Page 1: Table Of Contents
GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION MODEL INFORMATION ..........1.2 MODEL IDENTIFICATION .
Page 2: Model Information
Vehicle and Engine Serial Number Location Whenever corresponding about a Polaris ORV, refer to the vehicle identification number (VIN) and the engine serial number. The VIN can be found stamped on a portion of the front left frame rail, close to the left front wheel (see Figure 1-1).
Page 3: Vehicle Information
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product.
Page 4: General Specifications
GENERAL INFORMATION GENERAL SPECIFICATIONS MODEL: 2011 RANGER RZR MODEL NUMBER: R11VH76AA, AD, AF, AH ENGINE NUMBER: 1204276 Category Dimension / Capacity Length 103 in. / 261.6 cm Width 50 in. / 127 cm Height 69 in. / 175.3 cm Wheel Base 77 in.
Page 5 ENGINE NUMBER: 1204276 Shift Type In Line Shift - H / L / N / R / P Engine Front Gearcase Polaris Demand Drive Plus H.O. Domestic Twin Cylinder, Platform Fluid Type / Capacity 6.75 oz. (200 ml) Liquid Cooled, 4-Stroke...
Page 6 GENERAL INFORMATION MODEL: 2011 RANGER RZR S MODEL NUMBER: R11VE76AC, AD, AW ENGINE NUMBER: 1204276 Category Dimension / Capacity Length 104 in. / 264.2 cm Width 60.5 in. / 154 cm Height 70.5 in. / 179 cm Wheel Base 77 in. / 196 cm Ground Clearance 12.5 in.
Page 7 ENGINE NUMBER: 1204276 Shift Type In Line Shift - H / L / N / R / P Engine Front Gearcase Polaris Demand Drive Plus H.O. Domestic Twin Cylinder, Platform Fluid Type / Capacity 6.75 oz. (200 ml) Liquid Cooled, 4-Stroke...
Page 8 GENERAL INFORMATION MODEL: 2011 RANGER RZR 4 MODEL NUMBER: R11XH76AW ENGINE NUMBER: 1204276 Category Dimension / Capacity Length 130 in. / 330 cm Width 60.5 in. / 154 cm Height 75 in. / 190.5 cm Wheel Base 103 in. / 262 cm Ground Clearance 11.5 in.
Page 9 ENGINE NUMBER: 1204276 Shift Type In Line Shift - H / L / N / R / P Engine Front Gearcase Polaris Demand Drive Plus H.O. Domestic Twin Cylinder, Platform Fluid Type / Capacity 6.75 oz. (200 ml) Liquid Cooled, 4-Stroke...
Page 10: Misc. Specifications And Charts
GENERAL INFORMATION MISC. SPECIFICATIONS AND CHARTS Conversion Table °C to °F: (°C + 32) = °F °F to °C: (°F - 32) = °C 1.10...
Page 11: Standard Torque Specifications
GENERAL INFORMATION Standard Torque Specifications The following torque specifications are to be used only as a general guideline. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque. 1.11...
Page 12: Sae Tap / Drill Sizes
GENERAL INFORMATION SAE Tap / Drill Sizes Decimal Equivalents Metric Tap / Drill Sizes 1.12...
Page 13: Glossary Of Terms
CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches.
Page 14 GENERAL INFORMATION NOTES 1.14...
Page 15 MAINTENANCE CHAPTER 2 MAINTENANCE PERIODIC MAINTENANCE CHART ......... 2.3 BREAK-IN PERIOD / MAINTENANCE CHART KEY .
Page 16 MAINTENANCE SUSPENSION (STANDARD) ..........2.31 SPRING PRELOAD ADJUSTMENT.
Page 17: Periodic Maintenance Chart
Polaris dealer. = 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.
Page 18: Pre-Ride - 25 Hour Maintenance Interval
Engine Oil Change 25 H 250 (400) Perform a break-in oil change at one month (Break-In Period) Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.
Page 19: 50 - 500 Hour Maintenance Interval
Change shock oil and seals Inspect periodically; adjust when parts are Toe Adjustment replaced Headlight Aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.
Page 20: Maintenance Quick Reference
2 years Maintain fluid level between Check level during pre-ride Brake Fluid Polaris DOT 4 Brake Fluid “MAX and “MIN” lines on the inspection; change fluid every master cylinder reservoir two years * More often under severe use, such as operated in water or under severe loads.
Page 21: Maintenance Quick Reference, Continued
Lube Rec. Method Frequency* Add lubricant until it is visible Check level every 25 hours; Front Gearcase Polaris Demand Drive Plus at the fill hole threads change fluid yearly Polaris ATV Angle Drive Add lubricant until it is visible Check level every 25 hours;...
Page 22: Grease Lubrication Points
Item Recommended Lube Method Frequency Front Propshaft Yoke(s) Grease before long periods Grease fittings every 500 of storage, and after A-arm Pivot Bushings Polaris Premium U-Joint Grease miles (800 km). thoroughly washing or Stabilizer Bar Bushings submerging the vehicle.
Page 23: Lubricants / Service Products
MAINTENANCE LUBRICANTS / SERVICE PRODUCTS NOTE: Each item can be purchased separately at your local Polaris dealer. Polaris Lubricants, Maintenance and Service Part No. Description Products Additives / Sealants / Thread Locking Agents / Misc. Part No. Description Loctite™ Threadlock 242...
Page 24: General Vehicle Inspection And Maintenance
MAINTENANCE GENERAL VEHICLE INSPECTION Locate the shift cable in the rear LH wheel well area. AND MAINTENANCE Clevis Pin Shift Cable Pre-Ride / Daily Inspection Mount Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance. •...
Page 25: Fuel System And Air Intake
MAINTENANCE FUEL SYSTEM AND AIR INTAKE Fuel Pump / Fuel Filters The RZR 800 EFI engine uses a serviceable, high-volume, high- Fuel System pressure, fuel pump that includes a preliminary filter and an internal fine filter located before the pump regulator. WARNING Fuel Pump Asm Gasoline is extremely flammable and explosive...
Page 26: Throttle Pedal Inspection
MAINTENANCE Throttle Pedal Inspection Remove the (2) push rivets retaining the air intake box and remove the box from the frame. If the throttle pedal has excessive play due to cable stretch or cable misadjustment, it will cause a delay in throttle speed. Also, the throttle may not open fully.
Page 27: Air Filter Service
MAINTENANCE NOTE: While adjusting, lightly move the throttle NOTE: If the filter has been soaked with fuel or oil it pedal in and out. must be replaced. 7. Re-tighten the jam nut after final adjustment is made. Seal 8. Apply a small amount of grease to the inside of the boot and slide it over the cable adjuster to its original position.
Page 28 MAINTENANCE Air Box / Air Filter Exploded View Front Foam Seal Air Intake Duct Intake Box Foil Primary Foam Seal Intake Seal Seal Breather Filter Fitting Breather Hose Boot Clip (3) Filter Ring Air Box Can Clamps Seal Air Filter 2.14...
Page 29: Engine
MAINTENANCE ENGINE Reinstall the dipstick completely, but do not lock it. NOTE: Make certain the dipstick is inserted all the Engine Oil Level way into the filler tube to keep the angle and depth of The twin cylinder engine is a wet-sump engine, meaning the oil dipstick consistent.
Page 30: Engine Oil And Filter Service
MAINTENANCE Engine Oil and Filter Service NOTE: The sealing surface on the drain plug should be clean and free of burrs, nicks or scratches. Always change engine oil and filter at the intervals outlined in Reinstall drain plug and torque to 16 ft. lbs. (22 Nm). the Periodic Maintenance Chart.
Page 31: Engine Breather Hose Inspection
MAINTENANCE Engine Breather Hose Inspection Exhaust - Spark Arrestor The engine is equipped with a breather hose. Inspect the WARNING breather hose for possible kinks or wear. The hose is form fit- ted for a proper fit. Follow the breather hose from the side of Do not clean spark arrestor immediately after the the airbox to the engine valve cover.
Page 32: Transmission And Gearcases
MAINTENANCE TRANSMISSION AND GEARCASES Transmission / Gearcase Specification Chart RAIN EVEL HECK EARCASE UBRICANT APACITY ORQUE ORQUE Transmission AGL Plus 24 oz. (710 ml) 40-50 ft. lbs. (54-68 Nm) 30-45 in. lbs. (3-5 Nm) (Main Gearcase) Gearcase Lubricant Transmission AGL Plus 14 oz.
Page 33 MAINTENANCE Main Gearcase - Lubricant Level Check: Add the recommended fluid through the fill plug hole until it begins to flow out the level plug hole. Do not overfill. The fill plug is located on the side of the gearcase just below the shift lever bell crank.
Page 34: Front Gearcase Lubrication
Lubricant Change: Front Gearcase Specifications The drain plug is located on the bottom of the gearcase. Specified Lubricant: Polaris Demand Drive Plus (PN 2877922) Capacity: 6.75 oz. (200 ml) Fill Plug: 8-10 ft. lbs. (11-14 Nm) Drain Plug: 8-10 ft. lbs. (11-14 Nm)
Page 35: Rear Gearcase Lubrication
MAINTENANCE Rear Gearcase Lubrication Lubricant Change: The rear gearcase lubricant level should be checked and The drain plug is located on the bottom right side of the rear changed in accordance with the maintenance schedule. gearcase. • Be sure vehicle is positioned on a level surface when Remove the fill plug.
Page 36: Cooling System
Remove recovery bottle cap and add coolant using a funnel. Polaris Premium 60/40 is already premixed and ready to use. Do Fill recovery bottle to MAX level with Polaris 60/40 not dilute with water.
Page 37: Cooling System Pressure Test
MAINTENANCE Cooling System Pressure Test Carefully straighten any bent radiator fins. Refer to Chapter 3 for cooling system pressure test procedure. Remove any obstructions with compressed air or low pressure water. Cooling System Hoses CAUTION 1. Inspect all hoses for cracks, deterioration, abrasion or leaks.
Page 38: Final Drive / Wheel And Tire
MAINTENANCE FINAL DRIVE / WHEEL AND TIRE Radiator Removal Remove the front bumper (see Chapter 5). Wheel and Hub Torque Table Remove the upper engine outlet hose and recovery hose from the top of the radiator. Item Nut Type Specification Remove the (2) upper radiator retaining bolts and the (4) Aluminum Wheels Lug Nut...
Page 39: Tire Inspection / Pressure
MAINTENANCE 6. Torque the wheel nuts and/or hub nut to the proper torque Tread specification listed in the torque table at the beginning of Depth 1/8" (3 mm) this section. 7. If hub nut was removed, install a new cotter pin after the hub nut has been tightened.
Page 40: Electrical And Ignition System
MAINTENANCE ELECTRICAL AND IGNITION SYSTEM Battery Removal Remove the driver’s seat to access the battery. Battery Maintenance Keep battery terminals and connections free of corrosion. If Battery cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water.
Page 41: Battery Installation
MAINTENANCE Battery Installation Remove the cargo box assembly to access the spark plugs (see Chapter 5). IMPORTANT: Using a new battery that has not been fully charged can damage the battery and result in a Remove both spark plug caps and clean plug area so no dirt shorter life.
Page 42: Engine To Frame Ground
The engine ground cable runs from the starter motor to the chassis ground terminal. 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.
Page 43: Tie Rod End / Wheel Hub Inspection
MAINTENANCE Tie Rod End / Wheel Hub Inspection Wheel Toe Alignment Inspection • To check for play in the tie rod end, grasp the steering Place machine on a smooth level surface and set steering tie rod, pull in all directions feeling for movement. wheel in a straight ahead position.
Page 44: Wheel Toe Adjustment
MAINTENANCE Wheel Toe Adjustment • IMPORTANT: When tightening the tie rod end jam nuts, the rod ends must be held parallel to prevent rod If toe alignment is incorrect, measure the distance between end damage and premature wear. Damage may not be vehicle center and each wheel.
Page 45: Suspension (Standard)
MAINTENANCE SUSPENSION (STANDARD) SUSPENSION (FOX™) Spring Preload Adjustment Spring Preload Adjustment The front and rear shock absorber springs are adjustable by The front and rear shocks have a preload adjustment. rotating the adjustment cam to change spring tension preload. Suspension spring preload may be adjusted to suit different riding conditions or vehicle payloads.
Page 46: Shock Compression Adjustment
MAINTENANCE Shock Compression Adjustment Factory Preload Setting 4.2 in. (10.7 cm) The compression damping adjustment is located on top of the shock ‘Piggyback’ reservoir of each shock. Decrease Increase Use a flat blade screwdriver to make damping adjustments. Preload Preload NOTE: When the adjuster screw is turned clockwise until it stops, the damping is in the fully closed position.
Page 47: Suspension (Walker Evans™)
MAINTENANCE SUSPENSION (WALKER EVANS™) Shock Spanner Wrench Spring Preload Adjustment (PN 2870803) The front and rear shocks have a preload adjustment. Suspension spring preload may be adjusted to suit different riding conditions or vehicle payloads. Shock Compression Adjustment WARNING The compression damping adjustment is located on top of the shock reservoir of each shock.
Page 48: Brake System
MAINTENANCE BRAKE SYSTEM Brake Pad / Disc Inspection Check the brake pads for wear, damage, or looseness. Brake Fluid Inspection Inspect the brake pad wear surface for excessive wear. Always check the brake pedal travel and inspect the brake fluid reservoir level before each operation.
Page 49: Maintenance Log
MAINTENANCE MAINTENANCE LOG Service Date Hours / Miles (km) Service Performed / Comments Dealer / Technician 2.35...
Page 50 MAINTENANCE NOTES 2.36...
Page 51 ENGINE CHAPTER 3 ENGINE ENGINE SPECIFICATIONS ..........3.2 CRANKCASE .
Page 52: Engine Specifications
ENGINE ENGINE SPECIFICATIONS Crankcase Exploded Views...
Page 53: Oil Pump / Gears / Engine Cover
ENGINE Oil Pump / Gears / Engine Cover Exploded View...
Page 54: Stator Cover / Starter / Water Pump / Lubrication System
ENGINE Stator Cover / Starter / Water Pump / Lubrication System Exploded View...
Page 55: Cylinder / Cylinder Head / Piston
ENGINE Cylinder / Cylinder Head / Piston Exploded View...
Page 56: Engine Efi Sensors / Valve Cover / General Components
ENGINE Engine EFI Sensors / Valve Cover / General Components Exploded View NOTE: See chapter 4 for more information on the EFI System...
Page 57: Engine Torque Specifications
ENGINE Engine Torque Specifications Fastener Size in. lbs. (Nm) ft. lbs. (Nm) Camshaft Gear 8 mm 22 ± 2 (30 ± 3) Camshaft Phase Sensor Bolt 6 mm 50 ± 5 (5.65 ± 0.55) Camshaft Thrust Plate 6 mm 115 ± 12 (13 ± 1.35) 9.5 ±...
Page 58: 800 Efi Engine Service Specifications
ENGINE 800 EFI Engine Service Specifications Cylinder Head - Engine Specifications Main Component: Cylinder Head RZR800HO-11 (PN 1204276) Cam Lobe Height - Intake 1.357” (34.477 mm) Cam Lobe Height - Exhaust 1.342” (34.096 mm) Camshaft Journal Outer Diameter - Mag 1.654"...
Page 59 ENGINE Cylinder / Piston - Engine Specifications Main Components: Cylinder / Piston / Connecting Rod RZR800HO-11 (PN 1204276) Cylinder - Surface warp limit 0.004" (0.10 mm) (mating with cylinder head) Cylinder Bore - Standard 3.1495" (80 mm) Cylinder Cylinder Taper Limit 0.00031"...
Page 60: Special Tools
ENGINE Special Tools Part Number Tool Description PU-50105 OIL FILTER WRENCH PU-45257 VALVE SPRING COMPRESSOR PU-45652 VALVE PRESSURE HOSE 2871043 FLYWHEEL PULLER 2870390 PISTON SUPPORT BLOCK PU-45497-1 CAM GEAR SPRING INSTALLATION KIT PU-45497-2 CAM GEAR TOOTH ALIGNMENT TOOL PU-45498 CAM SPANNER WRENCH PU-45838 GEAR HOLDER PA-44995...
Page 61: Engine Cooling System
CAUTION: Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce Pressure Cap 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.
Page 62: Cooling System Exploded View
ENGINE Cooling System Exploded View Bypass Hose (To Cylinder Head) Engine Outlet Hose (Thermostat Housing) Radiator Inlet Hose To Lower Fitting on Filler Neck Engine Inlet Hose (Water Pump Cover) Fan Motor Shroud Pressure Cap Filler Neck Recovery Bottle Radiator Outlet Hose Radiator To Top Fitting on Filler Neck...
Page 63: Cooling System Bleeding Procedure
ENGINE Cooling System Bleeding Procedure Remove pressure cap and top off coolant. Remove recovery bottle cap and fill bottle to the full line. WARNING Recovery Bottle Always wear safety glasses and proper shop clothing when performing the procedures in this Pressure Cap manual.
Page 64: General Engine Service
ENGINE GENERAL ENGINE SERVICE 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. Engine Lubrication Specifications WARNING Be sure to install the pressure cap before shutting off the engine.
Page 65: Oil Flow Chart
ENGINE Oil Flow Chart This chart describes the flow of oil through the 800 EFI engine. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through the oil filter. If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element.
Page 66: Engine Removal
Remove the (2) screws 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.
Page 67 ENGINE IMPORTANT: Mark or note which ignition coil wire 11. Remove the (2) push rivets and remove the intake box from goes to which cylinder and ignition coil post. The the vehicle. engine will misfire if the spark plug wires are installed incorrectly.
Page 68 ENGINE 20. Remove the (4) fasteners retaining the stabilizer bar and 24. Remove the remaining bolt attaching the airbox to the bracket and remove the assembly from the vehicle. frame (see photo). Standard RZR Shown 21. Remove the engine breather hose from the valve cover. 25.
Page 69 ENGINE NOTE: If the upper jam nut is moved, shift cable 27. Disconnect the fuel line from the fuel injector rail by adjustment will required during engine slightly squeezing the lock tabs and gently pushing the connector lock out. To separate the lines, pull the fuel line installation (see Chapter 2 “Shift Cable Inspection / Adjustment”).
Page 70 ENGINE 33. Disconnect the transmission speed sensor harness. 36. Remove the through-bolt that attaches the upper A-arm to the rear hub on both sides of the vehicle. Speed Sensor Connector 34. Disconnect the cam phase sensor connector. 37. Pivot the A-arms upward and rear hub carriers downward and remove the drive shafts from the hub carriers.
Page 71 ENGINE 39. Disconnect the engine coolant temperature (ECT) sensor 45. Remove RH engine mount fastener. harness and the bypass coolant hose. Connector Coolant Bypass 46. Remove the (2) lower bolts that retain the LH transmission 40. Loosen the hose clamp and remove the lower coolant hose mount to the frame.
Page 72 ENGINE 48. Using an engine hoist, hook a chain between the engine / 50. Remove propshaft from the transmission output shaft. transmission mounting plate and the transmission / rear 51. Then move assembly towards the front of the vehicle while gearcase mounting plate.
Page 73: Engine / Transmission Separation
ENGINE Engine / Transmission Separation Tilt the assembly up and remove the remaining (2) nuts that retain the transmission to the engine. Once the engine / transmission / rear gearcase assembly has been removed from the vehicle, the engine and transmission will need to be separated to allow engine servicing.
Page 74: Engine Disassembly And Inspection
ENGINE ENGINE DISASSEMBLY AND INSPECTION Cylinder Head Assembly Exploded View Head Bolts Valves Rocker Arms Retainer Locks (keepers) Push Rods Spring Retainers Springs Valve Seals (2) Valve Spring Seats (2) Coolant Bleeder Cylinder Head Hydraulic Lifters 3.24...
Page 75: Rocker Arms / Push Rods
ENGINE Rocker Arms If the push rod (A) is visibly bent, it should be replaced. 1. Remove the valve cover. 2. Mark or tag rocker arms in order of disassembly to keep them in order for reassembly. Cylinder Head Removal NOTE: The cargo box assembly and the upper frame bolt-in brace must be removed to allow enough clearance to remove all the cylinder head bolts.
Page 76: Cylinder Head Inspection / Warp
ENGINE Cylinder Head Inspection Valve Seal / Spring Service (On Engine) NOTE: The following procedure is only for servicing Thoroughly clean cylinder head surface to remove all traces of the top end of the valve train when replacing valve gasket material and carbon. springs or replacing valve seals.
Page 77: Cylinder Head Disassembly
ENGINE Cylinder Head Disassembly Remove valve guide seals. 1. Carefully remove the cylinder components. IMPORTANT: It is recommended to replace seals whenever the cylinder head is disassembled. Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup. Mark the valves with a white pen.
Page 78: Valve Inspection
ENGINE Valve Inspection Remove all carbon from valves with a soft wire wheel or = In. / mm. brush. Check valve face for runout, pitting, and burnt spots. To Valve Stem Diameter: check for bent valve stems, mount valve in a drill or use “V” Intake: 0.2356"...
Page 79: Combustion Chamber
Valve Seat Reconditioning Apply cutting oil to valve seat and cutter. NOTE: Polaris recommends that the work be done by a local machine shop that specializes in this area. Place 46 cutter on the pilot and make a light cut.
Page 80 ENGINE Inspect the cut area of the seat: NOTE: When using an interference angle, the seat contact point on the valve will be very narrow, and is * If the contact area is less than 75% of the circumference of the a normal condition.
Page 81: Cylinder Head Reassembly
ENGINE Cylinder Head Reassembly 9. Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the NOTE: Assemble the valves one at a time to valve. maintain proper order. NOTE: Lapping is not required with an interference Apply engine oil to valve guides and seats.
Page 82: Valve Sealing Test
ENGINE Valve Sealing Test Valve Lifter Removal / Inspection Clean and dry the combustion chamber area (A). Remove the valve lifters by reaching into the crankcase and pushing the lifter up through the lifter bore by hand. Thoroughly clean the lifters in cleaning solvent and wipe them with a clean, lint-free cloth.
Page 83: Piston Removal
ENGINE Piston Removal The oil control ring is a three piece design consisting of a top and bottom steel rail and a center expander section. The top rail has 1. Remove the circlip. Mark the piston with a white pen to a locating tab on the end which fits into a notch (B) in the upper ensure proper orientation (if reused) during assembly.
Page 84: Cylinder Inspection
ENGINE Cylinder Inspection Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge. Measure in two Remove gasket material from cylinder sealing surfaces. different directions, front to back and side to side, on three different levels (1/2, down from top, in the middle, and 1/ Inspect the top of the cylinder (B) for warp using a straight 2, up from bottom).
Page 85: Cylinder Hone Selection And Honing Procedure
Using a common spring loaded glaze breaker for honing is not advised for nicasil cylinders. Polaris recommends using a rigid hone or arbor honing machine. Cylinders may be wet or dry Example of Cross Hatch Pattern honed depending upon the hone manufacturer's recommendations.
Page 86: Piston-To-Cylinder Clearance
ENGINE Piston-to-Cylinder Clearance Measure piston pin O.D. Replace piston and/or piston pin if out of specification. Measure piston outside diameter at a point 5 mm up from the bottom of the piston at a right angle to the direction of the piston pin.
Page 87: Piston Ring Installed Gap
ENGINE 4. Measure piston ring to groove clearance by placing the ring If the bottom installed gap measurement exceeds the in the ring land and measuring with a thickness gauge. service limit, replace the rings. If ring gap is smaller than Replace piston and rings if ring-to-groove clearance the specified limit, file ring ends until gap is within exceeds service limits.
Page 88: Flywheel / Stator Removal / Inspection
ENGINE Inspect gear teeth on starter drive (A). Replace starter drive if gear teeth are cracked, worn, or broken. Inspect the bendix bushing (C) in the mag cover for wear. Replace as needed. 2871043 Use caution when removing the wire holddown (B) and the stator assembly (D).
Page 89 ENGINE 2. Remove the nut (C), washer (D) and water pump impeller Remove the starter bendix (G), wire holddown plate (H), (E). Remove part of the water pump seal behind the and the woodruff key (I) from the crankshaft. The stator impeller.
Page 90 ENGINE Use a white pen to accent the timing marks on the following gears: camshaft gear (K), crankshaft gear (M), or CAUTION counterbalance gear (N) This will ensure proper gear alignment and timing during reassembly of the gears. Wear safety glasses at all times. Use caution when working with the top gear.
Page 91 ENGINE 14. Inspect the gear teeth and the three tabs on the gears for To Assemble: wear. • Hold the spring with one finger. • Start the pointed end of the tapered pin into the cam Inspect Teeth & Tabs gear hole.
Page 92 ENGINE 19. Once the gears are pressed together, firmly hold the gears 21. To remove the balance shaft gear, the flat side of the together with one hand. Carefully remove the Tapered Pins camshaft (P) must face the balance shaft gear. To rotate the (PU-45497-1) by pulling them out one at a time with the camshaft, use the Cam Spanner Wrench (PU-45498) to other hand.
Page 93 ENGINE 23. Inspect the crankshaft gear (Q) for broken or worn teeth. If 26. Rotate the water/oil pump gear (S), so that all four bolts are the crankshaft gear does not need to be replaced, it does not visible though the gear. Remove the four bolts with a hex need to be removed.
Page 94 ENGINE 29. Remove the oil pressure relief. The oil pressure relief 31. Carefully press the gear off the assembly while supporting consists of a bolt, washer, spring, and valve (dowel). the housing assembly. Inspect the valve (dowel) for signs of possible obstructions. Use compressed air to blow out any debris.
Page 95 ENGINE 34. Press shaft into the new bearing. 37. Remove thrust plate (U). Press On Bearing 35. Press the bearing/shaft assembly using the bearing's outer race. Do not use the shaft to press the assembly into the 38. Remove PTO end engine mount. Remove crankcase bolts. housing, as bearing damage may result.
Page 96: Camshaft Inspection
ENGINE Camshaft Inspection 39. Remove and clean oil pick up (V) and oil baffle weldment (W). Thoroughly clean the cam shaft. Visually inspect each cam lobe for wear, chafing or damage. Measure height of each cam lobe using a micrometer. Compare to specification.
Page 97: Engine Reassembly
ENGINE ENGINE REASSEMBLY 4. Measure camshaft journal outside diameters (O.D.). Crankcase Reassembly CAUTION After any reassembly or rebuild, the engine must be primed using the Oil Priming Adapter (PU-45778) and a 3/4-full oil filter before initial start-up (see “Oil Pump Priming”). NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2874275) to remove any debris.
Page 98 ENGINE NOTE: Always install new balance shaft bearings. Assemble the crankcase halves. Apply LocTite™ 242 (PN 2871949) to the threads and pipe sealant to the bolt flanges. Apply assembly lube to cam journals and balance shaft Torque bolts to specification following torque pattern at bearing surfaces of the MAG case halve.
Page 99 ENGINE 10. Lubricate connecting rods with PS-4 PLUS synthetic 13. Install piston assemblies into cylinder aligning the piston engine oil. pin holes, to ensure proper alignment of the pistons to the connecting rods upon assembly. Partially install the piston pins into the pistons. 11.
Page 100 ENGINE NOTE: While installing in piston circlips, cover all 17. Assemble rotors as marked when disassembled. Use a engine passages. The clip could fall into the engine cleaner to remove the marks previously made on the rotors. during installation. Line Up Marks 18.
Page 101 ENGINE 20. Install oil pump housing bolts (H). The new bolts contain 22. Before installing the crankshaft gear (I), heat the crankshaft patch lock, so Loctite is not needed on the new bolts. gear to 250 F (121 C) on a hot plate (J). Torque bolts to specification and follow the torque sequence at beginning of the chapter.
Page 102 ENGINE 25. Install counter balance shaft gear (J) with new key, aligning NOTE: Cam Spanner Wrench (PU-45498) is only needed to rotate the camshaft when the entire valve timing marks with crankshaft gear (I). Install washer and train is assembled. bolt.
Page 103 ENGINE NOTE: Install the crankshaft seal (P) with the seal lip 28. Before installing the gear / stator housing, replace the seals facing out (towards the crankcase). in the cover. Install a new water pump seal (N) into the gear / stator housing.
Page 104 ENGINE 32. Before installing the gear/stator housing cover, install the Water Pump Seal Saver (PA-45401) onto the water pump shaft. PA-45401 35. Install the gear/stator housing gasket onto the crankcase. Gear / Stator Housing Gasket 33. Install a NEW gasket to the gear/stator housing cover and crankcase.
Page 105 ENGINE NOTE: Before assembly, clean the bolts and bolt 39. Install water pump cover (R) with new O-ring seal. Torque holes with Primer N (PN 2874275) to remove any bolts to specification in proper sequence (see Page 3.4). debris. This will ensure proper sealing when Install the O-ring dry installing bolts.
Page 106: Flywheel / Stator Installation
ENGINE Flywheel / Stator Installation NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2874275) to remove any Flywheel Nut Torque debris. This will ensure proper sealing when 65 ± 7 ft. lbs. (88 ± 9.50 Nm) installing bolts.
Page 107 ENGINE 2. Install cylinder head on cylinder. Lubricate push rods (D) and install into lifters. 3. Lubricate threads and top of washers underside of bolt head with engine oil. Install head bolts (C) and torque to specification in sequence. Lubricate rockers (E) with engine oil. Verify pushrods are engaged in lifters.
Page 108: Oil Pump Priming
ENGINE Install breather reed (G) into rocker cover (H). Lightly 11. Install thermostat (J), new O-ring, and thermostat housing. apply black RTV sealant to the outer edges of the breather Torque to specification. reed. The reed has a tab and will assemble one-way only. Torque the breather bolts to specification.
Page 109: Engine Installation
Remove primer plug from the engine. Install Oil System Priming Adapter (PU-45778) into the oil plug hole. Push 40 ft. lbs. 3-5 oz. (approx.) of Polaris PS-4 PLUS engine oil into the (54 Nm) adapter or until resistance is felt. Remove the adapter.
Page 110: Engine Break-In Period
• Replace exhaust gaskets. Seal connections with high - Oil Pressure Specification - temp silicone sealant. Check to be sure all exhaust 27-35 psi @ 6000 RPM, Polaris PS-4 PLUS springs are in good condition. Synthetic, Engine at operating temperature.
Page 111: Troubleshooting
ENGINE TROUBLESHOOTING Engine Idles But Will Not Accelerate • Spark plug fouled/weak spark Engine • Broken throttle cable Spark Plug Fouling • Obstruction in air intake • Spark plug cap loose or faulty • Air box removed (reinstall all intake components) •...
Page 112 ENGINE Cooling System Excessive Smoke and Carbon Buildup • Excessive piston-to-cylinder clearance Overheating • Wet sumping due to over-full crankcase • Low coolant level • Worn rings, piston, or cylinder • Air in cooling system • Worn valve guides or seals •...
Page 113 ELECTRONIC FUEL INJECTION CHAPTER 4 ELECTRONIC FUEL INJECTION GENERAL INFORMATION ..........4.2 SPECIAL TOOLS .
Page 114: Electronic Fuel Injection Chapter
ELECTRONIC FUEL INJECTION GENERAL INFORMATION Throttle Position Sensor (TPS) Tester - 2201519-A This tester allows the use of a digital multi-meter to test TPS WARNING function as well as perform the TPS adjustment procedure. Gasoline is extremely flammable and explosive under certain conditions.
Page 115 PU-47468, Vehicle Interface Cable PU-47469 and PC Interface Cable PU-47470. This module kit is used on all 8 pin connector-based Polaris EFI systems. This kit is available to Polaris dealers through our tool supplier SPX at (1-800-328- 6657) or http://polaris.spx.com Adaptor shown is included with kit.
Page 116: Service Notes
• Do not charge battery with key switch "on." Digital Wrench™ software and update downloads • Always disconnect negative (-) battery cable lead please visit the website: www.polaris.diagsys.com before charging battery. • Always unplug ECU from the wire harness before...
Page 117: Efi System Exploded View
ELECTRONIC FUEL INJECTION EFI System Exploded View 1. Electronic Control Unit (ECU) 13. Spark Plug Wires 14. Idle Air Control (IAC) 2. Temperature / Manifold Absolute Pressure Sensor (T-MAP) 15. Camshaft Phase Sensor 3. Crankshaft Position Sensor (CPS) 4. Fuel Injectors 5.
Page 118: Efi System Component Locations
ELECTRONIC FUEL INJECTION EFI System Component Locations 3. Crankshaft Position Sensor (CPS) - Located in the magneto cover between the engine and 1. Electronic Control Unit (ECU) transmission, just in front of the rear gear case. - Located behind the driver’s seat (RZR / RZR S) or under the left rear passenger seat (RZR 4).
Page 119 ELECTRONIC FUEL INJECTION 9. Camshaft Phase Sensor Located in Fuel Tank - Located in the engine block above the oil filter. The sensor can be accessed through the right rear wheel well. Fuel Line Connection Regulator Pump / Sending Unit Fuel Pump Connection Camshaft Phase Sensor...
Page 120: Fuel Tank
ELECTRONIC FUEL INJECTION FUEL TANK Exploded View Fuel Flow Fuel Injectors Fuel Rail Fuel Tank Pressure Regulator Fuel Pump Assembly Fuel Filters Quick Connect Fuel Line...
Page 121: Fuel Lines - Quick Connect
ELECTRONIC FUEL INJECTION Fuel Lines - Quick Connect ELECTRONIC FUEL INJECTION Principal Components The Electronic Fuel Injection (EFI) system is a complete engine fuel and ignition management design. This system includes the following principal components: • Fuel Pump • Fuel Rai •...
Page 122: Initial Priming / Starting Procedure
ELECTRONIC FUEL INJECTION ELECTRONIC CONTROL UNIT (ECU) The ECU controls the amount of fuel being injected and the ignition timing by monitoring the primary sensor signals for intake air temperature, manifold absolute pressure (load), Operation Overview engine temperature, speed (RPM), camshaft position and The ECU is the brain or central processing computer of the throttle position.
Page 123: Temp / Manifold Absolute Pressure Sensor (T-Map)
For the purpose of troubleshooting, a known-good ECU from temperature and manifold absolute pressure readings, are another Polaris RANGER RZR EFI of the same model may be processed by the ECU and compared to its programming for used without system or engine component damage.
Page 124: Crankshaft Position Sensor (Cps)
ELECTRONIC FUEL INJECTION Install the sensor by inserting it with a twisting motion to The two-tooth gap creates an “interrupt” input signal, properly seat the grommet. corresponding to specific crankshaft position. This signal serves as a reference for the control of ignition timing by the ECU. Synchronization of the CPS and crankshaft position takes place Torque to Specification during the first two revolutions each time the engine is started.
Page 125: Cps Replacement
ELECTRONIC FUEL INJECTION 4. If the resistance is correct. Remove the bottom bolt that attaches the bracket to the rear - Test the main harness circuit between the sensor gearcase through the hole in the frame support as shown. connector terminals and the corresponding pin terminals at the ECU (see wiring diagram).
Page 126 ELECTRONIC FUEL INJECTION Lift the mounting bracket straight up and out from the Installation vehicle. IMPORTANT: When reinstalling the transmission to rear gearcase mount bracket, it is extremely important Remove to torque all (7) fasteners to specification. Refer to the Bracket following procedure.
Page 127 ELECTRONIC FUEL INJECTION 4. Using special tool (PA-48873), torque the (3) bolts that Remove the special tool and attach an extension to the retain the front portion of the mounting bracket to the torque wrench. Torque the bottom bolt that attaches the transmission.
Page 128: Fuel Injectors
ELECTRONIC FUEL INJECTION FUEL INJECTORS Upper Rear Gearcase Bolt Operation Overview NOTE: All EFI units utilize quick connect fuel lines. The fuel injectors mount into the cylinder head, and the fuel rail attaches to them at the top end. O-rings on both ends of the injector prevent external fuel leaks and also insulate it from heat and vibration.
Page 129 ELECTRONIC FUEL INJECTION Fuel Injector Service Fuel Injector Test NOTE: The harness connector and locking spring is Injector problems typically fall into three general categories- electrical, dirty / clogged, or leakage. An electrical problem bonded to the fuel injectors with an epoxy. DO NOT attempt to disconnect the connector from the fuel usually causes one or both of the injectors to stop functioning.
Page 130: Fuel Injector Replacement
ELECTRONIC FUEL INJECTION Fuel Injector Replacement NOTE: The harness connector and locking spring is bonded to the fuel injectors with an epoxy. DO NOT Be sure the engine has cooled enough to work on. attempt to disconnect the Bosch connector from the fuel injectors.
Page 131: Fuel Pump
ELECTRONIC FUEL INJECTION FUEL PUMP The ECU switches off the pump preventing the continued delivery of fuel in these instances: Operation Overview • If the key switch is not promptly turned to the "start" position. An electric fuel pump assembly is used to transfer fuel to the EFI system from inside the fuel tank.
Page 132: Fuel Pump Test
ELECTRONIC FUEL INJECTION Fuel Pump Test Normal Fuel Pressure: 45 +/- 2 psi. If a fuel delivery problem is suspected, make certain the fuel pump filters are not plugged, that the pump is being activated NOTE: If the fuel pressure is out of specification, through the ECU, all electrical connections are properly replace the fuel pump assembly.
Page 133: Fuel Pump Replacement
ELECTRONIC FUEL INJECTION Fuel Pump Replacement Be sure the top of the fuel tank is clean. If it requires cleaning, hand wash the top of the tank to ensure no debris will enter the fuel system when the fuel pump is removed. WARNING Clean this area Always wear safety goggles when working with...
Page 134 ELECTRONIC FUEL INJECTION Carefully lift the fuel pump out of the fuel tank. As the fuel 12. Install new PFA gasket onto fuel pump assembly using care pump assembly is being removed, be aware of float arm and not to damage gasket or bend float arm. pump pre-filter.
Page 135 ELECTRONIC FUEL INJECTION 13. Install fuel pump into fuel tank, hold float arm to the pump 17. Torque PFA nut to specification using the Fuel Pump body and tilt assembly to ensure float arm does not get Service Tool (PU-50326) and a calibrated torque wrench. caught or bent during installation.
Page 136: Fuel Tank Removal (Rzr / Rzr S)
ELECTRONIC FUEL INJECTION Fuel Tank Removal (RZR / RZR S) Remove the fuel tank vent hose clamp with a suitable pliers and remove the vent line from the tank vent fitting. IMPORTANT: Syphon as much fuel from the tank as possible before attempting to remove it from the vehicle.
Page 137 ELECTRONIC FUEL INJECTION Remove the lower bolt retaining the seat belt mechanism near the rear RH portion of the fuel tank. Once removed, Set bracket by place the mechanism in the rear cargo box to keep it out of shift lever the way.
Page 138: Fuel Tank Removal (Rzr 4)
ELECTRONIC FUEL INJECTION Fuel Tank Removal (RZR 4) Remove the lower bolt retaining the seat belt mechanism near the rear RH portion of the fuel tank. Once removed, IMPORTANT: Syphon as much fuel from the tank as place the mechanism in the rear cargo box to keep it out of possible before attempting to remove it from the the way.
Page 139 ELECTRONIC FUEL INJECTION 7. Remove the rear seat support by removing the 5/16” Disconnect the fuel pump electrical harness. fastener and 7/16” fastener retaining the right side of the rear seat support. Remove the 7/16” fastener from the left Disconnect side of the rear seat support.
Page 140: Fuel Tank Installation
ELECTRONIC FUEL INJECTION Fuel Tank Installation 12. Lift the rear of the fuel tank up first and carefully lift the fuel tank up and out from the vehicle. Carefully reinstall the fuel tank assembly. Reinstall the (2) fuel tank brackets and fasteners. Reinstall the (3) shift lever support bracket fasteners (RZR / RZR S).
Page 141: Idle Air Control (Iac)
ELECTRONIC FUEL INJECTION IDLE AIR CONTROL (IAC) IAC Replacement Remove the seats, rear service panel and the rear cargo box Operation Overview (see Chapter 5). The Idle Air Control (IAC) is used to stabilize the idle quality of Loosen the hose clamps retaining the throttle body. the engine at cold start-up and after warm-up operations.
Page 142: Throttle Position Sensor (Tps)
ELECTRONIC FUEL INJECTION THROTTLE POSITION SENSOR (TPS) TPS Resistance Tests The TPS is a non-serviceable item. If it is faulty, it must be Operation Overview replaced. It can be tested using the following method: The throttle position sensor (TPS) is used to indicate throttle With the test leads connected and the meter set to the ohms scale, plate angle to the ECU.
Page 143: Tps Replacement
ELECTRONIC FUEL INJECTION Verify TPS Tester Reference Voltage TPS Replacement A 5 volt reference voltage from the TPS Tester harness is NOTE: The correct position of the TPS angle on the required for the TPS test to be accurate. Refer to the instructions throttle body is established and set at the factory.
Page 144 ELECTRONIC FUEL INJECTION Set your voltmeter to read DC Volts. Insert the red and 12. Verify voltage reading did not change. If voltage reading black voltmeter probes into the test ports as shown. is now out of specification, repeat steps 9 - 11. 13.
Page 145: Camshaft Phase Sensor
ELECTRONIC FUEL INJECTION CAMSHAFT PHASE SENSOR Cam Phase Sensor Replacement Access the sensor through the right rear wheel well. Operation Overview Disconnect vehicle harness from the sensor. Mounted on the engine crankcase, the Cam Phase Sensor provides camshaft position information to the ECU to be used Remove the retaining bolt and remove the sensor from the along with the crankshaft position data to allow for sequential engine.
Page 146: Engine Coolant Temperature Sensor (Ect)
ELECTRONIC FUEL INJECTION ENGINE COOLANT TEMPERATURE Refer to Chapter 10 for additional ECT sensor information. Polaris dealers can test the sensor by using the Digital Wrench™ SENSOR (ECT) Diagnostic Software (dealer only). Operation Overview ECT Sensor Resistance Readings Mounted on the cylinder head, the engine temperature sensor...
Page 147: Ignition Coil
ELECTRONIC FUEL INJECTION IGNITION COIL Ignition Coil Tests The ignition coil can be tested by using an ohm meter. Use the Operation Overview following illustration and specification table to test the ignition The ignition coil is used to provide high voltage to fire the spark coil resistance.
Page 148: Efi Diagnostics
ELECTRONIC FUEL INJECTION EFI DIAGNOSTICS A set of three numbers will appear in the information area. • The first number (located far left) can range from 0 to 9. Instrument Cluster Trouble Code Display This number represents the total number of trouble code present (example: 2 means there are 3 codes present).
Page 149 ELECTRONIC FUEL INJECTION DIAGNOSTIC TROUBLE CODE TABLE Digital Wrench™ Component Condition P-Code P0563 Voltage Too High C1063 System Power (Battery Potential / Power Input) P0562 Voltage Too Low C1064 Engine Speed (This is applicable when the EPS module gets the Received Engine Speed Has Error C1066 engine speed from the ECM)
Page 150 ELECTRONIC FUEL INJECTION DIAGNOSTIC TROUBLE CODE TABLE Digital Wrench™ Component Condition P-Code Steering Torque Partial Failure Condition Exists 520223 C1052 Steering Torque Full Failure Condition Exists 520224 C1053 Greater than 110° C (230° F) C1054 EPS Inverter Temperature 520225 Greater than 120° C (248° F) C1055 EPS CAN Communications No RX Message for 2 Seconds...
Page 151: Efi Troubleshooting
ELECTRONIC FUEL INJECTION EFI Troubleshooting Poor Idle Symptom: Idle Too High (If greater than 1300 RPM when Fuel Starvation / Lean Mixture engine is warm). Symptoms: Hard start or no start, bog, backfire, popping • Throttle stop screw set incorrect through intake / exhaust, hesitation, detonation, low power, •...
Page 152: Digital Wrench™ Operation
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: •...
Page 153: Digital Wrench™ - Diagnostic Connector
Interface Cable to your laptop (see page 4.3). 2. Remove the protective cap from the Digital Wrench™ In this case, the version number is 3.1 with a 03/13/09 update. Proceed to http://polaris.diagsys.com to see if a connector. newer update is available.
Page 154: Digital Wrench™ Updates
If the update file date listed is newer than your current version and update (see “Digital Wrench™ Version and Updates are released for Digital Wrench™ via the Internet at: Update ID”), download the file. http://polaris.diagsys.com. The Digital Wrench™ website can also accessed through...
Page 155: Digital Wrench™ Feature Map
ELECTRONIC FUEL INJECTION Digital Wrench™ Feature Map 4.43...
Page 156: Engine Controller Reprogramming (Reflash)
Reflash Authorization site. The Request Code is automatically generated by Digital Wrench™ Proceed to http://polaris.diagsys.com for specific during the reprogramming process. The Reflash Authorization information and FAQs on how to troubleshoot site is located under the “Service and Warranty”...
Page 157 ELECTRONIC FUEL INJECTION 2. Connect the SmartLink Module cables to the PC and Select “Engine Controller Reprogramming”. vehicle. See “Digital Wrench™ - Diagnostic Connector” on page 4.41. Select the file you want to load into the ECU then click the “Continue”...
Page 158 ELECTRONIC FUEL INJECTION Copy (CTRL+C) the Request Code that will be required on 12. Select the same file type from the list that you selected the dealer website in the next step. DO NOT CLOSE previously while in Digital Wrench™. Enter the VIN along Digital Wrench™...
Page 159 ELECTRONIC FUEL INJECTION 15. At this point the reflash process will begin. Do not touch the vehicle or PC during the process. 16. Once the ECU reprogramming procedure is complete, click the ‘Finish’ button on the screen. Verify the reflash was a success by starting the vehicle.
Page 160: Efi System Electrical Operation
ELECTRONIC FUEL INJECTION EFI SYSTEM ELECTRICAL OPERATION Block Diagram 4.48...
Page 161 BODY / STEERING / SUSPENSION CHAPTER 5 BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS..........5.3 SPECIAL TOOLS .
Page 162 BODY / STEERING / SUSPENSION REAR A-ARMS ............5.36 REMOVAL .
Page 163: Torque Specifications
BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS SPECIAL TOOLS ITEM TORQUE VALUE TOOL DESCRIPTION PART NUMBER Gas Shock Recharging Kit 2200421 37 ft. lbs. (50 Nm) Front LH/RH Upper / Lower Shock Shaft Seal Protector A-Arm Bolt RZR S / RZR 4 2201640 .625"...
Page 164: Cab Frame (Rzr / Rzr S)
BODY / STEERING / SUSPENSION CAB FRAME (RZR / RZR S) Assembly / Removal NOTE: Finger tighten all components until cab frame is completely assembled on vehicle, then tighten to specifications listed. Assemble the rear cab frame and the front cab frame at the coupler joints and secure with four (3/8-16 x 1 1/4) screws and (3/8-16 Nyloc) nuts.
Page 165: Cab Frame (Rzr 4)
BODY / STEERING / SUSPENSION CAB FRAME (RZR 4) Assembly / Removal NOTE: Finger tighten all components until cab frame is completely assembled on vehicle, then tighten to specifications listed. 1. Place rear cab frame and mid cab frame in the vehicle so they line up with the mounting holes. You may have to pull the rocker panels out slightly to get the mid cab frame into place.
Page 166: Body Exploded Views
BODY / STEERING / SUSPENSION BODY EXPLODED VIEWS Side Safety Nets...
Page 167: Dash Instruments / Controls / Glovebox
BODY / STEERING / SUSPENSION Dash Instruments / Controls / Glovebox A. Instrument Cluster / Speedo B. Headlight Switch C. AWD/2WD or AWD/2WD/TURF Switch D. 12 Volt Accessory Receptacle E. Key Switch F. Hazard Switch (INT’L) G. Switch; Turn, Lights, Horn (INT’L)
Page 168: Hood / Front Body Work
BODY / STEERING / SUSPENSION Hood / Front Body Work 1/4 Turn Latch Center Access Hood Washer Grommet T27 Screws T25 Screws Push Rivets Hood / Dash Push Rivet Front LH Fender Flair Front RH Fender Flair T27 Screws Push Rivets Front Bumper Push Rivet Winch Pocket Cover...
Page 169: Front / Rear Bumper
BODY / STEERING / SUSPENSION Front Bumper Front Bumper Support Screws Front Bumper Radiator Screen O-Ring Bulb Screw Screw Headlight Winch Pocket Cover Rear Bumper LH Tail Light RH Tail Light Screw Speed Screws Nuts Rear Bumper Screws...
Page 170: Seat Assembly
BODY / STEERING / SUSPENSION Seat Assembly Seat Back Seat Hoop Tube 48 in. lbs. (5.4 Nm) Seat Bottom Latch Body Nuts Lever Seat Base Asm. Spring Plate 41-57 in. lbs. 41-57 in. lbs. Grommets (4.6-6.4 Nm) (4.6-6.4 Nm) Seat Belts / Mounting (RZR / RZR S) Driver 3 Point Seat...
Page 171: Seat Belts / Mounting (Rzr 4)
BODY / STEERING / SUSPENSION Seat Belts / Mounting (RZR 4) Rear Seats 40 ft. lbs. (54 Nm) 3 Point Seat Belts Rear Seat Base Front Seats 40 ft. lbs. (54 Nm) 40 ft. lbs. 40 ft. lbs. (54 Nm) (54 Nm) Rubber Bumpers...
Page 172: Floor / Rocker Panels (Rzr / Rzr S)
BODY / STEERING / SUSPENSION Floor / Rocker Panels (RZR / RZR S) Self-Tapping Screw LH Rocker Rear Support Bracket Push Rivets Self-Tapping Screws Console Cover Screws Front Support Bracket Rear Support Bracket Self-Tapping Screws Screw Screw Screws Push Rivets U-Type Upper Floor Nuts...
Page 173: Floor / Rocker Panels (Rzr 4)
BODY / STEERING / SUSPENSION Floor / Rocker Panels (RZR 4) LH Rocker Self-Tapping Screw Rear Support Bracket Self-Tapping Screws Push Rivets Console Cover Rear Floor Screw Screw Torx Screws Rear Support Bracket Lower Floor Screw Self-Tapping Screw Front Support Bracket U-Type Nuts Self-Tapping...
Page 174: Rear Cargo Box / Fenders (Rzr / Rzr S)
BODY / STEERING / SUSPENSION Rear Cargo Box / Fenders (RZR / RZR S) Rear LH Rear Rack Extender Rack Extender Torx Screw & Nut Screws Rear RH Rack Extender Rear LH Fender Flair Screws Push Tie Down Rear LH Rivets Bracket Fender...
Page 175: Rear Cargo Box / Fenders (Rzr 4)
BODY / STEERING / SUSPENSION Rear Cargo Box / Fenders (RZR 4) Tie Down Rear LH Bracket Fender Flair Rear LH Screws Tie Down Fender Bracket Torx Screw & Nut Rear Cargo Box Torx Screw & Nut Screws Torx Screw Screws Rear RH Fender...
Page 176: Chassis / Main Frame (Rzr / Rzr S)
BODY / STEERING / SUSPENSION Chassis / Main Frame (RZR / RZR S) 15 ft. lbs. Bolt-In Brace (20 Nm) Rear Bumper Support Main Frame 15 ft. lbs. 17 ft. lbs. (20 Nm) (23 Nm) Skid Plate Washer 6-8 ft. lbs. (8-11 Nm) 5.16...
Page 177: Chassis / Main Frame (Rzr 4)
BODY / STEERING / SUSPENSION Chassis / Main Frame (RZR 4) 15 ft. lbs. Bolt-In Brace (20 Nm) 17 ft. lbs. (23 Nm) Nylok Nuts 15 ft. lbs. (20 Nm) Main Frame Rear Bumper Support Plug 17 ft. lbs. (23 Nm) Rear Skid Plate 38 ft.
Page 178: Body Component Removal
BODY / STEERING / SUSPENSION BODY COMPONENT REMOVAL Rear Console Cover (RZR 4) Remove the rear passenger seats. Seats Turn both latches 1/4 turn to disengage the cover. To remove any of the seats, lift upward on the latch lever located behind the seat bottom.
Page 179: Rear Bumper
BODY / STEERING / SUSPENSION Rear Bumper Front Body / Dash Removal Remove the hood as previously described. 1. Remove the (4) Torx screws retaining the upper portion of the rear bumper to the cargo box. Remove the front bumper (see “BODY COMPONENT REMOVAL - Front Bumper”).
Page 180: Rear Fender, Flair And Tie Down Removal
BODY / STEERING / SUSPENSION Disconnect all electrical dash components noting their Remove the (3) Torx screws from the bottom side of the location and wire routing. fender and the upper push rivet from the top side. Remove the fender from the vehicle. Remove the dash assembly from the vehicle.
Page 181: Rocker Panels, Console And Floor
BODY / STEERING / SUSPENSION Rocker Panels, Console and Floor Rear Floor Removal (RZR 4) Remove all four seats and both rocker panels (see “Rocker Rocker Panel Removal Panel Removal”). 1. Remove the push rivets and Torx screws retaining the Remove the T27 screws retaining the console to the floor.
Page 182: Steering Assembly
BODY / STEERING / SUSPENSION STEERING ASSEMBLY Exploded View (Non-EPS Models) Spacer Thick Steering Wheel Washers Thin 25-31 ft. lbs. Washer (34-42 Nm) Thin Washer Thick Washer Thin Washer Steering Shaft Pivot Tube Spacer Bearing 7 ft. lbs. Bushing 42.5 ft. lbs. (10 Nm) (58 Nm) 23 ft.
Page 183: Steering Wheel Removal (Non-Eps Models)
BODY / STEERING / SUSPENSION Steering Wheel Removal (Non-EPS Models) Steering Shaft Removal (Non-EPS Models) Remove the pinch bolt retaining the lower portion of the CAUTION steering shaft to the steering gear box assembly. Steering Shaft This procedure should NOT be used on EPS Pinch Bolt models.
Page 184: Steering Shaft Bearing Replacement
BODY / STEERING / SUSPENSION Steering Shaft Bearing Replacement Reinstall the upper washers and spacers in the order in which they were removed. IMPORTANT: Replacement pivot tube assembly comes with new upper and lower bearings installed. 10. Install the steering wheel and hand tighten the nut. Use this procedure if replacing just the bearings only.
Page 185: Electronic Power Steering Assembly
BODY / STEERING / SUSPENSION ELECTRONIC POWER STEERING ASSEMBLY Exploded View (EPS Models) 25-31 ft. lbs. (34-42 Nm) Spacer Thick Thick Thin Washers Washer Washer Thin Thin Washer Washer Upper Steering Shaft Bearing Steering Wheel Pivot Tube Spacer 7 ft. lbs. 15 ft.
Page 186: Upper Steering Shaft Removal (Eps Models)
BODY / STEERING / SUSPENSION Upper Steering Shaft Removal (EPS Models) Lift the steering wheel up and remove the (2) fasteners that retain the pivot tube. Remove the (2) Torx-head fasteners retaining the black plastic cover and remove the cover from the vehicle. Remove Remove the steering shaft, pivot tube and steering wheel from the vehicle as an assembly.
Page 187: Steering Wheel Removal (Eps Models)
BODY / STEERING / SUSPENSION Steering Wheel Removal (EPS Models) Using a large bronze drift and hammer, strike the steering shaft nut to pop the steering wheel off the shaft taper. 1. Remove the upper steering shaft, pivot tube and steering wheel as an assembly before attempting to remove the steering wheel.
Page 188 BODY / STEERING / SUSPENSION Remove the pinch bolt retaining the lower steering shaft to If replacing the power steering unit, remove the (4) bolts the power steering unit. that retain the power steering unit to the mount bracket. Remove Remove While supporting the power steering unit, remove the (4) WARNING...
Page 189: Power Steering Unit Installation
BODY / STEERING / SUSPENSION Lower Steering Shaft Removal (EPS Models) Power Steering Unit Installation 1. Use the steering wheel to position the front wheels so they If the power steering unit was removed from the mount point straight ahead. bracket, reinstall it prior to vehicle installation.
Page 190: Upper Steering Shaft Installation (Eps Models)
BODY / STEERING / SUSPENSION Torque the (4) mount bracket nuts to specification. Install the upper steering shaft and align the skip-tooth spline on the power steering stub shaft with the opening in the upper steering shaft. Shaft Opening 17 ft. lbs. (23 Nm) Skip-Tooth Install the pivot tube and torque fasteners to specification.
Page 191: Front A-Arms
BODY / STEERING / SUSPENSION FRONT A-ARMS 18. If not replacing the A-arm, thoroughly clean the A-arm and pivot tube. Removal / Replacement 19. Install new ball joint into A-arm. Refer to “Ball Joint Replacement” section. The following procedure details upper and lower A-arm removal and replacement on one side of the vehicle.
Page 192: Exploded View
BODY / STEERING / SUSPENSION Exploded View (RZR) Exploded View (RZR S / RZR 4) Upper Fastener Upper Fastener Bushings Pivot Pivot Tube Tube Upper Upper Grease A-arm A-arm Zerk Ball Joint Ball Joint Lower Fastener Grease Zerk Pivot Bushings Tube Lower Fastener Bushings...
Page 193: Ball Joint Service
BODY / STEERING / SUSPENSION BALL JOINT SERVICE Use a press and correct size driver to remove the ball joint from the A-arm. Removal Correct Driver Placement IMPORTANT: Do not reuse a ball joint if it has been removed for any reason. If removed, it must be replaced.
Page 194: Installation
BODY / STEERING / SUSPENSION Installation FRONT STABILIZER BAR (RZR / RZR S INT’L) Place the A-arm in the correct position for ball joint installation. Face the A-arm end flat on top of the driver. Carefully drive the ball joint into place until the ball joint Sway Bar Linkage Removal is properly seated.
Page 195: Exploded View
BODY / STEERING / SUSPENSION 5. Remove the (4) bolts retaining the lower radiator mount Lift up on the stabilizer bar and remove it from the vehicle. bracket and remove the bracket from the frame. 10. Inspect the stabilizer bar for straightness. Inspect the 6.
Page 196: Rear A-Arms
BODY / STEERING / SUSPENSION REAR A-ARMS WARNING Removal The locking agent on the existing bolts was destroyed during removal. DO NOT reuse old The following procedure details upper and lower A-arm hardware. Serious injury or death could result if removal and replacement on one side of the vehicle.
Page 197: Installation
BODY / STEERING / SUSPENSION 6. If not replacing the A-arm, thoroughly clean the A-arm and If not replacing the A-arm, thoroughly clean the A-arm and pivot tubes. pivot tubes. 7. Insert new A-arm bushings and pivot tubes into new A-arm. Insert new A-arm bushings and pivot tubes into new A-arm.
Page 198: Exploded View
BODY / STEERING / SUSPENSION Exploded View (RZR) Exploded View (RZR S / RZR 4) Upper Fastener Pivot Tube Upper Fastener Pivot Tube Upper Upper A-arm A-arm Lower Fastener Grease Bushings Zerk Bushings Bushings Lower Grease Fastener Bushings Zerk Pivot Pivot Tube Tube...
Page 199: Rear Stabilizer Bar (Rzr)
BODY / STEERING / SUSPENSION REAR STABILIZER BAR (RZR) Remove the stabilizer bar and bracket from the frame as an assembly. Removal / Installation 1. Remove the exhaust pipe and exhaust silencer from the vehicle. Remove Fasteners Inspect the stabilizer bar for straightness. Inspect the bushings and replace if needed.
Page 200: Rear Stabilizer Bar (Rzr S / Rzr 4)
BODY / STEERING / SUSPENSION REAR STABILIZER BAR (RZR S / RZR 4) Removal / Installation Remove the stabilizer bar from the bracket (bracket can remain attached to the frame). Remove the exhaust pipe and exhaust silencer from the vehicle. Leave bracket attached to frame.
Page 201: Decal Replacement
BODY / STEERING / SUSPENSION DECAL REPLACEMENT SHOCKS / SPRINGS / FASTENERS Exploded View (RZR / RZR S) WARNING Retainer gap should be 180° from spring end The following procedure involves the use of an open flame. Perform this procedure in a well ventilated area, away from gasoline or other flammable materials.
Page 202: Exploded View (Rzr 4)
BODY / STEERING / SUSPENSION Exploded View (RZR 4) Shock Replacement Using a spring compressor, compress the shock spring far enough to remove the spring retainer. Shock Spring Compressor Tool 2870623 Retainer gap Remove the spring and adjusting cam from the existing should be 180°...
Page 203: Fox™ Shock Exploded Views
BODY / STEERING / SUSPENSION FOX™ SHOCK EXPLODED VIEWS FOX™ PODIUM X ‘Piggyback’ Shock (RZR S) 18 ft. lbs. (24 Nm) Preload Ring 10 ft. lbs. (14 Nm) Ref. Description Ref. Description Shaft Preload Ring Body Preload Ring Body Cap Asm. Lock Nut Reservoir Bearing, External...
Page 204: Fox™ 2.0 'Piggyback' Shock (Rzr 4)
BODY / STEERING / SUSPENSION FOX™ 2.0 ‘Piggyback’ Shock (RZR 4) 18 ft. lbs. (24 Nm) ® Loctite 638™ / Primer N™ ® 100 ft. lbs. (136 Nm) Loctite 638™ / Primer N™ 50 ft. lbs. (68 Nm) Preload Ring 10 ft.
Page 205: Fox™ Shock Service
BODY / STEERING / SUSPENSION FOX™ SHOCK SERVICE General Service Information Recommended Service Intervals FOX™ Racing Shocks will perform the best if serviced at regular intervals: • Every ride - Wash and dry the vehicle and suspension • Every 100 hours - Visually inspect shock seals •...
Page 206 BODY / STEERING / SUSPENSION Rear Shock Service Information (RZR S) Rear Shock Service Information (RZR 4) SHOCK DESIGN DETAILS SHOCK DESIGN DETAILS Travel 6.22” Travel 6.22” Extended Length 21.34” Extended Length 21.34” IFP Location 3.40” IFP Location 3.40” Nitrogen Pressure 200 psi Nitrogen Pressure 200 psi...
Page 207: Fox™ Shock Rebuild Information
BODY / STEERING / SUSPENSION FOX™ Shock Rebuild Information Special Tools Required: When performing maintenance on FOX™ shocks, use the Gas Body Holding Tool (PN 2871071) Shock Recharging Kit (PN 2200421), as it contains the Charging Needle (PN 7052069-A) necessary valves, pressure gauge, and fittings to deflate and Gas Shock Recharging Kit (PN 2200421) pressurize shocks.
Page 208: Fox™ Shock Disassembly
BODY / STEERING / SUSPENSION FOX™ Shock Disassembly Figure 2 NOTE: Read through all of these instructions first to familiarize yourself with the rebuild procedure. Make sure you have a clean work area, and all of the necessary tools are available. Always use proper safety equipment when...
Page 209 BODY / STEERING / SUSPENSION 12. Clamp the body cap of the shock securely in vise with shaft 17. Align the slot of the IFP Depth Setting Tool with the end side up. of the IFP (Internal Floating Piston). Engage the IFP by rotating the tool 90 degrees (Fig.
Page 210: Fox™ Shock Rebuild
BODY / STEERING / SUSPENSION Figure 9 Figure 7 Thoroughly clean the bearing housing, and piston assembly 24. Slide bearing assembly off of shaft. Use extreme caution with solvent. Dry with compressed air in a well ventilated not to scratch inside of the bearing assembly when passing area.
Page 211: Fox™ Shock Reassembly
Shock oil will come up through the IFP bleed hole. FOX™ Shock Reassembly Polaris Gas Shock Oil - 5 wt. 1. Clamp shaft eyelet securely in vise, and place seal bullet PN 2870995 - qt. tool on end of shaft.
Page 212 BODY / STEERING / SUSPENSION 12. Fill shock body to the bottom of bearing threads with oil. 20. Add oil to the body tube until the surface of the oil is to the top of the threads inside the body tube. 13.
Page 213 BODY / STEERING / SUSPENSION 34. Continue charging with gas as you pull the reservoir away Figure 17 from the FOX™ Nitrogen Safety Needle using a smooth, straight motion. Keep the reservoir as straight as possible to prevent the safety needle from bending. As the safety needle is pulled free from the FOX™...
Page 214: Walker Evans™ Shock Exploded View
BODY / STEERING / SUSPENSION WALKER EVANS™ SHOCK EXPLODED VIEW Walker Evans™ Compression Adjuster Reservoir Shock (RZR L.E.) Ref. Description Ref. Description Piggyback Knob Body Body, Reservoir Seal, Head Cap, End Seal, Head Piston, Reservoir Bushing, Shaft Valve O-Ring Bumper Seal Washer Wiper, D-Type...
Page 215: Walker Evans™ Shock Service
BODY / STEERING / SUSPENSION WALKER EVANS™ SHOCK SERVICE Recommended Service Intervals Walker Evans™ Racing Shocks will perform the best if serviced at regular intervals: • Every ride - Wash and dry the vehicle and suspension • Every 100 hours - Visually inspect shock seals •...
Page 216: Walker Evans™ Shock Rebuild Information
BODY / STEERING / SUSPENSION Walker Evans™ Shock Rebuild Information Special Tools When performing maintenance on Walker Evans™ shocks, use Special Tools the Gas Shock Recharging Kit (PN 2200421), as it contains the necessary valves, pressure gauge, and fittings to deflate and PART NUMBER DESCRIPTION pressurize shocks.
Page 217: Walker Evans™ Shock Disassembly
BODY / STEERING / SUSPENSION Walker Evans™ Shock Disassembly Using a snap ring pliers, remove the retaining ring from the reservoir. IMPORTANT: To prevent damage or marks to the shock, the use of soft jaws on a vise is recommended. WARNING Walker Evans™...
Page 218 BODY / STEERING / SUSPENSION Slowly lift up and remove the shock rod assembly from the IMPORTANT: Seal kits are available and should be installed at this time if seals or O-rings are damaged shock body. or worn. 12. Place the shock rod in a vise so the threaded part is facing up.
Page 219: Walker Evans™ Shock Assembly
BODY / STEERING / SUSPENSION 16. Using a 9/16" socket w/extension, remove the fastener Place a new lock nut onto the shock rod. Torque the new retaining the clicker valve stack. Place the valve stack on a lock nut to specification. clean shop towel in order of removal.
Page 220 BODY / STEERING / SUSPENSION Turn the compression adjuster knob counter-clockwise Using a 3/32" Allen wrench, remove the IFP bleed screw. (soft) until it stops, so damping is in the full open position. 10. Apply a thin film of oil to the IFP O-ring and wear band. Insert the IFP into the reservoir until it is completely Secure the shock body in a vise by its lower mount.
Page 221 BODY / STEERING / SUSPENSION NOTE: During installation, some shock oil will over 13. Pull the IFP up until its top is approximately 1" (2.54 cm) flow. Wrap a shop cloth around the shock body to from the top of the reservoir and remove the IFP Tool. Using a 3/32"...
Page 222 BODY / STEERING / SUSPENSION 25. Install the reservoir cap. Push down on the reservoir cap WARNING using even pressure until the retaining ring groove is exposed. CHARGE THE SHOCK USING NITROGEN 26. Install the retaining ring and check to make sure retaining GAS ONLY.
Page 223 CLUTCHING CHAPTER 6 CLUTCHING SPECIAL TOOLS AND SUPPLIES ......... . 6.2 TORQUE SPECIFICATIONS.
Page 224: Special Tools And Supplies
The internal components of the drive clutch and driven clutch control engagement (initial vehicle movement), clutch upshift and backshift. During the development of the Polaris vehicle, the PVT system is matched first to the engine power curve; then TORQUE SPECIFICATIONS to average riding conditions and the vehicle’s intended usage.
Page 225: Driven Clutch Operation
CLUTCHING Driven Clutch Operation Maintenance / Inspection Under normal use the PVT system will provide years of trouble Driven clutches primarily sense torque, opening and closing free operation. Periodic inspection and maintenance is required according to the forces applied to it from the drive belt and the to keep the system operating at peak performance.
Page 226: Overheating / Diagnosis
10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Clutch component inspection should be performed by a Polaris MSD certified Clutch malfunction. technician.
Page 227: Pvt System Service
CLUTCHING PVT SYSTEM SERVICE PVT Covers and Ducting Components Clutch Push Clamps Inlet Duct Rivets Boot Clutch Boot Outlet Duct Cover Screws Clamp Clamps Bolt & Washer Inner Clutch Cover Retainer Outer Screws Outer Cover Seal Clutch Cover...
Page 228: Pvt Disassembly
CLUTCHING PVT Disassembly • RZR 4: Slide the rear seat base towards the left side of the vehicle to free it from the plastic and remove it. Some fasteners and procedures will vary. Refer to the Electronic Parts Catalog for proper fastener placement. Remove the driver’s seat (RZR / RZR S only).
Page 229: Pvt Assembly
CLUTCHING PVT Assembly 10. Install the Drive Clutch Holder (PN 9314177) (A). 11. Remove drive clutch retaining bolt and remove drive clutch Inspect inner clutch cover. Replace if cracked or damaged. using the Drive Clutch Puller (PA-48595) (B). Inspect the seal on the transmission input shaft. Replace if damaged.
Page 230: Clutch Offset Procedure
CLUTCHING Clutch Offset Procedure 11. Clean end of taper on crankshaft and the taper bore inside drive clutch. If the vehicle exhibits drive clutch drag or hard shifting while at idle speed, a clutch offset adjustment is required. Washers 12. Install drive clutch and torque retaining bolt to located behind the driven clutch on the transmission input shaft specification.
Page 231 CLUTCHING 4. Reinstall the driven clutch and drive belt. Torque the driven Install the outer clutch cover and torque the cover screws clutch retaining bolt to 17 ft. lbs. (23.5 Nm). Be sure to to 45-50 in. lbs. (5-5.6 Nm). rotate the driven clutch counterclockwise several times to Install the clutch cover outlet duct and tighten the clamps.
Page 232: Drive Belt
CLUTCHING DRIVE BELT Belts with thin spots, burn marks, etc., should be replaced to eliminate noise, vibration, or erratic PVT operation. See Belt Removal the Troubleshooting Chart at the end of this chapter for possible causes. Remove outer clutch cover as described in the “PVT Disassembly”...
Page 233: Drive Clutch Service
CLUTCHING DRIVE CLUTCH SERVICE Spring Specifications The drive clutch spring has two primary functions: 1. To control clutch engagement RPM. The springs, which have a higher rate when the clutch is in neutral, will increase clutch engagement RPM. 2. To control the rate at which the drive belt moves Red/White 7043349 upward in the drive clutch sheaves.
Page 234: Shift Weights
CLUTCHING Shift Weights Shown below are the shift weights which have been designed for the PVT system. These shift weights have many factors designed into them for controlling engagement RPM and shifting patterns. Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to sheave clearance, clutch balance and shifting pattern.
Page 235: Clutch Disassembly
CLUTCHING Clutch Disassembly Inspect area on shaft where bushing rides for wear, galling, nicks, or scratches. Replace clutch assembly if worn or 1. Using a permanent marker, mark the cover, spider, and damaged. moveable and stationary sheaves for reference, as the cast in X's may not have been in alignment before disassembly.
Page 236: Roller, Pin, And Thrust Washer Inspection
CLUTCHING Roller, Pin, and Thrust Washer Inspection NOTE: It is important that the same number and thickness of washers are reinstalled beneath the Inspect all rollers, bushings and roller pins by pulling a flat spider during assembly. Be sure to note the number metal rod across the roller.
Page 237: Button To Tower Clearance Inspection
CLUTCHING Button To Tower Clearance Inspection Remove shift weight bolts and weights. Inspect the contact surface of the weight. The surface should be smooth and 1. Inspect for any clearance between spider button to tower. free of dents or gall marks. Inspect the weight pivot bore If clearance exists, replace all buttons and inspect surface and pivot bolts for wear or galling.
Page 238: Clutch Inspection
CLUTCHING Clutch Inspection Inspect surface of shaft for pitting, grooves, or damage. Measure outside diameter compare NOTE: Remove cover, spring, and spider following specifications. Replace the drive clutch assembly if shaft is instructions for drive clutch removal, then proceed worn or damaged. as follows: Remove the moveable sheave spacer sleeve (1) and the thrust washer (2).
Page 239: Moveable Sheave Bushing Inspection
CLUTCHING Moveable Sheave Bushing Inspection Bushing Service IMPORTANT: Special Tools Required Inspect the Teflon coating (arrow) on the moveable sheave bushing. Inspect both sheaves for signs of wear, grooving or EBS Clutch Bushing Tool Kit - 2201379 cracking. De-glaze sheave surfaces with a 3M Scotch-Brite Pad if needed.
Page 240 CLUTCHING NOTE: Use Bushing Tool PA-47336. CAUTION Install nut (C) onto end of puller rod and hand tighten. Turn puller barrel to increase tension on sheave if needed. Using Clutch components will be hot! In order to avoid a hand held propane torch, apply heat around outside of serious burns, wear insulated gloves during the bushing until tiny smoke tailings appear.
Page 241: Clutch Assembly
CLUTCHING Cover Bushing Removal Clutch Assembly 1. Install main adapter (Item 8) on puller. NOTE: It is important that the same number and thickness of washers are reinstalled beneath the Removal Tool Nut (C) spider during assembly. The Teflon bushings are self-lubricating.
Page 242 CLUTCHING Torque spider to specification using the holding fixture and spider tool. Torque with smooth motion to avoid damage to the stationary sheave. Spider Torque: 200 ft. lbs. (271 Nm) CAUTION Be sure the spider spacer washers are fully seated in the recessed area in the spider. Any misalignment will alter clutch balance.
Page 243: Driven Clutch Service
CLUTCHING DRIVEN CLUTCH SERVICE Exploded View Compression Spring Spacer Outer Stationary Spring Retainer Secondary Sheave Inner Retaining Spring Retainer Ring Moveable Secondary Sheave Clutch Disassembly / Inspection Place the clutch into the Clutch Compression Tool PN CAUTION 8700220. Using Compression Extensions PN PS-45909, apply and hold downward pressure on the outer spring retainer.
Page 244 CLUTCHING With the snap ring (A) removed and spring pressure Remove the inner spring retainer from the inner sheave. relieved, remove the outer spring retainer (B), compression Inspect for wear and replace as needed. spring (C), spacer (D), and inner spring retainer (E). Inspect for Abnormal Wear Check the rollers in the stationary sheave for wear.
Page 245: Clutch Assembly
CLUTCHING 10. Inspect the Teflon™ coating on the moveable sheave bearings. 11. Inspect driven clutch sheave faces for wear or damage. 12. Clean and inspect splines on helix and transmission input shaft. 13. Lube splines with a light film of grease. Do not lubricate the bearings! Clutch Assembly Assemble Sheaves...
Page 246: Troubleshooting
CLUTCHING TROUBLESHOOTING Situation Probable Cause Remedy -Wrong or broken drive clutch spring. -Replace with recommended spring. Engine RPM below specified operating -Drive clutch shift weight too heavy. -Install correct shift weight kit to match engine range, although application. engine is properly tuned.
Page 247 CLUTCHING Troubleshooting, Continued..Situation Probable Cause Remedy -Plugged air intake or outlet. -Clear obstruction -Belt slippage due to water, oil, grease, etc., rubbing -Inspect system. Clean , repair or replace as necessary. on cover. Seal PVT system ducts. PVT cover -Clutches or weight being applied to cover while in -Remove weight.
Page 248 CLUTCHING NOTES 6.26...
Page 249 FINAL DRIVE CHAPTER 7 FINAL DRIVE SPECIAL TOOLS ............7.2 TORQUE SPECIFICATIONS.
Page 250: Special Tools
FINAL DRIVE SPECIAL TOOLS FRONT BEARING CARRIER Bearing Carrier Inspection / Removal PART NUMBER TOOL DESCRIPTION Elevate front of vehicle and safely support machine under 2872608 Roll Pin Removal Tool the frame area. CV Boot Clamp Pliers 8700226 (earless type) CAUTION PU-48951 Axle Boot Clamp Tool...
Page 251: Bearing Replacement
FINAL DRIVE Bearing Replacement 6. Remove the two front brake caliper mounting bolts and remove the caliper from the brake disc (see Chapter 9). Bearing Removal CAUTION: Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. Remove the outer snap ring.
Page 252: Bearing Carrier Installation
FINAL DRIVE Bearing Installation Install pinch bolts and torque to specification. Thoroughly clean the front bearing carrier housing and the outer race on the new bearing. Be sure that all oil residue has been removed from each surface. Support the bottom of the bearing carrier housing. CAUTION 23 ft.
Page 253 FINAL DRIVE Torque wheel hub nut to specification and install a new cotter pin. Tighten nut slightly if necessary to align cotter pin holes. Front Caliper Mounting Bolts: 80 ft. lbs. 31-34 ft. lbs. (42-46 Nm) (108 Nm) CAUTION New bolts have a pre-applied locking agent which is destroyed upon removal.
Page 254: Front Drive Shaft
FINAL DRIVE FRONT DRIVE SHAFT Remove the upper ball joint pinch bolt. Drive Shaft Removal Pinch Bolt Elevate front of vehicle and safely support machine under the frame area. CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure.
Page 255: Drive Shaft / Cv Joint Handling Tips
FINAL DRIVE Drive Shaft / CV Joint Handling Tips Make sure the circlip remains on the shaft and not left in the joint. Discard the circlip as it will be replaced. Care should be exercised during drive shaft removal or when Circlip servicing CV joints.
Page 256: Inner Plunging Joint / Boot Replacement
FINAL DRIVE Inner Plunging Joint / Boot Replacement 11. Slide the joint onto the drive shaft splines and align the circlip with the lead-in chamfer on the inner race. Remove the front drive shaft from the vehicle (see “FRONT DRIVE SHAFT - Removal”). 12.
Page 257 FINAL DRIVE 12. Grease the joint with the special joint grease provided in the 21. Position the boot lip in its groove. Install and secure the boot replacement kit. Fill the cavity behind the balls and the boot with the large clamp using the “earless” clamp pliers. splined hole in the joint’s inner race.
Page 258: Drive Shaft Installation
FINAL DRIVE Drive Shaft Installation Install the upper pinch bolt and torque to specification. Install new spring ring on drive shaft. Apply an anti-seize 23 ft. lbs. compound to splines. (31 Nm) Spring Ring RZR / RZR S Apply Shown Anti-Seize Align splines of drive shaft with front gearcase and reinstall 23 ft.
Page 259: Propshaft Service
FINAL DRIVE PROPSHAFT SERVICE 8. Torque wheel hub nut to specification and install a new cotter pin. Tighten nut slightly if necessary to align cotter pin holes. Removal / Installation (RZR / RZR S) Locate the propshaft roll pin and use the Roll Pin Removal 80 ft.
Page 260: Removal / Installation (Rzr 4)
FINAL DRIVE Remove the fasteners retaining the plastic skid plate and Remove the fasteners retaining the center console to access remove the skid plate from the vehicle. the propshaft support bearing. Torx Screw Screws Torx Screws Cupped Washers Torx Screws Screws Remove the propshaft from the vehicle.
Page 261: Support Bearing Replacement (Rzr 4)
FINAL DRIVE Support Bearing Replacement (RZR 4) 9. If removing the rear portion of the propshaft, remove the bearing support (upper & lower half) from the shaft. Follow steps 1-8 of the “Removal / Installation (RZR 4)” procedure. 10. Remove the fasteners retaining the front plastic skid plate to allow for propshaft removal.
Page 262: Propshaft U-Joint Service
FINAL DRIVE ® ™ PROPSHAFT U-JOINT SERVICE Apply Loctite to the set screw threads and torque the (2) bearing set screws to specification. Disassembly 65-75 in. lbs. Remove internal or external snap ring from bearing caps. (7.3-8.4 Nm) CAUTION Always wear eye protection. Retaining Ring Bearing Set Screws:...
Page 263 FINAL DRIVE 3. Support U-joint in vise as shown and drive inner yoke down Using a suitable arbor, fully seat the bearing cap in one side. to remove remaining bearing caps. Continually check for free movement of bearing cross as bearing caps are assembled.
Page 264: Front Gearcase / Centralized Hilliard
FINAL DRIVE FRONT GEARCASE / CENTRALIZED HILLIARD Centralized Hilliard Exploded View 8-10 ft. lbs. (11-14 Nm) 8-10 ft. lbs. (11-14 Nm) 7-11 ft. lbs. (10-15 Nm) ESCRIPTION ESCRIPTION O-Ring Hub Sub-Assembly (Female) O-Ring Hub Sub-Assembly (Male) Dowel Pin Rollers Vent Hose Fitting Torsion Spring Ball Bearing Spring, Wireform...
Page 265: All Wheel Drive Operation
FINAL DRIVE All Wheel Drive Operation AWD Engagement: When the AWD switch is activated, the AWD coil is powered by a 12 Vdc input which creates a The AWD switch may be turned on or off while the vehicle is magnetic field.
Page 266: Awd Diagnosis
FINAL DRIVE AWD Diagnosis Check to make sure the coil is seated in the U-shaped insert that is pressed into the gearcase cover. The top of the coil Symptom: AWD Will Not Engage should be seated below the U-shaped insert. The U-shaped insert controls the pole gap.
Page 267 FINAL DRIVE Gearcase Removal Remove the gearcase from the front LH wheel well area and slide it between the upper and lower A-arm. 1. Stop engine and place gear selector in Park. 2. Refer to “FRONT DRIVE SHAFT - Drive Shaft Removal” and remove both front drive shafts from the front gearcase.
Page 268 FINAL DRIVE Remove the LH output hub assembly from the clutch Remove the torsion spring retainer and torsion spring from housing or outer cover plate assembly. the top of the ring gear. Spring Retainer LH Output Hub Non-serviceable Torsion Spring DO NOT Remove LH Output Hub NOTE: Nylon spacer is non-serviceable and should...
Page 269 FINAL DRIVE 7. Remove the RH output hub assembly from the gearcase 10. Inspect the AWD coil located in the outer cover plate housing. assembly. Refer to “AWD Diagnosis” for detailed inspection process. Replace the cover plate seal and O-ring. Inspect Coil Replace...
Page 270: Gearcase Assembly
FINAL DRIVE Gearcase Assembly 14. Inspect the roll cage assembly (B) sliding surfaces and H- springs. The sliding surfaces must be clean and free of As mentioned during gearcase disassembly section, nicks, burrs or scratches. If damaged, replace the roll cage replace all O-rings, seals and worn components.
Page 271 FINAL DRIVE NOTE: Install the roll cage so that the ring gear Check the action of the torsion spring by rotating in both grooves line up with the roll cage slots (see below). directions to ensure the spring and retainer are installed properly.
Page 272: Gearcase Installation
FINAL DRIVE Gearcase Installation 11. Install a new O-ring on the cover plate assembly. Install the gearcase back into the vehicle through the LH NOTE: Be sure the square O-ring is placed flat on wheel well area, between the upper and lower A-arms. the cover surface.
Page 273 Installation” and install both front drive shafts into the gearcase. 7. Add the proper lubricant to the front gearcase. Refer to Chapter 2 for fluid fill and change information. Polaris Demand Drive Plus (PN 2877922) Front Housing Capacity 6.75 fl. oz. (200 ml)
Page 274: Rear Bearing Carrier
FINAL DRIVE REAR BEARING CARRIER Remove the rear wheel hub assembly. Bearing Carrier Inspection / Removal Elevate rear of vehicle and safely support machine under the frame area. CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure.
Page 275: Bearing Replacement
FINAL DRIVE NOTE: Due to extremely close tolerances and Bearing Installation minimal wear, the bearings must be inspected Thoroughly clean the rear bearing carrier housing and the visually, and by feel. While rotating bearings by outer race on the new bearing. Be sure that all oil residue hand, inspect for rough spots, discoloration, or has been removed from each surface.
Page 276: Bearing Carrier Installation
FINAL DRIVE Bearing Carrier Installation Install rear wheel hub assembly, cone washers, and hand tighten the castle nut. Install washers with domed side out. Install drive shaft axle through the backside of the bearing Cone Washers carrier. Be sure bushings and pivot tubes are installed. Wheel Install brake caliper mounting bolts and torque to 18 ft.
Page 277: Rear Drive Shaft
FINAL DRIVE Torque wheel hub nut to 80 ft. lbs. (108 Nm) and install a Remove the cotter pin and loosen the rear wheel hub castle NEW cotter pin. Tighten nut slightly if necessary to align nut. Remove the nut, and (2) cone washers from the rear cotter pin holes.
Page 278: Outer Cv Joint / Boot Replacement
FINAL DRIVE Outer CV Joint / Boot Replacement Remove the bolt that attaches the rear bearing carrier to the upper A-arm. Using a side cutters, cut away and discard the boot clamps. Slide the rear drive shaft out of the bearing carrier by Remove the large end of the boot from the CV joint and pulling the bearing carrier assembly outward and tipping it slide the boot down the shaft.
Page 279 FINAL DRIVE NOTE: Shiny areas in ball tracks and on the cage 5. Make sure the circlip is on the shaft and not left in the joint. spheres are normal. Do not replace CV joints because parts have polished surfaces. Replace CV Circlip joint only if components are cracked, broken, worn or otherwise unserviceable.
Page 280 FINAL DRIVE 13. Slide the joint onto the drive shaft splines and align the 19. While pulling out on the CV shaft, slide a straight O-ring circlip with the lead-in chamfer on the inner race of the pick or a small slotted screw driver between the small end joint.
Page 281: Inner Plunging Joint / Boot Replacement
FINAL DRIVE Inner Plunging Joint / Boot Replacement Make sure the circlip is on the shaft and not left in the joint. 1. Using a side cutters, cut away and discard the boot clamps. Circlip Remove the boot from the shaft. 2.
Page 282 FINAL DRIVE 11. Install a NEW circlip on the end of the shaft. 17. Remove excess grease from the plunging joint’s external surfaces and place the excess grease in the boot. 12. Grease the joint with the special joint grease provided in the 18.
Page 283 FINAL DRIVE Drive Shaft Exploded View Drive Shaft Installation Install new spring ring on drive shaft. Apply anti-seize REAR SHAFT compound to splines. RZR S / RZR 4 Spring Ring Spring Ring Plunging Joint Spring Ring Apply Large Clamp Anti-Seize Grease Pack Gear Side Align splines of drive shaft with rear gearcase and reinstall...
Page 284 FINAL DRIVE Lift bearing carrier into place and install the bolt attaching the bearing carrier to the upper A-arm. Torque fastener to specification. Rear Caliper Mounting Bolts: 18 ft. lbs. (24 Nm) CAUTION New bolts have a pre-applied locking agent which is destroyed upon removal.
Page 285: Rear Gearcase
FINAL DRIVE REAR GEARCASE Remove the (2) rear gearcase mount bracket fasteners and mount bolt and remove bracket from vehicle. Gearcase Removal 1. Drain the fluid from the rear gearcase and remove the rear drive shafts from each side of the rear gearcase. See “REAR DRIVE SHAFT”...
Page 286: Gearcase Disassembly
FINAL DRIVE Pull the rear gearcase towards the rear of the vehicle to disengage it from the transmission. NOTE: If the splined coupler doesn’t slide off the input shaft on the rear gearcase, use a screwdriver to hold back the coupler while pulling the rear gearcase back further to disengage it.
Page 287 FINAL DRIVE 5. Inspect the ring gear for chipped, worn, or broken teeth. If Remove the input shaft seal using a seal puller or other damaged, replace the gearcase assembly. suitable method. Inspect NOTE: In the event damage to the gears or housing Inspect the input shaft by rotating the assembly in the requires replacement, the entire assembly must be gearcase housing while checking for any looseness or...
Page 288: Gearcase Assembly
FINAL DRIVE Gearcase Assembly If removed, install each axle spool bearing race using standard bearing installation tools and an arbor press. Install a new input shaft seal using a standard seal installer or other suitable method. Install new seals on each side of the gearcase housing using a standard seal installer or other suitable method.
Page 289: Gearcase Installation
6. Install the gearcase cover. Verify the O-ring is in position. Install the cover screws onto the rear gearcase. Torque to specification. Add Polaris ATV Angle Drive Fluid to rear gearcase. Refer to maintenance information in Chapter 2 for more details. Torque drain and fill plugs to specification.
Page 290: Gearcase Exploded View
FINAL DRIVE Gearcase Exploded View 23-27 ft. lbs. (31-37 Nm) 23-27 ft. lbs. (31-37 Nm) 70-80 ft. lbs. (95-108 Nm) 40 ft. lbs. (54 Nm) 23-27 ft. lbs. (31-37 Nm) 30-45 in. lbs. (3-5 Nm) ESCRIPTION ESCRIPTION Screw Axle, Spool Screw O-Ring Bracket, Rear Mount, RH...
Page 291: Rear Gearcase (Rzr S Int'l)
FINAL DRIVE REAR GEARCASE (RZR S INT’L) Shift Yoke Clutch Gear General Operation The RZR S INT’L rear gearcase has three traction operational modes: AWD, Differential Lock, and Differential Unlock. Locking the rear differential is beneficial in low traction and rough terrain conditions.
Page 292: Gearcase Removal
FINAL DRIVE Gearcase Removal When the clutch gear is unlocked the rear drive shafts are dependent on the differential allowing tighter turns. When it’s Drain the fluid from the rear gearcase and remove the rear locked it becomes a solid rear axle increasing traction. drive shafts from each side of the rear gearcase.
Page 293: Gearcase Disassembly
FINAL DRIVE Gearcase Disassembly 5. Disconnect the differential solenoid 2-wire harness. IMPORTANT: The pinion gear assembly is NOT 6. Remove the fasteners and bracket that secure the rear intended to be disassembled from the case, as it gearcase to the transmission. requires special OEM tooling in order to properly reassemble.
Page 294 FINAL DRIVE Remove the differential assembly from the housing. Remove the shim(s) from the differential assembly. Be sure to keep the shims together for reassembly. Inspect the ring gear and differential gears for chipped, worn, or broken teeth. Remove the bearing from the lower portion of the differential assembly.
Page 295 FINAL DRIVE 9. Inspect each differential bearing and race for signs of wear 12. Inspect the pinion shaft by rotating the assembly in the or damage. If bearing replacement is required, use standard gearcase housing while checking for any looseness or bearing puller tools to remove the bearing races.
Page 296 FINAL DRIVE 15. Remove the clutch gear from the gearcase. 18. Carefully remove the shift yoke assembly from the gearcase cover. 16. Inspect the shift lever (A), shift lever spring (B), shift return springs (C), and shift yoke (D) for excessive wear or 19.
Page 297: Differential Disassembly
FINAL DRIVE Differential Disassembly Use a scribe to mark the ring gear and differential case. Remove the (8) bolts that secure the ring gear to the 1. Use a scribe to mark the differential cover and case. differential and allow the ring gear to slide down and off. Remove the (10) screws retaining the differential cover.
Page 298: Differential Assembly
FINAL DRIVE Inspect the gears, thrust washers and differential case for Install the side differential gears and thrust washers and excessive wear or damage. Replace components if needed. slide the cross pin into position with the hole side facing the hole in the differential case.
Page 299: Gearcase Assembly
If previously removed; assembly the shift lever (A), shift NOTE: Grease all seals and O-rings with Polaris All lever spring (B), shift return springs (C), shift yoke (D), and Season Grease (PN 2871322) upon assembly.
Page 300 FINAL DRIVE Carefully install the shift yoke assembly into the gearcase. 11. Install the differential assembly into the gearcase housing and install a new lightly greased O-ring onto the cover. O-Ring Install the shift yoke assembly with the shift return springs (C), facing down in the housing.
Page 301: Gearcase Installation
Refer to the “Installation” procedure listed on page 4.14. Special Tool PA-48873 2. Add Polaris ATV Angle Drive Fluid to rear gearcase. Refer to maintenance information in Chapter 2 for more details. Torque drain and fill plugs to specification. Rear Gearcase Capacity: 22 fl.
Page 302: Gearcase Exploded View
FINAL DRIVE Gearcase Exploded View 70-80 ft. lbs. (95-108 Nm) 130-155 in. lbs. (15-18 Nm) 30-40 ft. lbs. (41-54 Nm) 23-27 ft. lbs. (31-37 Nm) 40 ft. lbs. (54 Nm) 23-27 ft. lbs. 30-45 in. lbs. (31-37 Nm) (3-5 Nm) ESCRIPTION ESCRIPTION Screw...
Page 303: Wheel Hubs
FINAL DRIVE WHEEL HUBS Front Hub Exploded View Sealed Ball Bearing Bolts Wheel Hub Front Rim Cone (Aluminum) Bearing Washers Front Tire Cotter Pin Carrier Wheel Nuts Retaining 30 ft. lbs. Ring + 90° (1/4 turn) Brake Disc Studs Castle Nut 80 ft.
Page 304 FINAL DRIVE NOTES 7.56...
Page 305 TRANSMISSION CHAPTER 8 TRANSMISSION TORQUE VALUES / SPECIFICATIONS ........8.2 SHIFT LEVER .
Page 306: Torque Values / Specifications
TRANSMISSION TORQUE VALUES / SPECIFICATIONS SHIFT LEVER Removal Maintain and check/change these items in accordance with the maintenance schedule in Chapter 2 or during service repairs. Pry the shift lever cover using a suitable tool and remove the screw. Pull knob off the shifter. ITEM TORQUE VALUE Transmission Fill Plugs...
Page 307: Shift Cable Inspection / Adjustment
TRANSMISSION Shift Cable Inspection / Adjustment Adjust the shift cable so there is the same amount of cable travel when shifting slightly past the detents of HIGH (H) Shift cable adjustment may be necessary if symptoms include: gear and PARK (P). •...
Page 308: Transmission Service
TRANSMISSION TRANSMISSION SERVICE Remove the (7) fasteners retaining the transmission to rear gearcase mount bracket. Transmission Removal / Service Notes Note the number or thickness of shims for The engine, transmission and rear differential are bolted reassembly purposes. together as a unit. Removal of the transmission is not possible without removing the engine and differential.
Page 309 TRANSMISSION 8. After removing the cover, remove the intermediate shaft 10. Remove the intermediate pinion shaft assembly from the bearing cup and shims from the cover. Bearing cup is a slip- housing. Check bearings and gear teeth for wear or damage fit.
Page 310 TRANSMISSION 13. Remove the front output pinion shaft assembly. The shaft 15. Remove the lower snap ring from under the gear. can be disassembled as shown using a press and standard bearing removal tools. 16. Remove the intermediate shaft seal using a seal puller or other suitable method.
Page 311: Transfer Case Reassembly
TRANSMISSION Transfer Case Reassembly Install the shims, bearing cup and alignment dowels into the retaining bracket. 1. Install the intermediate shaft seal (circled) flush or slightly below the case. Install circlips and gear onto the input intermediate shaft as shown. Install a new output shaft seal flush with the case.
Page 312 TRANSMISSION Reinstall the intermediate pinion shaft assembly and Install the transfer case cover. Align the dowels (#1 & #7) bearing cup. and insert the cover screws (note position of the longest screw #4). Torque the screws evenly to specification in sequence as shown.
Page 313: Transmission Shift Housing Disassembly
TRANSMISSION Transmission Shift Housing Disassembly Place the transmission shift housing onto a flat surface as shown. Lift the transmission case half straight up and IMPORTANT: Shift housing repairs are not possible remove. without performing transfer case disassembly. Read and understand all instructions before beginning disassembly.
Page 314 TRANSMISSION Remove the (5) screws retaining the park flange. Inspect the Remove the input shaft seal and clutch intermediate shaft park flange for wear or damage. Replace if needed. seal using a seal puller or punch. Remove the (2) screws that attach the gear position sensor to the shift housing.
Page 315 TRANSMISSION 10. Remove the spacer, contact pins, springs, drum gear and 13. Pull back fully on gear selector arm to bring shift collar up washer from the shift housing. Replace any worn or and disengage the shift collar from the clutch yoke. Lifting damaged components.
Page 316 TRANSMISSION 19. Remove the clutch shaft assembly from the housing. The 22. Locate the retaining ring on the shifter assembly and move forward gear assembly and bearings will remain on the the retaining ring out of the groove to allow the shifter shaft upon removal.
Page 317: Transmission Shift Housing Reassembly
TRANSMISSION Transmission Shift Housing Reassembly 26. Remove the screw from the end of the shift cable lever and remove the shifter assembly from the housing. Install a new shift cable lever seal and press it flush with the case. Apply lubricant to the seal lip. Lubricate the shaft of the shifter assembly and install the assembly into the housing with a new retaining ring and washer.
Page 318 TRANSMISSION Install the input shaft assembly into the transmission housing. Pivot Pin Set Screw: 100-125 in. lbs. (11-14 Nm) Assemble the clutch shaft with new needle bearings. Press a new ball bearing onto the end of the shaft and install a new retaining ring.
Page 319 TRANSMISSION 10. Install the shift collar onto the clutch shaft. Pull back fully 12. With the transmission in neutral, lubricate and install the on gear selector arm to bring the shift yoke arms up and thrust washer, drum gear, plate, springs, contact pins and engage the shift shoes onto the center groove of the shift the gear position sensor/O-ring assembly.
Page 320 TRANSMISSION 14. Install the reverse idler lower washer, needle bearing, gear, 17. Install the reverse clutch assembly onto the park flange. upper washer and retaining ring onto the idler shaft. Note the orientation of the needle bearing. 15. Install a new shaft bearing (if required). 18.
Page 321 TRANSMISSION 20. Place the transmission shift housing onto a flat surface as 22. Install the (2) shift housing case screws to the backside as shown. Apply a bead of crankcase sealant onto the mating shown. Torque to specification. surfaces. Align the dowels and install the transmission case NOTE: Shift cable bracket installation is required.
Page 322: Troubleshooting
TRANSMISSION TROUBLESHOOTING Troubleshooting Checklist Check the following items when shifting difficulty is encountered: • Idle speed adjustment • PVT alignment • Transmission oil type/quality • Transmission torque stop adjustment (where applicable) • Engine torque stop adjustment (where applicable) • Drive belt deflection •...
Page 323: Transmission Exploded View
TRANSMISSION TRANSMISSION EXPLODED VIEW Shift Housing / Transfer Case Exploded View 8.19...
Page 324 TRANSMISSION NOTES 8.20...
Page 325 BRAKES CHAPTER 9 BRAKES GENERAL SPECIFICATIONS..........9.2 TORQUE SPECIFICATIONS.
Page 326 BRAKES GENERAL SPECIFICATIONS FRONT BRAKE SYSTEM Item Standard Service Limit RZR / RZR S: .300 ± .007" (7.62 ± .178 mm) Front Brake Pad Thickness .180" (4.6 mm) RZR 4: .297 ± .007" (7.54 ± .178 mm) Front Brake Disc Thickness .188"...
Page 327: Brake System Service Notes
BRAKES BRAKE SYSTEM SERVICE NOTES Disc brake systems are light weight, low maintenance, and perform well in the conditions this vehicle will routinely encounter. There are a few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function and maximum pad service life.
Page 328: Hydraulic Brake System Operation
Never overfill the reservoir! Do not fill the reservoir beyond the MAX LEVEL line! When servicing Polaris brake systems use only Polaris DOT 4 Brake Fluid (PN 2872189). WARNING: Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws.
Page 329: Brake System Exploded View
BRAKES BRAKE SYSTEM EXPLODED VIEW RZR / RZR S / RZR S INT’L LH Rear Line LH Front Brake Line Brake Switch Cross Master Cylinder Fitting Front Calipers Rear Calipers MC Rear Brake Line RH Rear Line RH Front Brake Line Caliper Banjo Style Fittings: Master Cylinder Side View 15 ft.
Page 330: Master Cylinder
BRAKES MASTER CYLINDER NOTE: Make note of front and rear brake line locations to master cylinder. Removal Loosen the brake line banjo bolts (C) and allow fluid to drain. Locate the master cylinder above the left front tire in the wheel well area.
Page 331: Brake Bleeding / Fluid Change
13. Check brake system for fluid leaks. Mity Vac™ (PN 2870975) 3. Add brake fluid to the indicated MAX level of reservoir. Polaris DOT 4 Brake Fluid (PN 2872189) 4. Begin bleeding procedure with the caliper that is farthest from the master cylinder. Install a box end wrench on caliper bleeder screw.
Page 332: Front Brake Pads
BRAKES FRONT BRAKE PADS Push the mounting bracket inward and the slip outer brake pad out between the bracket and caliper body. Pad Removal RZR / RZR S Elevate and support front of vehicle. CAUTION Use care when supporting vehicle so that it does not tip or fall.
Page 333 BRAKES Pad Inspection Pad Assembly / Installation 1. Measure the thickness of the pad material. Replace pads if Lubricate mounting bracket pins with a light film of worn beyond the service limit. silicone grease and install rubber dust boots. Apply Grease to Each Bracket Pin Compress mounting bracket and make sure dust boots are fully seated.
Page 334: Brake Burnishing Procedure
BRAKES Slowly pump the brake pedal until pressure has been built up. Maintain at least 1/2, (12.7 mm) of brake fluid in the reservoir to prevent air from entering the brake system. Install the adjustment set screw and turn clockwise until stationary pad contacts disc, then back off 1/2 turn (counterclockwise).
Page 335: Front Caliper Service
BRAKES FRONT CALIPER SERVICE Caliper Exploded View (RZR / RZR S / RZR S INT’L) Apply Polaris DOT 4 Brake Fluid 47 in. lbs. (5.3 Nm) to Component Apply Silicone Grease A. Socket Set Screw B. Bleeder Screw C. Caliper Assy.
Page 336: Caliper Removal
BRAKES Caliper Removal Loosen brake pad adjustment set screw 2-3 turns to allow brake pad removal after the caliper is removed. Elevate and safely support the front of the vehicle. Remove the (4) wheel nuts and the front wheel. CAUTION Use care when supporting vehicle so that it does not tip or fall.
Page 337: Caliper Disassembly
BRAKES Caliper Disassembly IMPORTANT: Do not remove the caliper pistons with a standard pliers. The piston sealing surfaces will 1. Remove both brake pads from the caliper (see “FRONT become damaged if a standard pliers is used. BRAKE PADS - Pad Removal”). Once the pistons are removed, use a pick to carefully 2.
Page 338: Caliper Inspection
BRAKES Caliper Inspection Inspect caliper body for nicks, scratches, pitting or wear. = In. / mm. Measure bore size and compare to specifications. Replace if damaged or worn beyond service limit. RZR / RZR S: Front Caliper Piston O.D.: Std: 1.002” (25.45 mm) Service Limit: 1.000”...
Page 339 Shown O-Rings Front Caliper Mount Bolt Torque: 2. Coat pistons with clean Polaris DOT 4 Brake Fluid. Install 31-34 ft. lbs. (42-46 Nm) pistons with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance.
Page 340: Front Brake Disc
BRAKES FRONT BRAKE DISC Install the adjustment set screw and turn clockwise until stationary pad contacts disc, then back off 1/2 turn (counterclockwise). Disc Runout Mount dial indicator as shown to measure disc runout. Slowly rotate the disc and read total runout on the dial indicator.
Page 341: Disc Replacement
BRAKES CAUTION Brake Disc Thickness New .188” (4.78 mm) Service Limit .170” (4.32 mm) Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal. Brake Disc Thickness Variance Install wheel hub assembly, washers, and castle nut. Torque Service Limit: .002”...
Page 342: Rear Brake Pads
BRAKES REAR BRAKE PADS Push caliper piston into the caliper bore slowly using a C- clamp or locking pliers with pads installed. Pad Removal Elevate and support rear of vehicle. CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls.
Page 343: Brake Burnishing Procedure
BRAKES Pad Inspection Install caliper and torque mounting bolts to specification. 18 ft. lbs. 1. Clean the caliper with brake cleaner or alcohol. (24 Nm) 2. Measure the thickness of the pad material. Replace pads if worn beyond the service limit. Measure Thickness Rear Brake Pad Thickness...
Page 344: Rear Caliper Service
BRAKES REAR CALIPER SERVICE Caliper Exploded View Apply Polaris DOT 4 Brake Fluid to Component 47 in. lbs. Apply Silicone Grease (5.3 Nm) A. Brake Pad B. Mount Bracket C. Piston D. Caliper Assy. E. Square Ring (thick) F. Square Ring (thin) G.
Page 345 BRAKES Caliper Disassembly Caliper Inspection 1. Remove brake pad adjustment set screw (K). Inspect caliper body for nicks, scratches or wear. Measure bore size and compare to specifications. Replace if damage 2. Push upper pad retainer pin inward and slip brake pads past is evident or if worn beyond service limit.
Page 346: Caliper Assembly
Service Limit: 1.498” (38.05 mm) Inspect the brake disc and pads as outlined in this chapter. Coat piston with clean Polaris DOT 4 Brake Fluid (PN 2872189). Install piston (D) with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly with light resistance.
Page 347: Caliper Installation
BRAKES Caliper Installation REAR BRAKE DISC 1. Install the rear caliper with the mounting bolts. Torque Disc Inspection mounting bolts to specification. Visually inspect disc for scoring, scratches, or gouges. 18 ft. lbs. Replace the disc if any deep scratches are evident. (24 Nm) Use a 0-1”...
Page 348: Disc Replacement
BRAKES Disc Replacement TROUBLESHOOTING Remove rear brake caliper (see “REAR CALIPER Brakes Squeal / Poor Brake Performance SERVICE”). • Air in system Remove wheel hub cotter pin, castle nut and washers. • Water in system (brake fluid contaminated) Remove the hub assembly from the vehicle and remove the (4) bolts retaining the disc to the hub.
Page 349 ELECTRICAL CHAPTER 10 ELECTRICAL GENERAL INFORMATION ..........10.3 SPECIAL TOOLS / ELECTRICAL SERVICE NOTES .
Page 350 ELECTRICAL STARTING SYSTEM........... 10.30 TROUBLESHOOTING .
Page 351: General Information
ELECTRICAL GENERAL INFORMATION Under-Dash Components The following switches and components can be accessed Special Tools underneath the instrument / dash panel: • Speedometer Part Number Tool Description • Digital Wrench Diagnostic Connector PV-43568 Fluke™ 77 Digital Multimeter • AWD Switch PV-43526 Connector Test Kit •...
Page 352: Headlamp Switch
ELECTRICAL Headlamp Switch Ignition Key Switch Disconnect the headlamp switch harness by depressing the Disconnect the key switch harness by lifting the connector connector locks and pulling on the connector. Do not pull lock and pulling on the connector. Do not pull on the on the wiring.
Page 353: Ignition Key Switch (Int'l)
ELECTRICAL Ignition Key Switch (INT’L) AWD / 2WD Switch 1. Disconnect the key switch harness by lifting the connector Disconnect the AWD / 2WD switch harness by depressing lock and pulling on the connector. Do not pull on the the connector locks and pulling on the connector. Do not wiring.
Page 354: Awd / 2Wd / Turf Switch (Int'l)
ELECTRICAL AWD / 2WD / TURF Switch (INT’L) Turn Signal Switch (INT’L) Disconnect the AWD / 2WD / TURF switch harness by Disconnect the Turn Signal switch harness by depressing depressing the connector locks and pulling on the the connector locks and pulling on the connector. Do not connector.
Page 355: Transmission (Gear Position) Switch
ELECTRICAL Transmission (Gear Position) Switch VEHICLE SPEED SENSOR 1. Disconnect the transmission switch harness by lifting the Speed Sensor Location connector lock and pulling on the connector. Do not pull The speed sensor is located in the transmission transfer case on the wiring.
Page 356: Rear Diff Solenoid (Int'l)
ELECTRICAL REAR DIFF SOLENOID (INT’L) Differential Solenoid Overview The differential solenoid is located on the rear gear case. The solenoid actuates an engagement dog, which locks and unlocks the rear differential. Refer to Chapter 7 for more information on the rear differential mechanical operation. Differential Solenoid Circuit Operation The Rear Diff Solenoid Relay is attached to the rear plastic LH panel divider behind the driver’s seat.
Page 357: Instrument Cluster
ELECTRICAL INSTRUMENT CLUSTER Overview The instrument cluster displays critical vehicle information to the user. Reference the following page for display functions and descriptions. NOTE: Some features are not applicable to all models. IMPORTANT: The use of a high pressure washer may damage the instrument cluster. Wash the vehicle by hand or with a garden hose using mild soap.
Page 358: Rider Information Display
ELECTRICAL Rider Information Display 13. Gear Position Indicator - Displays gear selector position. H = High The rider information display is located in the instrument cluster. All segments will light up for 1 second at start-up. L = Low N = Neutral NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the R = Reverse...
Page 359 ELECTRICAL Trip Meter Engine Hours The trip meter records the miles traveled by the vehicle on each Engine hours are logged anytime the engine is running. Total trip. To reset the trip meter: hours can not be reset. 1. Toggle the MODE button to TRIP 1. Programmed Service Interval 2.
Page 360 ELECTRICAL Clock Units of Measurement Standard Display Metric Display Distance Miles (MPH) Kilometers (KM/H) Time 12-Hour Clock 24-Hour Clock Temperature Fahrenheit Celsius To change between Standard and Metric units of measurement, follow these steps: Turn the key to the OFF position. Press and hold the MODE button while turning the key to the ON position.
Page 361: Diagnostic Mode
ELECTRICAL Diagnostic Mode Under / Over Voltage This warning usually indicates that the vehicle is operating at an The diagnostic mode is accessible only when the check engine RPM too low to keep the battery charged. It may also occur MIL has been activated.
Page 362 ELECTRICAL Use the trouble code reference table in the EFI Chapter for Push the instrument cluster out from the back side of the a description of each code. dash while securely holding the dash and rubber mount. If more than one code exists, press the MODE button to Push Instrument Dash Panel Cluster Outward...
Page 363: All Wheel Drive Coil
ELECTRICAL ALL WHEEL DRIVE COIL HEAD LIGHTS Operation Overview Headlight Adjustment • When the AWD switch is “ON”, 12 VDC power is The headlight beam is adjustable. present at the hub coil. Place the vehicle on a level surface with the headlight approximately 25 ft.
Page 364: Headlamp Bulb Replacement
ELECTRICAL Headlamp Housing Removal Adjust the beam to desired position. Repeat the procedure to adjust the other headlight. Disconnect the wire harness from the headlamp bulb. Be WARNING sure to pull on the connector, not on the wiring. Remove the O-rings (A) from the headlamp brackets on Due to the nature of light utility vehicles and both sides of the headlamp.
Page 365: Tail / Brake Lights
ELECTRICAL TAIL / BRAKE LIGHTS Bulb Replacement Before replacing the bulb(s), use a digital multi-meter to test the harness to ensure the lamp is receiving 12 volts and that a ground path is present. If a tail light, brake light or turn signal (INT’L Only) does not work the bulb may need to be replaced.
Page 366: Cooling System
ELECTRICAL COOLING SYSTEM Cooling System Break-Out Diagram 10.18...
Page 367: Coolant Temperature Sensor
ELECTRICAL Fan Control Circuit Operation / Testing EFI DIAGNOSTICS Power is supplied to the fan via the Orange/Black wire when the EFI Component Testing relay is ON. The ground path for the fan motor is through the Brown harness wire. Refer to “RELAYS” later in this chapter All EFI component information and diagnostic testing for more information on fan functions.
Page 368: Fuse Box: Fuses / Relays / Circuit Breaker
ELECTRICAL FUSE BOX: FUSES / RELAYS / CIRCUIT BREAKER Overview / Operation Located in the fuse box under the dash, the fuses provide overload protection for wiring and components such as the instrument cluster, ECU, EFI system, main harness, lights, accessories and power steering. The relays assist with component operation like the cooling fan, fuel pump, EFI system, drive system and electronic power steering.
Page 369: Fuse Box Detail
ELECTRICAL Fuse Box Detail IMPORTANT: All relays (PN 4011283) located in fuse box are the same and can be swapped out to help diagnose electrical problems. 10.21...
Page 370: Relay Operation
ELECTRICAL Relay Operation FAN RELAY provides power to the following system: • Fan Motor Located in the fuse box under the dash, the relays assist with component operation like the cooling fan, fuel pump and EFI FAN RELAY system, drive system and EPS. OLOR UNCTION NOTE: The Rear Diff Solenoid Relay is mounted...
Page 371 ELECTRICAL REAR DIFF SOLENOID RELAY (INT’L) provides power to the following system: • Rear Differential Solenoid REAR DIFF SOLENOID RELAY (INT’L) OLOR UNCTION 10-Amp fuse protected 12 Vdc battery Red / Dark Green voltage. Dark Green / White ECU input to enable relay. Brown Relay coil ground.
Page 372: Charging System
ELECTRICAL CHARGING SYSTEM WARNING Current Draw - Key Off Never start the engine with an ammeter connected in series. Damage to the meter or CAUTION meter fuse will result. Do not run test for extended period of time. Do not connect or disconnect the battery cable Do not run test with high amperage accessories.
Page 373: Regulator / Rectifier
ELECTRICAL NOTE: If there are any significant variations in ohm Regulator / Rectifier readings between the three legs it is an indication The Regulator / Rectifier is located behind the radiator cooling that one of the stator legs may be weak or failed. fan and can be accessed through the front left wheel well.
Page 374: Charging System Testing Flow Chart
ELECTRICAL Charging System Testing Flow Chart Whenever charging system problems are suspected, proceed with the following system check after verifying that all wires are in good condition, connected and not exposed or pinched. Remove the battery and properly ser- Using a multitester set on D.C. volts, mea- vice.
Page 375: Battery Service
CALIFORNIA PROPOSITION 65 WARNING: Battery PN 4011496 Batteries, battery posts, terminals and related accessories contain lead and lead compounds, and Polaris / Yuasa YTX20HL-BS other chemicals known to the State of California to Type Sealed - Maintenance Free cause cancer and birth defects or other reproductive harm.
Page 376: Battery Testing
NOTE: Battery charge can be maintained by using a Load Test Polaris battery tender charger or by charging once a month to make up for normal self-discharge. Battery tenders can be left connected during the storage...
Page 377: Battery Conductance Analyzer
An overheated battery could explode, causing severe injury or death. Always watch charging times carefully. Authorized Polaris dealers/distributors are required to use the Stop charging if the battery becomes very warm to the conductance analyzer when testing 12V Polaris batteries.
Page 378: Starting System
ELECTRICAL STARTING SYSTEM Voltage Drop Test The Voltage Drop Test is used to test for bad connections. When Troubleshooting performing the test, you are testing the amount of voltage drop through the connection. A poor or corroded connection will Starter Motor Does Not Run appear as a high voltage reading.
Page 379: Brush Inspection / Replacement
ELECTRICAL NOTE: Note the alignment marks on both ends of Measure resistance between insulated brush and starter the starter motor casing. These marks must align housing. Reading should be infinite (OL). Inspect during reassembly. insulation on brush wires for damage and repair or replace as necessary.
Page 380: Armature Testing
ELECTRICAL Brush Replacement Measure the resistance between each commutator segment and the armature shaft. The reading should be infinite (no Remove terminal nut with lock washer, flat washer, large continuity). phenolic washer, the small phenolic spacers, and sealing O-ring. Inspect O-ring and replace if damaged. Slide positive brush springs to the side, pull brushes out of their guides and remove brush plate.
Page 381: Starter Drive
ELECTRICAL NOTE: It is important to tighten the bottom starter 2. Install O-ring, two small phenolic spacers, large phenolic bolt first (circle), as the bottom hole acts as a pilot washer, flat washer, lock washer, and terminal nut. hole to properly align the starter drive (bendix) with 3.
Page 382: Starter Solenoid Bench Test
ELECTRICAL Remove the retaining ring, thrust washer, spring retainers and clutch return spring. Screw the overrun clutch off the end of the pinion shaft. Remove the old spring and install a new one. Lightly grease the pinion shaft and reinstall the clutch, spring, retainers, end washer and lock ring in the reverse order.
Page 383: Starter Exploded View
ELECTRICAL Starter Exploded View 10. Gear Assembly Indicates Do not reuse. 1. Rubber Ring* Replace with new parts. 11. Through Bolt 2. Brush Spring 12. Cover 3. Thrust Washer 13. Stopper 4. Gear Assembly 14. Snap Ring 5. O-Ring* 15. Washer 6.
Page 384: Starting System Testing Flow Chart
ELECTRICAL STARTING SYSTEM TESTING FLOW CHART Condition: Starter fails to turn over the engine. With the tester on the VDC position, place the tester's black lead on the battery negative and the Remove battery and properly service. Install red lead on the battery positive. Reading should fully charged shop battery to continue test.
Page 385: Electronic Power Steering (Eps)
FUNCTION affects the EPS system is detected, the system will illuminate a ORANGE (2-Pin) Main Power (30A Protected) fault indicator and transition to a normal mechanically coupled steering system. The system is Polaris Digital Wrench™ BROWN (2-Pin) Ground compatible simplified...
Page 386: Eps System Breakout
ELECTRICAL EPS System Breakout 10.38...
Page 387 ELECTRICAL EPS Troubleshooting (Power Steering Non-Functional with MIL ON) 10.39...
Page 388 ELECTRICAL EPS Troubleshooting (Power Steering Non-Functional with MIL OFF) 10.40...
Page 389: Eps Troubleshooting (Using Digital Wrench™)
ELECTRICAL EPS Troubleshooting (Using Digital Wrench™) 10.41...
Page 390: Electrical System Breakouts
ELECTRICAL ELECTRICAL SYSTEM BREAKOUTS Vehicle Speed Sensor 10.42...
Page 391: Cooling Fan
ELECTRICAL Cooling Fan 10.43...
Page 392: Charging System
ELECTRICAL Charging System 10.44...
Page 393: Chassis Power
ELECTRICAL Chassis Power 10.45...
Page 394: Key-On Battery Power
ELECTRICAL Key-On Battery Power 10.46...
Page 395: Electronic Power Steering (Eps)
ELECTRICAL Electronic Power Steering (EPS) 10.47...
Page 396: Engine Start (Starter Interlock)
ELECTRICAL Engine Start (Starter Interlock) 10.48...

Polaris Ranger RZR 800 Manual

General Information Chapter

Maintenance Chapter 2 Maintenance 2

Engine Chapter 3 Engine

Electronic Fuel Injection Chapter 4 Electronic Fuel Injection

Body / Steering / Suspension Chapter 5 Body / Steering / Suspension

Clutching Chapter 6 Clutching

Quick Links

Chapters

Troubleshooting

Related Manuals for Polaris Ranger RZR 800

Summary of Contents for Polaris Ranger RZR 800