Download Welcome To The 2012 ORV Technical Update
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© 2012 ORV Technical Update Welcome To The 2012 ORV Technical Update Home page 1 © 2012 ORV Technical Update Agenda • 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 • 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 2 2012 ORV Technical Update © ORV Fuel Pump • Most EFI ORV • Revised fuel pump pre-filter screen (running change) – 10 micron (model year 2011 30 micron) • Smaller the micron number, increased filtration – Service fuel pump kits to follow Fuel pump pre-filter screen 3 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 Isolation mounted YANMAR diesel; low vibration 2012 RANGER Crew Diesel 4 2012 ORV Technical Update © Full Size RANGER • 2012 RANGER 800 XP What changed? – All RANGERS • • • • New hood latch Revised seat base Added center seat support Revised heat management 2012 RANGER 800 6x6 – Reduced cab heat in the seated area • Improved transmission serviceability – RANGER with 800 engine • • • • 2012 RANGER 800 HD Revised air box lid Rotated pre-filter opening Two wire shift switch Revised throttle body wires and routing – RANGER HD • Added EBS 2012 RANGER Diesel – RANGER Diesel • Revised drive and driven clutch 5 2012 ORV Technical Update © Full Size RANGER • Revised hood latch • Now one piece Pre model year 2012 – Die cast – Will retrofit back to early models Model year 2012 6 © 2012 ORV Technical Update Full Size RANGER • Revised seat base – – – – – RANGER Diesel RANGER HD RANGER XP RANGER 6X6 RANGER CREW Added close off to seat base obstructs heat from entering drivers compartment Aluminum seat pegs Reinforced mounting • Rear only Added heat shield (replaced foil) Sandwiched material Not featured on Diesel 7 © Full Size RANGER 2012 ORV Technical Update Seat Support Fastened to cab seat base • Added Seat Support – – – – – RANGER Diesel RANGER HD RANGER XP RANGER 6x6 RANGER CREW • Rear only Seat support Seat base Floor rear transparent view Cab seat support Seat base transparent view 8 2012 ORV Technical Update © Full Size RANGER • Revised floor rear heat shield – – – – – – Sandwich material RANGER Diesel RANGER HD RANGER XP RANGER 6x6 RANGER CREW • Rear view Model year 2011 Model year 2012 Rear only Sandwich heat shield in red Heat shield Floor back Cut-away side view 9 2012 ORV Technical Update © Full Size RANGER • • Floor rear Model year 2011 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. 10 © Full Size RANGER 2012 ORV Technical Update Revised seat base with aluminum pegs and reinforced mounting, more robust • Seat and floor rear summary Added close off Reduces engine heat entering drivers compartment Seat support provides additional support for the seat center Added heat shield Not featured on Diesel Deflects heat away from seat Revised floor rear heat shield ¾ length deflects heat away from floor back panel Additional material added to the center section of floor back Reduces engine compartment heat from entering drivers compartment 11 2012 ORV Technical Update © Full Size RANGER • Revised panels – Hood liner – Left and right wheel well panels Radiator and fan assembly Hood liner Hood liner Right wheel well panel Heat deflector Left wheel well panel Front Radiator and fan assembly Front Left wheel well panel Heat deflector top view left side view 12 © Full Size RANGER 2012 ORV Technical Update Curved hood liner directs air down and forms a seal from the cockpit • Revised panels • Heat deflectors Heat deflector colored gray 13 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 Left wheel well panel removed left side view Front Viewed with hood liner removed top view 14 2012 ORV Technical Update © RANGER Gearcase • Revised hex plug locations • Full size – All except 6x6 and Diesel • Mid size – Except EV Fill plug Check plug Drain plug 15 © 2012 ORV Technical Update Shift switch Side X Side Shift Switch • 2 Pin switch – All 800 side by side • 6 pin switch – RANGER Diesel 2 Pin switch Internal resistors 6 Pin switch External resistors 16 © 2012 ORV Technical Update RANGER 800 • Revised engine air intake Pre-filter box air inlet opening faces inside 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 17 © 2012 ORV Technical Update RANGER 800 • • Throttle body wires pulled back tight and panduit secured Starter mounted bracket secures harness 18 2012 ORV Technical Update © RANGER 800 • Throttle body wires: – – – Wrapped with high temp, abrasion resistance tape Teflon insulated wires Revised length and routing Panduit Panduit behind connector Panduit 19 © 2012 ORV Technical Update RANGER Diesel • Revised drive clutch Weights and two-way bearing will not retrofit to 2011 models Complete drive clutch will retrofit to 2011 models Revised profile 180 gram weights 2-way idler bearing Pin location changed for new weights New 92lb spring (2011 80lb spring) 2011 weights 150 grams Reduces shift effort and improves belt deflection 20 © 2012 ORV Technical Update RANGER Diesel • Revised driven clutch 2012 spacer(s) removed 21 2012 ORV Technical Update © RANGER HD • • 2012 RANGER XP and HD gearcase features revised internal components for EBS function EBS added-HD only Specific gearcase – Internal component change – Kit-2012 RANGER XP only • • • • No Crew No Diesel No 6 X 6 No pre-2012 RANGERS Smooth one-way EBS drive clutch Y N Y N No offset tool. Visual adjustment only. Refer to service manual. Center-to-center adjustment using Center distance tool. Y N Y N EBS driven clutch MBL Belt 1322898 23/66 weights 2871710 10” (25.4 cm) Center distance tool 22 2012 ORV Technical Update © Midsize Ranger • RANGER 500 EFI and Crew 500 EFI – Speed key accessory • • same improvements as full size RANGER RANGER EV – – – – – – – – – – – 2012 RANGER 500 EFI 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 Added auxiliary battery relay Revised under hood fuse box Revised front gear box • • 25mph speed limit Improved transmission serviceability (all models) – • 2012 RANGER 500 EFI Crew 2012 RANGER EV 2012 RANGER EV LSV Added torsion spring Details to follow 23 2012 ORV Technical Update © RANGER 500 EFI and Crew 500 EFI • • • Solenoid 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 Instructions Air control valve Filter ECU Vehicle speed sensor Diagram Slide Intake boots EFI air control valve Similar to CV carb body 24 2012 ORV Technical Update © Traction battery charger and charger circuit • New charger • Revised charge indicator circuit RANGER EV/LSV – – 2 Flying leads Robust connections – • Revised charging circuit – 2011 Increased from 20 to 30 amp circuit 2 pin flying lead connector Harness connector attached to charger shell 2012 Charger fuse 48 volt 30 amp fuse Wire increase to match fuse Charger fuse 48 volt 20 amp 8 pin flying lead connector AC power cord AC power cord Charge indicator LED power supplied by DC to DC converter Supported by traction batteries Charge indicator LED power supplied by traction batteries 25 2012 ORV Technical Update © RANGER EV/LSV DC to DC Converter circuit • New converter • Added relay – – SEVCON 4 wire – – 48 volt side Key activated 2011 2012 DC to DC only powered with key on 48 V DC In 48 Volts from key switch Fused 48 Volt power supply Continuous, 48 volt power supply 12 volt power out 14.0 V DC out 26 2012 ORV Technical Update © 2012 RANGER EV/LSV DC to DC Relay Contact side 48 V DC to DC to DC converter • DC to DC Converter Relay – 48 volt coil – 48 volt contacts – Location • Mounted on DC to DC converter bracket Coil side Ground (B-) Coil side 48 V DC from ignition switch Contact side 48 V DC from fuse center • 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 27 2012 ORV Technical Update © 2011 RANGER EV/LSV • 13.5 volt circuit All accessory outlets Charger indicator LED Indicator fuse DC to DC converter Fuse/Relay splice Active when key in the ON position Chassis fuse Accessory fuse Switched power relay Constant power Unswitched fuse B + terminal under hood NOTE: A malfunction in the DC to DC converter, chassis fuse or switched relay could cause a motor controller fault. Light fuse All bulbs except: 1. Dash indicators 2. FNR switch 3. Mode switch 1. 2. 3. 4. 5. VCM Diagnostic plug Speed sensor Turf solenoid Accessory spade terminal 13.5 V DC Switched splice 1. 2. 3. 4. 5. 6. Dash plug Indicator bulbs HR meter FNR switch light bulbs Mode switch light bulbs AWD Switch 28 2012 ORV Technical Update © 2012 RANGER EV/LSV 14.0 volt circuit • Revised architecture Only active when the key is ON Light fuse DC to DC converter Chassis fuse Accessory fuse All bulbs except: 1. Dash indicators 2. FNR switch 3. Mode switch Power to : 1. AWD switch 2. VCM (wake up) 3. Speed sensor 4. Accessory spade lead 5. Turf solenoid Dc to Dc converter 14 v splice All accessory outlets To reduce motor controller faults chassis circuits are divided into two groups. 1. DC to DC converter 14 volt splice 2. Switched 12 volt splice All circuits shown on this slide will receive power from the DC to DC converter. Power to the light bulbs: 1. Forward-Neutral-Reverse switch 2. Mode switch 3. Indicator panel Diagnostic plug DC to DC Diode Switched 12 volt splice See next slide for more information 29 2012 ORV Technical Update © 2012 RANGER EV/LSV 14.0 volt circuit architecture revised • Redundant power source for Switched 12 Volt Splice Light fuse DC to DC converter Chassis fuse A redundant power source was added to support the Switched 12 Volt Splice with power. The DC to DC diode was added to block power from traveling to the DC to DC converter 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 converter 14 v splice Accessory fuse Battery #7 Diode/Fuse 12 v Only one battery is be used. The battery with the most pressure (voltage) will be dominant. Battery #4 Power to the light bulbs: 1. Forward-Neutral-Reverse switch 2. Mode switch 3. Indicator panel Diagnostic plug Diode/Fuse 12 v Contactor connector Switched power relay DC to DC Diode Switched 12 volt splice DC to DC converter is the dominant power source. The Switched 12 Volt Splice will only use battery power in the event there is a malfunction in the DC to DC converter circuit. As long as the switched 12 splice is powered Motor controller faults will be reduced if DC to DC circuit malfunctions. 30 2012 ORV Technical Update © 2012 RANGER EV/LSV 14.0 volt circuit Switched 12 Volt Splice - Power supply circuits comparison Light fuse DC to DC converter Normal operation Chassis fuse Accessory fuse Dc to Dc converter 14 v splice Normal operation / no malfunction: DC to DC converter supplying power to switched 12 Volt Splice. DC to DC Diode Switched 12 volt splice Battery #7 Malfunction Diode/Fuse 12 v Contactor connector Battery #4 Diode/Fuse 12 v Switched power relay DC to DC power source malfunction. Redundant power supply being used Switched 12 volt splice One battery supplies power to switched 12 Volt Splice if DC to DC circuit malfunctions. 31 2012 ORV Technical Update © 2012 RANGER EV/LSV • 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 Blue line Bat # 4 RED line SHARED • Function / feature – – Provides constant 12 V DC to LSV 2 Amp fuse circuit and Charge Indicator fuse circuit. Default power supply to light bulbs in: (only if DC to DC circuit malfunctions) • • Forward-Neutral-Reverse switch Mode Switch • • Indicator panel Diagnostic plug 32 2012 ORV Technical Update © 2012 RANGER EV/LSV Key ONContacts closed Power to the light bulbs in the: • Forward-Neutral-Reverse switch • Mode switch • Indicator panel 14.0 VDC normal 12.0 VDC if 14.0 DC to DC circuit malfunctions Diagnostic plug 14.0 VDC normal 12.0 VDC if 14.0 DC to DC circuit malfunctions If DC to DC converter circuit is functioning this circuit will be powered by the DC to DC converter 14.0 vdc. • 12 volt Switch Power Relay Circuit – – – The key switch controls the Switched Power Relay. Key on, power flow key off, no power 33 © RANGER EV/LSV • • Revised contactor connector Added the Diode leads – – – Model Year 2012 Model Year 2012 7 pin Pin C, D, E, and G are 48 volts Pin A, B, and F are 12 volts • • 2012 ORV Technical Update Constant power 48 volt fuse box 2012 – 1- 48 volt 20 amp fuse • – Dash 2 - 48 volt 30 amp fuses • • Traction batteries charge DC to DC converter primary power 34 © 2012 ORV Technical Update RANGER EV/LSV • • Auxiliary battery relay circuit 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 auxiliary 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. 35 © 2012 ORV Technical Update RANGER EV/LSV • • Auxiliary battery relay Power flow – Key ON red line 48 vdc AUX. DC TO DC CHARGER 14.0 vdc 36 © 2012 ORV Technical Update RANGER EV/LSV • • Auxiliary battery relay circuit Wiring diagram 48 Volt traction batteries 12 Volt batteries Auxiliary battery DC to DC charger connector 37 2012 ORV Technical Update © RANGER EV/LSV Charger fuse 48 V 5 amp Charger fuse 14 V 15 amp • • • Fuse box changes 2011 to 2012 Increased wire to match fuse Model Year 2011 Unswitched fuse Red outline indicates change between previous model years Spare15 amp Added Switched Auxiliary Relay Spare 25 amp Revised Charger fuse 48 V 30 amp Revised Charger fuse 14 V 25 amp LSV fuse provides constant power for hazard signals Model Year 2012 Added Chassis fuse 14 v 20 amp 38 © 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 39 © 2012 ORV Technical Update RANGER EV/LSV • Ring gear detail view Roller cage Torsion spring Ring gear 40 2012 ORV Technical Update © RZR • What changed? – New model • RZR 570 – New engine – Revised chassis – All RZR models • Gear selector – 2 wire (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 • RZR S LE - FOX shocks • RZR 4 and RZR XP - FOX shocks with toolless clickers – All RZR 800 • Revised rear gearcase • Revised drive clutch spring – RZR 50” (127 cm) • Revised spark arrestor • Revised sway bar – RZR XP • 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 41 © 2012 ORV Technical Update 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 42 2012 ORV Technical Update © RZR 570 Engine air inlet • RZR 570 Chassis PVT air inlet Similar to RZR 50” Revised from behind the seats to rear of vehicle 43 2012 ORV Technical Update © RZR 570 Similar to RZR XP • RZR 570 Left side view – Plastic removed Similar to RZR 50” Engine intake PVT intake RZR XP rear gearbox RZR XP PVT cover 44 © 2012 ORV Technical Update RZR 570 • Inspection panel removal – Provides easy access to air filter – New air filter design Removal panel Similar to RZR XP Air box assembly 45 © RZR 570 2012 ORV Technical Update RZR XP style air box • Lay out Removable frame section Thermostat housing hose Water pump hose Removable frame section PVT air exit By-pass hose Large diameter prop shaft 46 2012 ORV Technical Update © RZR 570 Rear mounted sway bar with rubber bushings on end links • Rear suspension Lower link attached through shock bolt – A-arm mounting – Sway bar mounting Revised upper and lower a-arm and mounting Revised bearing carrier 47 © 2012 ORV Technical Update RZR 570 • Rear A-arms • Lube location points Zerk fittings Zerk fittings 48 2012 ORV Technical Update © RZR 570 • Fuel Supply Fuel tank vent line (soft hose) Fuel tank Fuel tank shown in transparent view Fuel line (formed tube quick connect) 49 2012 ORV Technical Update © RZR 570 • Engine mounting • PTO side view – Through-bolt design – Plates Bolt A location Bolt B location Bolt C location Bolt D location A Engine mounting bolts A-D Plates B C D 50 2012 ORV Technical Update © RZR 570 • Engine mounting • Top view – No joint – Plates sandwich components • Gearcase • Engine case PTO mounting location Mag mounting location Plates Plates 51 2012 ORV Technical Update © RZR 570 Stator lead Coolant by-pass fitting • Engine layout Coolant bleed Revised fuel rail CPS T-MAP Throttle body not illustrated • Revised throttle body similar to 2011 800 M17 Side X Side • IAC and TPS common with 2011 800 M17 Side X Side CPS connector 52 2012 ORV Technical Update © RZR 570 • Engine layout Stator connector Engine temp sensor Engine breather Cam chain tensioner CPS connector 53 2012 ORV Technical Update © RZR 570 • Engine layout Stator connector CPS connector Oil Fill/Dipstick Water pump cover Water pump inlet Oil filter 54 2012 ORV Technical Update © RZR 570 • • • Top end Dual overhead camshafts Shim under bucket – Shims common with RZR XP Shim Cut-away view 55 2012 ORV Technical Update © RZR 570 Exhaust camshaft • Top end • Centrifugal design compression release Compression release mechanism Centrifugal feature 56 © 2012 ORV Technical Update RZR 570 • Water pump • Impeller • Shaft and seal Water pump shaft slotted drive coupler Impeller Water pump weep outlet Oil seal Mag cover houses the impeller, water pump shaft, oil seal, mechanical seal, and stator Mechanical seal NOTE: Mag cover removed for illustration 57 2012 ORV Technical Update © RZR 570 • Oil pump drive • Cam chain guide Counter balancer Oil pump drive chain Cam chain Crankshaft (mag end) Cam chain guide Oil pump 58 2012 ORV Technical Update © RZR 570 • Engine PTO view Piston at TDC Counter balancer PTO bearing retaining plate Oil pick up 59 © 2012 ORV Technical Update RZR 570 • Engine Management System – Based on 2011 RZR 800 – M 17 controller • Ignition Switch – 4 position • On - Start – Lights – Off • Headlight circuit – Relay controlled • Start circuit – Start solenoid grounds through brake light switch 60 © 2012 ORV Technical Update All RZRs • Removable front grille – Easy radiator access – Snaps into place Front grille upper tabs Lower tabs 61 2012 ORV Technical Update © All RZRs* Floor / cab seal • Reduced cab water and dust intrusion • Steering column boot added • Upper seal between floor and cab added – Similar to RZR XP *Not on the RZR 570 Steering shaft rubber boot Improved dash sealing to keep mud and heat off the driver 62 © 2012 ORV Technical Update All RZRs • Revised passenger grab tube – Larger tube – Bushing added – Welded bracket Grab tube bracket welded to frame tubes Will not retrofit back Passenger grab tube now square Anti-Rattle Passenger Grab Bar Grab tube bushing NOTE: Plastic removed for visual purpose 63 2012 ORV Technical Update © RZR Seat Belt • Model year 2011 RZR cab frame • Seat belt mounting location Net mounting bracket Seat belt bracket Passenger side seat belt Viewed from inside cab looking back Viewed from inside cab looking back 64 2012 ORV Technical Update © RZR Seat Belt • Model year 2012 RZR cab frame • Seat belt mounting location • Common seat belt with RANGER Passenger side seat belt Viewed from passenger side looking into cab Net and seat belt mounting bracket Viewed from passenger side looking into cab 65 2012 ORV Technical Update © RZR Push bar increased approximately 6 mm for 2012 • Master cylinder common with RZR XP – RZR – RZR S – RZR4 Pedal closer to operator for 2012 2011 push bar length 66 2012 ORV Technical Update © RZR Shocks • Shocks Twin Tube Mono tube – RZR 50” twin tube • Revised jounce bumper – More durable material – RZR S Base model • Sachs mono tube – RZR S LE models • Fox Podium X Podium X Screw adjust – RZR 4 and RZR XP • Podium X 2.0 • Clicker knobs • Revised calibration Podium X 2.0 Clicker knob 67 2012 ORV Technical Update © All RZR with 800 engine • Removed O-ring seal Oil ring removed Oil ring seal RZR final drive 2011 and older 68 © 2012 ORV Technical Update All RZR 800 • • • • Revised drive clutch spring Increased pressure 7043789 Neon Green Will retrofit to 2011 RZR 800 69 © 2012 ORV Technical Update RZR 50’’ (127cm) • Spark arrestor – Through-bolt design (similar to the RZR XP) Spark arrestor 70 2012 ORV Technical Update © RZR 50” (127 cm) Sway Bar Revised hollow tube sway bar • Revised front sway bar 50” (127 cm 800) and 570 – Tube – Mounting – Links Link with rubber ends P-Clamp Revised Sway Bar bushings Link with upper and lower joints Mounts with shock through bolt 2011 and older 2012 71 © 2012 ORV Technical Update RZR General Clutch Changes Revised RZR XP belt • • • • Stronger Splice-less Cut edge 3211148 MBL 72 © 2012 ORV Technical Update RZR XP Prop Shaft Revised prop shaft • Rubber isolated bearing • New bracket welded to frame • Retrofit to 2011 RZR XP requires the following: – – – – Both sections of shaft Rubber mounted bearing Shaft support bracket Fasteners to secure the bracket to frame Prop Shaft bearing mounting bracket Bracket mounting holes used when retrofitting bearing to 2011 RZR XP 73 2012 ORV Technical Update © RZR XP • Revised A-arm • Caster change • Reduces steering effort Front Overlay Black 2011 Green 2012 Trailing edge 2011 Model year 2011 Model year 2012 Trailing edge 2012 Ball joint moved back to reduced steering effort 74 2012 ORV Technical Update © RZR XP • Revised front wheel bearing carrier • Ball joint pinch bolt increased to 10 mm o.d. Ball joint cavity Bearing carrier 10 mm o.d. 75 2012 ORV Technical Update © RZR XP • Revised coolant surge tank • Increased capacity 2011 2012 76 2012 ORV Technical Update © RZR 570 and RZR XP • Cooling system • Revised filler neck • Revised radiator cap 47.8 mm 39.0 mm 56.5 mm 2011 RZR XP 43.0 mm 2012 RZR 570 and RZR XP 77 2012 ORV Technical Update © RZR XP • Revised box panels – Reduced water intrusion – Behind the grille and the foam – Both PVT and engine air inlet 2012 holes eliminated in panel to reduce water intrusion 2011 holes in panel View of left box panel 78 2012 ORV Technical Update © RZR XP • Revised side panel intake foam seal – Reduces water intrusion Left hand side panel Intake resonator Intake resonator drain Revised intake foam seal 79 2012 ORV Technical Update © RZR XP International • New features – External mechanical park brake – Turf mode • Differential Turf solenoid Park brake disc 80 2012 ORV Technical Update © RZR XP International • Revised Gearcase – Differential added – Output shaft Added Turf differential gear set Output shaft revised for park brake disc Case revised for park brake caliper Park brake disc 81 © 2012 ORV Technical Update RZR XP International • External mechanical park brake – Lever assembly – Caliper assembly Park brake lever assembly mounted between seat belt buckles NOTE: Rubber boot removed for illustration Park brake disc Park brake caliper 82 © 2012 ORV Technical Update ATV • 2012 Sportsman 850 XP Discontinued models – Outlaw – 850 X2 • What changed? – All ADC models • Added O-rings to hub clutch packs 2012 Sportsman 550 XP – All Sportsman XP • Revised A-arm – Sportsman XP 550 • Added Luk Coupler (similar to Sportsman 850) – Sportsman XP 850 • Increased power • Revised connecting rods 2012 Sportsman 500 HO – Classic Sportsman • Revised front cab – International Classic Sportsman • New procedure for headlight adjustment 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 84 © 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 85 2012 ORV Technical Update © Sportsman 550 • 2011 Sportsman XP550 built after 03/01/11 and all 2012 – – – Luk Coupler Revised main gearcase BOSS driven clutch PA-50420 Crankshaft Coupler Holder Application: Sportsman XP 550 units built after 03/01/11 Used to hold the crankshaft when applying torque to the coupler nut. Gearcase revised BOSS driven clutch shaft 2012 ADC O-rings added to hubs Luk engine to gearcase coupler 86 2012 ORV Technical Update © Sportsman 850 XP Revised intake runners • Revised – – – – Air box cover strap Intake system Throttle body Cylinder head Side covers (not shown) • Larger air box • Revised to fit around box • Increased power Revised throttle body Revised air box Revised valve cover Revised cylinder head 87 © 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 88 © 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 89 2012 ORV Technical Update © Sportsman 850 XP • Revised engine breather – Valve cover – Breather outlet Hollow cavity Revised valve cover Drains Valve cover transparent view 90 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 hose to throttle body 91 2012 ORV Technical Update © Sportsman 850 XP • Revised – Air box plenum – Intake runners Side view Air box plenum Intake runners Side view: transparent plenum 92 © 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. 93 2012 ORV Technical Update © Sportsman 850 XP • Visual comparison between model year 2011 to 2012 2011 2012 94 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 • New torque spec. Bolts cannot be reused. See service manual for specifications RPM limit – Model year 2011 • 8000 RPM – Model year 2012 • 7600 RPM • Drive clutch weight change – Model year 2011 • One-up utilizes 60 gram weights • Two-up utilizes 68 gram weights Revised connecting rod – Model year 2012 • Common 63 gram weight between one and two up 95 © Classic Sportsman 2012 ORV Technical Update Front plastic /mounting Storage location • Revised front cab • Under rack storage – – – – – Sportsman 400 HO Sportsman 500 HO Sportsman 800 Sportsman 500 HO Touring Sportsman 800 6x6 Front rack/mounting 96 © 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 97