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Service Manual, contact an authorized Slingshot dealer for service. Comments or suggestions about this manual should be submitted via Ask Polaris. Consumers can direct comments or suggestions to: Service Publications Department, Polaris Sales Inc., 2100 Hwy 55, Medina, MN 55340.
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Copyright Info 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.
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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.
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GENERAL INFORMATION MAINTENANCE ENGINE ELECTRONIC FUEL INJECTION BODY / STEERING / SUSPENSION CLUTCHING FINAL DRIVE TRANSMISSION BRAKES ELECTRICAL...
GENERAL INFORMATION Vehicle and Engine Serial Number Locations Whenever corresponding about a Polaris ORV, refer to the vehicle identification number (VIN) and engine serial number. The VIN can be found stamped on the rear upper frame rail, behind the left rear fender, near the air box (Figure 1-1).
9924707 9924729 NOTE: When ordering service parts be sure to use the correct parts manual. NOTE: Polaris factory publications can be found at www. polarisindustries. com or purchased from www. purepolaris.com. Replacement Keys Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number.
▶ = SEVERE USE ITEM: See information provided above. E = Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. WARNING Improperly performing the procedures marked ■ could result in component failure and lead to serious injury or death.
7. Remove recovery bottle cap and add coolant using a funnel. Coolant Level Inspection 8. Fill recovery bottle to MAX level with Polaris 60/40 The pressure cap and recovery bottle are located under premix Anti Freeze/Coolant or 50/50 or 60/40 the front hood of the vehicle.
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. Use only genuine Polaris replacement parts.
CAUTION: Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Polaris Premium 60/40 Antifreeze/ Coolant is recommended for use in all cooling systems and comes pre-mixed, ready to use.
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NOTE: If there is air in the system you will see air bubbles forming through the radiator filler neck. 10. Add Polaris Premium Antifreeze to the radiator filler neck if the level goes down. If no bubbles are seen at the filler neck, the system should be purged of air.
• Crankshaft Main Bearings 3. Start engine and allow it to reach operating temperature, while monitoring the gauge. • Crankcase NOTE: Use only Polaris PS-4 or Extreme Duty Synthetic 4-Cycle Engine Oil. Oil Pressure at 6000 RPM (Engine Hot): Minimum: 27 PSI...
8. Remove the (2) screws (A) from the rear of the center console (RZR / RZR S only). Because of its design configuration and fastener torque requirements, Polaris recommends removing the engine, transmission and rear gearcase as one assembly. Use the following procedure when engine removal is required.
Valve Seat Reconditioning 0.23672" ± 0.000295" (6.0617 ± 0.0075 mm) NOTE: Polaris recommends that the work be done by a local machine shop that specializes in this area. 6. Subtract valve stem measurement from the valve guide measurement to obtain stem to guide NOTE: The cylinder head valve guides cannot be clearance.
A hone which will straighten as well as remove material from the cylinder is very important. Using a common spring loaded glaze breaker for honing is not advised for nicasil cylinders. Polaris recommends using a rigid hone orarbor honing machine. IMPORTANT: Clean the cylinder after honing Honing To Deglaze...
1. After the engine is completely assembled and ready for installation, the engine must be properly primed with engine oil. Fill the oil filter 3/4 full with Polaris PS-4 or PS-4 Extreme Duty Synthetic Engine Oil. Let the oil soak into the filter for 8-10 minutes. Install the filter onto the engine.
2. Remove primer plug from the engine. Install Oil System Priming Adapter (PU-45778) into the oil plug hole. Push 3-5 oz. (approx.) of Polaris PS-4 or PS-4 Engine Assembly and Installation Extreme Duty engine oil into the adapter or until Use the following procedure to reinstall the engine resistance is felt.
CAUTION Use only Polaris PS-4 or Extreme Duty Synthetic 4- Cycle engine oil or an equivalent. Never substitute or mix oil brands. NOTE: If isolator mounts were removed or...
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PU-47469 and PC Interface Cable PU-47470. This pressure once you have completed the fuel pressure module kit is used on all 8 pin connector-based Polaris test. EFI systems. This kit is available to Polaris dealers through our tool supplier Bosch Automotive Service Solutions at http://polaris.service-solutions.com or 1-800-...
TPS to the throttle body is altered, the TPS must be adjusted. For the purpose of troubleshooting, a known-good ECU from another Polaris RZR EFI of the same model may be used without system or engine component damage. ECU Replacement 1.
ELECTRONIC FUEL INJECTION ENGINE COOLANT TEMPERATURE Refer to Chapter 3 and 10 for additional ECT sensor information. Polaris dealers can test the sensor by using SENSOR (ECT) the Digital Wrench® Diagnostic Software (dealer only). Operation Overview ECT Sensor Resistance Readings Mounted on the cylinder head, the engine temperature Temperature °F (°C)
IMPORTANT: Refer to Section 2, 3 and 4 in the Instruction Manual provided in the Digital Wrench® Diagnostic Kit to install the Polaris Digital Wrench® diagnostic software on your computer. The Digital Wrench® diagnostic software allows the technician to perform the following tests and observations: •...
ID shown on the lower right side of the Digital Wrench® start-up screen. Located under the dash connected to a sealed plug. 2. Proceed to http://polaris. diagsys. com to see if a newer update is available. Follow these steps to connect the diagnostic interface cable to the vehicle to allow Digital Wrench®...
IMPORTANT: Always operate with the latest update. 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...
Authorization site. The Request Code is automatically generated by Digital Wrench® during the reprogramming • Proceed to http://polaris. diagsys. com for specific process. The Reflash Authorization site is located under information and FAQs on how to troubleshoot the “Service and Warranty”...
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8” from the top of the shock body. Pass a propane torch quickly over the shock body to eliminate any air bubbles. Polaris Gas Shock Oil - 5 wt. PN 2870995 - qt. PN 2872279 - 2.5 gal. 22. Slide the piston valve and bearing as an assembly down against the shock shaft valve stack (Fig.
(323445- (5000 - (56323- (70437- clutch upshift and backshift. During the development of 12000) the Polaris vehicle, the PVT system is matched first to the engine power curve; then to average riding conditions vehicle’s intended usage. Therefore, modifications or variations of components at random are never recommended.
10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Clutch component inspection should be performed by a Polaris MSD certified technician. Clutch malfunction. Fouled spark plugs, foreign material in fuel tank, restricted fuel lines, or faulty fuel pump may Poor engine performance.
FINAL DRIVE Gearcase Installation 2. Add Polaris ATV Angle Drive Fluid to rear gearcase. Refer to maintenance information in Chapter 2 for 1. Install the rear gearcase by reversing the procedure more details. Torque drain and fill plugs to listed under “REAR GEARCASE - Gearcase specification.
6. Install the ring gear and torque the retaining bolts to specification. Ring Gear Bolts: 70-80 ft-lbs (95-108 Nm) NOTE: Grease all seals with Polaris All Season Grease (PN 2871322) upon assembly. Gearcase Assembly 1. Replace all worn components. 3. Install new seals into the gearcase housing and gearcase cover using a standard seal installer or other suitable method.
FINAL DRIVE Gearcase Installation 2. Add Polaris ATV Angle Drive Fluid to rear gearcase. Refer to maintenance information in Chapter 2 for 1. Install the rear gearcase by reversing the procedure more details. Torque drain and fill plugs to listed under “REAR GEARCASE - Gearcase specification.
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.030” (.762mm) 27. Install selected shim(s) and slip fit bearing race into transfer case cover. Coating shim (s) and bearing race with Polaris All Purpose Grease may be necessary to hold the assembly together during installation. 28. Apply a thin coat of sealant to the case mating surfaces.
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.
Be sure groove is clean and free of residue or brakes Torque mounting bolts to specification. may drag upon assembly. 2. Coat piston with clean Polaris DOT 4 Brake Fluid. Install piston (D) with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly with light resistance.
11.8 V or less NOTE: Battery charge can be maintained by using a Polaris battery tender charger or by charging once a Load Test month to make up for normal self-discharge. Battery tenders can be left connected during the storage...
EPS unit. If not, update to the latest to a normal mechanically coupled steering system. The version for each and follow the guided diagnostic system is Polaris Digital Wrench® compatible for procedure(s) available in Digital Wrench®. simplified diagnostics...