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GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
1
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL NUMBER DESIGNATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION . . . . . . . . . . . . . . . . . . . . . 1.2
N
VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . 1.3
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
O
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
SI
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
GENERAL: 2013 BRUTUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
DETAILED: 2013 BRUTUS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
GENERAL: 2013 BRUTUS HD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
R
DETAILED: 2013 BRUTUS HD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
GENERAL: 2013 BRUTUS HDPTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
DETAILED: 2013 BRUTUS HDPTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
VE
FUEL INFORMATION, USAGE AND RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . 1.12
FUEL INFORMATION / RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
BIO-DIESEL FUELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
B5 DIESEL FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
BIO-FUEL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
B6 TO B20 BIO-DIESEL FUEL BLEND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
Y
ENGINE WARRANTY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
COLD WEATHER OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
AR
BLOCK HEATER USAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
STANDARD BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15
METRIC BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15
IN
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16
IM
EL
PR
1.1
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual
© Copyright 2013 Polaris Sales Inc.
GENERAL INFORMATION
VEHICLE IDENTIFICATION
Model Number Designation
Example: D131D9JDJ
MODEL
GROUP CHASSIS DRIVELINE ENGINE CATEGORY OPTION REGION
YEAR
N
1st digit 2/3rd digit 4th digit* 5th digit* 6th digit* 7th digit* 8th digit 9th digit** 10th digit
C = Sportsman 6x6
D = Sportsman Tour Displacement in cc divided
O
A = 2x4 Chain
E = Trail Boss by 10 and rounded to two
B = 2x4 Shaft
F = Sportsman Youth digits
C = 4x4 AC Drive
G = Sport (i.e. 50 = 498cc)
D = 4x4 Shaft, DeDion
SI
H = RANGER 6x6 ------------
E = 4x4 Shaft / IRS
J = RZR XP For electric vehicles A = ORV
G = 4x4 Chain rear /
K = Sport Youth 08 = 48 Volt D = Diesel
shaft front
M = Sportsman 12 = 72 Volt E = EU On-road
H = 4x4 Shaft / IRS
R
A = ATV 11 N = Trail Blazer F = INT'L
J = 2x4 Swing arm Manual
D = BRUTUS 12 P = Phoenix G = EV C = Calif.
L = DeDion w/Non Powered - - OR - -
R = RANGER 13 R = RANGER Midsize L = LSV
Attach - "Lifter"
VE
S = RZR M = Military
M = DeDion w/Powered
T = Sportsman X2 S = Scandinavian
Attach - "Mower" 5 = 550 E = EPS
U = RANGER Fullsize V = EU On-road
N = 4x4 Shaft ADC 6 = 570 D = Diesel
V = RZR
P = 2x4 / IRS Manual 7 = 760 F = D + E
W = Multi-pass RGR
R = 6x6 Shaft / IRS 8 = 850 G = Gauge
X = Multi-pass RZR
T = 4x4 Shaft / Trailing Arm 9 = 875 Option #1
Z = Sportsman XP
X = 4x4 Shaft EBS
Y
1 = BRUTUS (No Cab) or 904 J=F+G
2 = BRUTUS (w/Cab)
AR
* = 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.
Engine Designation Number
IN
3TNM72-APB13-Cylinder, Liquid Cooled, Diesel, Electric Start
IM
Vehicle Identification Number (VIN) Designation
Example: 4XA1D9JD3D2000000
EL
Vehicle Descriptors Vehicle Identifiers
Engine Modifier
Mfg. Location
Model Year *
Engine Size
Check Digit
World Mfg. ID
PR
Category
Individual Serial No.
Driveline
Chassis
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4 X A 1 D 9 J D 3 D 2 0 0 0 0 0 0
* Model Year: A = 2010; B = 2011; C = 2012; D = 2013
1.2
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual
© Copyright 2013 Polaris Sales Inc.
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 1
(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. Refer to Figure 1-1.
Figure 1-1
N
O
SI
R
VE
Y
VIN
AR
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. Refer to Figure 1-2.
IN
Figure 1-2 Engine
Numbers
IM
EL
PR
1.3
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual
© Copyright 2013 Polaris Sales Inc.
GENERAL INFORMATION
VEHICLE INFORMATION
Publication Numbers
Model Model No. Owner's Manual Parts Manual
2013 BRUTUS D131D9JDJ 9924341 9924343
2013 BRUTUS HD D131L9JDJ 9924341 9924343
N
2013 BRUTUS HDPTO D132M9JDJ 9924341 9924343
NOTE: When ordering service parts be sure to use the correct parts manual.
O
NOTE: Polaris factory publications can be found at www.polarisindustries.com or purchased from
www.purepolaris.com.
SI
Replacement Keys
R
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.
VE
Series# Part Number
KEY COVER
P/N 5533534
20 4010278
21 4010278
22 4010321
Y
23 4010321
AR
Key Series 27 4010321
Number 28 4010321
31 4110141
32 4110148
IN
67 4010278
68 4010278
IM
EL
PR
1.4
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual
© Copyright 2013 Polaris Sales Inc.
GENERAL INFORMATION
SPECIAL TOOLS
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other 1
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, SPX Corporation,
by phone at 1-800-328-6657 or on-line at http://polaris.spx.com/
N
O
SI
R
Select "SPX Website - Tools, diagnostics" from
the "Service and Warranty" drop down menu VE
Y
AR
IN
IM
EL
PR
1.5
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual
© Copyright 2013 Polaris Sales Inc.
GENERAL INFORMATION
GENERAL SPECIFICATIONS
MODEL: 2013 BRUTUS
MODEL NUMBER: D131D9JDJ
ENGINE NUMBER: 3TNM72-APB
Category Dimension / Capacity
Length 123.5 in. / 310.4 cm
N
Width (tires) 63.2 in. / 160.5 cm
Height 73 in. / 185.4 cm
Wheel Base 84 in. / 213.4 cm
O
Ground Clearance 10 in. / 25.4 cm
Min. Turning Radius
90 in. / 229 cm
SI
(Unlocked "Turf Mode")
Cargo Box Dimensions 43.5 x 54 x 11.5 in.
(inside dimensions) (108 x 137 x 29 cm)
R
Dry Weight 1643 lbs. / 745.3 kg
Curb Weight 1741 lbs. / 790 kg
VE
Operator / Passenger
500 lbs. / 227 kg
Capacity
Cargo Box Capacity 1250 lbs. / 567 kg
Hitch Tongue Capacity 150 lbs. / 68 kg
Rated Vehicle Payload
(includes weight of
Y
1750 lbs. / 794 kg
operator, passenger
and cargo)
AR
Rated Vehicle Capacity
3450 lbs. / 1565 kg
(GVWR)
Hitch Towing Capacity 2000 lbs. / 907 kg
IN
IM
EL
PR
1.6
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual
© Copyright 2013 Polaris Sales Inc.
GENERAL INFORMATION
MODEL: 2013 BRUTUS Electrical
STD MODELS: D131D9JDJ Alternator Rated Output
Headlights
90A / 1215 Watts @ 3000 RPM
Halogen: Low 55W / High 60W x 2
1
ENGINE NUMBER: 3TNM72-APB
Tail Lights L.E.D. (10): 0.2 Watts x 2
Engine
Brake Lights L.E.D. (10): 2.9 Watts x 2
Yanmar 3-Cylinder,
Platform Starting System Electric Start
Liquid Cooled, Diesel
Engine Number 3TNM72-APB1 Flooded-Filled / 32 Amp Hr.
Battery
575 CCA / 12 Volt
Engine Displacement 904 cc
N
DC Outlets (2) - Standard 12 Volt
Number of Cylinders 3
Located in Fuse/Relay Boxes:
Bore & Stroke 72 x 74 mm
O
Chassis - ECM - Fuel Hold - Fuel
Compression Ratio 23.5:1 Relays Pull - Glow Plug - Starter
Compression Pressure 470 ± 15 PSI Externally Mounted Relays:
SI
High Idle 3700 ± 100 RPM - Rear Differential - Cooling Fan
Low Idle 1350 ± 100 RPM 40 Amp:
Circuit Breakers
- Cooling Fan Motor
Lubrication Pressurized Wet Sump
20 Amp:
R
Oil Requirements Polaris DIESEL Oil
- Accessory - Drive - ECU - Fuel
Oil Capacity 2.75 qts. (2.6 L) Hold Solenoid - Hydro - Lights
Fuses
VE
Coolant Capacity 6.6 qts. (6.2 L) 30 Amp:
Overheat Warning Instrument Cluster Indicator - Chassis - Fuel Pull Solenoid -
Glow Plug
Exhaust System Canister Style
Steering / Suspension
Starting Aid Glow Plugs / Opt. Block Heater
Steering Type Hydraulic Power Steering
Fuel System
Toe Out 1/8 - 1/4 in. (3.2 - 6.35 mm)
Y
Fuel Injection Unit Yanmar MC Fuel Injection Pump
(non-serviceable) Indirect Injection Front Suspension Dual A-arm
Fuel Transfer System Electronic Fuel Pump (in-line) Front Travel 6 in. (15.2 cm)
AR
Fuel Pump Pressure 1-5 psi (7-34 kPa) Rear Suspension Multi-Link Coil Over De-Dion
Fuel Tank Capacity 10 gal. (37.8 L) Rear Travel 6 in. (15.2 cm)
Fuel Requirement Low Sulfur or Ultra Low Sulfer Shock Preload Adjustment Cam Adjustment
Hydrostatic Drive / Hydraulics / Drivetrain Wheels / Brakes
IN
Transmission Type Hydrostatic Driven Front Wheel Size / Type 12 x 6 / Steel
Shift Type In Line Shift - H / L / N / P Rear Wheel Size / Type 12 x 8 / Steel
Pedal Drive Hydrostatic Drive Front Tire
Travel Control Carlisle / AT489 / 25 x 10 R12
IM
Forward / Reverse Make / Model / Size
Hydraulic Pump Engine Driven Gear Type Rear Tire
Carlisle / AT489 / 25 x 11 R12
Make / Model / Size
Hydraulic Pump Capacity 7.6 gpm (28.8 L) @ 3600 RPM
Front: 10 psi (69 kPa)
Steering Flow 2.2 gpm (8.3 L) @ 3600 RPM Tire Air Pressure
EL
Rear: 20 psi (138 kPa)
Steering Relief Valve 850 psi (58.6 bar)
Brake System 4 Wheel Hydraulic Disc
Charge Relief Valve 87 psi (6 bar)
Brake Fluid DOT 4
Full flow with 50 psi (3.4 bar)
Hydraulic Filtration
cold weather bypass valve
PR
Hydraulic Fluid Capacity
2.75 qts. (2.6 L)
(Reservoir Only)
Hydraulic Fluid Capacity
7.2 qts. (6.8 L)
(Full System)
Front Gearcase Demand Drive
Lubricant Requirements 6.75 oz. (200 ml)
Transmission AGL
Lubricant Requirements 41 oz. (1200 ml)
1.7
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual
© Copyright 2013 Polaris Sales Inc.
GENERAL INFORMATION
MODEL: 2013 BRUTUS HD
MODEL NUMBER: D131L9JDJ
ENGINE NUMBER: 3TNM72-APB
Category Dimension / Capacity
Length (with bucket) 157.9 in. / 401 cm
Width (tires) 63.2 in. / 160.5 cm
Height 73 in. / 185.4 cm
N
Wheel Base 84 in. / 213.4 cm
Ground Clearance 10 in. / 25.4 cm
O
Min. Turning Radius
90 in. / 229 cm
(Unlocked "Turf Mode")
Cargo Box Dimensions 43.5 x 54 x 11.5 in.
SI
(inside dimensions) (108 x 137 x 29 cm)
Dry Weight 1830 lbs. / 830.1 kg
Curb Weight 1919 lbs. / 870 kg
R
Operator / Passenger
500 lbs. / 227 kg
Capacity
VE
Cargo Box Capacity 1250 lbs. / 567 kg
Attachment Arm Rated
500 lbs. / 227 kg
Operating Capacity
Hitch Tongue Capacity 150 lbs. / 68 kg
Rated Vehicle Payload
(includes weight of
Y
2000 lbs. / 907 kg
operator, passenger,
cargo and attachment)
AR
Rated Vehicle Capacity
4000 lbs. / 1814 kg
(GVWR)
Hitch Towing Capacity 2000 lbs. / 907 kg
IN
IM
EL
PR
1.8
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual
© Copyright 2013 Polaris Sales Inc.
GENERAL INFORMATION
MODEL: 2013 BRUTUS HD Electrical
STD MODELS: D131L9JDJ Alternator Rated Output
Headlights
90A / 1215 Watts @ 3000 RPM
Halogen: Low 55W / High 60W x 2
1
ENGINE NUMBER: 3TNM72-APB
Tail Lights L.E.D. (10): 0.2 Watts x 2
Engine
Brake Lights L.E.D. (10): 2.9 Watts x 2
Yanmar 3-Cylinder,
Platform Starting System Electric Start
Liquid Cooled, Diesel
Engine Number 3TNM72-APB Flooded-Filled / 32 Amp Hr.
Battery
575 CCA / 12 Volt
Engine Displacement 904 cc
N
DC Outlets (2) - Standard 12 Volt
Number of Cylinders 3
Located in Fuse/Relay Boxes:
Bore & Stroke 72 x 74 mm
O
Chassis - ECM - Fuel Hold - Fuel
Compression Ratio 23.5:1 Pull - Glow Plug - Starter - Tilt Lock
Relays
Compression Pressure 470 ± 15 PSI Externally Mounted Relays:
SI
High Idle 3700 ± 100 RPM - Rear Differential - Cooling Fan -
Cargo Box Lift
Low Idle 1350 ± 100 RPM
20 Amp:
Lubrication Pressurized Wet Sump
- Cargo Box Lift
R
Oil Requirements Polaris DIESEL Oil Circuit Breakers
40 Amp:
Oil Capacity 2.75 qts. (2.6 L) - Cooling Fan Motor
VE
Coolant Capacity 6.6 qts. (6.2 L) 20 Amp:
Overheat Warning Instrument Cluster Indicator - Accessory - Drive - ECU - Fuel
Hold Solenoid - Hydro - Lights
Exhaust System Canister Style Fuses
30 Amp:
Starting Aid Glow Plugs / Opt. Block Heater - Chassis - Fuel Pull Solenoid -
Fuel System Glow Plug
Y
Fuel Injection Unit Yanmar MC Fuel Injection Pump Steering / Suspension
(non-serviceable) Indirect Injection Steering Type Hydraulic Power Steering
Fuel Transfer System Electronic Fuel Pump (in-line)
AR
Toe Out 1/8 - 1/4 in. (3.2 - 6.35 mm)
Fuel Pump Pressure 1-5 psi (7-34 kPa) Front Suspension Dual A-arm
Fuel Tank Capacity 10 gal. (37.8 L) Front Travel 6 in. (15.2 cm)
Fuel Requirement Low Sulfur or Ultra Low Sulfer Rear Suspension Multi-Link Coil Over De-Dion
Hydrostatic Drive / Hydraulics / Drivetrain Rear Travel 6 in. (15.2 cm)
IN
Transmission Type Hydrostatic Driven Shock Preload Adjustment Cam Adjustment
Shift Type In Line Shift - H / L / N / P Wheels / Brakes
Pedal Drive Hydrostatic Drive Front Wheel Size / Type 12 x 6 / Steel
Travel Control
IM
Forward / Reverse
Rear Wheel Size / Type 12 x 8 / Steel
Hydraulic Pump Engine Driven Gear Type
Front Tire
Hydraulic Pump Capacity 7.6 gpm (28.8 L) @ 3600 RPM Carlisle / All Trail II / 25 x 9 R12
Make / Model / Size
Steering Flow 2.2 gpm (8.3 L) @ 3600 RPM
EL
Rear Tire
Steering Relief Valve 850 psi (58.6 bar) Carlisle / All Trail II / 25 x 11 R12
Make / Model / Size
Charge Relief Valve 87 psi (6 bar) Front: 20 psi (138 kPa)
Tire Air Pressure
Full flow with 50 psi (3.4 bar) Rear: 20 psi (138 kPa)
Hydraulic Filtration
cold weather bypass valve
PR
Brake System 4 Wheel Hydraulic Disc
Hydraulic Fluid Capacity Brake Fluid DOT 4
2.75 qts. (2.6 L)
(Reservoir Only)
Hydraulic Fluid Capacity
8.4 qts. (7.9 L)
(Full System)
Front Gearcase Demand Drive
Lubricant Requirements 6.75 oz. (200 ml)
Transmission AGL
Lubricant Requirements 41 oz. (1200 ml)
1.9
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual
© Copyright 2013 Polaris Sales Inc.
GENERAL INFORMATION
MODEL: 2013 BRUTUS HDPTO
MODEL NUMBER: D132M9JDJ
ENGINE NUMBER: 3TNM72-APB
Category Dimension / Capacity
Length (with bucket) 157.9 in. / 401 cm
Width (tires) 63.2 in. / 160.5 cm
Height 74 in. / 188 cm
N
Wheel Base 84 in. / 213.4 cm
Ground Clearance 7 in. / 17.8 cm
O
Min. Turning Radius
90 in. / 229 cm
(Unlocked "Turf Mode")
Cargo Box Dimensions 43.5 x 54 x 11.5 in.
SI
(inside dimensions) (108 x 137 x 29 cm)
Dry Weight 2148 lbs. / 974.3 kg
Curb Weight 2232 lbs. / 1012 kg
R
Operator / Passenger
500 lbs. / 227 kg
Capacity
VE
Cargo Box Capacity 1250 lbs. / 567 kg
Attachment Arm Rated
500 lbs. / 227 kg
Operating Capacity
Hitch Tongue Capacity 150 lbs. / 68 kg
Rated Vehicle Payload
(includes weight of
Y
1750 lbs. / 794 kg
operator, passenger,
cargo and attachment)
AR
Rated Vehicle Capacity
4000 lbs. / 1814 kg
(GVWR)
Hitch Towing Capacity 2000 lbs. / 907 kg
IN
IM
EL
PR
1.10
9924344 - 2013 BRUTUS / HD / HDPTO Service Manual
© Copyright 2013 Polaris Sales Inc.
GENERAL INFORMATION
MODEL: 2013 BRUTUS HDPTO Electrical
STD MODELS: D132M9JDJ Alternator Rated Output
Headlights
90A / 1215 Watts @ 3000 RPM
Halogen: Low 55W / High 60W x 2
1
ENGINE NUMBER: 3TNM72-APB
Tail Lights L.E.D. (10): 0.2 Watts x 2
Engine
Brake Lights L.E.D. (10): 2.9 Watts x 2
Yanmar 3-Cylinder,
Platform Starting System Electric Start
Liquid Cooled, Diesel
Engine Number 3TNM72-APB Flooded-Filled / 32 Amp Hr.
Battery
575 CCA / 12 Volt
Engine Displacement 904 cc
N
DC Outlets (2) - Standard 12 Volt
Number of Cylinders 3
Located in Fuse/Relay Boxes:
Bore & Stroke 72 x 74 mm
O
Chassis - Condenser Fan - ECM -
Compression Ratio 23.5:1 Fuel Hold - Fuel Pull - Glow Plug
Compression Pressure 470 ± 15 PSI Relays - PTO - Starter - Tilt Lock
SI
High Idle 3700 ± 100 RPM Externally Mounted Relays:
- Rear Differential - Cooling Fan -
Low Idle 1350 ± 100 RPM
HVAC - Cargo Box Lift
Lubrication Pressurized Wet Sump
20 Amp:
R
Oil Requirements Polaris DIESEL Oil - Cargo Box Lift
Oil Capacity 2.75 qts. (2.6 L) Circuit Breakers - Condenser Fan Motor
40 Amp:
VE
Coolant Capacity 6.9 qts. (6.5 L)
- Cooling Fan Motor
Overheat Warning Instrument Cluster Indicator
20 Amp:
Exhaust System Canister Style
- Accessory - Drive - ECU - Fuel
Starting Aid Glow Plugs / Opt. Block Heater Hold Solenoid - Hydro - Lights -
Fuel System PTO
Fuses
30 Amp:
Y
Fuel Injection Unit Yanmar MC Fuel Injection Pump
(non-serviceable) Indirect Injection - Chassis - Fuel Pull Solenoid -
Fuel Transfer System Electronic Fuel Pump (in-line) Glow Plug - HVAC*
AR
* Located external from Fuse/Relay Box
Fuel Pump Pressure 1-5 psi (7-34 kPa)
Air Conditioning
Fuel Tank Capacity 10 gal. (37.8 L)
A/C Refrigerant R134A
Fuel Requirement Low Sulfur or Ultra Low Sulfer
Steering / Suspension
Hydrostatic Drive / Hydraulics / Drivetrain
Steering Type Hydraulic Power Steering
IN
Transmission Type Hydrostatic Driven
Toe Out 1/8 - 1/4 in. (3.2 - 6.35 mm)
Shift Type In Line Shift - H / L / N / P
Front Suspension Dual A-arm
Pedal Drive Hydrostatic Drive
Travel Control Front Travel 6 in. (15.2 cm)
IM
Forward / Reverse
Hydraulic Pump Engine Driven Gear Type Rear Suspension Multi-Link Coil Over De-Dion
Hydraulic Pump Capacity 7.6 gpm (28.8 L) @ 3600 RPM Rear Travel 6 in. (15.2 cm)
Steering Flow 2.2 gpm (8.3 L) @ 3600 RPM Shock Preload Adjustment Cam Adjustment
EL
Steering Relief Valve 850 psi (58.6 bar) Wheels / Brakes
Charge Relief Valve 87 psi (6 bar) Front Wheel Size / Type 12 x 6 / Steel
Full flow with 50 psi (3.4 bar) Rear Wheel Size / Type 12 x 8 / Steel
Hydraulic Filtration Front Tire
cold weather bypass valve
PR
Carlisle / All Trail II / 25 x 9 R12
Hydraulic Fluid Capacity Make / Model / Size
2.75 qts. (2.6 L) Rear Tire
(Reservoir Only) Carlisle / All Trail II / 25 x 11 R12
Hydraulic Fluid Capacity Make / Model / Size
8.4 qts. (7.9 L) Front: 20 psi (138 kPa)
(Full System)
Tire Air Pressure
Front Gearcase Demand Drive Rear: 20 psi (138 kPa)
Lubricant Requirements 6.75 oz. (200 ml) Brake System 4 Wheel Hydraulic Disc
Transmission AGL Brake Fluid DOT 4
Lubricant Requirements 41 oz. (1200 ml)
PTO PTO Gearbox Oil
Lubricant Requirements 6 oz. (177 ml)
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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.
CAUTION
· Carbon residue content must not exceed 0.35% by
volume. Less than 0.1% is preferred.
NEVER use an engine starting aid such as ether.
Engine damage will result. · Total aromatics content should not exceed 35% by
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volume. Less than 30% is preferred.
NOTE: For the best engine performance, to prevent
· PAH (polycyclic aromatic hydrocarbons) content
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engine damage and to comply with EPA/ARB
warranty requirements, use ONLY the recommended should be below 10% by volume.
diesel fuels. Use only CLEAN Low Sulfur, Ultra Low · Metal content of Na, Mg, Si and Al should be equal
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Sulfur #2 or #1 Diesel Fuel containing no more than to or lower than 1 mass ppm (test analysis method
5% bio-diesel. JPI-5S-44-95).
· Lubricity: Wear mark of WS1.4 should be Max.
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Diesel fuel should comply with the following world-wide
0.018 in. (.460 µm) at HFRR test.
specifications:
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Diesel Fuel Specification Location Bio-Diesel Fuels
ASTM D975 NOTE: Never use bio-diesel blended fuel containing
No. 1D S15, S500 USA more than 5% bio-diesel in this vehicle.
No. 2D S15, S500
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EN590:96 European Union In Europe and in the United States, as well as some other
countries, non-mineral oil based fuel resources such as
ISO 8217 DMX International RME (Rapeseed Methyl Ester) and SOME (Soybean
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BS 2869-A1 or A2 United Kingdom Methyl Ester), collectively known as FAME (Fatty Acid
Methyl Esters), are being used as extenders for mineral oil
JIS K2204 Grade No. 2 Japan derived diesel fuels.
KSM-2610 Korea
YANMAR approves the use of bio-diesel fuels that do not
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GB252 China exceed a blend of 5% (by volume) of FAME with 95% (by
volume) of approved mineral oil derived diesel fuel. Such
Additional Technical Fuel Requirements bio-diesel fuels are known in the marketplace as B5 diesel
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fuels.
· The fuel cetane number should be equal to 45 or
higher.
B5 Diesel Fuel Requirements
· The sulfur content must not exceed 0.5% by
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volume. Less than 0.5% is preferred. Especially in 1. The bio-fuels must meet the minimum specifications
the U.S.A. and Canada, Low Sulfur (300 to 500 for the country in which they are used.
ppm (mg/kg) or Ultra Low Sulfur fuel should be
used. · In Europe, bio-diesel fuels must comply with the
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European Standard EN14214
· NEVER mix kerosene, used engine oil or residual
fuels with the diesel fuel. · In the United States, bio-diesel fuels must comply
with the American Standard ASTMD-6751.2
· Water and sediment in the fuel should not exceed
0.05% by volume. 2. Bio-fuels should be purchased only from recognized
· Keep the fuel tank and fuel-handling equipment and authorized diesel fuel suppliers.
clean at all times.
· Poor quality fuel can reduce engine performance
and/or cause engine damage.
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GENERAL INFORMATION
Bio-Fuel Precautions Engine Warranty
1. Free methanol in FAME may result in corrosion of Damages, performance or service concerns determined 1
aluminum and zinc FIE components. to be caused by the use of bio-diesel fuel not meeting the
specifications outlined above are not considered to be
2. Free water in FAME may result in plugging of fuel defects in material or factory workmanship and are not
filters and increased bacterial growth. covered under warranty. The same applies to damages or
other concerns induced by not complying with the
3. High viscosity at low temperatures may result in fuel recommended operating conditions of YANMAR engines
delivery problems, injection pump seizures, and poor
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with bio-diesel fuel.
injection nozzle spray atomization.
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4. FAME may have adverse effects on some elastomers
(seal materials) and may result in fuel leakage and Cold Weather Operation
dilution of the engine lubricating oil.
Cold weather operation can result in fuel gelling if the
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5. Even bio-diesel fuels that comply with a suitable incorrect fuel type is used. Use the fuel blending guide-
standard as delivered, will require additional care and line table below to prevent this from occurring.
attention to maintain the quality of the fuel in the
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equipment or other fuel tanks. It is important to Cold Weather Fuel Blending Guideline:
maintain a supply of clean, fresh fuel. Regular flushing
Temperature NO. 2 Diesel NO. 1 Diesel
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of the fuel system, and/or fuel storage containers, may
be necessary. Above 15° F (9° C) 100% 0%
6. The use of bio-diesel fuels that do not comply with the Down to -20° F (-29° C) 50% 50%
standards as agreed to by the diesel engine Below -20° F (-29° C) 0% 100%
manufacturers and the diesel fuel injection equipment
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manufacturers, or bio-diesel fuels that have degraded
as per the precautions and concerns above, may Block Heater Usage
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affect the warranty coverage of your engine.
If this vehicle will be operated when temperatures are in
the +5° to -25° F (-15° to -32° C) range, a block heater
B6 to B20 Bio-Diesel Fuel Blend must be installed. Please see your dealer to purchase a
block heater kit.
B6 to B20 bio-diesel is NOT approved for this Polaris
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vehicle application.
Approved Engines
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Only the YANMAR TNM engine series (3TNM72) may
operate with bio-diesel fuel concentrations up to B5 for
Polaris vehicle applications.
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Approved Fuel
IMPORTANT: Raw pressed vegetable oils are not
considered bio-diesel, and are unacceptable for use
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as fuel in any concentration in YANMAR engines.
Bio-diesel fuel blends up to B5 must comply with the
following standards:
· EN14214 (European standard) and/or ASTM D-
6751 (American standard)
· All applicable engines may operate with bio-diesel
fuel up to a maximum B5 (5% bio-diesel blend)
concentration
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GENERAL INFORMATION
MISC. SPECIFICATIONS AND CHARTS
Conversion Table
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AR
IN
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EL
PR
°C to °F: °C x 9/5 + 32 = °F °F to °C: °F - 32 x 5/9 = °C
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GENERAL INFORMATION
Standard Bolt Torque Specification
1
Grade 2 Grade 5 Grade 8
Grade 2 Grade 5 Grade 8
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Bolt Size
ft-lbs (Nm) ft-lbs (Nm) ft-lbs (Nm)
1/4-20 5 (7) 8 (11) 12 (16)
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1/4-28 6 (8) 10 (14) 14 (19)
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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)
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3/8-24 23 (32) 35 (48) 50 (69)
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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)
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Metric Bolt Torque Specification
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IN
Grade
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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)
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M4