of front and rear brake line

orientation on the master cylinder.
6. Dispose of brake fluid properly and DO NOT re-use.
Installation
1. Install brake lines on master cylinder with new seals.
Torque banjo bolts to specification.
Brake Line Banjo Bolts:

15 ft-lbs (20 Nm)
2. Attach the master cylinder to the frame and torque
mounting fasteners to specification.
2. Remove the two mounting bolts (Item 3) that secure

the master cylinder to the frame.
Master Cylinder Mounting Bolts:

23 ft-lbs (31 Nm)
3. Remove master cylinder and place a fluid catch

container under the master cylinder brake lines.
3. Attach the master cylinder to the brake pedal lever

by installing the clevis pin and retaining clip.
CAUTION
4. Follow the Brake Bleeding / Fluid Change

procedure.
Brake fluid will damage finished surfaces.

Do not allow brake fluid to come in contact
with finished surfaces.
5. Field test unit for proper braking action before putting

into service. Inspect for fluid leaks and firm brakes.
4. Loosen the brake line banjo bolt (Item 4) and brake

switch (Item 5) allowing the fluid to drain.
14.8
Copyright 2014
BRAKES
FOOT BRAKE PEDAL
BRAKE BLEEDING / FLUID CHANGE
Removal
1. Remove the clip (Item 1) from the end of the pedal
mount bracket (Item 2).
NOTE: When bleeding the brakes or replacing the

fluid always start with the furthest caliper from the
master cylinder. This procedure should be used to
change fluid or bleed brakes during regular
maintenance.
CAUTION
14
Always wear safety glasses.
CAUTION
Brake fluid will damage finished surfaces.
Do not allow brake fluid to come in contact
with finished surfaces.
1. Locate master cylinder reservoir (Item 1) in the front
LH wheel well area (see Figure 1-7). Clean reservoir
cover thoroughly.
2. Remove cover from reservoir.
3. If changing fluid, remove old fluid from reservoir with
a Mity Vac pump or similar tool.
Mity Vac (PN 2870975)
2. Remove the retaining clip (Item 3) and clevis pin
(Item 4) from the master cylinder (Item 5) to free it
from the brake pedal (Item 6).
4. Add brake fluid to the indicated MAX level of

reservoir
3. Slide the brake pedal and bushings (Item 7) off the

pedal mount bracket.
Installation
1. If the pedal mount bracket (Item 2) was removed,
torque retaining nuts (Item 8) to specification.
Pedal Mount Bracket Nuts:

18 ft-lbs (24 Nm)
2. Reverse Removal st 1-3 to complete foot brake
installation.
3. Use new retaining clips upon installation.
Polaris DOT 4 Brake Fluid

(P/N 2872189)
5. Begin bleeding procedure with caliper furthest from
master cylinder.
14.9
Copyright 2014
BRAKES
6. Install a box-end wrench on caliper bleeder screw.
7. Attach a tight-fitting, clear hose to the bleeder fitting.
13. Tighten bleeder screw and remove bleeder hose.

Torque bleed screw to specification.
Caliper Bleed Screws:

47 in-lbs (5.3 Nm)
14. Repeat Steps 9 - 13 for the remaining brake calipers.
15. Install master cylinder reservoir cover.
16. Field test machine at low speed before putting into
service. Check for proper braking action and pedal
reserve. With pedal firmly applied, pedal reserve
should be no less than 1/2" (1.3 cm).
17. Check brake system for fluid leaks.
8. Place a small amount of fresh brake fluid into a
small, clear container and place the other end of
bleeder hose into the container.
9. Have an assistant slowly pump the brake pedal until
pressure builds and then hold.
10. Quickly open and close the bleed screw while
holding pressure on the brake pedal.
NOTE: Do not release brake pedal before
bleeder screw is tight or air may be drawn into
master cylinder.
11. Release brake pedal pressure. Check level of fluid in
reservoir and add if necessary (Figure 1-7).
12. Repeat Steps 9, 10, and 11 until brake pedal is firm
and no air can be seen moving through the clear
hose. Add fluid as necessary to maintain level in
reservoir.
Master Cylinder Fluid Level:
Between the MIN and MAX line.
CAUTION
Maintain at least 1/2"(1.27 cm) of brake fluid in the
reservoir to prevent air from
entering the master cylinder.
14.10
Copyright 2014
BRAKES
FRONT BRAKE PADS
4. Push caliper piston into caliper bore slowly using a

C-clamp or locking pliers with pads installed.
Pad Removal
1. Elevate and support front of vehicle.
CAUTION
Use care when supporting vehicle so that it
does not tip or fall.
Severe injury may occur if machine tips or falls.
14
2. Remove the wheel nuts, washers and front wheel.

Loosen pad adjuster screw.
NOTE: Brake fluid will be forced through

compensating port into master cylinder fluid
reservoir when piston is pushed back into
caliper. Remove excess fluid from reservoir as
required.
5. Push the mounting bracket inward and slip outer
brake pad out between the bracket and caliper body.
3. Remove the upper and lower caliper mounting bolts

and remove the caliper from the front hub.
NOTE: When removing caliper, use care not to
damage brake line. Support caliper to avoid
kinking or bending brake line.
6. Remove the inner pad from the bracket and caliper.
14.11
Copyright 2014
BRAKES
Pad Inspection
Pad Assembly / Installation
1. Measure the thickness of the pad material. Replace

pads if worn beyond the service limit.
1. Lubricate mounting bracket pins with a light film of

silicone grease and install rubber dust boots.
2. Compress mounting bracket and make sure dust

boots are fully seated. Install pads with friction
material facing each other.
WARNING
If brake pads are contaminated with grease, oil, or
liquid soaked do not use the pads.
Use only new, clean pads.
3. Install caliper onto front hub and torque mounting
bolts (Item 1) to specification.
Front Brake Pad Thickness
New: .298 .007 (7.56 .178 mm)
Service Limit: .180 (4.6 mm)

30 ft-lbs (41 Nm)
14.12
Copyright 2014
BRAKES
4. Slowly pump brake pedal until pressure has been
built up. Maintain at least 1/2, (12.7 mm) of brake
fluid in reservoir to prevent air from entering brake
system.
5. Install the pad adjuster set screw and turn clockwise
until stationary pad contacts disc, then back off 1/2
turn (counterclockwise).
14
6. Verify fluid level in reservoir is up to MAX line inside

reservoir and install reservoir cap.
Master Cylinder Fluid
Up to MAX line inside reservoir
Wheel Nuts:
60 ft-lbs (81 Nm)
Brake Burnishing Procedure

Brake burnishing must be performed after installation of
new brake pads to extend service life and reduce noise.
Start machine and slowly increase speed to 30 mph.
Gradually apply brakes to stop machine. Allow pads and
disc to cool sufficiently during the procedure. Do not
allow pads or disc to become hot or warping may result.
Repeat this procedure 10 times. Do not make more
than 3 stops per 1 mile (1.6 km).
14.13
Copyright 2014
BRAKES
FRONT CALIPER SERVICE
Caliper Exploded View
Caliper Removal
1. Elevate and safely support the front of the vehicle.
2. Remove the (4) wheel nuts and the front wheel.
5. Loosen brake pad adjustment set screw to allow

brake pad removal after the caliper is removed.
6. Remove the caliper mounting bolts (Item 1) and
caliper.
CAUTION
Use care when supporting vehicle so that it does not tip
or fall. Severe injury may occur.
3. Clean caliper area before removal.
4. Place a container below the caliper to catch brake
fluid when removing line. Remove brake line from
caliper.
14.14
Copyright 2014
BRAKES
Caliper Disassembly
1. Remove both brake pads from the caliper (see
FRONT BRAKE PADS - Pad Removal).
4. Once the pistons are removed, use a pick to carefully

remove the square O-rings from the caliper. O-rings
should be replaced during caliper service.
2. Remove the mount bracket assembly and dust boots

from caliper. Thoroughly clean caliper before
disassembly and prepare a clean work area.
14
3. Use a commercially available caliper piston pliers to

extract the pistons from the caliper.
5. Clean the caliper body, piston, and retaining bracket

with brake cleaner or alcohol.
NOTE: Be sure to clean the seal grooves in

caliper body.
NOTE: The piston sealing surfaces will become
damaged if a standard pliers is used to remove
the pistons.
14.15
Copyright 2014
BRAKES
Caliper Inspection
1. Inspect caliper body for nicks, scratches, pitting or
wear. Measure bore size and compare to
specifications. Replace if damaged or worn beyond
service limit.
Front Caliper Piston Bore I.D.:

Standard: 1.373 (34.87 mm)
Service Limit: 1.375 (34.93 mm)
3. Inspect brake disc and pads as outlined in this

chapter.
Caliper Assembly
1. Install new O-rings in the caliper body. Be sure the
grooves are clean and free of residue or brakes may
drag upon assembly.
2. Coat pistons with clean Polaris DOT 4 Brake Fluid.

Install pistons with a twisting motion while pushing
inward. Piston should slide in and out of bore
smoothly, with light resistance.
3. Lubricate the mounting bracket pins with silicone
grease and install the rubber dust seal boots.
2. Inspect piston for nicks, scratches, pitting or wear.

Measure piston diameter and replace if damaged or
worn beyond service limit.
4. Compress the mounting bracket and make sure the

dust seal boots are fully seated. Install the brake
pads. Clean the disc and pads with brake parts
cleaner or denatured alcohol to remove any dirt, oil
or grease.
Front Caliper Piston O.D.:
Standard: 1.370 (34.80 mm)
14.16
Copyright 2014
BRAKES
Caliper Installation
1. Install the caliper and torque the mounting bolts
(Item 1) to specification.
3. Install the pad adjustment screw and turn until

stationary pad contacts disc, then back off 1/2 turn.
NOTE: If brake disc scraper (Item 2) was

removed, be sure to reinstall it upon caliper
installation.
14

procedure as outlined earlier in this chapter.

30 ft-lbs (41 Nm)
2. Install brake line and torque the banjo bolt to the
proper torque specification.
Wheel Nuts:
Steel Wheels: 60 ft-lbs (81 Nm)
Make sure the brake is not dragging when pedal is
released. If the brake drags, re-check assembly and
installation.
NOTE: If new brake pads are installed, brake
burnishing is recommended (see FRONT
BRAKE PADS - Brake Burnishing Procedure).
14.17
Copyright 2014
BRAKES
FRONT BRAKE DISC
Disc Inspection
Disc Runout
1. Visually inspect disc for scoring, scratches or

gouges. Replace the disc if any deep scratches are
evident.
1. Mount dial indicator as shown. Slowly rotate the disc

and read total runout on the dial indicator. Replace
disc if runout exceeds specification.
2. Use a 0-1 micrometer and measure disc thickness

at eight different points around the pad contact
surface. Replace disc if worn beyond service limit.
Brake Disc Thickness

New .188 (4.78 mm)
Service Limit .170 (4.32 mm)
Brake Disc Runout:

Service Limit .010 (.254 mm)
Brake Disc Thickness Variance

Service Limit: .002 (.051 mm)
difference between measurements
14.18
Copyright 2014
BRAKES
Front Disc Removal / Replacement
1. Remove the front brake caliper (see Front Caliper
Service).
5. Install wheel hub assembly, washers, and castle nut.

Torque castle nut to specification and install a new
cotter pin.
2. Remove cotter pin, castle nut and washers.

3. Remove the wheel hub assembly from the vehicle
and remove the four bolts retaining the disc to the
hub.
Front Wheel Hub Castle Nut:

75 ft-lbs (102 Nm)
14
4. Clean the wheel hub mating surface and install the

new disc on the wheel hub. Torque new disc
CAUTION
Always use new brake disc mounting bolts. The bolts
have a pre-applied locking agent which is destroyed
upon removal.
6. Install front brake caliper (see Front Caliper

Service). Follow the bleeding procedure outlined
earlier in this chapter.
installation.
Front Brake Disc Mounting Bolts:

18 ft-lbs (24 Nm)
14.19
Copyright 2014
BRAKES
REAR BRAKE PADS
6. Remove the brake pads (Item 3) from the caliper.
Pad Removal
1. Elevate and support rear of machine.
CAUTION
or fall. Severe injury may occur
if machine tips or falls.
2. Remove the rear wheel. Loosen the pad adjuster
screw (Item 1) 2-3 turns.
Pad Inspection
1. Clean the caliper with brake cleaner or alcohol.
2. Measure the thickness of the pad material. Replace
pads if worn beyond the service limit.

4. Remove caliper mounting bolts (Item 2) and lift
caliper off of disc.
NOTE: When removing caliper, be careful not to
damage brake line. Support caliper so as not to
kink or bend brake line.
5. Push caliper piston into caliper bore slowly with pads
installed.
NOTE: Brake fluid will be forced through
compensating port into master cylinder fluid
reservoir when piston is pushed back into
caliper. Remove excess fluid from reservoir as
required.
Rear Brake Pad Thickness

New .298 + .007 (7.56 + .178 mm)
14.20
Copyright 2014
BRAKES
Pad Installation
Brake Burnishing Procedure
1. Install new brake pads into the caliper body.
Brake burnishing must be performed after installation of

new brake pads to extend service life and reduce noise.
Start machine and slowly increase speed to 30 mph.
Gradually apply brakes to stop machine. Allow pads and
disc to cool sufficiently during the procedure. Do not
allow pads or disc to become hot or warping may result.
Repeat this procedure 10 times. Do not make more
than 3 stops per 1 mile (1.6 km).
14
2. Install caliper
specification.
and
torque
bolts
(Item
1)
to

48 ft-lbs (65 Nm)
3. Install the pad adjustment screw (Item 2) and turn
turn.
4. Slowly pump brake pedal until pressure has been
built up. Maintain at least 1/2" (12.7 mm) of brake
fluid in reservoir to prevent air from entering master
cylinder.
14.21
Copyright 2014
BRAKES
REAR CALIPER SERVICE
Caliper Exploded View
Caliper Removal
1. Elevate and safely support the rear of the vehicle.
4. Place a container below the caliper to catch brake

fluid when removing the brake line. Use a wrench to
remove the brake line banjo bolt (Item 1).
2. Remove the (4) wheel nuts and the rear wheel.
CAUTION
or fall. Severe injury may occur.
5. After fluid has drained into the container, remove the

two caliper mounting bolts (Item 2) and brake caliper.
6. Clean the brake disc, caliper body and caliper
pistons with brake cleaner or alcohol.
14.22
Copyright 2014
BRAKES
Caliper Disassembly
1. Remove brake pad adjustment set screw (Item 3).
2. Push upper pad retainer pin inward and slip brake
pads past the edge and remove from the caliper.
5. Clean the caliper body, piston, and retaining bracket

with brake cleaner or alcohol.
NOTE: Be sure to clean caliper body seal
grooves.
3. Remove bracket (Item 4) and dust boots (Item 5).
14
4. Using a hammer and a small punch, remove piston

(Item 6) from caliper body (Item 7). Remove square
O-rings (Item 8) and (Item 9) from the caliper body.
14.23
Copyright 2014
BRAKES
Caliper Inspection
1. Inspect caliper body for nicks, scratches or wear.
Measure bore size and compare to specifications.
Replace if damage is evident or if worn beyond
service limit.
3. Inspect the brake disc and pads as outlined in this

chapter.
Caliper Assembly
1. Install new caliper seals (Item 1) in the caliper body
(Item 2). Be sure groove is clean and free of residue
or brakes may drag upon assembly.
2. Coat piston with clean Polaris DOT 4 Brake Fluid

(PN 2872189). Install piston (Item 3) with a twisting
motion while pushing inward. Piston should slide in
and out of bore smoothly with light resistance.
Rear Caliper Piston Bore I.D.:
Standard: 1.505 (38.23 mm)
3. Lubricate the mounting bracket pins with silicone

grease and install the rubber dust seal boots.
2. Inspect piston for nicks, scratches, wear or damage.

Measure diameter and replace if damaged or worn
beyond service limit.
4. Compress the mounting bracket and make sure the

dust seals are fully seated. Install the brake pads.
Clean the disc and pads with brake parts cleaner or
denatured alcohol to remove any dirt, oil or grease.
Rear Caliper Piston O.D.:

Standard: 1.500 (38.10 mm)
14.24
Copyright 2014
BRAKES
Caliper Installation
1. Install the rear caliper and torque the mounting bolts
(Item 1) to specification.

procedure as outlined earlier in this chapter.
Wheel Nuts:
60 ft-lbs (81 Nm)
installation.
NOTE: If new brake pads are installed, brake
burnishing is recommended (see REAR BRAKE
PADS - Brake Burnishing Procedure).

48 ft-lbs (65 Nm)
2. Install the brake line and torque the banjo bolt (Item
Brake Line Banjo Bolt:

15 ft-lbs (20 Nm)
3. Install the pad adjustment screw (Item 3) and turn
turn.
14.25
Copyright 2014
14
BRAKES
REAR BRAKE DISC
Disc Inspection
Disc Runout
1. Visually inspect disc for scoring, scratches or

gouges. Replace disc if any are evident.
1. Mount a dial indicator and measure disc runout.

Slowly rotate the disc and read total runout on the
dial indicator. Replace the disc if runout exceeds
specification.
2. Use a 0-1" micrometer and measure disc thickness

at 8 different points around perimeter of disc.
Replace disc if worn beyond service limit.
Brake Disc Thickness:

New .188 (4.78 mm)
Brake Disc Runout
Brake Disc Thickness Variance:

difference between measurements
14.26
Copyright 2014
BRAKES
Rear Disc Removal / Replacement
1. Remove the rear brake caliper (see Rear Caliper
Service).
5. Install wheel hub assembly, washers, and castle nut.

Torque castle nut to specification and install a new
cotter pin.
2. Remove cotter pin, castle nut and washers.

3. Remove the wheel hub assembly from the vehicle
and remove the (4) bolts retaining the disc to the
hub.
Rear Wheel Hub Castle Nut:

110 ft-lbs (149 Nm)
14
4. Clean the wheel hub mating surface and install the

new disc on the wheel hub. Torque new disc
CAUTION
Always use new brake disc mounting bolts. The bolts
have a pre-applied locking agent which is destroyed
upon removal.
6. Install rear brake caliper (see Rear Caliper

Service). Follow the bleeding procedure outlined
earlier in this chapter.
installation.
Rear Brake Disc Mounting Bolts:

28 ft-lbs (38 Nm)
14.27
Copyright 2014
BRAKES
TROUBLESHOOTING
Brakes Squeal / Poor Brake Performance
Air in system
Water in system (brake fluid contaminated)
Caliper/disc misaligned
Caliper dirty or damaged
Brake line damaged or lining ruptured
Worn disc and/or friction pads
Incorrectly adjusted stationary pad
Worn or damaged master cylinder or components
Damaged break pad noise insulator
Pedal Vibration
Disc damaged
Disc worn (runout or thickness variance exceeds
service limit)
Caliper Overheats (Brakes Drag)

Compensating port plugged
Pad clearance set incorrectly
Brake pedal binding or unable to return fully
Residue build up under caliper seals
Operator riding brakes
Brakes Lock
Alignment of caliper to disc
Caliper pistons sticking
Improper assembly of brake system components
14.28
Copyright 2014
ELECTRICAL
CHAPTER 15
ELECTRICAL
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.4
ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.4
COMPONENTS UNDER HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.4
COMPONENTS BEHIND DASH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.4
COMPONENTS UNDER CENTER CONSOLE / PASSENGER SEAT BASE . . . . . . . . . . . . . . . . . . . . . . . .15.4
ELECTRONIC CONTROL UNIT (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.5
ECU REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.5
CRANKSHAFT POSITION SENSOR (CPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.5
CPS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.5
GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.6
GLOW PLUG TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.6
TWO SPEED MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.6
TWO SPEED MANIFOLD LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.6
REAR DIFFERENTIAL SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.7
DIFFERENTIAL SOLENOID OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.7
DIFFERENTIAL SOLENOID CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.7
ALL WHEEL DRIVE (AWD) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.7
AWD / 2WD / TURF SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.7
AWD COIL OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.7
FUEL SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.9
FUEL SOLENOID LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.9
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.9
VEHICLE SPEED SENSOR TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15.9
TRANSMISSION (GEAR POSITION) SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.10
TRANSMISSION (GEAR POSITION) SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.10
PUMP NEUTRAL (TREADLE) SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.11
PUMP NEUTRAL SWITCH LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.11
ENGINE OIL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.12
ENGINE OIL PRESSURE SWITCH LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.12
IGNITION (KEY) SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.12
IGNITION KEY SWITCH TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.12
HEADLAMP SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.13
HEADLAMP SWITCH TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.13
BRAKE LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.13
BRAKE LIGHT SWITCH LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.13
WORK, TILT LOCK AND AUX SWITCH (HD AND HDPTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.14
WORK, TILT LOCK AND AUX. SWITCH TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.14
BOX LIFT SWITCH (HD AND HDPTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.15
BOX LIFT SWITCH TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.15
HYDRAULIC OIL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.15
15.1
Copyright 2014
15
ELECTRICAL
HYDRAULIC OIL SWITCH LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.16
HYDRAULIC TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.16

HYDRAULIC TEMPERATURE SENSOR LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.16
PTO CONTROLS (HDPTO MODEL ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.17
PTO ENGAGEMENT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.17
PTO CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.17
SEAT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.17
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.18
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.18
RIDER INFORMATION DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.18
INSTRUMENT CLUSTER PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.20
INFORMATION DISPLAY AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.20
DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.25
INSTRUMENT CLUSTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.27
INSTRUMENT CLUSTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.27
HEADLIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.28
HEADLIGHT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.28
HEADLIGHT BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.29
HEADLIGHT HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.29
HEADLIGHT HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.30
TAIL LIGHT / BRAKE LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.31
LED LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.31
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.32
COOLING SYSTEM BREAK-OUT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.32
COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.33
FAN CONTROL CIRCUIT OPERATION / TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.33
FAN CONTROL CIRCUIT BYPASS TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.33
HVAC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.34
HVAC SYSTEM BREAK-OUT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.34
HVAC CONTROL CIRCUIT OPERATION / THEORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.34
AC SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.35
BLOWER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.35
TEMPERATURE CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.35
FUEL SENDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.36
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.36
FUSE BOX: FUSES / RELAYS / CIRCUIT BREAKERS / TVS DIODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.37
FUSE, RELAY, CIRCUIT BREAKER AND TVS DIODE LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.37
RELAY BOX DETAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.38
RELAY POWER FLOWCHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.40
FUSE / RELAY BOX DETAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.43
EXTERNAL RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.44
CHARGING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.46
CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.46
CHARGING SYSTEM BREAK EVEN TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.46
ALTERNATOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.47
ALTERNATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.48
ALTERNATOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.48
15.2
Copyright 2014
ELECTRICAL
BATTERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.48
BATTERY SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.49
GENERAL BATTERY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.49
BATTERY REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.49
BATTERY OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.49
BATTERY TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.49
OCV (OPEN CIRCUIT VOLTAGE) TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.50
VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.50
LOAD TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.50
BATTERY CONDUCTANCE ANALYZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.50
BATTERY CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.51
BATTERY TERMINAL BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.51
STARTER SYSTEM AND WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.52

STARTER SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.53
STARTER MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.54
STARTER MOTOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.54
STARTER MOTOR TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.55
STARTER MOTOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.57
STARTER SOLENOID OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.57
STARTER SOLENOID BENCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.58
DIGITAL WRENCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.59
DIGITAL WRENCH DIAGNOSTIC SOFTWARE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.59
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.59
DIAGNOSTIC SOFTWARE VERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.59
ECU REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.59
GUIDED DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.59
DIGITAL WRENCH COMMUNICATION ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.60
DIAGNOSTIC CONNECTOR LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.60
DIGITAL WRENCH SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.61
DIGITAL WRENCH VERSION AND UPDATE ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.61
DIGITAL WRENCH UPDATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.61
DIGITAL WRENCH FEATURE MAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.64
ENGINE CONTROLLER REPROGRAMMING (REFLASH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.64
SPECIAL TESTS MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.67
DATA ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.68
15.3
Copyright 2014
15
ELECTRICAL
GENERAL INFORMATION
Components Under Hood
Special Tools
The following electrical components can be accessed

under the hood.
Headlight Connectors
Part Number
Tool Description
PV-43568
Fluke 77 Digital Multimeter
PV-43526
Connector Test Kit
2870630
Timing Light
2460761
Hall Effect Sensor Probe Harness
2871745
Static Timing Light Harness
PU-50296
Battery Conductance Analyzer

(MDX-610P)
PU-49466
Relay Bypass
Terminal Block
Components Behind Dash Panel

with the upper dash panel removed.
Instrument Cluster (Speedometer)
AWD/2WD/TURF Switch
Headlight Switch
12 VDC Accessory Power Points
Ignition Key Switch

Dump Box Switch

Cargo Box Lift Relay
Electrical Service Notes
Cargo Box Lift Circuit Breaker
Keep the following notes in mind when diagnosing an

electrical problem:
Refer to wiring diagram for electrical component
resistance specifications.
When measuring resistance of a component that
has a resistance value under 10 Ohms, remember
to subtract meter lead resistance from the reading.
Connect the leads together and record the
resistance. The resistance of the component is
equal to tested value minus the lead resistance.
Become familiar with the operation of your meter.
Be sure leads are in the proper jack for the test
being performed (i. e. 10A jack for current
readings). Refer to the Owners Manual included
with your meter for more information.
Components Under Center Console /

Passenger Seat Base
with the passenger seat base / center console removed.
Battery / Battery Cables
Fuse / Relay Boxes
Terminal Block
ECU
Digital Wrench Diagnostic Connector
Transient-Voltage Suppression (TVS) Diodes
Voltage, amperage, and resistance values

included in this manual are obtained with a
Fluke 77 Digital Multimeter (PV-43568). This
meter is used when diagnosing electrical
problems. Readings obtained with other meters
may differ.
Pay attention to the prefix on the multimeter
reading (K, M, etc.) and the position of the decimal
point.
For resistance readings, isolate the component to
be tested. Disconnect it from the wiring harness or
power supply.
15.4
Copyright 2014
ELECTRICAL
ELECTRONIC CONTROL UNIT (ECU)
Located under the middle passenger seat on the
BRUTUS model and under the center console on the
BRUTUS HD and HDPTO models, the ECU manages
the fuel pull solenoid, the fuel hold solenoid, the fuel
pump, and glow plug operation. The ECU stores the logic
for hot lamps, radiator fan, 2-speed shift strategy, AWD
control, and starter lockout.
Digital Wrench also reports on the following items:
CRANKSHAFT POSITION SENSOR

(CPS)
The CPS is used to provide the ECU with engine speed
for AWD operation and to determine PTO speed.
CPS Location
The CPS is located on the transmission side of the
engine on the bell housing.
CPS Testing
1. Disconnect the main harness from the sensor
harness pigtail.
AWD and Diff Lock Status

Battery Voltage
2. Connect an ohmmeter between the CPS pin

terminals shown below and compare to the spec
below. The reading should be taken at room
temperature.
Brake Switch (on/off)

Cooling Fan Relay Driver
Crankshaft Signal Present
Engine RPM, Temperature and Run-Time
Fuel Pump (on/off)
Gear Switch Voltage
PTO Status / RPM
Seat Switch (Operator Present) Input / Output
Treadle / Pump Neutral Sensor Status
Two Speed Shift Coil Duty Cycle
Vehicle Speed
CPS Resistance Specification:

1000 10%
ECU Removal
1. Turn the ignition switch to the off position.
2. Remove the passenger seat or center console.
3. Remove the four plastic rivets retaining the ECU to
the base.
4. Disconnect the harness to the ECU and remove the
ECU from the vehicle.
15.5
Copyright 2014
15
ELECTRICAL
GLOW PLUGS
TWO SPEED MANIFOLD
The glow plugs are located on the engine assembly

below the valve cover. The valve cover will need to be
removed if the glow plugs are to be tested or replaced.
The two speed manifold modifies pressure and flow to

the shift plate in the pump motor depending on selected
gear and speed. There are two distinctive ramps per
drive gear.
Glow Plug Testing

1. Disconnect the air intake hose going to the valve
cover.
2. Remove the nine 10 mm bolts retaining the valve
cover to the engine and lift the valve cover off.
Two Speed Manifold Location

The two speed manifold is located under the drivers seat
above the fuel tank in the same block as the steering
priority and steering relief valves.
3. Remove the nuts (Item 1) retaining the sub-harness

to the glow plugs.
Two Speed Manifold Testing

The two speed manifold should be tested for proper
operation using Digital Wrench. Go to the Special Tests
menu - Output State Control and select Command a
Duty Cycle.
4. Using an ohmmeter, put the red lead on the glow
plug connector and the black lead to engine ground.
Glow Plug resistance: 0.4
5. If glow plugs require replacement, torque glow plug
fasteners to specification.
Glow Plug
M10: 12 ft-lbs
M4 nut: 15 in-lbs
15.6
Copyright 2014
ELECTRICAL
REAR DIFFERENTIAL SOLENOID
ALL WHEEL DRIVE (AWD) SYSTEM
Differential Solenoid Overview
AWD / 2WD / TURF Switch
The differential solenoid is located on the rear portion of

the transmission case. The solenoid actuates a shift fork
with an engagement dog, which locks and unlocks the
rear differential. Reference Chapter 9 for more
information.
1. Disconnect the AWD / 2WD / TURF switch harness

by depressing the connector locks and pulling on the
connector. Do not pull on the wiring.
2. Test between the 2 sets of outputs (AWD / TURF). If
any of the tests fail, replace the switch assembly.
Move the switch to AWD. There should be
continuity between switch pins 2 and 3.
Move the switch to 2WD. There should be no
continuity between pins 1 and 2; 2 and 3.
Move the switch to TURF. There should be
continuity between switch pins 1 and 2.
NOTE: Pins 7 and 3 provide power and ground
for the AWD indicator. Pins 1 and 7 provide
power and ground for the Turf indicator.
AWD Coil Overview

When the AWD switch is ON, 12 VDC power is present
at the hub coil and if the criteria is met, the ECU provides
a ground path on brown/white. The AWD icon should
display on the instrument cluster.
AWD Testing
Differential Solenoid Circuit Operation

The Rear Diff Solenoid Relay is attached to the rear
portion of the main frame and can be accessed by tilting
the rear cargo box.
When the switch is pushed to activate TURF, a ground
signal is provided to the ECU from the AWD switch.
Depending on engine speed and gear position criteria,
the ECU energizes the Rear Diff Solenoid Relay allowing
it to enable the differential solenoid.
If the rear diff fails to switch from operational modes:
Check the solenoid and relay connectors. Look for
loose wires or bad connections.
Check for power from the relay connector, to
ensure the solenoid has power to be activated.
Check the AWD
connections.
switch
wires
for
loose
Remove solenoid from rear differential and ensure

the solenoid plunger is actuating.
1. Verify AWD switch is functional and that a minimum

of 11 volts is present at the hub coil.
2. Verify AWD hub coil is functional. Test the AWD hub
coil using an ohm meter. See specifications below:
TEST
CONNECT
METER LEADS
TO:
OHMS
READING
AWD Coil
GY to BN/WH
~ 24 5%
AWD Coil
GY to Ground
Open Line (OL)
3. Verify the wiring harness, wiring, connectors,

connector pins and grounds are undamaged, clean
and connected properly.
4. Verify continuity of wire connections with a volt/ohm
meter.
NOTE: Verify all wires and wiring connections
have been tested properly before suspecting a
component failure. 80% of electrical issues are
caused by bad/failed connections and grounds.
CAUTION
Do not power the solenoid with 12 Volts for more than 1
second, or damage may occur to solenoid.
15.7
Copyright 2014
15
ELECTRICAL
AWD / Turf Circuit Break-Out Diagram
15.8
Copyright 2014
ELECTRICAL
FUEL SOLENOID
VEHICLE SPEED SENSOR
The pull coil is a strong coil that is energized to pull the

solenoid contacts together. The hold coil is a much
weaker coil that only needs to be strong enough to keep
the contacts closed.
The speed sensor is located on the ride side of the

transmission, accessed through the right rear wheel well.
Vehicle Speed Sensor Testing
15
1. Disconnect the 3 wire harness from the speed

sensor and remove the sensor from the
transmission.
Fuel Solenoid Location

The fuel solenoid is located on the engine block below
the air intake duct.
Fuel Solenoid Pull Coil Testing
2. Connect the wires from the Static Timing Light

Harness (PN 2871745) to the sensor 3 pin connector
using the Hall Sensor Probe Harness (PN 2460761).
3. Pass a screwdriver back and forth in front of the
sensor tip.
1. Disconnect the fuel solenoid.

2. Ohm across pins P1 and P3 on the solenoid.
Pull Coil: 0.33
Fuel Solenoid Hold Coil Testing
3. Disconnect the fuel solenoid.
4. Ohm across pins P2 and P3 on the solenoid.
Hold Coil: 24.5
15.9
Copyright 2014
ELECTRICAL
4. Be sure connections are good and 9V battery is in
good condition. If the light flashes, the sensor is
good.
TRANSMISSION (GEAR POSITION)

SWITCH
Transmission (Gear Position) Switch
The transmission switch is located on the right side of the
transmission. The switch can be accessed through the
right rear wheel well opening.
1. Disconnect the transmission switch harness by lifting
the connector lock and pulling on the 2-pin
2. Test transmission switch for continuity in each gear
position and compare to the specifications below.
NOTE: Some units may have a shim between the

speed sensor and the gearcase housing. If a
shim is removed, a shim should be installed on
reassembly.
15.10
Copyright 2014
ELECTRICAL
PUMP NEUTRAL (TREADLE) SWITCH
The Pump Neutral Switch is used for starting, speed
sensor, and AWD logic. The switch is normally closed
(treadle pedal is not being pushed).
Pump Neutral Switch Location

The Pump Neutral Switch is located under the plastic
covering on the hydraulic pump housing.
Pump Neutral Switch Testing
1. Put the cargo box in the fully open position.
2. Disconnect the main harness from the pump neutral
switch flying lead.
3. Using an ohmmeter, with the treadle pedal in the
neutral position there should be continuity between
the black (A) and blue (C) wires on the pump neutral
switch wiring.
15
4. The switch should read OL when the treadle pedal is

pushed in the forward or reverse position.
15.11
Copyright 2014
ELECTRICAL
ENGINE OIL PRESSURE SWITCH
IGNITION (KEY) SWITCH
The engine oil pressure switch closes and sends a

ground signal to the ECU if engine oil pressure is below
the 8 PSI. The ECU then signals the instrument cluster to
display the low oil pressure indicator light and the LCD
displays CK ENG. The switch is normally open.
Ignition Key Switch Testing
Engine Oil Pressure Switch Location
2. Test between the 3 sets of outputs (OFF / ON /

START). If any of the tests fail, replace ignition
switch assembly.
The engine oil pressure switch (Item 1) is located on the

engine block below the throttle cable bracket.
1. Disconnect the key switch harness by lifting the

connector lock and pulling on the connector. Do not
pull on the wiring.
Turn the ignition key to ON. There should be

continuity between switch pins C and D.
Turn the ignition key to START. There should be
continuity between switch pins A and B; C and D.
Engine Oil Pressure Switch Testing

1. Disconnect the pink wire on the vehicle harness
going to the engine oil pressure switch.
2. Start the engine and let it run for at least 5 seconds.
3. Ohm the connection on the sensor to chassis
ground. It should read OL. Continuity would indicate
low oil pressure or a faulty switch.
15.12
Copyright 2014
ELECTRICAL
HEADLAMP SWITCH
BRAKE LIGHT SWITCH
The headlamp switch is located on the upper dash panel.
The brake light switch senses pressure off the brake

master cylinder to determine if the brake pedal is
depressed. The switch is normally open.
Headlamp Switch Testing

1. Disconnect the headlamp switch harness by
depressing the connector locks and pulling on the
2. Test between the 3 sets of outputs (HIGH / LOW /
OFF). If any of the tests fail, replace headlamp
switch assembly.
Move the switch to HIGH. There should be
continuity between switch pins 2 and 3; 5 and 6.
Move the switch to LOW. There should be
Brake Light Switch Location

The brake light switch (A) is located on the front brake
line banjo bolt of the master cylinder. The brake switch
can be accessed through the front left wheel well
opening.
Brake Light Switch Testing
1. Disconnect the vehicle harness (Item 1) from the
brake switch (Item 2).
15
Move the switch to OFF. There should be

2. Connect an ohmmeter across switch contacts.

Reading should be infinite (OL).
3. Apply foot brake and check for continuity between
switch contacts. If there is no continuity or if
resistance is greater than 0.5 ohms, clean the switch
contacts and re-test. Replace switch if necessary.
4. Refer to Chapter 14 if replacing the brake switch, as
the brake bleeding procedure will need to be
performed.
NOTE: Pins 7 and 8 provide power and ground

to light the switch lamp.
15.13
Copyright 2014
ELECTRICAL
WORK, TILT LOCK AND AUX SWITCH (HD AND HDPTO)
Work, Tilt Lock and Aux. Switch Testing
2. Disconnect the harness to each switch.
1. Remove the plastic rivets retaining center console

cover to get access to the work, tilt lock and aux.
switches.
3. Using an ohmmeter, test the pins on the switch

according to the wiring diagram.
Work, Tilt Lock and Aux. Switch Wiring Diagram
15.14
Copyright 2014
ELECTRICAL
BOX LIFT SWITCH (HD AND HDPTO)
Box Lift Switch Testing
1. Remove the upper dash cover to get access to the
box lift switch.
3. Using an ohmmeter, test the pins on the switch

according to the wiring diagram.
2. Disconnect the harness to the box lift switch.

Box Lift Switch Wiring Diagram
15
15.15
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HYDRAULIC OIL SWITCH
The hydraulic pressure switch will check if the hydraulic
oil filter is plugged and illuminate the Oil Pressure
indicator and CK HYD will display on the LCD. The
switch is normally closed.
Hydraulic Oil Switch Location

The hydraulic oil switch (Item 1) is located on the
hydraulic oil filter housing behind the drivers seat.
Hydraulic Oil Switch Testing
1. Disconnect the vehicle harness from the hydraulic oil
switch.
2. Connect an ohmmeter from chassis ground to the
switch contact. The switch is closed when adequate
pressure is present. An OL reading would indicate a
plugged hydraulic oil filter or a bad switch.
HYDRAULIC TEMPERATURE
SENSOR
The hydraulic temperature sensor (Item 2) will check
hydraulic oil temperature at the hydraulic filter housing. If
the temperature gets too high, the Oil Temperature
indicator will illuminate on the instrument cluster and CK
HYD will display on the LCD.
Hydraulic Temperature Sensor Location

The hydraulic temperature sensor (Item 2) is located on
the hydraulic filter housing under the drivers seat
between the cargo box and the cab.
Hydraulic Temperature Sensor Testing
1. Disconnect the vehicle harness from the hydraulic
temperature sensor.
2. Using an ohmmeter, place one lead on a pin on the
sensor. Compare readings to the chart.
Temperature
Resistance
32 F (0 C)
~815
77 F (25 C)
~1000
212 F (100 C)
~1700
Function
Temperature
Hydraulic Lamp On Solid
197 F (92 C)
Hydraulic Lamp Off
185 F (85 C)
Hydraulic Lamp Starts

Blinking
201 F (94 C)
Hydraulic Lamp Stops

Blinking
199 F (93 C)
Cooling Fan On
190 F (88 C)
Cooling Fan Off
185 F (85 C)
Engine Shutdown
(when temp is sustained for
60 sec)
205 F (96 C)
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PTO CONTROLS (HDPTO MODEL
ONLY)
The PTO system is designed so the PTO clutch will
disengage when the PTO Engagement switch is ON and
the driver is not sitting on the seat.
PTO Engagement Switch

The PTO Engagement Switch is located on the center
console.
Seat Switch
Located under the drivers seat base, the seat switch
disengages the PTO clutch when pressure is lost on the
drivers seat.
Seat Switch Testing
1. Lift the drivers seat and disconnect the seat switch
harness.
2. Using a multimeter, check for battery voltage on pin
A on the main harness.
3. Check for less than 1 to ground on pin C of the
main harness.
4. Pin B will be the signal wire. It will have 5 V dc on it
when the switch is actuated and ground when the
switch is released.
1. Disconnect the PTO Engagement switch harness by

lifting the connector lock and pulling on the
2. With the switch if the off position, ohm pins A to C on
the switch. The reading should be OL.
3. Engage the PTO switch. There should now be
continuity between pins A and C and the reading
should be less than 1 .
PTO Clutch
Located between the PTO gearcase and the PTO shaft,
the PTO clutch engages when the PTO engagement
switch is in the ON position. A minimum of 12 Vdc is
required to engage the PTO clutch.
1. Disconnect the PTO clutch from the main harness.
2. Using a ohmmeter, ohm the two pins going to the
PTO clutch.
TEST
CONNECT
METER LEADS
TO:
OHMS
READING
PTO Clutch
Blk to Blk
~ 2.4 5%
PTO Clutch
Blk to Ground
Open Line (OL)
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ELECTRICAL
INSTRUMENT CLUSTER
Overview
The instrument cluster displays critical vehicle information to the user. Reference the following page for display
functions and descriptions.
NOTE: Some features are not applicable to all models.
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Rider Information Display
10. Unit Lock - N/A on this model.
The rider information display is located in the instrument

cluster. All segments will light up for 1 second at start-up.
11. Hour Meter - Illuminates when the display (2) is

showing hours.
NOTE: If the instrument cluster fails to illuminate, a

battery over-voltage may have occurred and the
instrument cluster may have shut off to protect the
electronic speedometer.
12. Low Oil Pressure Indicator - LED icon illuminates

when low engine oil pressure is sensed or the
hydraulic filter is plugged. If the engine oil pressure is
low, CK ENG will display on the LCD. If the
hydraulic filter is plugged, CK HYD will display.
1. Vehicle Speed Display - Analog display of vehicle

speed in MPH or km/h.
2. Information Display Area - Service Info - LCD
display of the service hour interval, total vehicle
miles or km., total engine hours, a trip meter, engine
RPM and engine temperature.
3. MPH / KM/H Display - MPH is displayed when the
instrument cluster is in the Standard mode. KM/H is
displayed when the instrument cluster is in the Metric
mode.
4. High Beam Indicator - LED icon illuminates
whenever the Headlamp switch is in the high beam
position.
5. Fuel Level Indicator - LCD bar graph indicating
current fuel level. All segments will flash when the
last segment is cleared indicating a low fuel warning.
6. Clock / PTO RPM - Displays current time in either
12-hour or 24-hour formats. When the PTO is
engaged, PTO RPM will be indicated instead of the
clock.
7. Engine / Hydraulic Fluid Temperature Indicator LED icon illuminates when the ECM determines the
engine or hydraulic oil is too hot. CK ENG will
display on the LCD if the engine oil temperature is
too high and CK HYD will display if the hydraulic oil
is too hot. The indicators will initially be on solid to
indicate overheating. The indicators will start blinking
if a severe overheating condition exists.
8. PTO Indicator - PTO is engaged when this is
illuminated. PTO RPM will be displayed in the Clock
field (6) ONLY when engine RPM is displayed in the
Information Display Area (2).
13. Gear Position Indicator - Displays gear selector

position.
H = High
L = Low
15
N = Neutral
P = Park
= Gear Signal Error (shifter stuck between gears)
14. Power Steering System MIL - N/A on this model.
15. Glow Plug Indicator - Illuminated when the glow
plugs are active. Light goes out when the engine is
ready to start.
16. Seat Belt Indicator - LED icon illuminates for
several seconds when the key is turned to the ON
position. The lamp is a reminder to the operator to
ensure all riders are wearing seat belts before
operating the vehicle.
17. AWD/TURF Indicator - Illuminate to indicate how
many drive wheels are active. This will tell you if you
are in AWD, 2WD, or Turf.
18. ADC Indicator - N/A on this model.
19. Service Interval Indicator - Preset at the factory
and adjustable by the user, a flashing wrench symbol
alerts the operator that the preset service interval
has been reached and maintenance should be
performed. The wrench icon will flash for 10 seconds
upon start-up once it reaches 0.
20. Unit of Measurement - Indicates the measurement
(Trip 1, Trip 2, KM, MI, RPM) being displayed in the
Information Display Area (Item 2).
9. Check Engine MIL - Illuminated when the ECM has

detected a Diagnostic Trouble Code in the engine
management system.
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Instrument Cluster Pinouts
Information Display Area

The LCD portion of the instrument cluster is the
information display area which displays the following
information: odometer, trip meter, RPM, battery voltage,
engine temperature, air temperature, engine hours,
trouble codes, service interval, and clock.
Units of Measurement
FUNCTION
PIN
CAN High
CAN Low
Switched Power (Vdc)
Constant Power (Vdc)
Ground
High Beam Input
Park Brake
Engine Oil Pressure Input
10
Fuel Level Sensor
11
Mode Function Input
13
Hydraulic Oil Pressure Input
14
Hydraulic Oil Temperature Input
15
Treadle Reverse Input
16
Distance
Miles (MPH)
Kilometers (KM/
H)
Temperature
Fahrenheit
Celsius
Time
12-Hour Clock
24-Hour Clock
To change between Standard and Metric units of

measurement, follow these steps:
1. Turn the key to the OFF position.
2. Press and hold the MODE button while turning the
key to the ON position.
3. When the display flashes the distance setting, tap
the MODE button to advance to the desired setting.
4. Press and hold the MODE button to save the setting

and advance to the next display option.
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5. Repeat the procedure to change remaining display
settings.
7. To reset to 0, push and hold the MODE button until

the distance display changes to 0.
Odometer
Engine Hours
The odometer records and displays the total distance

traveled by the vehicle. The odometer can not be
reset.
Engine hours are logged anytime the engine is

running. Total hours can not be reset.
Trip Meter
The trip meter records the miles traveled by the

vehicle on each trip. To reset the trip meter:
6. Toggle the MODE button to TRIP 1.
Tachometer (RPM)
Engine RPM can be displayed digitally.

PTO RPM, when engaged, is indicated after the gear
icon and will only display when engine RPM is
shown.
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ELECTRICAL
12. Repeat steps 3-4 twice to set the 10 minute and 1
minute segments. After completing the 1-minute
segment, step 4 will save the new settings and exit
the clock mode.
Engine Temperature
Battery Voltage
Cycle through the instrument cluster menu using the
mode button until dc appears in the middle of the
display. This will indicate the battery voltage.
Shows current engine temperature. Engine

temperature can be displayed in F or C. Refer to
Units of Measurement to change the format.
Clock
Battery Under / Over Voltage

This warning indicates that the vehicle is operating at
an RPM too low to keep the battery charged, the
electrical loads are too high, or there is a charging
system failure.
Battery Voltage Low
The clock displays the time in a 12-hour or 24-hour

format. Refer to Units of Measurement to change
the format (Standard 12-hour / Metric-24 hour). To
set the clock:
8. Toggle the MODE button until the odometer is
displayed.
9. Press and hold the MODE button until the hour
segment flashes. Release the button.
10. With the segment flashing, tap the MODE button to
advance to the desired setting.
11. Press and hold the MODE button until the next
segment flashes. Release the button.
If battery voltage drops below 11 volts, a warning

screen will display Lo and provide the present
battery voltage. If voltage drops below 8.5 volts, LCD
backlighting and icons will turn off.
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16. To turn off the service interval function, toggle the
MODE button until OFF is displayed.
Battery Voltage High
Check Hydraulic
If battery voltage rises above 15 volts, a warning

screen will display OV and provide the present
battery voltage. If voltage rises above 16.5 volts,
LCD backlighting and icons will turn off.
Programmed Service Interval
Indicates too low of hydraulic oil pressure caused by

a plugged/blocked hydraulic oil filter or too high of
hydraulic oil temperature. The Oil or Temperature
light will illuminate along with this message.
Check Engine / Trouble Code Display
The diagnostic mode is accessible only when the
check engine MIL has been activated.
Use the following procedure to display diagnostic
trouble codes that were activated during current
ignition cycle causing the MIL to illuminate.
Diagnostic trouble codes will remain stored in the
gauge (even if MIL turns off) until the key is turned
off.
The initial factory service interval setting is 50 hours.

Each time the engine is started, the engine hours are
subtracted from the service interval hours. When the
service interval reaches 0, the LCD wrench icon will
flash for approximately 10 seconds each time the
engine is started.
17. If the trouble codes are not displayed, use the MODE
button to toggle until CK ENG displays on the
information display area.
To change the hour setting or reset the function,

follow these steps:
13. Toggle the MODE button until the wrench icon is
displayed in the information area.
14. Press and hold the MODE button until the
information display area begins to flash.
15. Toggle the MODE button to increase the service
interval hours in 5 hour increments to a maximum of
100 hours.
18. Press and hold the MODE button to enter the

diagnostics code menu.
19. A set of three numbers will appear in the information
area.
20. The first number (located far left) can range from 0 to
9. This number represents the total number of
trouble codes present (example: 2 means there are 3
codes present).
21. The second number (located top right) can be 2 to 6
digits in length. This number equates to the
suspected area of fault (SPN).
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ELECTRICAL
22. The third number (located bottom right) can be 1 to 2
digits in length. This number equates to the fault
mode (FMI).
23. Use the Diagnostic Trouble Code Table on the

following pages for a description of each code.
24. If more than one code exists, press the MODE button
to advance to the next trouble code.
25. To exit the diagnostic mode, press and hold the
MODE button or turn the ignition key OFF once the
codes are recorded.
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ELECTRICAL
Diagnostic Trouble Codes
COMPONENT
CONDITION
SPN
FMI
DIGITAL
WRENCH PCODE
Vehicle Speed Signal
Data Erratic or Intermittent (or

missing)
84
P0503
P0118
P0117
16
P0217
P0563
P0562
Voltage Too High

Engine Temperature Sensor
(ECT)
Voltage Too Low
110
Temperature Too High

Voltage Too High
System Power
(Battery Potential / Power
Input)
Voltage Too Low
Gear Sensor Signal
Voltage Too Low
523
P0916
Crankshaft Position Sensor

(CPS)
Plausibility Fault
636
P0335
P1691
P1692
Driver Circuit Grounded
P1693
Driver Circuit Open / Grounded
P1481
P1482
P1483
P0230
P0232
P0231
P1310
P1311
P1312
P16A2
P16A1
P16A9
P16A8
16
P1218
P121A
19
P121B
P1836
P1835

Rear Differential Output
Fan Relay Driver Circuit
Fuel Pump Driver Circuit
PTO Solenoid Driver Circuit
Driver Circuit Short to B+
746
1071
1347
1888

ECU 3.3V Output Supply
Voltage
ECU 5V Output Supply
Voltage
Voltage Too High

Voltage Too Low
3597
Voltage Too High

Voltage Too Low
3598
Temperature Too High

Hydraulic Oil Temperature
Sensor
All Wheel Drive Control

Circuit (AWD)
Hydraulic Over-temp Shutdown
15
168
5536
Received Hydraulic Oil Temp Has

Error
520207
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ELECTRICAL
COMPONENT
Glow Plug Relay Driver

Circuit
Fuel Pull Solenoid Relay

Driver Circuit
Two Speed Shift Coil Driver

Circuit
FMI
DIGITAL
WRENCH PCODE
P1834
P1385
P1384
P1383
P125A
P125D
P125C
P1750
P1751
P1752
CONDITION
SPN
520272
520273
520274

Operator Presence Switch
Voltage Too High
524070
P251C
Hydraulic Oil Pressure

Sensor / Switch
Hydraulic Oil Filter Plugged
524075
17
P150F
Engine Oil Pressure Sensor /

Switch
Oil Level Low
524076
17
P151F
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ELECTRICAL
Instrument Cluster Removal
Instrument Cluster Installation
NOTE: Do not allow alcohol or petroleum products

to come in contact with the instrument cluster lens.
1. Spray a soap and water mixture onto the outer

surface area of the instrument cluster. This will help
the instrument cluster slide into the rubber mount
more easily.
1. Remove the push rivets (Item 1) and upper dash

panel (Item 2) from the vehicle.
15
2. Be sure the rubber mount is fully installed and that
the indexing key on the rubber mount is lined up with
the keyway in the dash panel.
3. Hold the dash panel securely and insert the
instrument cluster into the dash panel. Twist the
instrument cluster gently in a clockwise motion to
properly seat the instrument cluster. Apply pressure
on the bezel while pressing on the instrument cluster.
2. Disconnect the wire harness connector (Item 3) from
the back side of the instrument cluster.
4. Connect the wire harness to the instrument cluster.

5. Install the upper dash panel and push rivets.
3. Push the instrument cluster (Item 4) out of the lower

dash panel, while securely holding the panel and
rubber mount (Item 5).
NOTE: The instrument cluster bezel (Item 6) is a

snap-on assembly and is a serviceable part.
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ELECTRICAL
HEADLIGHTS
Headlight Adjustment
1. Place the vehicle on a level surface with the
headlight approximately 25 ft. (7.6 m) from a wall.
5. Remove the hood and locate the adjustment screw

(Item 1) on the side of the headlight housing (Item 2).
Adjust the beam to the desired position by loosening
the adjustment screw and moving the lamp to the
appropriate height.
2. Measure the distance from the floor to the center of

the headlight (X1) and make a mark on the wall at the
same height (X2).
3. With the vehicle in Park, start the engine and turn the
headlight switch to the LOW position.
6. Once the beam is set to the position, tighten the

adjustment screw. Repeat the procedure to adjust
the other headlight.
4. The most intense part of the LOW headlight beam

should be aimed 8 in. (20 cm) below the mark placed
on the wall in Step 2.
NOTE: Rider weight must be included in the seat
while performing this procedure.
WARNING
Due to the nature of light utility vehicles and where they
are operated, headlight lenses become dirty. Frequent
washing is necessary to maintain lighting quality. Riding
with poor lighting can result in severe injury or death.
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ELECTRICAL
Headlight Bulb Replacement
Headlight Housing Removal
2. Locate the bulb on the back side of the headlight

housing and Disconnect the harness (Item 3) from
the bulb. Be sure to pull on the connector, not on the
wiring.
2. Remove the Torx-head screw and push rivet

retaining the upper right portion of the front fender.
15
3. Turn the bulb counterclockwise and remove it from

the headlight housing.
3. Carefully lift up the front fender far enough to access

the entire headlight housing.
4. Disconnect the harness from
Headlight Bulb Replacement).
the
bulb
(see
5. Remove the O-rings (Item 1) from each side of the

headlight housing.
4. Install the new bulb into the housing and rotate it

clockwise 90 to lock it in place.
5. Install the harness onto the new headlight bulb and
install the hood.
6. Remove the adjustment screw (Item 2).
7. Carefully push on the face of the headlight housing
to disengage the housing tabs from the front fascia
brackets.
8. Remove the headlight housing from the vehicle.
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ELECTRICAL
Headlight Housing Installation
1. Install the headlight housing by pressing the housing
tabs back into the front fascia brackets.
2. Secure the headlight housing with the rubber O-rings
(Item 3) on each side. Install the adjustment screw
(Item 4).
NOTE: Be sure to twist the O-rings upon
installation as shown below.
3. Connect the harness to the bulb.

4. Install the Torx-head screw and push rivet retaining
the upper right portion of the front fender.
5. Install the hood.
6. Adjust headlights using the Headlight Adjustment
procedure.
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ELECTRICAL
TAIL LIGHT / BRAKE LIGHT
3. Remove the LED lamp from the rear cargo box and
disconnect the tail light / brake light wire harness.
LED Lamp Replacement

1. Open the rear tailgate.
2. Remove the two screws retaining the LED lamp
assembly.
15
NOTE: Before replacing the LED lamp assembly,
use a digital multi-meter to test the harness to
ensure the lamp is receiving 12 volts and that a
ground path is present.
4. Install the new LED lamp assembly by reversing this
procedure.
5. Test the tail light / brake light after installation to
verify proper function.
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ELECTRICAL
COOLING SYSTEM
Cooling System Break-Out Diagram
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ELECTRICAL
Coolant Temperature Sensor
Fan Control Circuit Operation / Testing
The Coolant Temperature Sensor is found on the top

right side of the engine by the water pump housing.
Power is supplied to the fan via the Orange/Black wire

when the relay is ON. The ground path for the fan motor
is through the Brown harness wire. Refer to RELAYS
later in this chapter for more information on fan functions.
CAUTION
Keep hands away from fan blades during operation.
Serious personal injury could result.
NOTE: The fan may not function or operation may
be delayed if coolant level is low or if air is trapped in
the cooling system. Be sure cooling system is full
and purged of air.
1. With the engine and temperature sensor
approximately 77F (25C), disconnect the harness.
Fan Control Circuit Bypass Test
2. With a multimeter set to ohms, place the meter leads

onto the sensor contacts.
1. Disconnect
sensor.
3. Use the Temperature / Resistance table to determine

if the sensor needs to be replaced.
Temperature
2. Turn the key on. After a few seconds, the fan should
start running and the Check Engine indicator
should display on the instrument cluster. This
indicates all other components are working properly.
1.22 k 2%
248 F (120
C)
3. If the fan does not run or runs slowly, check the fan
motor wiring, ground, motor condition, circuit breaker
and relay for proper operation. Repair or replace as
necessary.
Coolant Hot Lamp

(Blinking)
1.30 k 2%
240 F (116
C)
4. If the fan runs with the sensor harness disconnected,

but will not turn on when the engine is hot, check the
coolant temperature sensor and connector terminals.
Coolant Hot Lamp

(On Solid)
1.45 k 2%
230 F (110
C)
Cooling Fan On
2.80 k 2%
194 F (90
C)
Cooling Fan Off
3.40 k 2%
182 F (83
C)
Room
Temperature
29.9 k 2%
77 F (25
C)
System Capacity
Brutus / Brutus HD - 6.2 qts

(5.9 L)
Brutus HDPTO - 6.9 qts (6.5
L)
Radiator Cap
Relief Pressure
13 PSI
Condition
Engine Shutdown
(temp. is
sustained for 25
seconds)
Approx.
harness
from
coolant
temperature
NOTE: If the coolant temperature sensor or

circuit malfunctions the radiator fan will default
to 'ON' while the engine is running.
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ELECTRICAL
HVAC SYSTEM
HVAC System Break-Out Diagram
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ELECTRICAL
HVAC Control Circuit Operation / Theory
Blower Switch
Power is supplied to the HVAC system through the 30

amp fuse found in its own fuse holder outside of the main
fuse box under the center console. The condenser fan is
powered by a 20 amp circuit breaker through the
condenser fan relay.
The Blower Switch can be tested using an ohmmeter.
The HVAC relay is powered by the 30 Amp HVAC fuse.

When they key is in the ON position, the HVAC relay is
energized. Power is sent on the Red/Green wires to the
blower switch, the temperature knob (temp pot 10k) and
the water valve. Power only travels from the blower
switch to the AC switch on the white wire when the knob
is in the low, medium or high setting. If the AC switch is
ON, power is sent out on the blue wire to power the
condenser fan relay and the thermostat on the AC
evaporator. The evaporator thermostat will send power
on the white wire to the HPCO (high pressure cut-out)
switch located in the AC hose. The switch is normally
closed. When the switch is closed, power is sent to the
AC compressor. When the pressure in the AC line gets
too high, the switch opens and the compressor cycles
off. The condenser fan will always be running when the
AC system is on and it is powered by a 20 Amp circuit
breaker just outside the relay box.
3. Use the table to determine if the switch needs to be

replaced.
As the temperature knob is moved towards the warm

setting, the voltage through the potentiometer is
interpreted by the water valve to control the flow of warm
water through the heater core to warm the air.
AC Switch
The AC Switch can be tested using an ohmmeter.
1. Disconnect harness from AC Switch.
2. With the meter in the ohms mode, place the leads on
pins P1 and P3.
1. Disconnect the harness going to the Blower Switch.

2. With the meter in the ohms mode, place the meter
leads onto the switch contacts.
15
Temperature Control
The Temperature Control potentiometer can be tested
using an ohmmeter.
1. Disconnect the harness going to the Temperature
Control potentiometer.
2. With the meter in the ohms mode, place the meter
leads onto the potentiometer flying lead contacts.
3. Use the table to determine if the switch needs to be
replaced.
3. With the switch off, the reading should be OL.
KNOB
POSITION
PINS
OHMS
READING
4. With the switch on the reading should be less than 1

.
Full Cold
A to B
~ 81.5k
Between Cold/
Hot
A to B
~ 86.5k
Full Hot
A to B
~ 91.5k
Any Position
A to C
~ 10k
CAUTION
Keep hands away from fan blades during operation.
Serious personal injury could result.
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ELECTRICAL
FUEL SENDER
4. Slowly move the sender float to the full position and

compare to specification.
Testing
1. Remove the fuel level assembly from the fuel tank
(see Chapter 4 Fuel Pick-Up / Sending Unit
Removal).
2. Using an Ohm meter, measure the resistance of the
fuel sender as shown below.
Fuel Sender - Full: 102 2 W

5. If the readings are out of specification, or if the
reading is erratic or LCD display sticks, check the
following before replacing the fuel level assembly:
Loose float
Float contact with tank
Bent float rod
6. If none of the conditions exist, the fuel sender
assembly is faulty. Replace the fuel level sender
assembly (see Chapter 4).
3. Allow the sender float to sit in the empty position

and compare to specification.
Fuel Sender - Empty: 6 2 W
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FUSE BOX: FUSES / RELAYS / CIRCUIT BREAKERS / TVS DIODES
Fuse, Relay, Circuit Breaker and TVS Diode Locations
Located under the center console, the fuses provide overload protection for wiring and components. The relays assist
with high load component operation. A separate relay and 40 amp circuit breaker protects the cooling fan motor circuit
and can be found outside of the relay / fuse boxes. On PTO models, a separate HVAC relay and 30 amp HVAC fuse
can be found in a fuse holder just outside the relay / fuse boxes. If equipped, the box lift relay and 20 Amp circuit
breaker is located under the upper dash cover near the box lift switch.
15
Component Descriptions
1. Radiator / Cooling Fan Relay
2. HVAC Relay - HD and HDPTO models only.
Provides power to the heating and air conditioning
system.
3. HVAC 30 Amp Fuse - HD and HDPTO models only.
Provides power to the HVAC Relay
7. Relay Block - houses the fuel pull, ECM, PTO, glow

plug, fuel hold, and chassis relays. All relays in this
box are interchangeable.
8. TVS (transient-voltage-suppression) Diode - used
to protect electrical components from voltage spikes.
PTO (HDPTO model only)
Hydraulic Solenoid (HD and HDPTO model only)
4. Radiator / Cooling Fan 40 Amp Circuit Breaker
Fuel Solenoid / Fuel Pump
5. Condenser Fan 20 Amp Circuit Breaker
Start Solenoid
6. Fuse / Relay Block - houses the condenser fan,

starter and tilt lock relays as well as the glow plug,
drive, fuel hold, fuel pull, ECU, PTO, hydro, acc. and
light fuses.
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Relay Box Detail
15.38
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ELECTRICAL
FUEL PULL SOLENOID RELAY provides power to the
pull coil side of the fuel solenoid.
FUEL HOLD SOLENOID RELAY provides power to the

fuel solenoid hold coil and the fuel pump.
FUEL PULL SOLENOID RELAY
FUEL HOLD SOLENOID RELAY
PIN
COLOR
FUNCTION
PIN
COLOR
FUNCTION
86
Red / Dark
Blue
12 V switched power from ECM

relay.
86
Red/Dark
Blue
12 V switched power from ECM

relay.
85
Brown / Blue
ECU ground input to enable

relay.
85
Grey/Dark
Green

relay.
30
Red
12 V circuit powered by the 30

Amp Fuel Pull Solenoid fuse
through the 30 Amp Chassis
fuse.
30
Red
12 V circuit powered by the 20

Amp Fuel Hold Solenoid fuse
through the 30 Amp Chassis
fuse.
87
White
Provides 12 V power for fuel pull

solenoid coil.
87
Red
Provides 12 Vdc power for fuel

pump and fuel solenoid hold
coil.
PTO RELAY provides power to the PTO Clutch and Tilt

Lock Relay.
PTO RELAY (HDPTO model only)
ECM RELAY provides power to the ECU, Fuel Pull relay,

Fuel Hold relay, Glow Plug relay, Cooling Fan relay, Seat
Pressure switch (HDPTO model only), and Two Speed
Manifold.
PIN
COLOR
FUNCTION
86
White /
Orange
12 Vdc from PTO switch.
PIN
COLOR
FUNCTION
85
White / Black

relay.
86
Red / Dark
Blue
20 Amp ECU fuse protected 12

Vdc constant battery voltage.
30
Red / Dark
Blue
12 Vdc power from PTO fuse

through PTO splice #1.
85
Dark Green /
Yellow

relay.
87
Red / Dark
Blue
Provides 12 Vdc power for PTO

splice #2 for clutch engagement
and tilt lock relay.
30
Red / White

87
Red / White
Provides 12 Vdc power to the

ECU relay B+ splice.
ECM RELAY
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ELECTRICAL
GLOW PLUG RELAY provides power to the Glow Plugs.
GLOW PLUG RELAY

PIN
COLOR
FUNCTION
86
Red / Dark
Blue
12 Vdc switched power from

ECU relay.
85
Brown /
Green

relay.
30
Red
30 Amp Glow Plug fuse

protected 12 Vdc constant
battery voltage.
87
Black / Red
Provides 12 Vdc power for glow

plug operation.
CHASSIS RELAY provides power to the following

systems:
Lights (Headlights / Taillights)
Drive (AWD / TURF)
Accessory (12V Receptacles / Accessory Options)
CHASSIS RELAY
PIN
COLOR
FUNCTION
86
Orange
12 Vdc power input from key

switch to enable relay.
85
Brown
Relay coil constant ground.
30
Red
BUSS Bar - 12 Vdc constant

battery voltage
87
White
Provides 12 Vdc power for

lights, drive and accessory
circuits.
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Relay Power Flowcharts
Fuel Pull Relay, PTO Relay, Fuel Hold Relay
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ECM Relay, Glow Plug Relay, Chassis Relay
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Fuse / Relay Box Detail
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Fuse / Relay Box Detail
TILT LOCK RELAY provides power to the hydraulic
control valve tilt lock when activated to prevent tilting of
the hydraulic attachment when the PTO switch is
engaged or when the tilt lock switch is turned on.
TILT LOCK RELAY
CONDENSER FAN RELAY provides power to the air

conditioner condenser fan.
CONDENSER FAN RELAY (HDPTO model

only)
PIN
COLOR
FUNCTION
PIN
COLOR
FUNCTION
86
Blue
12 Vdc power from AC switch.
Red / Dark
Blue

PTO fuse through the PTO
switch.
85
Brown
Chassis ground to enable relay.
86
30
White / Black
20 Amp circuit breaker

battery power.
87
White / Grey

condenser fan operation.
85
Brown
Chassis Ground
Beige / Black
Provides 12 Vdc power for tilt

spool lock when the tilt lock
switch is engaged (relay
unswitched)
87
Beige / Black
Provides 12 Vdc power for tilt

spool lock when PTO is
engaged. (relay switched)
87A
Dark Green
Power to control valve to lock

the tilt spool. (relay unswitched)
30
External Relays
HVAC RELAY is found under the center console outside
of the relay boxes. The HVAC relay provides power to
the following:
Blower Switch
Temperature Control Switch
STARTER RELAY provides power to the starter

solenoid.
Water Valve
STARTER RELAY
HVAC RELAY (HDPTO model only)
PIN
COLOR
FUNCTION
PIN
COLOR
FUNCTION
86
White / Red
(154)
12 Vdc switched power from key

switch
86
Orange
12 Vdc switched power
White / Red
(E201)

relay.
85
Brown
Chassis ground.
85
30
30 Amp HVAC fuse protected

12 Vdc constant battery power.
Red / White

Red / Dark
Blue
87
Red / Dark
Green

HVAC operation.
30
87
White / Red
(111)

starter solenoid operation.
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RADIATOR FAN RELAY is found outside the relay
boxes in the center console and provides power to the
cooling fan
REAR DIFF SOLENOID RELAY provides power to the

rear differential solenoid and is located below the cargo
box by the rear frame support.
COOLING FAN RELAY
REAR DIFF SOLENOID RELAY
PIN
COLOR
FUNCTION
86
Red / Dark
Blue
BUSS Bar - 12 Vdc switched

power from EFI relay.
85
Brown / Red

relay.
30
Red
40 Amp circuit breaker

battery power.
87
Orange/Black
Provides 12 Vdc power for fan

operation.
COLOR
FUNCTION
Brown
Relay coil ground.
Dark Green /
White
ECU input to enable relay.
Red / Dark Green
10-Amp fuse protected 12 Vdc

battery voltage.
Red
Relay switched power to operate

the Rear Diff Solenoid.
Blue
Ground to energize the Rear Diff

Solenoid.
CARGO BOX LIFT RELAY provides power to the cargo

box lift actuator and is mounted on the sub-harness for
the cargo box lift switch under the upper dash cover.
CARGO BOX LIFT RELAY

PIN
COLOR
FUNCTION
86
Orange /
White

20A Accessory fuse
85
Brown
Chassis ground through the

front terminal block.
30
Red
20 Amp Circuit Breaker

battery power.
87
Red
Provides 12 Vdc power to the

Box Lift switch for lift operation.
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ELECTRICAL
CHARGING SYSTEM
Charging System Break Even Test
The BRUTUS alternator is rated 12v, 90A, 1215 watts (at

13.5 V nominal voltage).
CAUTION
Current Draw - Key Off

Do not allow the battery cables to become
disconnected while the engine is running. Follow the
steps below as outlined to reduce the chance of
damage to electrical components.
CAUTION
Do not connect or disconnect the battery cable or
ammeter with the engine running. Damage will occur to
electrical components.
Connect an ammeter in series with the negative battery
cable. Check for current draw with the key off. If the draw
is excessive, loads should be disconnected from the
system one by one until the draw is eliminated. Check
component wiring as well as the component for partial
shorts to ground to eliminate the draw.
The break even point of the charging system is the

point at which the alternator overcomes all system loads
(lights, etc.) and begins to charge the battery. Depending
on battery condition and system load, the break even
point may vary slightly. The battery should be fully
charged before performing this test.
WARNING
Never start the engine with an ammeter connected in
series. Damage to the meter or meter fuse will result.
Do not run test for extended period of time.
Do not run test with high amperage accessories.
1. Using an inductive amperage metering device, (set
to DC amps) connect to the negative battery cable.
2. With engine off, and the key switch and lights in the
ON position, the ammeter should read negative
amps (battery discharge). Reverse meter lead if a
positive reading is indicated.
3. Shift transmission into neutral with the parking brake
applied and start the engine. With the engine running
at idle, observe meter readings.
4. Increase engine RPM while observing ammeter and
tachometer.
Current Draw - Key Off:

Maximum of .01 DCA (10 mA)
5. Note RPM at which the battery starts to charge

(ammeter indication is positive).
6. With lights and other electrical loads off, the break
even point should occur at approximately just above
idle RPM.
7. With the engine running, turn the lights on and
engage brake to keep the brake lights on.
8. Repeat test, observing ammeter and tachometer.
With lights on, break even charging should occur
below 2000 RPM.
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Charging System Alternator Wiring Diagram
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Alternator Service
Alternator Installation
Disconnect the negative (-) battery cable before

servicing the electrical system.
Check electrical harnesses for cracks, abrasions,
and damaged or corroded connectors. ALWAYS
keep the connectors and terminals clean.
Alternator Removal
1. Position the alternator on the gear case. Loosely

reinstall the nut on the gear case stud and the V-belt
adjuster bolt.
Lower Alternator Mount Bolt

24 ft-lbs (33 Nm)
WARNING
2. Reconnect the battery cable to the alternator.

Tighten the nut to specification.
Electrical Shock and Pinch Hazard

1. Disconnect the electrical wires from the alternator.
2. Loosen the alternator adjuster bolt (Item 1) and
carefully rotate the alternator towards the cylinder
block.
Alternator B+ Cable Nut

54 in-lbs (6 Nm)
3. Reinstall the V-belt. Tighten the V-belt to the proper
tension. See Cooling Fan V-Belt adjustment.
Alternator Adjuster Bolt

24 ft-lbs (33 Nm)
NOTE: Using a non-specified V-belt will cause
inadequate charging and shorten the belt life.
Use the specified belt.
3. Remove the lower mounting bolt (Item 2) from the

alternator. Remove the alternator.
4. Start the engine. Listen for any unusual sounds from

the alternator.
NOTE: Do not operate the engine if the
alternator is producing unusual sounds.
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BATTERY SERVICE
General Battery Information

NOTE: Never attempt to open the battery.
WARNING
CALIFORNIA PROPOSITION 65 WARNING:
Batteries, battery posts, terminals and related
accessories contain lead and lead compounds, and
other chemicals known to the State of California to
cause cancer and birth defects or other reproductive
harm. WASH HANDS AFTER HANDLING.
WARNING
Battery electrolyte is poisonous. It contains acid!
Serious burns can result from contact with the skin,
eyes, or clothing.
ANTIDOTE:
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow
with milk of magnesia, beaten egg, or vegetable oil. Call
a physician immediately.
Eyes: Flush with water for 15 minutes and get prompt
medical attention.
Batteries produce explosive gases. Keep sparks, flame,
cigarettes, etc. away. Ventilate when charging or using
in closed space. Always shield eyes when working near
batteries.
Keep out of reach of children.
1. Check battery voltage with a volt/ohm meter. A fully

charged battery should be 12.8 V or higher.
2. If the voltage is below 12.6 V, the battery will need to
be recharged (see Charging Procedure).
To service a Maintenance Free battery:
3. Remove battery from the vehicle (see Chapter 2).
4. Test battery with a voltage meter or load tester to
determine battery condition. This will determine the
length of time required to charge the battery to full
capacity. Refer to OCV table (see OCV - Open
Circuit Voltage Test).
5. Charge the battery as recommended (see Charging
Procedure).
Battery Removal / Installation

See Chapter 2 Maintenance for battery removal and
installation procedures.
Battery Off Season Storage

Whenever vehicle is not used for a period of three
months or more, remove the battery from the vehicle,
ensure that it's fully charged, and store it out of the sun in
a cool, dry place. Check battery voltage each month
during storage and recharge as needed to maintain a full
charge.
NOTE: Battery charge can be maintained by using a
Polaris battery tender charger or by charging once a
month to make up for normal self-discharge. Battery
tenders can be left connected during the storage
period, and will automatically charge the battery if
the voltage drops below a pre-determined point.
Battery Specifications
Battery PN 4014132
Type
Polaris / Flooded-Filled
Voltage
12 Vdc
Nominal Capacity
@ 20 HR Rate
32 AH
CCA
575
Nominal Open
Circuit Voltage
12.8 Vdc or more.
Recommended
Charging Rate
1.8A @ 5-10 HR or 6.0A @ 1

HR
Battery Testing
Whenever a service complaint is related to either the
starting or charging systems, the battery should be
checked first.
The following are two tests which can easily be made on
a sealed Maintenance Free battery to determine its
condition: OCV Test and a Load Test.
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ELECTRICAL
OCV (Open Circuit Voltage) Test
Load Test
Battery voltage should be checked with a digital

multitester. Readings of 12.6 volts or less require further
battery testing and charging. See the following chart and
Load Test.
A battery may indicate a full charge condition in the OCV

test, but still may not have the storage capacity
necessary to properly function in the electrical system.
For this reason, a battery capacity or load test should be
conducted whenever poor battery performance is
encountered.
NOTE: Maintenance Free batteries should be kept at

a high state of charge during storage. If the battery is
stored or used at a low state of charge, hard crystal
sulfation will form on the plates, reducing the
efficiency and service life of the battery.
Use a volt/ohm meter to test battery voltage.
Battery PN 4014132
To perform this test, use a load testing device that has an

adjustable load. Apply a load of three times the amperehour rating. At 14 seconds into the test, check battery
voltage. A good 12V battery will have at least 10.5 volts.
If the reading is low, charge the battery and retest.
Battery Conductance Analyzer
OPEN CIRCUIT VOLTAGE

State of Charge
Maintenance Free
100%
12.8 V and up
75% Charged
12.6 V
50% Charged
12.3 V
25% Charged
12.0 V
0% Charged
11.8 V or less
Conductance describes the ability of a battery to conduct

current. A conductance tester functions by sending a low
frequency AC signal through the battery and a portion of
the current response is captured, from this output a
conductance measurement is calculated. Conductance
testing is more accurate than voltage, specific gravity, or
load testing.
Authorized Polaris dealers/distributors are required to
use the conductance analyzer when testing 12V Polaris
batteries.
Voltage Drop Test

The Voltage Drop Test is used to test for bad
connections. When performing the test, you are testing
the amount of voltage drop through the connection. A
poor or corroded connection will appear as a high
voltage reading. Voltage shown on the meter when
testing connections should not exceed 0.1 VDC per
connection or component.
To perform the test, place the meter on DC volts and
place the meter leads across the connection to be tested.
Refer to the voltage drop tests in the Starter System
Testing Flow Chart.
Voltage should not exceed
.1 DC volts per connection
Polaris MDX-610P
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Battery Charging Procedure
Battery Terminal Block
If battery voltage is 12.6 Vdc or less, the battery may

need recharging. When using an automatic charger, refer
to the charger manufacturers instructions for recharging.
A terminal block located under the hood (Item 1)

provides easy hookup for accessories. On the non-PTO
models, you will need to run a positive and negative wire
from the rear terminal block to the front terminal block in
order to make the front terminal block functional. The
rear terminal block (Item 2) can be found under the seat
next to the battery.
Recommended Charging Rate: 1 hour @ 6-10 Amps.

Do not exceed 10 amps when charging the battery.
NOTE: Charge the battery using an automatic
charger that will not exceed 14.6 Vdc. An automatic
charger will signal when charging is complete.
Allow the battery to stand disconnected for at least
1-2 hours after being properly charged. If the voltage
drops below 12.6 volts, charging was ineffective or
the battery needs to be replaced.
15
WARNING
An overheated battery could explode, causing severe
injury or death. Always watch charging times carefully.
Stop charging if the battery becomes very warm to the
touch. Allow it to cool before resuming charging.
Battery PN 4014132
STATE OF
CHARGE
VOLTAGE
(DC)
ACTION
CHARGE TIME
100%
12.8 or
more
None, check
again in 3
months
None
Required
75% 100%
12.6 - 12.8
May need
slight charge
3 - 6 hrs
50% - 75%
12.3 - 12.6
Needs
Charge
5 - 11 hrs
25% - 50%
12.0 - 12.3
Needs
Charge
At least
13 hrs
0% - 25%
12.0 or less
Needs
Charge
At least
20 hrs
NOTE: Follow the charger instructions supplied by

the manufacture regarding the order or connections,
switch positions and when to connect the charger to
an outlet.
Terminal Block Nuts:

20-25 in-lbs (2.3-2.8 Nm)
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STARTER SYSTEM AND WIRING DIAGRAM
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Starter System Troubleshooting
15
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Starter Motor Removal
1. Disconnect the positive and negative battery cables.
2. Using a 10mm wrench, remove the nut retaining the
battery cable to the starter motor.
3. Remove the two nuts (Item 3) retaining the solenoid

switch assembly to the pinion housing. Remove the
solenoid switch assembly and dust covers. Remove
the plunger and torsion spring (Item 4) from the
pinion housing.
3. Remove the lower starter mounting bolt (Item 1) first.
4. Remove the two bolts (Item 5) retaining the rear

cover to the brush holder assembly (Item 6).
4. Remove the upper starter mounting bolt (Item 2) and
nut.
5. Remove the starter motor from the flywheel housing.
Starter Motor Disassembly

1. Scribe alignment marks across all mating joints prior
to removing that part.
2. Disconnect the field wire from the solenoid switch.
5. Remove the two through bolts retaining the rear

cover and remove the rear cover.
6. Pull the brush springs up using a brush spring puller.
On the negative side, bring the brush spring into
contact with the side of the brushes to hold the
brushes clear of the commutator surface. On the
positive side, remove the brushes from the brush
holder assembly.
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7. Remove the brush plate and holder (Item 7).
13. Remove the pinion stop (Item 13) and pinion clutch
assembly (Item 14) from the pinion shaft (Item 15).
15
8. Pull the field assembly (Item 8) off from the armature
assembly (Item 9).
9. Remove the armature from the intermediate housing.
10. Remove the intermediate housing, gear and pinion
shaft assembly (Item 10) from the pinion housing.
Disengage it from the shift lever as it is removed.
14. Remove the snap ring (Item 16) and pull out the
pinion shaft (Item 17), planetary gears (Item 18),
washers and reduction gear (Item 19) from the
intermediate housing (Item 20).
11. Remove the shift lever (Item 11), pin and spacer
(Item 12).
15. Inspect the intermediate bushing (Item 21) and

armature bushings (Item 22) and replace if worn or
damaged.
12. Pull the pinion stop down to expose the retaining
ring. Using a flat-blade screwdriver, remove the
retaining ring from the pinion shaft.
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Starter Motor Testing
Armature Coil Continuity Test
Check for continuity between the commutator segments
using a multimeter. There should be continuity present
between any two segments. If the continuity is present,
replace the armature.
Field Coil Insulation Test

Check for continuity between either field coil terminal and
the yoke using a multimeter. There should not be
continuity present. If there is continuity, replace the field
coil assembly.
Armature Coil Insulation Test

Check for continuity between a commutator segment and
the shaft or armature using a multimeter. The multimeter
should not indicate continuity. If there is continuity
present, replace the armature.
Field Coil Continuity Test

Check for continuity between the field coil terminals
using a multimeter. There should be continuity present. If
there is not continuity, replace the field coil assembly.
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Brush Holder Insulation Test
Check for continuity between each brush holder and the
base using a multimeter. There should not be continuity
present. If there is continuity, replace the brush holder.
4. Torque upper starter mounting bolt and nut to

specification.
Upper Starter Mounting Bolt and Nut:

7 ft-lbs (10 Nm)
5. Install the starter motor battery cable to the starter
solenoid stud. Torque nut to specification.
15
Pinion Clutch Assembly Inspection

Manually rotate the pinion clutch assembly. It should
rotate freely in the drive direction and should lock by
turning it in the opposite direction. Replace the pinion
clutch assembly if the results are different.
Slide the pinion clutch assembly on the pinion shaft. It
should slide smoothly on the shaft. Rust, too much
grease or damage could prevent the pinion clutch from
sliding smoothly. If the pinion clutch assembly does not
slide smoothly, clean the shaft and pinion clutch
assembly or replace the damaged component causing
the binding.
Starter B+ Cable Nut

54 in-lbs (6 Nm)
Starter Motor Installation

1. Install the starter motor onto the flywheel housing.
2. Hand tighten the upper starter motor bolt and nut.
Starter Solenoid Operation
3. Install the lower mounting bolt and torque to

specification.
To energize the Starter Solenoid the following must

occur:
The unit in Park or Neutral gear selection OR the
treadle pedal must be in the neutral position.
Upper Starter Mounting Bolt and Nut:

40 ft-lb (53 Nm)
Lower Starter Mounting Bolt:
32 ft-lb (45 Nm)
The key switch must be turned to the start

position to provide 12V power to the starter
solenoid via the Green / White wire.
Once the pull-in coil is energized, the solenoid
provides a current path for 12V power to reach the
starter motor.
NOTE: Tighten the lower starter bolt first, as the

bottom hole acts as a pilot hole to properly align
the starter drive with the flywheel. This helps
prevent binding and starter damage.
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Starter Solenoid Bench Test
Test the start solenoid by powering the solenoid using
battery voltage for a maximum of 5 seconds. With the
solenoid energized, you should get continuity between
the battery positive post of the solenoid and the starter
housing
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DIGITAL WRENCH
Digital Wrench Diagnostic Software
Overview
NOTE: Refer to Section 2, 3 and 4 in the Instruction
Manual provided in the Digital Wrench Diagnostic
Kit to install the Polaris Digital Wrench diagnostic
software on your computer.
The Digital Wrench diagnostic software allows the

technician to perform the following tests and
observations:
View or clear trouble codes
Analyze real-time engine data
Reflash ECU calibration files
Perform guided diagnostic procedures
Create customer service account records
Perform output state control tests (some models)
Special Tools
DIGITAL WRENCH DIAGNOSTIC SOFTWARE
PART NUMBER
Digital Wrench Diagnostic Kit
PU-47063-B
15
Digital Wrench Software: PU-48731

PU-47063-B (listed above) INCLUDES:
Standard Interface Cable: PU-47151

SmartLink Module Kit: PU-47471
USB-Serial Adapter Cable: PU-50621
Fluke 73 Digital Multi-Meter or Fluke 77 DMM
PV-43546 (Fluke 77: PV-43568)
Laptop or Desktop Computer
Commercially Available (refer to diagnostic software

user manual or HELP section for minimum
requirements)
Diagnostic Software Version
Guided Diagnostics
Always use the most current version of the Digital

Wrench software to ensure you have the latest updates
or enhancements. New reprogramming files and guided
diagnostic procedures are added to these updates as
they become available. For information on how to
determine if you have the latest update available, refer to
Digital Wrench Version and Update ID.
Guided diagnostics are available within Digital Wrench

for all supported Trouble Codes (that is, any fault that will
turn on the Check Engine indicator).
ECU Replacement
Although the need for ECU replacement is unlikely, a
specific replacement procedure is required to ensure that
all essential data contained within the original ECU is
transferred to the replacement ECU.
In addition, guided diagnostics are also available for

many other electrical sub systems.
Diagnostic procedures are added to subsequent versions
of Digital Wrench as they become available. Check
your release version often and upgrade when available
to be sure you are using the most current software
available.
Refer to procedure and carefully follow all instructions

provided in Digital Wrench.
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Digital Wrench Communication Errors
Diagnostic Connector Location
If you experience problems connecting to a vehicle or

any Digital Wrench related problem, visit the Digital
Wrench Knowledge Base for the most current
troubleshooting information, FAQs, downloads and
software updates at: http://polaris.diagsys.com/.
BRUTUS - The diagnostic plug (Item 1) is located under

the passenger seat in the center tray by the ECU.
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BRUTUS HD / HDPTO - Located under the center
console. It may be accessed without removing the center
console by removing the cup holder (Item 2) and
removing the connector (Item 3) from the retainer (Item
4).
Digital Wrench Version and Update ID

Knowing what Digital Wrench version and update is
installed will help determine which updates are required.
NOTE: Versions and updates are subject to change.
1. Open the Digital Wrench software. Locate the
version ID shown on the lower right side of the Digital
Wrench start-up screen.
15
2. Proceed to http://polaris. diagsys. com to see if a

newer update is available.
Digital Wrench Serial Number Location

Open the configuration screen by clicking on the wrench
icon. Serial number is located on right side of the screen.
3. If a newer update is available, it should be

downloaded before using Digital Wrench (see
Digital Wrench Updates).
NOTE: Always operate with the latest update.
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Digital Wrench Updates
Updates are released for Digital Wrench via the
Internet at: http://polaris. diagsys. com. The Digital
Wrench website can also be accessed through the
dealer website at: www.polarisdealers.com.
NOTE: Only authorized Polaris dealers
distributors can access the dealer website.
6. If the update file date listed is newer than your

current version and update (see Digital Wrench
Version and Update ID), download the file.
and
1. Log on to www.polarisdealers.com.
2. Locate the Service and Warranty drop-down
menu.
3. Click on Digital Wrench Updates.
7. Click on the link shown above, save the file to your

hard disk and then double-click the icon to start the
update process.
NOTE: Do not "run" or "open" the file from
where they are. Select "save" and download
them to your PC before running the install.
4. The Digital Wrench portal website should appear in

a new web browser.
5. Click on Digital Wrench Version Updates.
NOTE: You must already have the current

version installed before adding an update.
Updates will not install if you are using an older
version loaded on your PC.
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8. When the update is complete, the version shown on
the right side of the Digital Wrench start-up screen
should match the update you just downloaded.
NOTE: Versions and updates are subject to

change.
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Digital Wrench Feature Map
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Engine Controller Reprogramming (Reflash)
Process Overview
The reprogramming feature is in the Special Tests menu
on the Digital Wrench screen. Start Digital Wrench
and click on the Special Tests menu icon (red tool box). A
technician should be familiar with the process and with
computer operation in general before attempting to
reprogram an ECU.
The Digital Wrench Engine Controller Reprogramming
(or Reflash) feature allows reprogramming of the ECU.
To successfully reprogram the ECU, an Authorization
Key must be obtained by entering a Request Code in the
box provided on the Reflash Authorization site. The
Request Code is automatically generated by Digital
Wrench during the reprogramming process. The
Reflash Authorization site is located under the Service
and Warranty drop down menu on the dealer website
at: www.polarisdealers.com.
COMMUNICATION PROBLEMS: If you have had

problems communicating with a vehicle while
performing diagnostic functions, do not attempt
reprogramming until the cause has been identified
and fixed. Check all connections, and be sure
battery voltage is as specified.
Proceed to http://polaris. diagsys. com for specific
information and FAQs on how to troubleshoot
communication problems.
15
NOTE: Replacement ECUs require a reflash for

them to work.
Reprogramming (Reflash) Tips:
BATTERY VOLTAGE: The majority of problems
with reprogramming can be attributed to a low
battery. Be sure the battery voltage (no load) is at
least 12.8 volts and at least 12.5 volts with the key
ON. Connect a battery charger if necessary to
bring voltage level above minimum. Fully charge
the battery before you attempt to reprogram.
DEDICATED LAPTOP: Best results are obtained
using a laptop computer that is dedicated to
Digital Wrench. A laptop that is used by a variety
of people and in several applications around the
dealership is more likely to cause a
reprogramming problem than one dedicated to
Digital Wrench diagnostics only.
OBTAINING
THE
LATEST
UPDATE:
Reprogramming updates are provided periodically
and contain the most recent calibrations (see
Digital Wrench Updates).
CLOSE NON-ESSENTIAL PROGRAMS: Polaris
recommends that you DO NOT install nonessential programs on a Service Department
laptop. Camera detection software, Virus
Scanners, Tool Bars, etc. may clog up memory if
running in the background and make it harder for
the diagnostic software to operate.
DONT DISTURB THE PC: While reprogramming

is in progress, dont move the mouse and dont
touch the keyboard. The process only takes a few
minutes, and is best left alone until complete.
Reprogramming (Reflash) Procedure:
If you are not familiar with the reprogramming process,
review the Reprogramming (Reflash) Tips before you
begin. Follow the on-screen instructions as you progress
through the steps. If you encounter a problem, always
check the On-Line help for current tips and information.
1. Verify the most current update has been downloaded
and loaded into Digital Wrench.
2. Connect SmartLink Module cables to PC and
vehicle.
3. Open the Digital Wrench program.
KNOW THE PROCESS: If you are not familiar with

the entire reprogramming process, review the
HELP section of the diagnostic software before
you attempt reprogramming. Click on the ? on the
tool bar or press F11. The information in the online help is the most current and complete
information available. This should be your first step
until you are familiar with the process.
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ELECTRICAL
4. Select the model year, product line and vehicle
description by selecting the Change Vehicle Type
icon.
8. Copy (CTRL +C) the Request Code that will be

required on the dealer website in the next step. DO
NOT CLOSE Digital Wrench or the Request Code
will be invalid. NOTE: All characters are letters;
there are no numbers in a request code.
5. Select the Special Tests icon.

NOTE: Request Codes and Authorization Keys
must be entered EXACTLY as they appear on the
screen.
9. Go to www.polarisdealers.com and click on ReFlash
Authorization from the Service and Warranty dropdown menu.
6. Select Engine Controller Reprogramming.

7. Select the file you want to load into the ECU then
click the Continue icon to proceed to the Integrity
Check and obtain a Request Code.
10. Enter or paste (CTRL+V) the Request Code into the

box.
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ELECTRICAL
11. Select the same file type from the list that you
selected previously while in Digital Wrench. Enter
the VIN along with the customers name and
address. When completed, click the Authorize button
once to proceed.
14. At this point the reflash process will begin. Do not

touch the vehicle or PC during the process.
15
12. An Authorization Key will appear in the upper left
corner of the screen. Copy (CTRL +C) this key
exactly as it appears.
15. Once the ECU reprogramming procedure is

complete, click the Finish button on the screen.
Verify the reflash was a success by starting the
vehicle.
13. Enter or paste (CTRL +V) the Authorization Key in

the box located on the Digital Wrench screen. Click
the Continue button and follow instructions provided
on the screen to complete reprogramming
procedure.
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ELECTRICAL
Special Tests Menu
Data Items
The following items are available on the Special Tests

menu (red toolbox):
The following items can be monitored on Digital

Wrench:
Vehicle Historical Information - indicates total engine

run-time, RPM and speed histograms and engine
overheats.
Engine RPM
Output State Control - Command the ECU to run the

following tests:
Engine Temperature Sensor Voltage
Engine Temperature
Battery Voltage
Differential Unlock Solenoid Test
Fuel Pump Status
Fan Driver Test
Crankshaft Sensor Signal Present
Front Wheel Drive Output Test
Vehicle Speed
Fuel Pull Solenoid Test
Cooling Fan
Fuel Pump Test
Differential Lock
Glow Plug Relay Test
AWD
PTO Solenoid Relay Test (if equipped)
Treadle Sensor
Reverse Alarm Test (if equipped)
Seat Sensor
Two Speed Shift Coil Test
PTO Status
Service Report - Take a freeze frame of all the data

items in their present state.
PTO RPM
Two Speed Shift Coil Duty Cycle
ECU Replacement - When the ECU is replaced, run this

program to input the model number into the new ECU.
PTO Enable/Disable Procedure - Enable / Disable PTO
engagement until this procedure is run again.
Engine Controller Reprogramming - This program will
update or install a calibration in the ECU. It is required to
be performed on all new ECUs AFTER the ECU
Replacement procedure is performed.
Vehicle Information - This brings up the software
calibration numbers for the ECU and instrument cluster.
Feature Configuration/Registration - This is only used
when registering Digital Wrench and is not specific to
this unit.
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A
A/C Condenser Cleaning........................................ 2.46
A/C Diagram ........................................................... 6.5
A/C Drive Belt........................................................ 2.47
AC Switch ........................................................... 15.35
Air Conditioning System ........................................... 6.4
Air Filter Service .................................................... 2.28
Airbox Housing Removal and Installation................. 3.11
All Wheel Drive (AWD) Coil .................................... 15.7
Alternator ............................................................ 15.48
Alternator / Fan / Water Pump Drive Belt ................. 2.36
Alternator, Installation .......................................... 15.48
Alternator, Removal ............................................. 15.48
Attachment Mount (BRUTUS HD / HDPTO)............. 7.19
Authorization Key ................................................ 15.65
Authorization, Reflash.......................................... 15.65
Auxiliary Control Valve, Assembly ......................... 13.40
Auxiliary Control Valve, Disassembly..................... 13.36
Auxiliary Control Valve, Parts Identification ............ 13.35
Auxiliary Control Valve, Removal .......................... 13.34
Auxiliary Hydraulic Coupler, Removal/Installation ... 13.47
Auxiliary Switch ................................................... 15.14
AWD Switch .......................................................... 15.7
AWD, Diagnosis .................................................. 11.14
AWD, Operation .................................................. 11.13
B
B5 Diesel Fuel Requirements ................................. 1.19
B6 to B20 Bio-Diesel Fuel Blend ............................. 1.20
Ball Joint Service ................................................... 8.11
Battery Charging Procedure ................................. 15.51
Battery Information .............................................. 15.49
Battery Installation ................................................. 2.62
Battery Load Test................................................. 15.50
Battery Maintenance .............................................. 2.61
Battery Removal.................................................... 2.62
Battery Service.................................................... 15.49
Battery Storage ................................................... 15.49
Battery Tester ...................................................... 15.50
Battery Testing .................................................... 15.49
Bearing, Rear Axle................................................. 8.16
Bio-Diesel Fuels .................................................... 1.19
Bio-Fuel Precautions ............................................. 1.19
Block Heater Usage ............................................... 1.20
Body Removal....................................................... 7.18
Brake Burnishing ....................................... 14.13, 14.21
Brake Caliper Assembly, Front.................... 14.14, 14.16
Brake Caliper Assembly, Rear .............................. 14.22
Brake Caliper Inspection, Front............................. 14.16
Brake Caliper Installation, Front ............................ 14.17
Brake Caliper Removal, Front............................... 14.14
Brake Disc, Front................................................. 14.18
Brake Disc, Rear ................................................. 14.26
Brake Fluid Inspection............................................ 2.66
Brake Hose and Fitting Inspection........................... 2.66
Brake Pad and Disc Inspection ............................... 2.66
Brake Pad Assembly, Front .................................. 14.12
Brake Pad Thickness, Front ................................. 14.12
Brake Pads, Front................................................ 14.11

Brake Pads, Rear ................................................ 14.20
Brake Pads, Removal, Front................................. 14.11
Brake Pedal, Removal/Installation .......................... 14.9
Brake Switch ....................................................... 15.13
Brake System, Bleeding ......................................... 14.9
Brake System, Exploded View ................................ 14.7
Brake System, Operation ....................................... 14.6
Brake System, Troubleshooting ............................ 14.28
Break Even Test .................................................. 15.46
Break-In Period ....................................................... 2.4
C
Cab Frame Assembly .............................................. 7.3
Cab Seals (BRUTUS HDPTO).................................. 7.4
Caliper, Front ...................................................... 14.14
Caliper, Rear ....................................................... 14.22
Cargo Box Frame .................................................. 7.16
Cargo Box Lift Switch........................................... 15.15
Cargo Box, Removal/Installation ............................. 7.17
Centralized Hilliard Exploded View........................ 11.12
Charging Procedure............................................. 15.51
Charging System ................................................. 15.46
Charging System, Alternator Tests ........................ 15.46
Chassis / Main Frame (BRUTUS HD / HDPTO).......... 7.7
Chassis / Main Frame (BRUTUS) ............................. 7.6
Circuit Breakers................................................... 15.37
Clutch, PTO ........................................................ 15.17
Codes, Diagnostic Trouble ................................... 15.25
Cold Start Guide .................................................... 1.21
Cold Weather Operation......................................... 1.20
Communication Problems, Digital Wrench ............. 15.60
Controls, PTO ..................................................... 15.17
Conversion Table................................................... 1.22
Coolant Level Inspection ........................................ 2.45
Coolant Sensor Testing ........................................ 15.33
Coolant Strength and Type ..................................... 2.44
Cooling Fan Control Operation ............................. 15.33
Cooling Fan Control Test ...................................... 15.33
Cooling System, Bleeding Procedure ........................ 5.5
Cooling System, Component Locations ..................... 5.4
Cooling System, Specifications................................. 5.2
Cooling System, Testing........................................... 5.3
Cooling System, Troubleshooting............................ 5.11
CPS ..................................................................... 15.5
Crankshaft Position Sensor (CPS) .......................... 15.5
Current Draw Test................................................ 15.46
D
Dash Panel Removal ............................................. 7.21
Dash Panels.......................................................... 7.14
Decal Replacement ............................................... 7.26
Decimal Equivalent Chart ....................................... 1.25
Diagnostic Plug Location ...................................... 15.60
Diagnostic Trouble Codes .................................... 15.25
Differential Solenoid............................................... 15.7
Digital Wrench Communication Errors ................... 15.60
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IX
Digital Wrench Diagnostic Plug ............................. 15.60

Digital Wrench Diagnostic Software ...................... 15.59
Digital Wrench Items............................................ 15.68
Digital Wrench Menus .......................................... 15.68
Digital Wrench Versions ....................................... 15.59
Digital Wrench, ECU Reprogramming ................... 15.65
Digital Wrench, Guided Diagnostics ...................... 15.59
Digital Wrench, Updates....................................... 15.62
Digital Wrench, Version and Update ID.................. 15.61
Doors (BRUTUS HDPTO) ........................................ 7.4
Drive Performance Checks Type 2 ........................ 10.63
Drive Performance RPM Checks Type 1................ 10.61
Drive Shaft / CV Joint, Service .............................. 11.26
Drive Shaft Boot Inspection .................................... 2.59
Dump Box Switch ................................................ 15.15
E
ECU ..................................................................... 15.5
ECU Replacement ............................................... 15.59
Electrical, Cooling System Breakout Diagram ........ 15.32
Electrical, HVAC System Diagram......................... 15.34
Electronic Control Unit (ECU) ................................. 15.5
Engine Compression Test....................................... 2.35
Engine Crankcase Breather Inspection.................... 2.34
Engine Designation Number..................................... 1.3
Engine Intake Pre-Filter Screen Service .................. 2.28
Engine Leakdown Test ........................................... 2.36
Engine Oil and Filter Change .................................. 2.32
Engine Oil Level .................................................... 2.31
Engine Oil Pressure Switch .................................. 15.12
Engine Oil Recommendations ................................ 2.31
Engine Serial Number Location ................................ 1.4
Engine Specifications............................................... 3.5
Engine Speed Control ............................................ 3.58
Engine Speed Control Cable Adjustment ....... 2.24, 10.57
Engine Speed Control Lever................................... 2.25
Engine Temperature Sensor Testing...................... 15.33
Engine Warranty.................................................... 1.20
Engine, Camshaft and Timing Gears ....................... 3.40
Engine, Camshaft Inspection / Servicing.................. 3.43
Engine, Camshaft Removal .................................... 3.43
Engine, Connecting Rod Inspection ........................ 3.49
Engine, Connecting Rod Removal / Inspection......... 3.45
Engine, Cooling System ........................................... 5.2
Engine, Crankshaft and Bearing Service ................. 3.55
Engine, Crankshaft and Bearings Installation ........... 3.56
Engine, Crankshaft and Bearings Removal.............. 3.53
Engine, Crankshaft and Pistons .............................. 3.45
Engine, Crankshaft Oil Seal Replacement ............... 3.56
Engine, Cylinder Bore - Inspection .......................... 3.53
Engine, Cylinder Head ........................................... 3.24
Engine, Cylinder Head - Servicing........................... 3.29
Engine, Cylinder Head Assembly ............................ 3.35
Engine, Cylinder Head Installation .......................... 3.39
Engine, Cylinder Head Removal ............................. 3.25
Engine, Cylinder Honing and Boring........................ 3.50
Engine, Description.................................................. 3.4
Engine, Glow Plugs ............................................... 3.25
Engine, Idler Gear Inspection ................................. 3.41

Engine, Installation ................................................ 3.16
Engine, Intake and Exhaust Valves ......................... 3.27
Engine, Intake Manifold Assembly .......................... 3.39
Engine, Intake Manifold Removal............................ 3.24
Engine, Lubrication Specifications ............................ 3.9
Engine, Mount Replacement .................................. 3.20
Engine, Oil Pan Removal / Installation ..................... 3.20
Engine, Oil Pressure - Testing................................. 3.23
Engine, Oil Pump Inspection................................... 3.21
Engine, Oil Pump Removal / Installation .................. 3.20
Engine, Piston and Connecting Rod Installation ....... 3.50
Engine, Piston Inspection ....................................... 3.47
Engine, Piston Removal / Inspection ....................... 3.45
Engine, Removal ................................................... 3.12
Engine, Rocker Arm / Push Rod Inspection.............. 3.33
Engine, Rocker Arms ............................................. 3.26
Engine, Special Tools............................................... 3.3
Engine, Thermostat ............................................... 5.10
Engine, Timing Gearcase Cover Installation............. 3.40
Engine, Timing Gearcase Cover Removal ............... 3.40
Engine, Timing Gears Backlash - Checking ............. 3.41
Engine, Timing Gears Installation............................ 3.42
Engine, Timing Gears Removal .............................. 3.42
Engine, Valve Clearance Inspection / Adjustment..... 3.37
Engine, Valve Cover Assembly ............................... 3.39
Engine, Valve Cover Removal ................................ 3.24
Engine, Valve Spring Inspection.............................. 3.31
Engine, Valve Tappet Inspection ............................. 3.34
Exhaust Clean Out Plug ......................................... 2.39
Exhaust Removal / Installation................................ 3.10
F
Fan Control Circuit Bypass Test ............................ 15.33
Fan Control Circuit Operation ............................... 15.33
Floor (BRUTUS HD / HDPTO) ................................ 7.11
Floor (BRUTUS) .................................................... 7.10
Floor, Front ........................................................... 7.25
Floor, Main ............................................................ 7.24
Flowcharts, Relay Power...................................... 15.41
Forward Speed Control Cable Adjustment ..... 2.23, 10.56
Frame (BRUTUS HD / HDPTO) ................................ 7.7
Frame (BRUTUS) .................................................... 7.6
Front A-arm Assembly ............................................. 8.8
Front Attachment (BRUTUS HD / HDPTO ................. 7.7
Front Bearing Carrier ............................................. 11.3
Front Bumper (BRUTUS) ....................................... 7.18
Front Caliper, Piston Bore I.D. .............................. 14.16
Front Drive Shaft, Removal/Installation.................... 11.7
Front Fascia (BRUTUS HD / HDPTO) ....................... 7.9
Front Fascia (BRUTUS HD/HDPTO) ....................... 7.20
Front Fascia (BRUTUS) ...................................7.8, 7.19
Front Fender Removal ........................................... 7.21
Front Fenders (BRUTUS HD / HDPTO) ..................... 7.9
Front Fenders (BRUTUS)......................................... 7.8
Front Gearcase Lubrication .................................... 2.42
Front Gearcase, Assembly ................................... 11.20
Front Gearcase, Disassembly............................... 11.16
IX.2
Copyright 2014
Front Gearcase, Exploded View............................ 11.12

Front Gearcase, Installation.................................. 11.22
Front Gearcase, Removal .................................... 11.15
Front Lower A-arm, Removal .................................... 8.9
Front Propshaft, Removal (BRUTUS HD /
HDPTO) .............................................................. 11.9
Front Propshaft, Removal (BRUTUS)...................... 11.8
Front Upper A-arm, Removal .................................. 8.10
Front Wheel Bearing Inspection .............................. 2.59
Fuel Filter / Water Separator................................... 4.18
Fuel Filter / Water Separator Draining..............2.26, 4.18
Fuel Filter / Water Separator Replacement ......2.26, 4.19
Fuel Information / Recommendations ...................... 1.19
Fuel Injection Lines................................................ 4.22
Fuel Injection Pump ............................................... 4.21
Fuel Injection Pump, Installation ............................. 4.26
Fuel Injection Pump, Removal ................................ 4.24
Fuel Injection System............................................. 4.20
Fuel Injection Timing .............................................. 4.29
Fuel Injector, Assembly .......................................... 4.37
Fuel Injector, Disassembly and Inspection ............... 4.36
Fuel Injector, Installation......................................... 4.37
Fuel Injector, Pressure Adjustment.......................... 4.37
Fuel Injector, Removal ........................................... 4.33
Fuel Injector, Test Results ...................................... 4.35
Fuel Injector, Testing .............................................. 4.34
Fuel Lines / Vent Line.......................................2.27, 4.9
Fuel Pick-Up / Sending Unit Removal...................... 4.10
Fuel Pick-up Screen............................................... 2.27
Fuel Pick-up Screen Service..................................... 4.9
Fuel Pump Replacement ........................................ 4.18
Fuel Pump Test ..................................................... 4.17
Fuel Return Line .................................................... 4.23
Fuel Sender Test ................................................. 15.36
Fuel Sender Tests.................................................... 4.9
Fuel Solenoid ................................................4.22, 15.9
Fuel System Service Notes ...................................... 4.5
Fuel System Torque Specifications ........................... 4.3
Fuel System, Assembly View.................................... 4.7
Fuel System, Test and Adjustment Specifications....... 4.4
Fuel Tank Assembly................................................. 4.8
Fuel Tank, Installation ............................................ 4.14
Fuel Tank, Removal ............................................... 4.12
Fuel Transfer Pump ............................................... 4.16
Fuse / Relay Box Details ...................................... 15.43
Fuses ................................................................. 15.37
G
General Specifications, Brakes ............................... 14.3
GENERAL: 2013 - 2014 BRUTUS CAB................... 1.13
Glove Box ............................................................. 7.14
Glove Box Removal ............................................... 7.21
Glow Plugs............................................................ 15.6
Ground, Engine / Chassis....................................... 2.62
H
Headlight Switch.................................................. 15.13
Headlights........................................................... 15.28
High Pressure Cut Out ........................................... 6.19
High-Pressure Injection Lines ................................. 4.22
Hood .................................................................... 7.18
Hood (BRUTUS HD / HDPTO).................................. 7.9
Hood (BRUTUS)...................................................... 7.8
HPCO................................................................... 6.19
HVAC Blower Switch............................................ 15.35
HVAC Control Circuit Operation ............................ 15.35
HVAC Filter Inspection / Replacement..................... 2.47
HVAC System Electrical Diagram.......................... 15.34
HVAC, A/C Evaporator Coil Filter ............................ 6.11
HVAC, A/C Oil ....................................................... 6.14
HVAC, A/C Oil Check............................................. 6.15
HVAC, Blower Fan................................................. 6.22
HVAC, Charging with Recovery / Charging Unit ....... 6.12
HVAC, Components................................................. 6.8
HVAC, Compressor ............................................... 6.13
HVAC, Compressor Drive Belt Inspection ................ 6.10
HVAC, Compressor Removal / Installation ............... 6.13
HVAC, Condenser .........................................6.10, 6.16
HVAC, Evaporator Coil........................................... 6.21
HVAC, Expansion Valve ......................................... 6.20
HVAC, Heater Coil ................................................. 6.21
HVAC, Heater Valve............................................... 6.24
HVAC, High Pressure Cut-Out Switch (HPCO)......... 6.19
HVAC, Maintenance .............................................. 6.10
HVAC, Pressure Relief Valve .................................. 6.19
HVAC, Receiver / Drier........................................... 6.18
HVAC, Reclamation with Recovery / Charging Unit .. 6.12
HVAC, Refrigerant ................................................. 6.11
HVAC, System Recovery and Charging................... 6.11
HVAC, Thermostat................................................. 6.21
HVAC, Troubleshooting.......................................... 6.27
Hydraulic / Hydrostatic Symbols............................ 13.61
Hydraulic Control Valve, Installation ...................... 13.17
Hydraulic Control Valve, Joystick Assembly ........... 13.25
Hydraulic Control Valve, Joystick Disassembly....... 13.19
Hydraulic Control Valve, Joystick Exploded View.... 13.18
Hydraulic Control Valve, Port Relief Valve Testing .. 13.14
Hydraulic Control Valve, Relief Valve Testing ......... 13.13
Hydraulic Control Valve, Removal ......................... 13.15
Hydraulic Cylinder, Exploded Views ........................ 13.7
Hydraulic Cylinder, Lift Cylinder Installation.............. 13.5
Hydraulic Cylinder, Lift Cylinder Removal ................ 13.5
Hydraulic Cylinder, Rebuilding ................................ 13.8
Hydraulic Cylinder, Testing ..................................... 13.4
Hydraulic Cylinder, Tilt Cylinder Installation.............. 13.6
Hydraulic Cylinder, Tilt Cylinder Removal ................ 13.5
Hydraulic Filter, Housing Removal and
Installation......................................................... 13.55
Hydraulic Fluid and Filter Replacement ................... 2.51
Hydraulic Fluid Level.............................................. 2.51
Hydraulic Gear Pump, Disassembly ...................... 13.59
Hydraulic Gear Pump, Exploded View ................... 13.58
Hydraulic Gear Pump, Removal and Installation..... 13.56
Hydraulic Lubrication ............................................. 13.3
Hydraulic Manifold Valve, Assembly ...................... 13.53
Hydraulic Manifold Valve, Disassembly ................. 13.51
Hydraulic Manifold Valve, Exploded View .............. 13.50
IX.3
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IX
Hydraulic Manifold Valve, Pressure Testing............ 13.48

Hydraulic Manifold Valve, Removal ....................... 13.49
Hydraulic Oil Cooler, Removal and Installation ....... 13.56
Hydraulic Pressure Switch.................................... 15.16
Hydraulic Reservoir, Removal and Installation ....... 13.45
Hydraulic System Information ............................... 13.61
Hydraulic Temperature Switch .............................. 15.16
Hydraulic Troubleshooting.................................... 13.65
Hydrostatic / Treadle Pedal Adjustments ....... 2.19, 10.52
Hydrostatic Drive Lubrication .................................. 10.3
Hydrostatic Drive Motor.......................................... 10.4
Hydrostatic Drive Motor, Assembly........................ 10.11
Hydrostatic Drive Motor, Disassembly ..................... 10.7
Hydrostatic Drive Motor, Exploded View .................. 10.6
Hydrostatic Drive Motor, Removal / Installation ........ 10.4
Hydrostatic Drive, Charge Pressure ...................... 10.15
Hydrostatic Drive, Coupler Removal / Installation ... 10.37
Hydrostatic Drive, Drive Relief Pressure Testing..... 10.16
Hydrostatic Drive, Hydrostatic Pump ..................... 10.16
Hydrostatic Drive, Neutral Adjustment ................... 10.53
Hydrostatic Drive, Travel Cable Adjustment ........... 10.55
Hydrostatic Drive, Travel Control (Treadle) Pedal ... 10.58
Hydrostatic Drive, Troubleshooting ....................... 10.67
Hydrostatic Pump Removal / Installation...... 10.16, 10.27
Hydrostatic Pump, Assembly ................................ 10.46
Hydrostatic Pump, Disassembly ........................... 10.40
Hydrostatic Pump, Exploded View ........................ 10.39
Hydrostatic Pump, Inspection ............................... 10.45
Hydrostatic System Information .............................. 10.3
Hydrostatic Travel Control Adjustments ......... 2.19, 10.52
I
Ignition Switch ..................................................... 15.12
Inner Plunging Joint / Boot Replacement ............... 11.29
Instrument Cluster ............................................... 15.18
Instrument Cluster, Installation.............................. 15.27
Instrument Cluster, Removal ................................ 15.27
K
Key Off Current Draw........................................... 15.46
Key Switch .......................................................... 15.12
Keys, Replacement.................................................. 1.5
L
Lower Seat Base ................................................... 7.18
Lubrication Grease Points ..............................2.122.13
M
Maintenance Quick Reference Chart...............2.142.16
Maintenance, Air Intake System.............................. 2.28
Maintenance, Brake System ................................... 2.66
Maintenance, Cooling System ................................ 2.44
Maintenance, Electrical System .............................. 2.61
Maintenance, Engine ............................................. 2.31
Maintenance, Final Drive / Wheel and Tire............... 2.59

Maintenance, Fuel System ..................................... 2.25
Maintenance, General Vehicle Inspection ................ 2.17
Maintenance, HVAC System................................... 2.46
Maintenance, Hydraulic / Hydrostatic System .......... 2.50
Maintenance, Power Take-Off System (PTO)........... 2.53
Maintenance, Service Products and Lubricants........ 2.11
Maintenance, Steering ........................................... 2.63
Maintenance, Suspension ...................................... 2.65
Maintenance, Transmission and Front Gearcase ..... 2.40
Master Cylinder, Installation.................................... 14.8
Master Cylinder, Removal ...................................... 14.8
Metric Bolt Torque Specification .............................. 1.23
Model Number Designation ...................................... 1.2
MODEL: 2013 - 2014 BRUTUS CAB ....................... 1.14
Muffler Removal and Installation ............................. 3.10
N
Neutral Adjustment ................................................ 2.20
Neutral Switch ..................................................... 15.11
Non-Relay Box Relays ......................................... 15.44
O
Outer CV Joint / Boot Replacement....................... 11.26
P
Performance Checks Flow Chart Command Lever
Type 1............................................................... 10.68
Performance Checks Flow Chart Command Lever
Type 2............................................................... 10.69
Periodic Maintenance Chart ..................................... 2.4
Power Steering Unit, Installation ............................... 8.6
Power Steering Unit, Removal .................................. 8.6
Priming the Fuel System .......................................... 4.6
Propshaft, U-Joint Service.................................... 11.10
PTO Clutch ......................................................... 15.17
PTO Clutch Brake Inspection / Adjustment .............. 2.58
PTO Controls ...................................................... 15.17
PTO Drive Belt Inspection ...................................... 2.57
PTO Engagement Switch ..................................... 15.17
PTO Gearbox Oil Change ...................................... 2.55
PTO Gearbox Oil Level .......................................... 2.53
PTO Lubrication .................................................... 12.2
PTO U-Joint Inspection .......................................... 2.57
PTO, Clutch Brake Adjusting .................................. 12.9
PTO, Clutch Removal ............................................ 12.8
PTO, Drive Belt Pulley Installation........................... 12.4
PTO, Drive Belt Pulley Removal.............................. 12.3
PTO, Drive Belt Removal ....................................... 12.2
PTO, Gearbox Disassembly and Assembly.............. 12.6
PTO, Gearbox Exploded View ................................ 12.5
PTO, Gearbox Removal and Installation.................. 12.6
Publication Numbers................................................ 1.5
Publication Part Numbers......................................... 1.5
IX.4
Copyright 2014
R
Radiator Cleaning.................................................... 5.6
Radiator Fan Control Operation ............................ 15.33
Radiator Fan Control Test..................................... 15.33
Radiator, Coolant Drain ............................................ 5.6
Radiator, Installation ................................................ 5.7
Radiator, Removal ................................................... 5.6
Rear Axle Bearing Replacement ............................. 8.16
Rear Axle Brace, Installation................................... 8.17
Rear Axle Brace, Removal ..................................... 8.16
Rear Cargo Box..................................................... 7.15
Rear Drive Shaft, Installation ................................ 11.25
Rear Drive Shaft, Removal ................................... 11.24
Rear Fenders (BRUTUS HD / HDPTO) ................... 7.11
Rear Fenders (BRUTUS) ....................................... 7.10
Rear Lower Suspension Link .................................. 8.15
Rear Suspension Link and Axle Brace Assembly ..... 8.13
Rear Suspension Upper Link .................................. 8.14
Reflash Authorization........................................... 15.65
Relay Circuit Details............................................. 15.38
Relay Power Flowcharts....................................... 15.41
Relays ................................................................ 15.37
Relays, Other ...................................................... 15.44
Reverse Speed Control Cable Adjustment..... 2.24, 10.57
Rocker Panel Removal .......................................... 7.23
Roof (BRUTUS HDPTO) .......................................... 7.5
S
Safety Labels .............................................................2
Safety Precautions, Air Conditioning ......................... 6.6
Safety Precautions, Diesel Fuel ................................ 4.3
Seat Assembly (BRUTUS HD / HDPTO).................. 7.13
Seat Assembly (BRUTUS) ..................................... 7.12
Seat Belts (BRUTUS HD / HDPTO)......................... 7.13
Seat Belts (BRUTUS) ............................................ 7.12
Seat Switch......................................................... 15.17
Sender, Fuel........................................................ 15.36
Sensor, Crankshaft Position ................................... 15.5
Sensor, Hydraulic Temperature............................. 15.16
Sensor, Speed....................................................... 15.9
Shift Cable Inspection / Adjustment......................... 2.40
Shift Cable Inspection and Adjustment ...................... 9.6
Shift Cable Replacement.......................................... 9.7
Shift Lever / Shift Cable............................................ 9.4
Shift Lever, Removal................................................ 9.5
Shocks ................................................................. 8.18
Software Version ................................................. 15.59
Solenoid, Fuel ....................................................... 15.9
Solenoid, Rear Differential...................................... 15.7
Special Tools........................................................... 1.6
Special Tools, Body / Cab / Frame ............................ 7.2
Special Tools, Brakes............................................. 14.4
Special Tools, Electrical ......................................... 15.4
Special Tools, Engine............................................... 3.3
Special Tools, Final Drive ....................................... 11.2
Special Tools, Fuel System....................................... 4.4
Special Tools, HVAC ................................................ 6.3
Special Tools, Hydraulics ....................................... 13.3
Special Tools, Hydrostatic Drive.............................. 10.3

Special Tools, Steering / Suspension......................... 8.2
Special Tools, Transmission ..................................... 9.2
Specification, Coolant Sensor Resistance ............. 15.33
Specification, Wheel Toe-Out.................................. 2.64
Specifications, Cooling System................................. 5.2
Specifications, Engine.............................................. 3.5
Specifications, Engine Lubrication ............................ 3.9
Specifications, Transmission and Gearcase............. 2.40
Specifications, Vehicle ............................................. 1.7
Speed Sensor ....................................................... 15.9
Speedometer ...................................................... 15.18
Speedometer Installation...................................... 15.27
Speedometer Removal ........................................ 15.27
Springs ................................................................. 8.18
Standard Bolt Torque Specification ......................... 1.23
Starter Motor, Disassembly .................................. 15.54
Starter Motor, Installation ..................................... 15.57
Starter Motor, Removal ........................................ 15.54
Starter Motor, Testing........................................... 15.56
Starter Solenoid, Operation .................................. 15.57
Starter Solenoid, Test........................................... 15.58
Starter System .................................................... 15.52
Starter System, Troubleshooting........................... 15.53
Steering Assembly................................................... 8.3
Steering Shaft, Bearing Replacement........................ 8.5
Steering Wheel / Upper Steering Shaft Removal ........ 8.4
Steering, Inspection ............................................... 2.63
Suspension Inspection ........................................... 2.65
Suspension Link, Rear Lower ................................. 8.15
Suspension Link, Upper Rear ................................. 8.14
Suspension Spring Pre-Load Adjustment ................ 2.65
Switch, AC .......................................................... 15.35
Switch, Auxiliary .................................................. 15.14
Switch, AWD/2WD/TURF ....................................... 15.7
Switch, Brake Light .............................................. 15.13
Switch, Cargo Box Lift .......................................... 15.15
Switch, Engine Oil Pressure ................................. 15.12
Switch, Gear Position........................................... 15.10
Switch, Headlight................................................. 15.13
Switch, HVAC Blower Switch ................................ 15.35
Switch, Hydraulic Oil Filter.................................... 15.16
Switch, Ignition .................................................... 15.12
Switch, PTO Engagement .................................... 15.17
Switch, Seat ........................................................ 15.17
Switch, Temperature Control ................................ 15.35
Switch, Tilt Lock................................................... 15.14
Switch, Transmission ........................................... 15.10
Switch, Treadle Pedal Neutral............................... 15.11
Switch, Work ....................................................... 15.14
Symbols, Hydraulic / Hydrostatic........................... 13.61
T
Taillights.............................................................. 15.31
Tap/Drill Sizes ....................................................... 1.24
Temperature Control Switch ................................. 15.35
Temperature Sensor Testing................................. 15.33
Terminal Block..................................................... 15.51
IX.5
Copyright 2014
IX
Thermistor Testing ............................................... 15.33

Thermostat ........................................................... 5.10
Tie Rod End Inspection .......................................... 2.63
Tilt Lock Switch ................................................... 15.14
Tire Inspection....................................................... 2.60
Tire Pressure......................................................... 2.61
Toe Adjustment ..................................................... 2.64
Torque Specifications, Body / Cab / Frame ................ 7.2
Torque Specifications, Brakes................................. 14.4
Torque Specifications, Cooling System...................... 5.2
Torque Specifications, Final Drive ........................... 11.2
Torque Specifications, Fuel System........................... 4.3
Torque Specifications, HVAC .................................... 6.3
Torque Specifications, Hydraulics ........................... 13.3
Torque Specifications, Hydrostatic Drive.................. 10.3
Torque Specifications, PTO .................................... 12.2
Torque Specifications, Steering / Suspension............. 8.2
Torque Specifications, Transmission ......................... 9.2
Torque Specifications, Wheel and Hub .................... 2.60
Transmission Lubrication .................................2.41, 9.2
Transmission Mounting and Torque Value................ 10.3
Transmission Switch ............................................ 15.10
Transmission, Assembly ........................................ 9.31
Transmission, Disassembly .................................... 9.20
Transmission, Exploded View ................................. 9.39
Transmission, Installation ....................................... 9.13
Transmission, Mounting and Torque Values ............... 9.3
Transmission, Operation ........................................ 9.19
Transmission, Planetary Differential Assembly......... 9.31
Transmission, Planetary Differential Bushings.......... 9.29
Transmission, Planetary Differential Disassembly .... 9.27
Transmission, Removal............................................ 9.8
Transmission, Shaft Service ................................... 9.25
Transmission, Snorkel Gear Backlash ..................... 9.31
Transmission, Snorkel Shaft Removal ..................... 9.23
Transmission, Troubleshooting ............................... 9.41
Travel Cable Adjustment ........................................ 2.22
Travel Control (Treadle) Pedal ................................ 2.17
Travel Control (Treadle) Pedal, Cable Removal...... 10.59
Travel Control (Treadle) Pedal, Inspection ............. 10.58
Travel Control (Treadle) Pedal, Pedal Removal...... 10.59
Treadle Pedal Switch ........................................... 15.11
Trouble Codes..................................................... 15.25
Troubleshooting, Brake Noise................................. 14.5
Troubleshooting, HVAC.......................................... 6.27
Troubleshooting, Hydraulics ................................. 13.65
Troubleshooting, Hydrostatic Drive ....................... 10.67
Troubleshooting, Transmission ............................... 9.41
Turf Solenoid......................................................... 15.7
TVS Diodes......................................................... 15.37
Two Speed Manifold .............................................. 15.6
Voltage Drop Test ................................................ 15.50
W
Water Pump Installation ........................................... 5.9
Water Pump Removal .............................................. 5.8
Water Pump Weep Hole........................................... 5.8
Weep Hole, Water Pump .......................................... 5.8
Wheel Alignment ................................................... 2.64
Wheel, Installation ................................................. 2.60
Wheel, Removal .................................................... 2.60
Windshield (BRUTUS HDPTO)................................. 7.5
Wipers (BRUTUS HDPTO)....................................... 7.5
Work Switch ........................................................ 15.14
V
Valve Clearance Inspection / Adjustment ................. 2.38
Vehicle Identification Numbers.................................. 1.2
Vehicle Information .................................................. 1.3
VIN......................................................................... 1.3
VIN Location ........................................................... 1.4
VIN Number ............................................................ 1.3
IX.6
Copyright 2014
2013 - 2014 BRUTUS
2013 - 2014 BRUTUS
2013 - 2014 BRUTUS
2013 - 2014 BRUTUS
2013 - 2014 BRUTUS HD PTO
2
3
HYDRAULIC FILTER
COOLER
HYDRAULIC
RESERVOIR
CAP HYDRAULIC BREATHER
FILTER - HYDRAULIC
SPRING LOADED FILTER BY-PASS

VALVE: 344 kPa (3,4 bar) (50 psi)
COOLER - HYDRAULIC
RELIEF VALVE - MAIN: 586 kPa (58,6 bar)

( 850 psi) at Front Quick Couplers
SOLENOID ACTIVATED DIRECTIONAL

CONTROL VALVE TWO SPEED SHIFT
14
13
PROPEL PUMP
HYDROSTATIC
MOTOR
19
PRIORITY VALVE
RESTRICTION - 2,39 mm (0.094 in)
10
11
HYDRAULIC PROPEL PUMP

71.99 L/min (19.02 U.S. gpm) at High Engine Idle
12
HYDRAULIC GEAR PUMP - Gear Type

28.80 L/min (7.61 U.S. gpm) at High Engine Idle
13
RELIEF/REPLENISHING VALVE HIGH PRESSURE: 3450 kPa

(345 bar) (5004 psi)
14
RELIEF VALVE - CHARGE INLET:

2654 kPa (26,5 bar) (385 psi) at High
Engine Idle With 60 C (140 F) Fluid
15
RESTRICTION . . . . . 0,85 mm (0.033 in)
16
17
FIXED CAPACITY DISPLACEMENT

BIDIRECTIONAL HYDROSTATIC MOTOR
18
TWO SPEED SHIFT VALVE
19
DRIVE MOTOR SHUTTLE VALVE
20
TEST PORT
MA
M1
18
M3
15
RESERVOIR:
Capacity at sight gauge . . 2,6 L (2.8 qt)
System Capacity . . . . . . . 6,8 L (7.2 qt)
12
11
MIN
17
16
X1
M2
L1, L2
B
L1
L2
L3
13
MB
20
9
PF
10
X1
LEGEND
PRESSURE
DRAIN
T
PRIORITY VALVE
EF
STEERING VALVE
6
IN
OUT
CD
PILOT
COMPONENT
HYDRAULIC / HYDROSTATIC SCHEMATIC 1
RESERVOIR:
Capacity at sight gauge. . 2,6 L (2.8 qt)
System Capacity. . . . . . . 8,0 L (8.4 qt)
CAP HYDRAULIC BREATHER
FILTER - HYDRAULIC
SPRING LOADED FILTER BY-PASS

VALVE: 344 kPa (3,4 bar) (50 psi)
RELIEF VALVE - MAIN: 586 kPa (58,6 bar)

(850 psi) at Front Quick Couplers
RELIEF VALVE - SAFETY: 950 - 1049 kPa

( 95 - 105 bar) (1378 - 1522 psi)
COOLER - HYDRAULIC
RELIEF/ANTICAVITATION VALVE PORT (Rod End Lift and Tilt):

1150- 1349 kPa (115 - 135 bar)
(1740 - 1957 psi)
RELIEF/ANTICAVITATION VALVEPORT (OPTIONAL): 1150 - 1299 kPa
(115 - 130 bar) (1668 - 1885 psi)
10
LIFT LOCKOUT
11
TILT LOCKOUT
12
SOLENOID ACTIVATED DIRECTIONAL

CONTROL VALVE TWO SPEED SHIFT
13
PRIORITY VALVE
14
15
16
VARIABLE CAPACITY DISPLACEMENT

BIDIRECTIONAL HYDROSTATIC PUMP
28,8 L/min (7.6 U.S. gpm) at High Engine Idle
17
HYDRAULIC PUMP . . . . . . Gear Type

8,3 L/min (2.2 U.S. gpm) at High Engine Idle
18
RELIEF/REPLENISHING VALVE HIGH PRESSURE: 3450 kPa

( 345 bar) (5004 psi)
19
RELIEF VALVE - CHARGE INLET:

2654 kPa (26,5 bar) (385 psi) at High
Engine Idle With60 C (140 F) Fluid
LIFT CYLINDER
2
3
21
RESTRICTION . . . . .1,397 mm (0.055 in)
22
FIXED CAPACITY DISPLACEMENT

BIDIRECTIONAL HYDROSTATIC MOTOR
23
TWO SPEED SHIFT VALVE
24
DRIVE MOTOR SHUTTLE VALVE
25
TEST PORT
HYDRAULIC FILTER
COOLER
HYDRAULIC
RESERVOIR
20
TILT CYLINDER
MALE
FEMALE
HYDROSTATIC
MOTOR
24
18
HYDROSTATIC
PUMP
23
M3
20
MA
M1
11
10
19
FEMALE B3
MALE A3
ATTACHMENT
CARRIER
VALVE
BASE B2
ROD A1
1
ROD A2
BASE B1
17
16
MIN
22
21
X1
M2
L1, L2
B
L1
L2
L3
18
MB
25
LIFT
13
T
AUX
TILT
14
PF
15
X1
12
T
PRIORITY VALVE
EF
STEERING VALVE
LEGEND
PRESSURE
DRAIN
IN
OUT
CD
PILOT
HYDRAULIC / HYDROSTATIC SCHEMATIC 2
COMPONENT
T2

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2013 - 2014 BRUTUS

Publication Printed January 2014 (PN 9925342)

UNDERSTANDING SAFETY LABELS AND DIRECTIONS

ENGINE COOLING SYSTEM

BODY / CAB / FRAME

3TNM72-APB1 3-Cylinder, Liquid Cooled, Diesel, Electric Start

Vehicle Identification Number (VIN) Designation

Individual Serial No.

* Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014

2013 - D131D9JDJ, 2014 D141D9JDJ

2013 - D131L9JDJ, 2014 D141L9JDJ

2013-2014 BRUTUS CAB

2013 - D132D9JDJ, 2014 D142D9JDJ

2013-2014 BRUTUS HDPTO

2013 - D132M9JDJ, 2014 D142M9JDJ

GENERAL : 2013 - 2014 BRUTUS

Hitch Tongue Capacity

MODEL NUMBER 2013: D131D9JDJ

Rated Vehicle Payload

1750 lbs. / 794 kg

Rated Vehicle Capacity

3450 lbs. / 1565 kg

Hitch Towing Capacity

2000 lbs. / 907 kg

MODEL NUMBER 2014: D141D9JDJ

123.5 in. / 310.4 cm

63.2 in. / 160.5 cm

Min. Turning Radius

Cargo Box Dimensions

43.5 x 54 x 11.5 in.

1643 lbs. / 745.3 kg

1741 lbs. / 790 kg

500 lbs. / 227 kg

Cargo Box Capacity

1250 lbs. / 567 kg

Fuel Pump Pressure

1-5 psi (7-34 kPa)

Fuel Tank Capacity

Low Sulfur or Ultra Low

STD MODELS: 2014 - D141D9JDJ

Hydrostatic Drive / Hydraulics / Drivetrain

Pedal Drive Hydrostatic

Engine Driven Gear Type

Bore & Stroke

7.6 gpm (28.8 L) @ 3600

2.2 gpm (8.3 L) @ 3600

3700 100 RPM

Steering Relief Valve

850 psi (58.6 bar)

1350 100 RPM

Charge Relief Valve

Pressurized Wet Sump

Full flow with 50 psi (3.4 bar)

2.75 qts. (2.6 L)

7.2 qts. (6.8 L)

Demand Drive Fluid

AGL Gearcase Lubricant

Polaris DIESEL Oil

2.75 qts. (2.6 L)

6.6 qts. (6.2 L)

Instrument Cluster Indicator

Glow Plugs / Opt. Block

Yanmar MC Fuel Injection

Fuel Transfer System