Welcome To The 2012 ORV Technical Update
Contents
1. Charger indicator LED All accessory outlets 1 VCM 2 Diagnostic plug 3 Speed sensor Indicator fuse Active when key inthe Accessory fuse 4 Turf solenoid ON position 5 Accessory spade terminal DC to DC Fuse Relay F Switched 13 5 V DC converter splice Chassis fuse PM ower relay Switched splice oe i v Unswitched z 1 Dash plug figs Light fuse 2 Indicator bulbs 3 HR meter 4 FNR switch light bulbs 5 Mode switch light bulbs B terminal under hood All bulbs except 6 AWD Switch 1 Dash indicators 2 FNR switch NOTE A malfunction in the DC to DC converter chassis 3 Mode switch fuse or switched relay could cause a motor controller fault GH POLARIS INDUSTRIES INC 2012 ORV Technical Update 2012 RANGER EV LSV 14 0 volt circuit Power to 1 AWD switch Revised architecture 2 VCM wake up Only active when All balbsexcept 3 Speed sensor the key is ON Light fuse 1 Dashindicators 4 Accessory spade lead 2 FNR switch 5 Turf solenoid 3 Mode switch DC to DC p De to De converter Chassis fuse converter 14 v splice All Accessory fuse tr accessory outlets Power to the light bulbs DC to DC Diode 1 Forward Neutral Reverse switch ae oe 2 Mode switch Y To reduce motor controller faults chassis circuits are divided 3 Indicator panel into two groups s2. New converter Added relay RAN G E R EV LSV SEVCON 48 volt side Awire Key activated 2011 2012 e be converter RELAY CONVERTER oR D i 8 j ETT DC to DC only powered i 3 with key on J 48 Volts from key switch eg k sev w Cosmo varar Continuous 48 volt power supply 12 volt power out L g neman wone 14 0 V DC out emne Let ne GP POLARIS GE 11000 48 vout Fs center Fused 48 Volt power supply INDUSTRIES INC 2012 RANGER EV LSV DC to DC Converter Relay 48 volt coil 48 volt contacts Location Mounted on DC to DC converter bracket Key ON Battery to converter relay contact circuit closed Key OFF Opens 48 volt battery side of circuit No 14 0 V DC circuits No power to accessory circuits No power with key OFF 2012 ORV Technical Update DC to DC Relay Contact side 48 V DC to DC to DC converter Coil side maten 7 Dam Coil side Ground B 0 48 V DC from ignition switch Contact side 48 V DC from fuse center 12V RECEPTACLE P N 4012393 7 TERMINAL BLOCK P N 4011892 Elele B GND ACC OG WH GP POLARIS INDUSTRIES INC 2012 ORV Technical Update 2011 RANGER EV LSV 13 5 volt circuit
3. 2012 ORV Technical Update Welcome To The 2012 ORV Technical Update Home page INDUSTRIES I ORV general information Fuel pump pre filter Full Size RANGER information New model ALL 800 models RANGER HD RANGER Diesel Mid Size RANGER information RANGER EV RANGER 500 EFI RANGER 500 Crew EFI 2012 ORV Technical Update RZR information New model All RZR models All 800 models All 50 models RZR XP ATV information All ADC models All Sportsman XP models Sportsman 550 XP Sportsman 850 XP Classic Sportsman Team Tip and Service Bulletins GP POLARIS INDUSTRIES INC 2012 ORV Technical Update ORV Fuel Pump Most EFI ORV Revised fuel pump pre filter screen running change 10micron model year 2011 30 micron Smaller the micron number increased filtration Service fuel pump kits to follow Fuel pump pre filter screen Xe PSLARIS INDUSTRIES INC 2012 ORV Technical Update RANGER Diesel Crew YANMAR 900 Diesel New model added to the RANGER line up RANGER Diesel Crew All the Features of RANGER CREW with Diesel Power 900 Diesel Engine 90 of peak torque available at 1600 RPM 55 Amp Alternator 40 more range than the comparable gas model 2012 RANGER Crew Diesel GP PSLARIS INDUSTRIES INC Full Size RANGER What changed All RANGERS
4. Blue line Bat 44 RED line SHARED pe sen Provides constant 12 V DC to LSV 2 Amp fuse circuit and Charge Indicator fuse circuit B Function feature Default power supply to light bulbs in only if DC to DC circuit malfunctions Forward Neutral Reverse switch Indicator panel Mode Switch Diagnostic plug PSLARIS INDUSTRIES INC 2012 ORV Technical Update DIAGNSOTIE QHASSIS DASH INTERCONNECT _ Key ON 2012 RANGER EV LSV 1 contacts closed Power to the light bulbs in the TG Forward Neutral Reverse switch Ei Mode switch Indicator panel a 14 0 VDC normal 12 0 VDC if 14 0 DC to DC circuit malfunctions Diagnostic plug 14 0 VDC normal 4 lt 12 0 VOC if 14 0 DC to DC circuit malfunctions ano 8 z 8 5 ste vor sure reniri FE S ee tt 2 d If DC to DC converter circuit is functioning o this circuit will be powered by the DC to DC R converter 14 0 vdc J Susno 127 Y NG gee ee SPLICE 14 0 WY oe oe coveren 12 volt Switch Power Relay Circuit 129 no 00 BEE 122 ROOK TEI The key switch controls the Switched Power Relay ice 12v costat Pover ogs 108 Pe Key on power flow TE icin wan Gaal a ate _ key off no po
5. New hood latch Revised seat base Added center seat support Revised heat management Reduced cab heat in the seated area Improved transmission serviceability RANGER with 800 engine Revised air box lid Rotated pre filter opening Two wire shift switch Revised throttle body wires and routing RANGER HD Added EBS RANGER Diesel Revised drive and driven clutch 2012 ORV Technical Update 2012 RANGER 800 XP ia 2012 RANGER 800 6x6 y 2012 RANGER 800 HD 2012 RANGER Diesel Ai PSLARIS INDUSTRIES INC 2012 ORV Technical Update Full Size RANGER A Revised hood latch AJ Now one piece Pre model year 2012 A Die cast Will retrofit back to early models Model year 2012 PELARIS NDUSTRIESINC 2012 ORV Technical Update Full Size RANGER Revised seat base Added close off to seat base RANGER Diesel obstructs heat from entering drivers compartment RANGER HD RANGER XP RANGER 6X6 RANGER CREW Aluminum seat pegs Reinforced mounting Rear only Added heat shield replaced foil Sandwiched material Not featured on Diesel G POLARIS INDUSTRIES MC 2012 ORV Technical Update Seat Support Fastened to cab seat base Full Size RANGER Added Seat Support RANGER Diesel RANGER HD RANGER XP RANGER 6x6 RANGER CREW Rear only Seat support Seat base S
6. Revised rear gearcase Revised drive clutch spring RZR 50 127 cm Revised spark arrestor Revised sway bar RZRXP Splice less belt Revised prop shaft Revised A arm Reduced steering effort Revised front wheel bearing carrier Revised coolant surge tank and filler neck Reduced water intrusion RZR XP International Revised gearcase with differential External mechanical park brake EPS standard Front sway bar standard GP POLARIS PEE RZR 570 Features Trail Capable 50 Wide True On Demand AWD 10 Ground Clearance 9 5 Suspension Travel ProStar 570 Engine 45 Horsepower Single Cylinder 567cc 4 Valve DOHC Wet Sump 650 Watts RZR XP Style GearCase Helical Cut Gears Low Friction Bearings No Power robbing right angle drives Compact design 2012 ORV Technical Update GP POLARIS INDUSTRIES INC 7 2012 ORV Technical Update RZR 570 Engine air inlet RZR 570 Chassis 1 lt Similar to RZR 50 ___________ i Revised from behind the seats to rear of vehicle GP PSLARIS sn RZR 570 Similar to RZR XP RZR 570 Left side view Engine intake Plastic removed PVT intake RZR XP rear gearbox RZR XP PVT cover GP POLARIS 2012 ORV Technical Update INDUSTRIES INC 44 RZR 570 Inspection panel removal Provides easy access to
7. will only Diode Fuse use battery power in the event there is a malfunction in the DC to DC converter circuit 12v As long as the switched 12 splice is powered Motor controller faults will be reduced if DC to DC circuit malfunctions PSLARIS INDUSTRIES INC ED 2012 ORV Technical Update 2012 RANGER EV LSV 14 0 volt circuit Switched 12 Volt Splice Power supply circuits comparison Light fuse Normal operation DC to DC Chassis Dc to De converte converter fuse 14 v splice M DCto DC Accessory Normal operation no malfunction DC to DC converter Diode fuse supplying power to switched 12 Volt Splice E Switched 12 n volt splice Malfunction Pere Diode Fuse DC to DC power source malfunction ately nv VI Redundant power supply being used Contactor Switched Switched 12 connector power relay volt splice Diode Fuse One battery supplies power to switched 12 Volt Splice if DC to DC Battery 4 AN circuit malfunctions GP POLARIS INDUSTRIES INC ED 2012 RANGER EV LSV 2012 ORV Technical Update Redundant power supply wiring diagram to contactor plug Each circuit is connected to one battery in each bank 12 volts Each circuit contains a diode and 2 amp 12 volt fuse Green line Bat 7 EE
8. Diagnostic plug 1 DC to DC converter 14 volt splice 2 Switched 12 volt splice All circuits shown on this slide will receive power from the Switched 12 volt DC to DC converter splice See next slide for more information GP POLARIS INDUSTRIES INC 2012 RANGER EV LSV 14 0 volt circuit architecture revised Redundant power source for Switched 12 Volt Splice 2012 ORV Technical Update A redundant power source was added to support the Switched 12 Volt Splice with power Light fuse The DC to DC diode was added to block power from traveling to the DC to DC converter DC to DC converter voltage will be di lominant 14 v splice Power to the light bulbs Forward Neutral Reverse switch Mode switch Indicator panel Switched 12 volt DC to DC Chassis fuse converter Accessory fuse x 2 Diode Fi 5 Battery 7 HODE Fuse Diagnostic plug 12v Only one battery is be used The Contactor Switched battery with the most pressure connector power relay splice Battery 4 splice A Diode Fuse was added to both batteries to block power from entering the batteries from the DC to DC converter The key switch controls the Switched Power Relay key on power flow key off no power DC to DC Diode DC to DC converter is the dominant power source The Switched 12 Volt Splice
9. K Floor rear transparent view Seat base transparent view GP PSLARIS INDUSTRIES INE 2012 ORV Technical Update Full Size RANGER Revised floor rear heat shield Sandwich material RANGER Diesel RANGER HD RANGER XP RANGER 6x6 Reat viR i Model year 2011 RANGER CREW 1 1 Model year 2012 Rear only Sandwich heat shield in red Heat shield Floor back Cut away side view PSLARIS Ts 2012 ORV Technical Update Floor rear Model year 2011 Full Size RANGER Revised floor rear Added material Where seat contacts floor rear Model year 2012 Enlarged view Additional material added to the center section of floor rear 5 GP POLARIS INDUSTRIES INC gt GED 2012 ORV Technical Update Full Size RANGER Revised seat base with aluminum pegs and reinforced mounting more robust Seat and floor rear summary Kl S support provides additional support for the seat center Added close off Reduces engine heat entering drivers compartment Added heat shield Not featured on Diesel Deflects heat away from seat Revised floor rear heat shield Additional material added to the center section of floor back length deflects heat away from floor back panel Reduces engine compartment heat from entering drivers compartment GP PSLARIS INDUSTRIES INC Full Size RANGER Revised panels Hood l
10. R 570 and RZR XP GP POLARIS forene GED 2012 ORV Technical Update RZR XP Revised box panels Reduced water intrusion Behind the grille and the foam 2012 holes eliminated in panel to reduce water intrusion Both PVT and engine air inlet 2011 holes in panel View of left box panel POLARIS ae 8 2012 ORV Technical Update RZR XP Revised side panel intake foam seal Reduces water intrusion Left hand side panel Intake resonator J Intake resonator drain Revised intake foam seal GP PSLARIS INDUSTRIES INC 7 2012 ORV Technical Update RZR XP International New features External mechanical park brake Turf mode Differential Turf solenoid gt Park brake disc GP PSLARIS INDUSTRIES INC 15 2012 ORV Technical Update RZR XP International Revised Gearcase Differential added Output shaft Added Turf differential gear set O 2 A oP ote er park brake disc ex a Case revised for park brake caliper ET Park brake disc GP PSLARIS INDUSTRIES INC 81 GED 2012 ORV Technical Update RZR XP International External mechanical park brake Lever assembly Caliper assembly Park brake lever assembly mounted Park brake disc Park brake caliper between seat belt buckles NOTE Rubber boot removed for illustrati J illustration GP POLA
11. RIS INDUSTRIES INC ATV Discontinued models Outlaw 850 X2 What changed All ADC models Added O rings to hub clutch packs All Sportsman XP Revised A arm Sportsman XP 550 Added Luk Coupler similar to Sportsman 850 Sportsman XP 850 Increased power Revised connecting rods Classic Sportsman Revised front cab International Classic Sportsman New procedure for headlight adjustment 2012 Sportsman 850 XP 2012 Sportsman 500 HO GP PSLARIS 2012 ORV Technical Update INDUSTRIES INC 83 2012 ORV Technical Update Sportsman ADC ADC hubs Revised ADC hub O rings added to hubs Separates friction plates Allows oil to penetrate between plates O rings GP POLARIS 2012 ORV Technical Update Sportsman XP Revised A arm Improved bushing to tube fit Drawn Over Mandrel DOM pivot tubes Controlled inner diameter tube New process to control ID of tube Pivot tubes GP POLARIS PREE Sc 2012 ORV Technical Update D Sportsman 550 2011 Sportsman XP550 built after 03 01 11 and all 2012 Crankshaft Coupler Holder Luk Coupler Application Sportsman XP 550 units built after Revised main gearcase 03 01 11 N i Used to hold the crankshaft when applying BOSS driven clutch torque to the coupler nut Gearcase revised BOSS driven clutch shaft 2012 ADC O
12. S Base model Sachs mono tube RZR S LE models Fox Podium X RZR 4 and RZR XP Podium X 2 0 Clicker knobs Revised calibration 2012 ORV Technical Update me paka TT Mono tube Podium X Screw adjust Podium X 2 0 Clicker knob 4 GP POLARIS INDUSTRIES INC 2012 ORV Technical Update All RZR with 800 engine Oil ring removed Removed O ring seal RZR final drive 2011 and older GP POLARIS INDUSTRIES INC GED 2012 ORV Technical Update All RZR 800 Revised drive clutch spring Increased pressure 7043789 Neon Green e Will retrofit to 2011 RZR 800 GP POLARIS INDUSTRIES INC GED 2012 ORV Technical Update RZR 50 127cm Spark arrestor Through bolt design similar to the RZR XP Spark arrestor amp GH POLARIS INDUSTRIES INC RZR 50 127 cm Sway Bar 2012 ORV Technical Update Revised hollow tube sway bar Revised front sway bar 50 127 cm 800 and 570 Tube Mounting Links Link with upper and lower joints gt 2011 and older s 2 Link with a rubber ends SS Revised Sway Bar bushings Mounts with shock through bolt POLARIS INDUSTRIES INC 7 2012 ORV Technical Update RZR General Clutch Changes Revised RZR XP belt Stronger Splice le
13. air filter New air filter design Removal panel Similar to RZR XP Air box assembly 2012 ORV Technical Update GD POLARIS INDUSTRIES INC 45 YS 2012 ORV Technical Update RZR 570 Layout RZR XP style air box Removable frame section Thermostat housing hose Water pump hose Removable frame section PVT air exit By pass hose Large diameter prop shaft 2012 ORV Technical Update RZ R 5 70 Rear mounted sway bar with rubber bushings on end links Lower link attached Rear suspension through shock bolt A arm mounting Sway bar mounting Revised upper and lower a arm and mounting Revised bearing carrier GD POLARIS INDUSTRIES INC 7 2012 ORV Technical Update RZR 570 Rear A arms Lube location points Zerk fittings GP PSLARIS Er 7 2012 ORV Technical Update o RZR 57 Fuel Supply Fuel tank vent line soft hose Fuel tank Fuel tank shown in transparent view Fuel line formed tube quick connect PSLARIS Er GED 2012 ORV Technical Update RZR 570 Engine mounting PTO side view Bolt A location Through bolt design Bolt B location Plates Bolt C location Bolt D location Engine mounting bolts A D GD POLARIS INDUSTRIES INC 17 2012 ORV Technical Update RZR 570 Engine mounting Top view No joint Plates sandw
14. er Water pump weep outlet Oil seal Mechanical seal Mag cover houses the impeller water pump shaft oil seal NOTE Mag cover removed for illustration mechanical seal and stator GP PSLARIS INDUSTRIES INC 1 GED 2012 ORV Technical Update RZR 570 Oil pump drive Counter balancer S Oil pump drive chain Cam chain guide Crankshaft mag end Cam chain guide GP POLARIS PREE GED 2012 ORV Technical Update RZR 57 Engine PTO view Piston at TDC Counter balancer PTO bearing retaining plate Oil pick up GD POLARIS INDUSTRIES INC 2012 ORV Technical Update RZR 570 Engine Management System Based on 2011 RZR 800 M17 controller Ignition Switch Aposition On Start Lights Off Headlight circuit Relay controlled Start circuit Start solenoid grounds through brake light switch GH POLARIS INDUSTRIES INC GED 2012 ORV Technical Update All RZRs Removable front grille Easy radiator access Snaps into place Front grille upper tabs Lower tabs PSLARIS INDUSTRIES INC 61 GED 2012 ORV Technical Update Floor cab seal Reduced cab water and dust intrusion Steering column boot added Upper seal between floor and cab adde Similar to RZR XP Not on the RZR 570 Steering shaft rubber boot sil Improved dash sealing to keep mud and heat off the drive
15. ich components Gearcase 7 i PTO mounting location Engine case Mag mounting location Plates Plates GP PSLARIS INDUSTRIES INE 1 GED 2012 ORV Technical Update RZR 570 Coolant by pass fitting J Engine layout Coolant bleed Revised fuel rail CPS Throttle body not illustrated CPS connector Revised throttle body similar to 2011 800 M17 Side X Side IAC and TPS common with 2011 800 M17 Side X Side GP PSLARIS INDUSTRIES INC 7 2012 ORV Technical Update RZR 570 Engine layout Engine temp sensor Stator connector baa Cam chain tensioner CPS EE Gp PULARIS INDUSTRIES INC 2012 ORV Technical Update D RZR 570 Engine layout Stator connector CPS connector Oil Fill Dipstick Water pump cover Water pump inlet lie filter GD POLARIS INDUSTRIES INC gt GED 2012 ORV Technical Update RZR 570 Top end Dual overhead camshafts Shim under bucket Shims common with RZR XP Shim Cut away view Ge 3 GP PSLARIS INDUSTRIES INC 2012 ORV Technical Undate Exhaust camshaft RZR 570 Top end Centrifugal design compression release Centrifugal feature PSLARIS Compression release mechanism INDUSTRIES INC 56 MED 2012 ORV Technical Update RZR 570 e Water pump Impeller Shaft and seal Water pump shaft slotted Impeller drive coupl
16. iner Left and right wheel well panels Radiator and fan assembly Hood liner 2012 ORV Technical Update Hood liner Right wheel well panel Heat deflector Left wheel well panel Radiator and fan assembly Front Left wheel well panel top view Heat deflector left side view GP POLARIS INDUSTRIES INC 2012 ORV Technical Update Full Size RANGER Curved hood liner directs air down and forms a seal from the cockpit Revised panels Heat deflectors Heat deflector colored gray PSLARIS 2012 ORV Technical Update Full Size RANGER Radiator air flow Reduces radiator air from entering drivers compartment through foot pedals and steering shaft openings Front Front Left wheel well panel removed Viewed with hood liner removed left side view top view GP PSLARIS INDUSTRIES INC 7 GED 2012 ORV Technical Update RANGER Gearcase Revised hex plug locations Full size Allexcept 6x6 and Diesel Mid size C Except EV Fill plug m 1 I Check plue Drain plug B PSLARIS INDUSTRIES INC Side X Side Shift Switch 2 Pin switch All 800 side by side 6 pin switch RANGER Diesel E223 vi E2308 VT UO 2 Pin switch Internal resistors 2012 ORV Technical Update Shift switch RESISTOR MODULE je La er om 110820 T 24 o i mw d i ce ZAN 035 peke E 160 08 iss woot p l
17. nged for new weights 2011 weights 150 grams Reduces shift effort and improves belt deflection GD POLARIS INDUSTRIES INC eA 2012 ORV Technical Update RANGER Diesel Revised driven clutch GP POLARIS PEE gt 2012 ORV Technical Update RANGER HD EBS added HD only Specific gearcase Internal component change 2012 RANGER XP and HD gearcase features revised internal components for EBS function Kit 2012 RANGER XP only No Diesel oe GE GEER 2 No pre 2012 RANGERS Smooth one way No offset tool Visual adjustment only EBS driven clutch EBS drive clutch Refer to service manual Center to center adjustment using Center distance tool 2 I 2871710 23 66 weights 10 25 4 cm Center distance tool PSLARIS INDUSTRIES INC Midsize Ra nger 2012 RANGER 500 EFI Crew RAN 2012 ORV Technical Update GER 500 EFI and Crew 500 EFI Speed key accessory 25mph speed limit Improved transmission serviceability all models RAN same improvements as full size RANGER GER EV 2012 RANGER 500 hd Revised motor controller calibration New motor temp sensor Revised traction battery charger New DC to DC converter Added a DC to DC converter relay Revised switch 12 splice circuit Redundant power supply New contactor connector Revised 48 volt fuse box 2012 RANGER EV 2012 RANGER EV LSV Added auxiliary battery rela
18. r GDP LARIS INDUSTRIES INC 25 7 2012 ORV Technical Update All RZRs Revised passenger grab tube Larger tube Bushing added Welded bracket Will not retrofit back Grab tube bracket welded to frame tubes Passenger grab tube now square Grab tube wel Anti Rattle Passenger Grab Bar NOTE Plastic removed for visual purpose GP PSLARIS INDUSTRIES INC 63 RZR Seat Belt Model year 2011 RZR cab frame Seat belt mounting location Net mounting bracket LE gg FG Viewed from inside cab looking back 2012 ORV Technical Update Passenger side seat belt Viewed from inside cab looking back GH POLARIS INDUSTRIES INC MED RZR Seat Belt Model year 2012 RZR cab frame Seat belt mounting location Common seat belt with RANGER Net and seat belt mounting bracket Viewed from passenger side looking into cab 2012 ORV Technical Update Passenger side seat belt Viewed from passenger side looking into cab GP POLARIS INDUSTRIES INC 2012 ORV Technical Update RZ R Push bar increased approximately 6 mm for 2012 a MER i e Master cylinder common with RZR XP RZR RZRS Pedal closer to operator for 2012 RZR4 2011 push bar length PSLARIS INDUSTRIES INC 66 RZR Shocks Shocks RZR 50 twin tube Revised jounce bumper More durable material RZR
19. r hazard signals Added Chassis fuse 14 v 20 amp 2012 ORV Technical Update Charger fuse 48 V 5 amp Charger fuse 14 V 15 amp Vag Year 2011 Unswitched fuse Spare15 amp Spare 25 amp DL C Ce o0 cd eT oA oO I By Game FANE ee ar Revised Charger fuse 48 V 30 amp Revised Charger fuse 14 V 25 amp ode Year 2012 GP PSLARIS INDUSTRIES INC ___ 2012 ORV Technical Update RANGER EV LSV Front gearcase Torsion spring added No spring retainer Revised hub coil 27 1 10 ohms 1 Revised torsion spring 2 Revised roller cage 3 Revised ring gear GP POLARIS INDUSTRIES INC gt 2012 ORV Technical Update RANGER EV LSV Ring gear detail view mm Roller cage Torsion spring Ring gear GP POLARIS COSTES re RZR What changed New model RZR 570 New engine Revised chassis All RZR models Gear selector 2wire identical to RANGER 800 Removable front grille Decreased cab water and dust intrusion Revised passenger grab tube Common seat belt with full size RANGER Common master cylinder with RZR XP Shocks RZRS LE FOX shocks RZR 4 and RZR XP FOX shocks with tool less clickers 2012 ORV Technical Update All RZR 800
20. rings added to hubs Luk engine to gearcase coupler GD POLARIS INDUSTRIES INC 2012 ORV Technical Update Sportsman 850 XP Revised intake runners Air box cover strap Revised Intake system Throttle body Cylinder head Side covers not shown Larger air box Revised to fit around box Revised air box TT Revised valve cover Increased power Revised throttle body Fl Revised cylinder head GP PSLARIS INDUSTRIES INC 7 GED 2012 ORV Technical Update Sportsman 850 XP Revised Throttle body and mounting TPS T MAP Throttle body is secured to cylinder head with 4 mounting screws TPS Changed to conform with airbox GP PSLARIS er 8 MED 2012 ORV Technical Update Sportsman 850 XP Cylinder head revisions Thermostat housing change to conform with airbox Cooling passage revised Pressed in bypass fitting Revised engine coolant mounts facing downward GD POLARIS INDUSTRIES INC 7 2012 ORV Technical Update Sportsman 850 XP Revised engine breather Valve cover Breather outlet Hollow cavity Revised valve cover Drains Valve cover transparent view GD POLARIS INDUSTRIES INC 775 2012 ORV Technical Update Sportsman 850 New locations ECU mounted in front of air box ECU IAC IAC mounts on shifter side of air box Air inlet tube Air outlet ho
21. se to throttle body GD POLARIS INDUSTRIES INC 7 Sportsman 850 XP Revised Air box plenum Intake runners 2012 ORV Technical Update EN Air box plenum Intake runners Side view transparent plenum PSLARIS INDUSTRIES INC 2012 ORV Technical Update Sportsman 850 XP Air box Drain Plenum cutaway Drain plug unscrews from bottom of plenum lowest section of plenum Tail retains plug when removed PSLARIS INDUSTRIES INC GED 2012 ORV Technical Update Sportsman 850 XP Visual comparison between model year 2011 to 2012 PSLARIS INDUSTRIES INC 47 2012 ORV Technical Update Sportsman 850 XP Specification changes Connecting rod bolt torque specification Torque to yield bolts Removed paint dot Stamped with letter to identify color RPM limit Model year 2011 8000 RPM Model year 2012 7600 RPM Drive clutch weight change Model year 2011 Revised connecting rod One up utilizes 60 gram weights Two up utilizes 68 gram weights Model year 2012 Common 63 gram weight between one and two up New torque spec Bolts cannot be reused See service manual for specifications GP PSLARIS INDUSTRIES INC Classic Sportsman Revised front cab Under rack storage Sportsman 400 HO Sportsman 500 HO Sportsman 800 Sportsman 500 HO Touring Sport
22. sman 800 6x6 2012 ORV Technical Update Front plastic mounting Ke Y Storage location Front rack mounting GP POLARIS INDUSTRIES INC MED 2012 ORV Technical Update International Tractor Forest Sportsman Headlight adjustment Headlight adjustment access plug Remove plug to adjust headlight beam Headlight upper access location Headlight lower mounting GH POLARIS INDUSTRIES INC
23. ss 32 5mm Cut edge e 3211148 MBL 5 4mm COS BEEBE REE BAY ELIS III III 16 7 0 6mm GP POLARIS INDUSTRIES INC 2012 ORV Technical Update RZR XP Revised prop shaft Rubber isolated bearing New bracket welded to frame Retrofit to 2011 RZR XP requires the following Prop Shaft Both sections of shaft Rubber mounted bearing Shaft support bracket Fasteners to secure the bracket to frame Prop Shaft bearing Bracket moWnting holes mounting bracket used when retrofitting bearing to 2011 RZR XP PSLARIS INDUSTRIES INC 7 2012 ORV Technical Update RZR XP rau J Revised A arm Caster change Fee Reduces steering effort ET Overlay Black 2011 Green 2012 Trailing edge 2011 Trailing edge 2012 Ball joint moved back to reduced steering effort GP PSLARIS Model year 2011 Model year 2012 INDUSTRIES INC 2012 ORV Technical Update Revised front wheel bearing carrier Ball joint pinch bolt increased to 10 mm o d Bearing ane PSLARIS INDUSTRIES INC GED 2012 ORV Technical Update RZR XP Revised coolant surge tank Increased capacity 2012 GP POLARIS INDUSTRIES INC RZR 570 and RZR XP Cooling system Revised filler neck Revised radiator cap 2012 ORV Technical Update 2011 RZR XP 2012 RZ
24. t eee 148 pas Poem E 148 08 0 he i ia 1 Tapas agaaa y ate orev 206000 NG cd D me E s eLow 6 Pin switch F o onion External resistors PSLARIS INDUSTRIES INC 16 2012 ORV Technical Update RANGER 800 i wal Pre filter box air inlet opening faces inside Revised engine air intake right fender instead of forward Pre filter Air box lid Material change for high temp Air box lid Integrated shield No foil used on air box lid GP PSLARIS INDUSTRIES INC GED 2012 ORV Technical Update RANGER 800 Throttle body wires pulled back tight and panduit secured Starter mounted bracket secures harness GP PSLARIS INDUSTRIES INC 1 2012 ORV Technical Update RANGER 800 Throttle body wires Wrapped with high temp abrasion resistance tape Panduit Teflon insulated wires Revised length and routing Panduit behind connector Panduit GP PSLARIS INDUSTRIES INC 1 2012 ORV Technical Update RANGER Diesel Weights and two way bearing will not retrofit to 2011 models A Complete drive clutch will retrofit to 2011 models Revised drive clutch Ka Revised profile 180 gram weights Pan way idler bearing New 92lb spring Pin location 2011 80lb spring cha
25. wer GP P LARIS INDUSTRIES INC gt RANGER EV LSV Revised contactor connector Added the Diode leads 7pin PinA B and F are 12 volts Constant power 48 volt fuse box 2012 1 48 volt 20 amp fuse Dash 2 48 volt 30 amp fuses Traction batteries charge 2012 ORV Technical Update SPLICE 12V CONSTANT POWER 2 FUSERELAY MODULE R re 109 mn 110 PR 110 PR SPLICE 48V UNSWITOHED KEY SWITCH 108 1 48 VOLT CHASSIS DASH FUSE 4 025 RD 175 0 115 a A es on 1 11488 sa 14 mo 1 Ro 48 VOLT DELTA Q POWER FUSE 035 ROT 035 ovr SPLICE BATTERY 124 2 DIODE LEAD FUSE pr o 1 0084 PK 0888 PK 48 VOLT DE DE CONVERTER RELAY FUSE ce Ra Model Year 2012 contactor CONTACTOR OATTERY HARNESS Pin C D E and G are 48 volts 48 VOLT FUSE CENTER Ee RD Ro i km rina DC to DC converter primary power CHARGER DELTA Q POWER out Model Year 2012 20 Ar H Model Year 12 DC DC CONVERTER RELAY CONTACTOR BATTERY HARNESS CONTACTOR BATTERY HARNESS GP POLARIS INDUSTRIES INC 2012 ORV Technical Update TOP VIEW RANGER EV C oe a LSV Ac z a J Auxiliary battery relay circuit er ay 1 3 Key ON Auxiliary relay closed Power 14 0 volts from the auxiliary DC to DC converter to auxiliary batteries DC to DC relay closed Allows 48 volts to au
26. xiliary battery DC to DC converter Key OFF Auxiliary relay open Open circuit between DC to DC converter 14 0 volts to auxiliary batteries DC to DC relay open Open 48 volt circuit to auxiliary battery DC to DC converter BUS 83 85 BUS A3 A5 A7 FUSE RELAY MODULE GP POLARIS INDUSTRIES INC 2012 ORV Technical Update RANGER EV LSV aan Auxiliary battery relay Power flow Key ON red line pg AUX BATTERY CHARGER POWER FROM r gt CHARGER 14V FUSE D 1 GROUND B lt 7 pg f 48 vdc Y g k 20A CHARGER 14V AUX DC TO DC c6 CHARGER AUX BATTERY age car 8 S an 14 0 vde sj voc SWITCHED IGNITION co FROM AUX BATTERY CHARGER B POWER TO D7 08 GP PSLARIS INDUSTRIES INC GED 2012 ORV Technical Update RANGER EV LSV Auxiliary battery relay circuit Wiring diagram Auxiliary battery Hi 4 DC to DC charger t a connector PSLARIS INDUSTRIES INC 7 RANGER EV LSV Fuse box changes 2011 to 2012 Increased wire to match fuse Red outline indicates change between previous model years Added Switched Auxiliary Relay LSV fuse provides constant power fo
27. y Revised under hood fuse box Revised front gear box Added torsion spring Details to follow PSLARIS INDUSTRIES INC 2012 ORV Technical Update RANGER 500 EFI and Crew 500 EFI Accessory Speed Key Kit 2878400 Limits vehicle to 25 mph Kit contains RF module Key cap with RFID chip Air control valve Inline filter Solenoid Intake boots Hardware Vehicle speed sensor Solenoid Air control valve Filter Instructions Diagram Intake boots Slide EFI air control valve Similar to CV carb body GD POLARIS INDUSTRIES INC RANGER EV LSV 2012 ORV Technical Update Traction battery charger and charger circuit New charger 2 Flying leads Robust connections Revised charge indicator circuit Supported by traction batteries Revised charging circuit Increased from 20 to 30 amp circuit 2011 Harness connector attached to charger shell Charger fuse 48 volt 20 amp Con indicator LED power supplied by DC to DC converter 2 pin flying lead connector 2012 Charger fuse 48 volt 30 amp fuse Wire increase to match fuse 4 8 pin flying lead connector AC power cord Charge indicator LED power supplied by traction batteries GP PSLARIS INDUSTRIES INC 2012 ORV Technical Update DC to DC Converter circuit
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